Horizon Family Vacuum Systems

Transcript

EVAC North America Supermarket Group OPERATION AND MAINTENANCE MANUAL HORIZON FAMILY VACUUM SYSTEMS PART NUMBERS 2900418-001 2900419-002 2900420-001 2900421-002 2900465-002 2900418-003 2900419-004 2900420-003 2900421-004 2900465-004 2900418-005 2900419-006 2900420-005 2900421-006 2900465-006 - NOTICE The information contained herein is proprietary to EVAC NORTH AMERICA INC. and shall not be reproduced, used or disclosed to others, in part, except as authorized in writing by contract with EVAC NORTH AMERICA INC. EVAC NORTH AMERICA INC reserves the right to alter the information contained herein without prior notice. EVAC NORTH AMERICA INC 1445 Huntwood Drive Cherry Valley, IL 61016 USA MANUAL NUMBER: 2504460 Rev C RECORD OF REVISIONS Retain this record in front of manual. On receipt of revision, insert revised pages in the manual, and enter revision number, date inserted and initial. REVISION NUMBER REVISION DATE DATE FILED REVISION NUMBER Rev A 10/4/2010 SKC Rev B 3/5/2012 SKC Rev C 3/3/2015 CLB BY REVISION DATE EVAC NORTH AMERICA PROPRIETARY - SEE COVER PAGE FOR DETAILS Page ii DATE FILED BY RECORD OF TEMPORARY REVISIONS TEMPORARY REV. NO. PAGE NUMBER ISSUE DATE BY DATE REMOVED EVAC NORTH AMERICA PROPRIETARY - SEE COVER PAGE FOR DETAILS Page iii BY SERVICE BULLETIN LIST SERVICE BULLETIN NUMBER SERVICE BULLETIN DATE DATE INSERTED IN MANUAL EVAC NORTH AMERICA PROPRIETARY - SEE COVER PAGE FOR DETAILS Page iv EVAC NORTH AMERICA OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 TABLE OF CONTENTS SECTION DESCRIPTION PAGE LIST OF FIGURES ......................................................................................................................... viii LIST OF TABLES ............................................................................................................................ ix INTRODUCTION .............................................................................................................................. x 1. 2. 3. Scope ............................................................................................................................ x List of Abbreviations ...................................................................................................... x Safety Summary ........................................................................................................... xi GENERAL INFORMATION .............................................................................................................. 1 1. 2. General Description ....................................................................................................... 1 A. Purpose ............................................................................................................ 1 B. Terminology ...................................................................................................... 1 Functional Description ................................................................................................... 3 A. Principle of Operation ....................................................................................... 3 B. System Components ........................................................................................ 5 (1) Vacuum Central .......................................................................................... 5 (2) Interface Valve Assemblies ......................................................................... 8 (3) Buffer Box ................................................................................................. 10 (4) Vacuum Check Valve ................................................................................ 11 (5) Isolation Valves ......................................................................................... 12 INSTALLATION .............................................................................................................................. 13 1. 2. Overhead Piping Network ............................................................................................ 13 (1) Installation of Piping .................................................................................. 13 (2) Riser Installation ....................................................................................... 14 (3) Standard Riser .......................................................................................... 18 (4) Gang Lift ................................................................................................... 21 (5) Trench Drains ........................................................................................... 24 (6) Sinks ......................................................................................................... 27 Vacuum Central Installation ......................................................................................... 30 A. System Location ............................................................................................. 30 B. Mechanical Installation.................................................................................... 31 (1) Inlet Connection Kit ................................................................................... 31 (2) Outlet Connection ..................................................................................... 32 (3) Vent Connection ....................................................................................... 33 (4) Fresh Water Connection ........................................................................... 33 C. Electrical Connection ...................................................................................... 34 (1) Power Supply ............................................................................................ 34 (2) Customer Connections ............................................................................. 34 EVAC NORTH AMERICA PROPRIETARY - SEE COVER PAGE FOR DETAILS Page vi EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. Startup A. B. C. ........................................................................................................................ 36 Vacuum Central Pre-Startup Procedure ......................................................... 36 Vacuum Central Startup Procedure ................................................................ 36 Piping Network Startup Procedure ................................................................. 39 OPERATION.................................................................................................................................. 40 1. 2. 3. 4. System Operation ....................................................................................................... 40 A. Vacuum Volume Tank .................................................................................... 40 B. Vacuum Pumps .............................................................................................. 40 C. Water Reservoir ............................................................................................. 40 D. Collection Tanks............................................................................................. 40 Electrical Control Panel ............................................................................................... 40 A. Control System Operation .............................................................................. 40 B. Control Logic .................................................................................................. 40 C. OIT Key Pad Operation .................................................................................. 42 Manual Operations ...................................................................................................... 50 A. Manually Initiated Discharge .......................................................................... 50 B. Manually Initiated Pump Start ......................................................................... 50 C. Reservoir Tank Drain ..................................................................................... 50 Shutdown Procedure ................................................................................................... 50 A. Normal Shutdown ........................................................................................... 50 B. Extended Shutdown ....................................................................................... 51 TROUBLESHOOTING ................................................................................................................... 51 1. 2. 3. General ....................................................................................................................... 52 Fault Isolation .............................................................................................................. 52 Diagnostic Procedures ................................................................................................ 58 A. Pump Rotation ............................................................................................... 58 B. Pump Performance Test ................................................................................ 58 C. Float and Discharge Verification..................................................................... 59 D. Vacuum Central Leak Test ............................................................................. 59 E. Piping and Component Leak Test .................................................................. 60 F. Pinch Valve Inspection and Replacement ...................................................... 60 G. Activator Inspection and Replacement ........................................................... 60 PREVENTATIVE MAINTENANCE ................................................................................................. 62 1. 2. 3. General ....................................................................................................................... 62 Preventative Maintenance Schedule ........................................................................... 62 Inspection and Cleaning Procedures ........................................................................... 62 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Page vii EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 LIST OF FIGURES FIGURE NO. 1 2 3 4 5 6 7 8 9 10 11 12, 12a 13 14, 14a 15, 15a 16 17 18 19 20 21 DESCRIPTION Vacuum Central Electrical Control Panel Assembly Activator Pinch Valve Buffer Box Vacuum Check Valve Slope Requirements Hanger Detail Obstruction Piping Wye Roll Riser Pipe Offset Standard 1” Riser Gang Lift Trench Drain Sink Configuration System Accessibility Inlet Piping Floor Sink Water Connection Electrical Connections OIT Key Pad EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Page viii PAGE 4 6 9 10 11 12 13 13 14 15 17 19, 20 23 25, 26 28, 29 30 31 32 33 34 43 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 LIST OF TABLES TABLE NO. 101 102 103 104 105 106 107 DESCRIPTION PAGE Terminology Riser Kit (US, Canada, Mexico) Riser Kit (Europe, Asia) Riser Kit (Australia) Power Requirements Fault Isolation Preventative Maintenance Schedule EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Page ix 1 15 16 16 35 54 62 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INTRODUCTION 1. Scope A. This manual provides operation and maintenance instructions with illustrated parts list for the Horizon Supermarket System, Part Numbers 2900418, 2900420, and 2900421. The instructions in this manual provide the information necessary to perform maintenance functions ranging from simple checks to replacement. Refer to the Table of Contents for the location of the applicable sections. 2. List of Abbreviations A. Listed below are the English and SI abbreviations and symbols used in this publication. Refer to ANSI Y14.5M-1994 for symbols used for dimensioning and tolerance. Abbreviation and Symbol Definition Abbreviation and Symbol AC Amps Am AR AWG BVP DC Dia, ∅ DS EFF alternating current amperes analog module as required American wire gage booster valve direct current diameter disconnect switch effectivity code mA mL mm MMP N/A NC NO NHA OD PLC Fig. FLA Fu gpm hr in. in. HgV in. HgA IPL lb-in lbs LG LSH LSB LSL m max min figure full load amp fuse gallons per minute hour inch inch mercury gauge (vacuum) inch mercury absolute illustrated parts list pound-inch (torque) pounds long level sense high level sense block level sense low meter maximum minimum P/N QTY RF sec SV VAC VDC °C °F Ω % Definition milli-ampere milliliter millimeter manual motor protector not applicable normally closed normally opened next higher assembly outside diameter programmable logic controller part number quantity required reference second solenoid valve volt alternating current volt direct current degrees centigrade degrees Fahrenheit ohm (electrical resistance) percent EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Page x EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. Safety Summary A. Personnel must observe all safety regulations while performing maintenance, operation, or repair procedures. The following precautions are related to the many different procedures applicable to the Horizon Supermarket System. Every practical safety feature has been incorporated into the design and manufacture of this equipment. However, personnel must be aware of potential hazards and follow the safety rules listed below when servicing equipment. WARNING: ALL WARNINGS, CAUTIONS, AND NOTES FOUND THROUGHOUT THIS MANUAL MUST BE FOLLOWED TO MINIMIZE THE RISK OF PERSONAL INJURY, EQUIPMENT DAMAGE, OR MALFUNCTIONS. WARNING: BE CAREFUL WHEN WORKING WITH ELECTRICAL DEVICES, SPECIFICALLY, AROUND MOISTURE. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID ACCIDENTAL SHOCK OR INJURY. THE POWER SUPPLY TO THE EQUIPMENT MUST BE TURNED OFF WHILE YOU ARE PERFORMING MAINTENANCE. TURN ON THE POWER SUPPLY ONCE THE WORK IS COMPLETE OR TO VERIFY OPERATION AT SPECIFIC STEPS BELOW. WARNING: FOR SANITARY REASONS, ALWAYS WEAR RUBBER GLOVES, PREFERABLY ELBOW LENGTH, WHEN WORKING WITHIN THE HORIZON SUPERMARKET SYSTEM AND HANDLING PARTS THAT CONTACT WASTE. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Page xi EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 GENERAL INFORMATION 1. General Description A. Purpose (1) The Evac Vacuum Collection System is designed to collect, transport, and discharge condensate and other gray water wastes, while eliminating or significantly reducing the under-floor drainage piping in the supermarket’s sales area. Refer to Figure 1 for an overview of the Vacuum Collection System. (2) The following are some basic benefits of an Evac Vacuum Collection System for supermarkets. (a) Complete floor plan design flexibility. (b) Easy and less costly relocation of refrigerated display cases and other plumbing fixtures. (c) For retrofits, the Evac Vacuum Collection System eliminates the additional cost and inconvenience associated with concrete cutting and floor patching. Table 101 Terminology Terminology Description Activator A pneumatic device that detects the presence of water at a preset level and opens the interface valve for a preset period of time. Branch Part of the overhead piping network that connects into the main piping system as a secondary feed of the piping system. Risers are typically connected to a branch. Buffer Box Component used to interface between refrigeration fixtures and the vacuum system. Collects waste water to a preset level, which is pneumatically sensed by the activator. Buffer Pipe Piping configuration used in place of a buffer box. See Buffer Box. Booster Valve (BVP) A valve that allows small amounts of air into a riser, to prevent stalling. Check Valve A valve that prevents backflow of waste water in vacuum system. Collection Tanks Two tanks, part of the Vacuum Central, used to collect the waste water. Discharge Valve See interface valve. Gang Lift A pipe configuration consisting of multiple primary risers and one secondary riser that is used with low flow fixtures. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORMATION Page 1 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 101 Terminology Terminology Description Interface Valve A valve that discharges waste water and air from a fixture into the overhead vacuum piping. The downstream side of the valve is constantly under vacuum. Interface Valve Assembly A valve assembly that includes the 3 main components of a riser: the buffer box, activator, and the interface valve. Isolation Valve A valve that can be manually shut-off. Commonly used to isolate a branch from the main for maintenance. Pinch Valve A pneumatically operated valve that is used as an interface valve. Lift An upward vertical change in the vacuum drainage piping. Main The main pipeline that is part of the piping network. Branches are connected into the main. Mini-Check Valve A valve that prevents backflow in the sensor tubing connected to the activator. Overhead Pipe Network Piping, made up of multiple branches and a main that connects the risers and the Vacuum Central. Reformer Pocket A low point placed in a pipeline before a lift is made to allow a slug of water to be maintained. Also called a transport pocket. Riser A vertical lift that is regularly at atmospheric pressure and is the means of moving waste water from the buffer box through the interface valve. Slug An isolated quantity of waste water flowing full bore through the vacuum pipeline. Stalling A condition that occurs when a slug of waste water is stopped in a vertical lift due to insufficient pressure differential. Vacuum Central Vacuum generation and collection point of the complete vacuum system containing vacuum pumps, waste tanks, vacuum volume tank and necessary controls. Vacuum Pressure A pressure below the atmospheric pressure that is measured in inches of mercury (Hg). Vacuum Volume Tank A component, part of the Vacuum Central connected to the vacuum pumps and the collection tanks, used as a buffer when surges of vacuum are needed. GENERAL INFORMATION Page 2 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 2. Functional Description A. Principle of Operation (1) The Evac Vacuum Collection System uses differential air pressure to transport waste water as opposed to the gravity-induced flow of a conventional waste water collection system. A Vacuum Collection System consists of: (a) Vacuum Central (b) Interface Valve Assemblies 1. Activator 2. Vacuum Interface Valve 3. Mini-Check Valve 4. Booster Valve (BVP) (c) Buffer (d) Vacuum drainage piping 1. Evac Check Valve 2. Full Port Isolation Valve EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORM ATION Page 3 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Vacuum Central Unit Figure 1 (2) The Vacuum Central has vacuum pumps, collection tanks, and system controls. The Vacuum Central is responsible for supplying and maintaining negative pressure (vacuum) on the system piping, receiving all waste water collected, and the discharge of waste water to the building sewer system. (3) Vacuum is retained in the drainage piping with the installation of normally-closed vacuum interface valves. When the vacuum interface valve is opened, waste water is pushed through the piping by in-rushing air into the vacuum drainage piping. The valve then closes and waits for another cycle. The vacuum interface valves are pneumatically operated using the negative pressure contained in the vacuum drainage piping. GENERAL INFORMATION Page 4 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 B. (4) The buffer box receives the waste water from a fixture(s). The activator pneumatically senses the accumulation of waste water in the buffer. The interface valve assembly cycle begins when the amount of water reaches a preset level. (5) Vacuum drainage piping is simple to install and is smaller in diameter compared to gravity drainage piping. Vacuum drainage piping is designed with vertical lifts resulting in design flexibility and installation savings. System Components (1) Vacuum Central (a) Electrical Control Panel Assembly (Figure 2) 1. Operator Interface Touch pad – The touch pad is referred to as the OIT. The OIT allows visual access to system history and control of the system by the user. 2. Disconnect Operator – The disconnect switch is used to shut off the main 3-phase power entering the control panel when maintenance is required. 3. Transformer – The transformer is used to drop the voltage level of the incoming power to 110V so those control devices can operate on the same power source. 4. Fuse Holders and Fuses – The fuses are connected to the high voltage side of the transformer and are sized to protect the connecting equipment from current spikes. The fuse holder has lights that will illuminate if the corresponding fuse has blown. 5. Programmable Logic Controller - The Logic Controller is referred to as the PLC. The PLC monitors all of the floats and alarm contacts and then reacts by turning on pumps, solenoids and alarms. 6. Analog Module – The analog module is an attachment to the PLC that can read analog voltage or current inputs and convert it to a digital signal that the PLC can use. 7. Manual Motor Protectors – The manual motor protectors are current sensitive devices that act as 3-phase circuit breakers. The current trip point is adjustable to match the motor requirement. 8. Auxiliary Contact - The auxiliary contacts are dry contacts connected to the motor protectors. They allow the PLC to monitor the motor protector and determine if it has tripped. 9. Motor Contactors – The contactors act as a relay for the motors. They receive a signal from the PLC, which energizes a coil connecting the 3phase power to the motors. 10. Transient Suppressor - The transient suppressor protects the PLC output from transients caused by the contactor’s coil. 11. Vacuum Transducer – The vacuum transducer is a 4 to 20 mA, 0 to 30 inch Hg, analog sensor that electronically feeds the vacuum level to the analog module. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORM ATION Page 5 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Electrical Control Panel Assembly Figure 2 GENERAL INFORMATION Page 6 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (b) Vacuum Pumps The liquid-ring vacuum pump generates a vacuum by forming a sealing ring of liquid water. Liquid-ring pumps are rotary displacement pumps particularly suited to pumping gases and vapors, which may contain small amounts of liquid. The liquid-ring pump is insensitive to contamination present in the gas stream. The Vacuum Central uses a fresh water connection in series with a water reservoir to supply the liquid-ring pump with the proper amount of sealing fluids. Without the proper amount of sealing fluids, the pump will not operate properly. 1. Water Reservoir The water reservoir tank provides a partially recirculated flow for sealing fluid to the liquid-ring pumps. The water reservoir also separates the gas/liquid output of the vacuum pump. This mixture is separated by gravity in the reservoir tank. The warm gases exit through an exhaust port and the water remains in the reservoir. The reservoir is designed to hold enough water to adequately run the vacuum pumps for an extended period of time. 2. Isolation Valves Each vacuum pump is piped with a single union isolation ball valve used when a pump must be taken offline for maintenance or replacement. The ball valve isolates the inlet to the pump from the main vacuum header and allows the system to continue operating with the remaining vacuum pump(s) until the pump in question can be repaired or replaced. (c) Vacuum Volume Tank The vacuum volume tank acts as a reservoir for vacuum potential. A vacuum is held at a minimum of 50% (15 inch Hg) at all times. This vacuum is sent to the waste collection tanks through the manifold housing and the control solenoid valves. 1. Vent Valves A ¼ inch full port vent valve is located on the main leg of the inlet piping to the vacuum volume tank. This valve can be used to vent the volume tank. If the system is in automatic operation, opening this valve will cause a vacuum pump to start. (d) Waste Collection Tanks Two waste collection tanks are provided to collect waste water from the piping network. Each tank operates independently of the other, based on the status of the level float switches. Each tank has a collection capacity of 75% before a dump cycle is initiated. The remaining 25% is the surge capacity before a high-level dump cycle is initiated. Following a dump cycle, vacuum is restored to the tank so that it may again begin to collect waste water. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORM ATION Page 7 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 1. Level Sensors The level sensors in the waste collection tanks are ball type float switches. The dump level switches (LSH1 & LSH2) are normally open. When the waste water rises to the switches, the floats rise closing the switch contacts, and initiate a dump cycle. If the LSH switches fail, the waste water level continues to rise to the block level switches (LSB1 & LSB2). These switches are normally closed. When the float rises, the switch contacts open and a dump cycle is initiated. 2. Discharge Check Valves Each waste collection tank is equipped with a discharge check valve. This valve prevents atmospheric air from entering the tank to reverse waste water flow from the discharge piping. The check valves are flapper style valves and are serviceable by removing the cap from the valve. 3. Vent Valves A ¼ inch full port ball valve is located on the vacuum piping tee of each waste collection tank lid. The valves may be used to vent the tanks and initiate a manual dump. (e) Vacuum Control Solenoid Valves 1. (2) Each waste collection tank is connected to the vacuum volume tank through a 3-way control solenoid valve. The solenoid valves are operated by vacuum supplied from the inlet header to the vacuum volume tank. These solenoids work the float switches in the waste collection tanks to send vacuum used for collection or to initiate discharge by venting the tanks. Interface Valve Assemblies The interface valve assembly consists of a discharge valve, mini-check valve, tubing, and an activator. The interface valve assembly is used in conjunction with a buffer. The activator senses the waste water in the buffer and opens the discharge valve to transport the waste water toward the vacuum central. The interface valve assembly uses no electrical components and operates using the negative pressure available in the vacuum drainage piping. (a) Activator (Figure 3) 1. The Evac activator is designed to detect a preset amount of head pressure from the buffer box. When the proper pressure is detected, the valve supplies vacuum to the interface valve for a period of time determined by the timing jets. 2. The activator has a manual activation, button that will initiate a timed cycle discharge. The source line of the activator, located above the buffer box, should always have a mini-check valve in line. GENERAL INFORMATION Page 8 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Activator Figure 3 (b) Vacuum Interface Valves 1. (c) a. The Evac pinch valve is used as an interface valve. The valve is typically used with the buffer box connected to hand sinks, water fountains, and refrigerator cases. b. The valve uses a pinched rubber tube to seal the valve. When vacuum is applied to the valve through the activator, the tube is pneumatically pulled open. Mini-Check Valve 1. (d) Pinch Valve (Figure 4) A mini-check valve is installed between the vacuum source piping and the activator to prevent the passage of waste water into the activator. BVP 1. The BVP is installed on all 1 inch risers and higher flow 1.5 inch risers to improve the performance of the vacuum lift. The BVP acts to prevent a stall in the vacuum drainage piping by breaking up the formation of a solid fluid column in the riser. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORM ATION Page 9 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Pinch Valve Figure 4 (3) Buffer Box (Figure 5) (a) The Evac Buffer Box is a component that receives waste water from fixture drains. A buffer’s functions include: [1] receiving and holding waste water, [2] metering quantity of water per discharge cycle, [3] sending a signal to activator, and [4] to provide an atmospheric air intake for discharge cycle. The buffer also prevents backflow into refrigerated cases in the event of system malfunction. It is sized so that it can handle the intermittent heavy flow generated during a wash-down of a display case. (b) The buffer box is made from PVC material and has a 1.5 inch diameter female socket inlet and outlet. When waste water from a hand sink or a refrigerator display case enters the buffer box, the water begins to fill buffer box and creates a head pressure in the activator sense line. When the head pressure has built to the preset level, the activator opens the interface valve and air pushes the water up the riser and through the valve into the pipe network. GENERAL INFORMATION Page 10 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Buffer Box Figure 5 (4) Vacuum Check Valve (Figure 6) (a) The Evac check valve is used to prevent back flow in a vacuum system. It is a 2 inch diameter, full port, vacuum-rated, flapper style valve. The valve is typically used with the buffer box connected to hand sinks, water fountains, and refrigerator cases. The valve must always be used in the horizontal position. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS GENERAL INFORM ATION Page 11 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Vacuum Check Valve Figure 6 Note: Drill out port when using vacuum check valve in gang lift detail, see page 22, Figure 13 (5) Isolation Valves (a) As an option, full-port ball valves may be specified in the vacuum drainage piping for isolation. Isolation valves allow for maintenance, troubleshooting, or remodeling to be performed on the system without losing use of the whole system. GENERAL INFORMATION Page 12 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INSTALLATION 1. Overhead Piping Network A. The overhead piping network is the interface that connects risers to the Vacuum Central. The piping consists of a main and a branch. The main pipe must be at least 2 inches in diameter. A branch pipe can be as a small as 2 inch diameter pipe. (1) Installation of Piping (a) When installing pipe for the vacuum pipe network, a slope of 1/16 inch per foot must be maintained. Piping should begin at the riser outlet and slope towards the Vacuum Central. Refer to Figure 7 Slope Requirements Figure 7 (b) Support and brace the piping with bi-directional braces at 5 inch intervals or per code, whichever is more restrictive. Use either of the hanger rod configurations shown in Figure 8 Hanger Detail Figure 8 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page13 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (c) When making a turn with a vacuum pipe, always use a 45° wye fitting. Make sure a cleanout is located at the end of each branch and main or when there is a 90° change in direction (d) If there is an obstruction in the path of your piping use the guidelines below (refer to Figure 9) to work around it. Obstruction Piping Figure 9 (e) (2) A vacuum rated full-port check-valve and shut-off valve should be placed at the beginning of each branch leaving the main. Riser Installation INSTALLATION Page 14 (a) A riser is a vertical lift interface between the waste water collection point and the overhead piping network. (b) A riser kit that contains Evac required components necessary to construct a riser is shown in Table 102. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 102 Riser Kit (US, Canada, Mexico) 1 inch Riser Kit 2999986-001 Type 90 Activator 5821001 Activator mounting bracket 5800262 BVP valve assembly 2701141 50 ft. Vacuum Hose 5599000 Pinch Valve 2601481 Mini-Check Valve 5959900 Vinyl Cap 2601152-021 (c) A 45° wye fitting must be installed at the top of all risers to connect to the piping network. The wye must not be rolled more than 45° from vertical as shown in Figure 10. Wye Roll Figure 10 (d) Obstructions with risers should be avoided at all times. If an obstruction is inevitable, use two 45° Schedule 80 fittings to make the offset shown in the middle of Figure 106. The offset must not be more than 1 foot and only one offset is allowed per riser. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 15 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 103 Riser Kit (Asia) Riser Kit 2999988 Type 90 Activator 5821001 Activator mounting bracket 5800262 BVP valve assembly 2701141 50 ft. Vacuum Hose 5599000 Pinch Valve 2601481 Mini-Check Valve 5959900 Vinyl Cap 2601152-021 Buffer Box 2801055 Buffer Box A Inlet Adapter (Gravity side) 2601394 Buffer Box Outlet Adapter (Vacuum side) 2601386 Table 104 Riser Kit (Australia) Riser Kit Type 90 Activator 5821001 Activator mounting bracket 5800262 BVP valve assembly 2701141 50 ft. Vacuum Hose 5599000 Pinch Valve 2601481 Mini-Check Valve 5959900 Vinyl Cap 2601152-021 Buffer Box 2801055 Buffer Box Inlet Adapter (Gravity side) 2601479 Buffer Box Outlet Adapter (Vacuum side) 2601480 INSTALLATION Page 16 2999987 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Riser Pipe Offset Figure 11 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 17 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (3) Standard Riser (a) A standard riser contains a Buffer Box, an Activator, and a Pinch Valve connected together and used to transport waste water from a plumbing fixture or refrigerated display case to the Vacuum Central. Refer to Figure 12 and install a standard riser according to the following instructions. INSTALLATION Page 18 1. Install the wye fitting into the branch and roll no more than 45° from vertical. The riser must not exceed the height of 22 feet from the floor level. 2. Install the discharge valve at the top of the riser pipe within 3 feet of the riser pipe in the horizontal position. The discharge valve must be installed with a smooth transition shielded rubber coupling. 3. Install pipe braces on the branch or main within 1 foot of the 45° wye on both sides of the discharge valve. The vertical portion of the riser must be braced every 3 to 4 feet, and within 6 inches of direction change. 4. The BVP valve must be installed in the vertical riser 2 feet from the floor level. 5. Install the Buffer Box and air intake vent Tee and pipe to refrigerator case or plumbing fixture following local code. The buffer box must be installed with a smooth transition shielded rubber coupling. 6. Install the Activator in an accessible location where freezing cannot occur. Make sure that the position arrows on the activator point upwards. The Activator must be installed within 8 feet from the floor level. 7. Connect the vacuum hose as shown in Figure 12. The activator ports are labeled SENSOR, VACUUM, and DISCHARGE VALVE (INTERFACE VALVE). The hose can be attached to the riser with nylon wire ties. Do not over tighten or the tubing may kink and collapse. 8. Install the mini-check valve in the vacuum source line near the vacuum source as shown in Figure 12. The valve must be placed in the proper direction or the activator will not work properly. Failure to install the mini-check valve will cause failure of the activator, and will not be covered by warranty. 9. Do not paint any of the Evac components. This will void the warranty. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Standard 1” Riser Figure 12 (Sheet 1 of 2) EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 19 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Standard 1” Riser Figure 12a (Sheet 2 of 2) INSTALLATION Page 20 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (4) Gang Lift (a) A Gang lift should only be used with refrigerator cases classified as either low or medium flow. Gang lifts are not to be used with high flow plumbing fixtures; such as refrigerator cases classified as high flow, and any type of sink. (b) A gang lift connects multiple cases and risers to one lift that connects a branch or main. Up to 3 risers can be connected to a gang lift. If more than 3 risers are desired, contact your Evac representative. Refer to Figure 13 and install a gang lift according to the following instructions. 1. Install the wye fitting into the branch and roll no more than 45° from vertical. The riser must not exceed a height of 20 feet from the floor level. 2. Install an Evac 2 inch check valve at the top of the riser pipe in the horizontal position within 3 feet of the riser pipe. The check valve should be installed with a smooth transition shielded rubber coupling. NOTE: Drill out vacuum port on top of check valve 3. Install pipe braces on the branch or main within 1 foot of the 45° wye on both sides of the check valve. The vertical portion of the riser must be braced every 3 to 4 feet and within 6 inch of direction change. 4. Install a horizontal length of 2 inch diameter pipe no higher than 8 feet from the floor. Reduce to 1 inch and install a reform pocket. Then install the secondary riser not exceeding 12 feet from the reform pocket. 5. Install the discharge valve at the top of the horizontal pipe in the horizontal position within 3 feet of the primary riser pipe. The valve must be installed with a smooth transition shielded rubber coupling. 6. Install pipe braces on the horizontal pipe within 1 foot of the 45° wye on both sides of the discharge valve. The vertical portion of the riser must be braced every 3 to 4 feet, and within 6 inches of direction change. 7. The BVP valve must be installed in the vertical riser 2 feet from the floor level. 8. Install the Buffer Box and air intake vent Tee, and then pipe to refrigerator case or plumbing fixture following local code. The buffer box must be installed with a smooth transition shielded rubber coupling. 9. Install the Activator in an accessible location where freezing cannot occur. Make sure that the position arrows on the activator point upwards. The Activator must be installed within 8 feet from the floor level. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 21 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INSTALLATION Page 22 10. Connect the vacuum hose as shown in the diagram. The activator ports are labeled SENSOR, VACUUM, and DISCHARGE VALVE (INTERFACE VALVE). The hose can be attached to the riser with nylon wire ties. Do not over tighten or the tubing may kink and collapse. 11. Install the mini-check valve in the vacuum source line on top of the 2 inch Check valve as shown. The valve must be placed in the proper direction or the activator will not work properly. Failure to install the mini-check valve will cause failure of the activator, and will not be covered by warranty. 12. Do not paint any of the Evac components, as this will void the warranty. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Gang Lift Figure 13 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 23 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (5) Trench Drains (a) A trench drain is a standard riser with underground plumbing that utilizes a buffer pipe. This is often used to avoid false columns in center isles or a store. Refer to Figure 14 and 14a install trench drains according to the following instructions. 1. Install conventional plumbing from the refrigerator case drain to an approved receptor. 2. Provide under-slab or trench piping from the receptor. Make a 90° turn down and reduce to 1.5 inch pipe under the floor level. Make an additional 90° turn using two 1.5 inch and 45° and connect to 24 inches of 1.5 inch pipe. Install a standpipe in the middle to bring the sense hose above floor level. 3. Install the wye fitting into the branch and roll no more than 45° from vertical. The riser must not exceed a height of 22 feet from the floor level. 4. Install the discharge valve at the top of the riser pipe in the horizontal position within 3 feet of the riser pipe. The discharge valve must be installed with a smooth transition shielded rubber coupling. 5. Install pipe braces on the branch or main within 1 foot of the 45° wye on both sides of the discharge valve. The vertical portion of the riser must be braced every 3 to 4 feet, and within 6 inches of direction change. 6. The BVP valve must be installed in the vertical riser 2 feet from the floor level. 7. Install the Activator in an accessible location where freezing cannot occur. Make sure that the position arrows on the activator point upwards. The Activator must be installed within 8 feet from the floor level. 8. Connect the vacuum hose as shown in the diagram. The activator ports are labeled SENSOR, VACUUM, and DISCHARGE VALVE (INTERFACE VALVE). The hose can be attached to the riser with nylon wire ties. Do not over tighten or the tubing may kink and collapse. 9. Install the mini-check valve in the vacuum source line near the vacuum source as shown. The valve must be placed in the proper direction or the activator will not work properly. Failure to install the mini-check valve will cause failure of the activator and will not be covered by warranty. 10. Do not paint any of the Evac components. This will void the warranty. INSTALLATION Page 24 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Trench Drain Figure 14 (Sheet 1 of 2) EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 25 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Trench Drain Figure 14a (Sheet 2 of 2) INSTALLATION Page 26 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (6) Sinks (a) The Sink configuration should be used with all sinks. This configuration provides special ventilation and BVP placement. Refer to Figure 15 and install the sink according to the following instructions. 1. Install the wye fitting into the branch and roll no more than 45° from vertical. The riser must not exceed a height of 22 feet from the floor level. 2. Install the discharge valve at the top of the riser pipe in the horizontal position within 3 feet of the riser pipe. The discharge valve must be installed with a smooth transition shielded rubber coupling. 3. Install pipe braces on the branch or main within 1 foot of the 45° wye on both sides of the discharge valve. The vertical portion of the riser must be braced every 3 to 4 feet, and within 6 inches of direction change. 4. The BVP valve must be installed above, but no more than 6 inches above the sink overflow level. 5. Install the Buffer Box and then pipe to the sink P-trap and add a vent to the roof following local code. The buffer box must be installed with a smooth transition shielded rubber coupling. Install a 1.5 inch pipe to the top buffer box vent and tee into the roof vent above the sink overflow point. 6. Install the Activator in an accessible location where freezing cannot occur. Make sure that the position arrows on the activator point upwards. The Activator must be installed within 8 feet from the floor level. 7. Connect the vacuum hose as shown in the diagram. The activator ports are labeled SENSOR, VACUUM, and DISCHARGE VALVE (INTERFACE VALVE). The hose can be attached to the riser with nylon wire ties. Do not over tighten or the tubing may kink and collapse. 8. Install the mini-check valve in the vacuum source line near the vacuum source as shown. The valve must be placed in the proper direction or the activator will not work properly. Failure to install the mini-check valve will cause failure of the activator, and will not be covered by warranty. 9. Do not paint any of the Evac components. This will void the warranty. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 27 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Sink Configuration Figure 15 (Sheet 1 of 2) INSTALLATION Page 28 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Note: Bracing on vacuum riser and pinch valve must be secure as shown in detail to ensure no movement in riser and/or pinch valve during cycle Sink Configuration Figure 15a (Sheet 2 of 2) EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 29 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 2. Vacuum Central Installation A. System Location (1) The Vacuum Central connects the vacuum pipe network with the gravity sewage piping. When installing the system, place it in an accessible area allowing approximately a 9 by 11 foot area for the system. This will allow enough space for maintenance to be done. Refer to Figure 16. System Accessibility Figure 16 INSTALLATION Page 30 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 B. Mechanical Installation (1) Inlet Connection Kit (a) The inlet connection kit includes 2 – 2 inch check valves and 2 shut-off valves needed to connect the Vacuum Central to the vacuum pipe network main. 1. Install wye fittings into the main for connection into the vacuum system and for clean out purposes. 2. Install one check valve horizontally on each of the tanks. Connect to the waste tank using two of the 45° Schedule 80 fittings 3. Install the shut-off valves provided between the check valves and the main. They may be installed vertically or horizontally. If a turn is made between the check valves and the shut-off valves, use two of the 45° Schedule 80 fittings. 4. Install the remaining pipe between the main and the shut-off valve. If any offsets are required, use two of the 45° Schedule 80 fittings. Brace the piping every 3 to 4 feet and within 6 inches of any change of direction. 5. Do not paint any of the Evac components. This will void the warranty. Inlet Piping Detail Figure 17 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 31 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (2) Outlet Connection (a) The Vacuum system collection tanks are supplied with check valves that must be mated to and piped to a floor sink. (b) Refer to Figure 18, and connect the collection tanks to a floor sink according to the following requirements. 1. Install a floor sink that is connected to the gravity sewage line. The floor sink must be installed according to Local Code and must be sized to handle a 60-gallon surge. 2. Install piping and braces from the collection tank check valves to the floor sink per Local Code. At the floor sink, leave a 1 inch air gap or greater per Local Code. 3. The plastic water reservoir on the Vacuum Central unit has a 1 inch drain line that must connect to the floor sink. Provide a 1 inch air gap or an air gap according to Local Code, whichever is greater. This may be hard-piped with PVC, copper, or water rated flexible hose. FROM VACUUM CENTRAL COOLING TANK AIR GAP (1" OR CODE) FROM VACUUM CENTRAL DISCHARGE FLOOR SINK TO CITY SEWER SYSTEM Floor Sink Figure 18 INSTALLATION Page 32 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (3) Vent Connection (a) (4) The water reservoir has a 2 inch exhaust that must be vented outside or connected to the floor sink. It is to be a dedicated pipe with a minimum diameter of 2 inches. Provide a 1 inch air gap or pipe according to Local Code, whichever is the greater requirement. This connection may be hardpiped with PVC, copper, or water rated flexible hose. Fresh Water Connection (a) The Vacuum Central requires a source of fresh water. Connect the water source using a ¾ inch NPT fitting to the solenoid valve connected to the water treatment canister. Refer to Figure 19. The flow rate of the water connection must be a minimum of 2 gpm to handle peak requirements, a 5 gpm max, and must have a backflow prevention device as required by Local Code. Water Connection Figure 19 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 33 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 C. Electrical Connection WARNING – BE CAREFUL WHEN WORKING WITH ELECTRICAL DEVICES, SPECIFICALLY, AROUND MOISTURE. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID ACCIDENTAL SHOCK OR INJURY. THE POWER SUPPLY TO THE EQUIPMENT MUST BE TURNED OFF WHILE YOU ARE PERFORMING MAINTENANCE. (1) Power Supply (a) (2) Two normally closed alarm contacts are available to be connected to a remote monitoring device. Refer to figure 20 Customer Connections (b) Refer to Figure 20 and connect power according to local electrical code, providing branch circuit protection. Power requirements are listed in Table 105. Electrical Connections Figure 20 INSTALLATION Page 34 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 105 Power Requirements EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 35 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INTENTIONALLY LEFT BLANK INSTALLATION Page 36 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. Startup A. Vacuum Central Pre-startup Procedure (1) Perform the following step-by-step procedures after completing the installation of the vacuum central. (a) Ensure that all vacuum collection piping, waste water discharge piping, tank drains, tank vents, overflow plumbing, and electrical connections are in place as described in the INSTALLATION procedures 1 through 12. (b) Verify that water reservoir tank is either empty (initial startup) or that the water level is below the LSL float switch. (c) Make sure following valves are in the proper position: (d) 1. Close the manual isolation valves at the inlets of the vacuum collection tanks. 2. Make sure that all isolation valves between the vacuum collection tanks and the vacuum pumps are open. 3. Verify all manual vent valves for the waste collection and vacuum volume tanks are closed. 4. Verify water supply connection isolation valve (customer supplied) is open. 5. Verify water reservoir tank drain valve is closed. On the control panel, make the following checks and settings: 1. Ensure Power Disconnect Switch is in the OFF position. 2. Open the control panel door. 3. Check the power supply voltage to the disconnect switch. The supply voltage must match the data listed on the electrical schematic on the inside of the panel door. 4. Check to be sure that the control panel is properly grounded before applying power to the unit. 5. Adjust motor protector overloads to FLA rating as listed on the electrical schematic inside the control panel door. 6. Press the START pushbutton on motor protectors. 7. Close panel door. B. Vacuum Central Startup Procedure (1) Once the pre-startup procedure has been completed, the following startup procedure should be performed. If any of the steps cannot be completed properly, please refer to the TROUBLESHOOTING section. (a) Place the Power Disconnect Switch in the ON position to supply power to the unit. Verify that the OIT initializes. A low water alarm will display since the water reservoir tank is below the LSL level. Press the ALARM key on the OIT to acknowledge the alarm. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 37 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 NOTE: Refer to OPERATION, paragraph 2, for detail and usage of any keys on the OIT. 1. Check for additional alarms on the OIT display. If an alarm is displayed, press the ALARM key on the OIT to acknowledge the alarm. Please refer to TROUBLESHOOTING section to resolve the issue resulting in the alarm. 2. Once the OIT is initialized, verify that the water level in the reservoir tank rises to the LSL float switch and then stops typically within two and one half minutes. (b) Press the TIME key to display current time and date. If it is incorrect or not set, enter service mode. Refer to OPERATION, paragraph 2.C for a description of the service mode. (c) Set the pump 3 ON/OFF option by entering service mode. Refer to OPERATION, for description of service mode operation. 2-pump systems must be set to OFF and 3-pump systems must be set to ON. CAUTION: DO NOT ALLOW THE MOTOR TO OPERATE IN THE WRONG DIRECTION OF ROTATION. OPERATION IN THE WRONG DIRECTION OF ROTATION WILL DAMAGE THE VACUUM PUMP. (d) Check the rotation of the motor to verify it corresponds to the rotation arrow marked on the pump housing. The pump should only be “bumped” long enough to determine rotation, for period of only about 1 second. Note: This procedure may require two persons to perform properly. (e) INSTALLATION Page 38 1. Press PUMP 1 On-Line key to start the pump motor. 2. Check rotation of motor fan. 3. Press PUMP 1 Off-Line key to stop the pump motor. 4. Repeat for pumps 2 and 3 as necessary by selecting the appropriate PUMP key. Open the relief valve for the vacuum volume tank to ensure the system is at atmospheric pressure. Close the relief valve. Follow the steps below to verify the operation of the vacuum pumps: 1. Press PUMP 1 On-Line key to start the pump and begin to evacuate air from the system. 2. Observe vacuum level on OIT display. Pump should achieve approximately 22 in. Hg within one minute of starting for L380 & L280 models, two minutes for L235 model, and then shut down. If the pump cannot achieve 22 in. Hg or it takes longer than the specified period to reach this level, please refer to TROUBLESHOOTING section. 3. Press PUMP 1 Off-Line key to take the pump off-line. 4. Vent the vacuum volume tank to atmospheric pressure by opening the relief valve. Close the relief valve when complete. 5. Repeat for pumps 2 and 3 as necessary. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (f) (g) Perform leak test by pumping vacuum central to 22 in. Hg and checking the leak rate of the system. 1. Press PUMP 1 On-Line key to start the pump and evacuate the system. Pump 1 will shut off when vacuum level reaches approximately 22 in. Hg. 2. Record vacuum level as displayed on OIT and note the time. 3. After 5 minutes have passed; the vacuum level should be no less than 0.5 in. Hg from the starting vacuum level as noted in step 2. if the vacuum level has dropped more the 0.5 in. Hg, refer to TROUBLESHOOTING section to determine the source of the leak. Verify that all pumps are On-Line. Open the manual isolation valve between the vacuum piping network and waste tank 1. Make sure waste tank 2 is still isolated from the vacuum piping network. This will cause the vacuum central to start bringing the vacuum system down to 22 in. Hg Vacuum. Once the pump(s) has stopped running perform the following tasks: 1. Turn on a sink or run a hose to a buffer box that is connected to the vacuum system. This will begin collection into waste tank 1 from the piping network. The flow into the buffer box should be between 2 and 5 gpm. Choose a sink or buffer box as close to the vacuum central as possible to minimize the time needed to fill the collection tank. 2. While the system is filling waste tank 1, open the control panel. To do this, press the release on the Power Disconnect Switch with a small pointed object and pull on the switch. This should disengage the switch from the shaft. The release is a tiny inset button located on the side of the switch near the OFF position. WARNING – BE CAREFUL WHEN WORKING WITH ELECTRICAL DEVICES, SPECIFICALLY, AROUND MOISTURE. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID ACCIDENTAL SHOCK OR INJURY. THE POWER SUPPLY TO THE EQUIPMENT MUST BE TURNED OFF WHILE YOU ARE PERFORMING MAINTENANCE. 3. Disconnect wire number 20 from TB2 inside the control panel. PLC light 0CH-02 (LSB1) should be ON. When it turns OFF, waste tank 1 will discharge and the LSH1 alarm will display on the OIT. If the PLC light 0CH-02 (LSB1) was not ON initially, a LSB1 problem has occurred. Press the ALARM key on the OIT to acknowledge the alarm and refer to TROUBLESHOOTING section. 4. Reconnect wire 20 to TB2. Watch for PLC light 0CH-00 (LSH1), which should be OFF, to change. When it turns ON, waste tank 1 will discharge. If PLC light 0CH-00 (LSH1) does not turn ON and PLC light 0CH-02 (LSB1) turns OFF, waste tank 1 LSH1 alarm will display on the OIT and the tank will discharge. This indicates a problem with LSH1. Press the ALARM key on the OIT to acknowledge the alarm and refer to TROUBLESHOOTING section. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS INSTALLATION Page 39 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 5. Open waste tank 2 inlet isolation valve and close waste tank 1 isolation valve. 6. While the system is filling waste tank 2, disconnect wire number 21 from TB2 inside the control panel. PLC light 0CH-03 (LSB2) should be ON. When it turns OFF, waste tank 2 will discharge and the LSH2 alarm will display on the OIT. If the PLC light 0CH-03 (LSB2) was not ON initially, a LSB2 problem has occurred. Press the ALARM key on the OIT to acknowledge the alarm and refer to TROUBLESHOOTING section. 7. Reconnect wire 21 to TB2. Watch for PLC light 0CH-01 (LSH2), which should be OFF, to change. When it turns ON, waste tank 2 will discharge. If PLC light 0CH-01 (LSH2) does not turn ON and PLC light 0CH-03 (LSB2) turns OFF, waste tank 2 LSH2 alarm will display on the OIT and the tank will discharge. Press the ALARM key on the OIT to acknowledge the alarm and refer to the TROUBLESHOOTING section. 8. Close the control panel by pressing the release button on the side of the Power Disconnect Switch and pressing the panel door back into the closed position. 9. Open the isolation valve between waste tank 1 and the vacuum piping network so that both tanks can collect waste. 10. Turn off the sink or the water supply connected to the buffer box. The system is now in Automatic operation. (h) For initial startup, continue to piping network startup procedure (1) (a), otherwise, move to procedure (1) (b). C. Piping Network Startup Procedure (1) Once the vacuum central startup procedure has been completed, the following startup procedure should be performed. If any of the steps cannot be completed properly, refer to the TROUBLESHOOTING section. (a) (b) INSTALLATION Page 40 Perform a pinch valve and activator test by following the steps below. 1. Verify all pumps are turned to the on-line position and tank 1 and 2 isolation valves are open. 2. Check each riser by dumping water into a case and verifying that the activator opens the pinch valve and evacuates the water from the buffer box. If any problem occurs with a pinch valve or activator, refer to TROUBLESHOOTING section. Perform a system vacuum leak test by pumping the system to 22 in. Hg and check the leak rate. 1. Press PUMP 1 On-Line key and hold for 3 seconds to start the pump and evacuate the system. Pump 1 will shut off when vacuum level reaches approximately 22 in. Hg. 2. Record vacuum level as displayed on OIT and note the time. 3. After 5 minutes have passed; the vacuum level should be no less than 1 in. Hg from the starting vacuum level as noted in step 2. if the vacuum level has dropped more the 1 in. Hg, please refer to TROUBLESHOOTING section to determine the source of the leak. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 OPERATION 1. System Operation This section describes the operation of the Supermarket System components. A. Vacuum Volume Tank (1) The vacuum tank maintains a constant vacuum of 15 to 22 in. Hg. when the vacuum drops below 15 in. Hg, a vacuum transducer that monitors the vacuum level of the vacuum tank will turn on the vacuum pumps. The Horizon systems are typically sized so that only one pump runs at a time. However, additional pumps may come on line if needed to achieve 22 in. Hg. B. Vacuum Pumps (1) The pumps are water sealed liquid ring pumps that require a continuous supply of water when the pumps are running. When a pump starts, a small amount of water is added to the water supply tank to help keep the water fresh. There is a float in the water tank that will shut down the pumps, when the water level becomes insufficient and will initiate a fill cycle. C. Water Reservoir (1) A 30-gallon water tank is connected to the pumps where water is re-circulated. D. Collection Tanks (1) 2. The overhead vacuum piping is connected to the inlet of the twin 40-gallon tanks. The tanks each have a 30-gallon collection capacity with a 10-gallon surge capacity. There are two floats located in each of the collection tanks. One float is regularly used for initiating a dump cycle. The other float initiates the dump cycle if the first float fails. Electrical Control Panel A. Control System Operation (1) B. The control panel uses a PLC and other components to monitor and react to inputs from floats, fail contacts, transducers, and the OIT. The inputs are used to turn the outputs that control the pumps, solenoid valves, and alarms on or off. Control Logic (1) This section describes the operation of the electrical components connected to the vacuum central. (a) Pump Run Sequence 1. A vacuum transducer monitors the vacuum level of the system. if the vacuum drops below 15 in. Hg, a pump will turn on. This pump is called the Lead pump. Once a pump is running and the vacuum remains below 22 in. Hg for more than 2 minutes an additional pump may be turned on. This pump is called LAG1. After an additional 1 minute, if the vacuum still remains below 22 in. Hg, a third pump is turned on, when three pumps are available. This pump is called LAG2. When the vacuum level reaches 22 in. Hg, all pumps will shut off. EVAC NORTH AMERICA PROPRIETARY - SEE COVER PAGE FOR DETAILS OPERATION Page 41 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (b) 2. For the pump to operate, the MMP corresponding to the pump must be switched to the start position. The user must also have the corresponding pump turned to the On-Line position. See OIT OPERATION for more details. 3. The pumps rotate the positions of Lead, LAG1, and LAG2. Every time a pump is required to run, the pump that is chosen for Lead will be the pump that has not started for the longest period of time. When LAG1 is required, the Lead pump is shifted to the LAG1 position and the pump that has not been started for the longest period of time will be moved to the Lead position. When LAG2 is required and a third pump is available, LAG1 pump is shifted to LAG2, the Lead pump is shifted to LAG1, and the remaining pump becomes the Lead pump. 4. If either LAG1 or LAG2 is started and runs for more than 2 minutes, the time and date of the start will be recorded in the PLC memory. Water Reservoir Operation 1. (c) (d) OPERATION Page 42 While a pump is running, water is re-circulated through the pumps and the reservoir. Each time a pump starts; a small amount of water is added to the reservoir for 3 seconds. If the level becomes too high, the water will overflow into the floor sink. If the level becomes too low, the LSL float will activate and turn on SV3 to return the water level to normal operation. The pumps will not be allowed to run until LSL has reset itself. Waste Tank Operation 1. Each of the waste tanks has two floats and a solenoid valve corresponding to Tank 1 or Tank 2. The lower float in the tank LSH1 or LSH2 is normally open and is set to trip when the tank reaches 30 gallons. The upper float in the tank LSB1 or LSB2 is normally closed and set to trip when the tank reaches 35 gallons. The solenoid valves are SV1 or SV2. 2. When the waste level reaches the LSH float, the solenoid valve corresponding to the tank is energized, shifting the waste tank from vacuum to atmosphere for 20 seconds. The tank will discharge by gravity. After the 20 seconds, the tank will return to vacuum and continue to collect waste. 3. If the waste level reaches the LSB float, the solenoid valve corresponding to the tank is energized, shifting the waste tank from vacuum to atmosphere for 20 seconds. The tank will discharge by gravity. After the 20 seconds, the tank will return to vacuum only if the float resets itself. If the float fails to reset itself, the solenoid valve will remain energized until the float is reset. Alarms 1. Low Vacuum – condition that occurs when vacuum is below 12 in. Hg for more than 2 minutes, this alarm resets itself. 2. LSL trip – notification that water level has dropped below the required operating level. This alarm resets itself. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. LSH1/LSH2 trip – the LSH float can fail open or closed. If the float does not open after a dump cycle is complete, the alarm will be turned on. If the LSB float is activated, the LSH alarm will be turned on due to the float not tripping when the trip point is reached. This alarm will reset if the float changes from open to closed or from closed to open before LSB tripping again. 4. LSB1/LSB2 trip – The LSB alarm can only be turned on if the float remains open after the 20 second dump cycle. When this alarm occurs the tank will not return to vacuum until the float is reset. This alarm resets itself when the float is returned to the closed position. 5. MMP1/MMP2/MMP3 – The MMP alarm is turned on if the motor protector is turned to the stop position. If the motor pulls more than the set current level, the MMP will automatically trip. This alarm must be manually reset. This is done by returning the MMP to the start position. C. OIT Key Pad Operation (refer to Figure 21) Figure 21 OIT Key Pad (1) Pump 1 On-Line Key (a) When this key is pressed, it switches pump 1 to the on-line status. ON will be displayed on the home screen after P1: (b) On-line refers to the pump being available to run. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS P1: ON P2: ON P3:ON VAC LEVEL 22.00” HG Current vacuum level (This screen will be referred to as the home screen.) OPERATION Page 43 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (c) (2) Pump 2 On-Line Key (a) (3) (7) P1: OFF P2: ON P3: ON VAC LEVEL 22.00” HG This key performs the same function as the pump 1 Off-Line Key for pump 2. Pump 3 Off-Line Key (a) This key performs the same function as the pump 1 Off-Line Key for pump 3. (b) When in service mode, the pump 3 Off-Line Key can be used to add or remove a third pump to the system. Press and hold the pump 3 Off-Line Key for 10 seconds. The pump select ON/OFF screen will appear. Use the << >> keys to change the pump to ON or OFF. The status will be displayed. Press Enter to exit. Third pump is OFF ******************** Note: * = Scrolling message: << OR >> TO TOGGLE, THEN ENTER TO EXIT. Service Key (a) OPERATION Page 44 When this key is pressed, it switches pump 1 to the Off-line status. OFF will be displayed on the home screen after P1: Pump 2 Off-Line Key (a) (6) This key performs the same function as the pump 1 On-Line Key for pump 3. Pump 1 Off-Line Key (a) (5) This key performs the same function as the pump 1 On-Line Key for pump 2. Pump 3 On-Line Key (a) (4) When the vacuum level is less than 22 in. Hg, the pump 1 on-line key can be pressed for 3 seconds and the pump will run. The pump will automatically shut off when 22 in. Hg is reached. The Service Key is used to enter and exit service mode. Service mode is used to reset counters and timers, set the clock time, and use for system installation features. A password is used to avoid accidental system changes. ENTER PASSWORD #### EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (b) (c) (8) To enter the service mode, press the Service Key, and the Enter Password Screen will appear. The password is 3822, which spells Evac numerically. To enter the password, use the arrow keys to set the first character to 3. Press Enter and use the arrow key to set the second character to 8. Press Enter and use the arrow key to set the third character to 2. Press Enter and use the arrow key to set the fourth character to 2. Press Enter and a screen prompting to press Enter to Continue or Service to Exit will be displayed. Once in the service mode, pressing the service key will exit service mode and display the Exiting Service mode screen for 3 seconds. If the touch pad is left inactive for more than 5 minutes, the system will automatically exit the service mode. Enter to Continue Service to Exit Exiting Service mode Time Key (a) Pressing the time key will display the current time and date. The time is based on a 24 hour clock. It is important that the time be set correctly because the system logs the time and date of alarms and resets on counters and timers. (b) To change the time and date press and hold the time key for 3 seconds while in service mode. An instruction screen will pop up with the option to cancel the time and date set process. Current set time 06-17-03 14:24 **************************** PRESS CANCEL TO EXIT * = Scrolling message: USE << OR >> TO CHANGE TIME THEN PRESS ENTER TO MOVE TO NEXT CHARACTER. WHEN FINISHED PRESS ENTER. (c) Press the Enter key and the Set Month Screen will be displayed. Use the arrow keys to change the value from 1 to 12. The new value is displayed on the bottom of the screen. Press Enter to continue. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS SET MONTH (1-12) 6 OPERATION Page 45 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (d) Press the Enter key and the Set Day Screen will be displayed. Use the arrow keys to change the value from 1 to 31. Press Enter to continue. (e) Press the Enter key and the Set Year Screen will be displayed. Use the arrow keys to change the last 2 digits of the year from 00 to 99. Press Enter to continue. (f) Press the Enter key and the Set Hour Screen will be displayed. Use the arrow keys to change the value from 0 to 23. Press Enter to continue. (g) Press the Enter key and the Set Minute Screen will be displayed. Use the arrow keys to change the value from 0 to 59. Press Enter to continue. (h) The new time and date will be displayed and instructions given to continue or reset the time and date. (i) (j) (8) SET HOUR (0-23) 14 SET MINUTE (0-59) 26 ***************** 6/17/03 14:26 When Cancel is pressed the screen will go back to the Set Month Screen. * = Scrolling message: When Enter is pressed, a new Time Screen is displayed for 3 seconds and then the system goes back to the home screen. IF THE BELOW DATE IS CORRECT PRESS ENTER, IF NOT PRESS CANCEL TO CORRECT. At any time the Help Key can be pressed and a general description of the currently displayed screen will be displayed. Pump 1 Information Key (a) OPERATION Page 46 SET YEAR (2000-2099) 03 Help Key (?) (a) (9) SET DAY (1-31) 17 When the Pump 1 Information Key is pressed, the status of the pump will be displayed along with options to view alarms and counters. The status will display stopped if the pump is not running and will display running if it is running. P1: RUNNING << ALARMS | COUNTS>> EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (b) If right arrow is then pressed, the pumps resettable hour meter will be displayed. The meter is capable of displaying 99,999,999 hours and can be reset by the user if the system is in service mode. To reset the meter, press Reset and the current time and date will be displayed below to indicate the time the meter was reset. (c) The arrow keys can be pressed to view the next meter. The next meter displayed will be a pump start counter. The meter can display up to 99,999,999 starts and can also be reset when in service mode. After pressing the reset button, the time and date will be logged. The arrow keys can be pressed again and a non-resettable hour meter will be displayed. 99,999,999 starts can be displayed before the counter will automatically reset. (d) Press the arrow keys again and the pump 1 total hours will be displayed. 99,999,999 hours of run time will be displayed before the meter automatically resets itself. Press Enter to exit the counter mode. (e) When the Pump 1 Information Key, followed by the left arrow key is pressed, motor activates can be viewed. Up to 15 previous alarms will be displayed. Use the arrow keys to scroll through the 15 alarms and press Enter to exit. (f) The screen will display the pump number, the alarm number for the pump failed, the time, and date when the alarm occurred. If no alarm has occurred, then OK will be displayed and no time and date will be present. P1: HOURS 00000000 RSET 06/24/03 07:55 P1: COUNTS 00000000 RSET 06/24/03 07:55 PUMP 1 TOTAL STARTS 99999999 PUMP 1 TOTAL HOURS 99999999 Pump number Alarm number (1-15) PUMP 1 –1 FAIL 06/24/03 07:55 Ok or Fail (10) Pump 2 Information Key (a) This key performs the same function as the pump 1 Information Key for pump 2. (11) Pump 3 Information Key (a) This key performs the same function as the pump 1 Information Key for pump 3. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS OPERATION Page 47 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (12) Holding Tank 1 Information Key (a) (b) (c) OPERATION Page 48 When the Holding Tank 1 Information Key is pressed, information related to the collection tank 1 can be retrieved. The screen will display the current condition of the tank (holding or dumping). When viewing this screen, the reset key can be pressed and the tank will discharge for the 20 second dump cycle. The left arrow key can be pressed to view the alarms related to this tank. An option to select LSB1 or LSH1 will then be displayed. Press the left arrow key to select the LSH1 float alarms or press the right arrow key to select the LSB1 float alarms. Enter can be pressed from any screen to exit. Each of the float screens will display the float status (open or closed) at time of failure. If no failure has occurred, the log will display OK, and no time and date will be present. Tank dumps can be viewed by pressing the Holding Tank 1 Information Key and then pressing the arrow right key. Each float has a user resettable float counter and a non-resettable counter. The counter can be reset when in service mode and pressing reset when the desired counter is displayed. Use the arrow keys to change which counter is being viewed. LSH1 counter can hold up to 99,999,999 trips and LSB1 counters can hold up to 9,999 trips. T1: HOLDING << ALARMS | COUNTS>> << LSH 1 >> LSB 1 Float ALARM HISTORY Alarm number (1-15) LSB 1 -1: FAIL CLOSED 06/24/03 07:55 LSB1 TRIPS 0000 RSET 06/24/03 07:55 LSB1 TOTAL TRIPS 0064 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (13) Holding Tank 2 Information Key (a) This key performs the same function as Holding Tank 1 Key for tank 2. (14) Water Tank Information Key (a) When the Water Tank Information Key is pressed, the alarm and count option for the LSL float is displayed. (b) When the right arrow is pressed, the float counter will be displayed. When the arrow key is pressed again, the length of time the water has been running will be shown. Pressing the Reset key when in service mode can reset both of these counters. When the arrow key is pressed again, the total float trip count and the total time of the water run can be displayed. These counters are not resettable. (c) When the alarm option was selected, the LSL Alarm Screen is displayed. The time and date of the last alarm will be displayed if an alarm has occurred. If not, it will be blank. The (open or closed) status of the switch at the time of the alarm will also be displayed. Use the arrow keys to scroll through the 15 alarms. Press the Enter key to exit at any time. COLD WATER TANK INFO <> LSL TRIPS 00000004 RSET 06/26/03 06:28 WATER RUN 00000072 RSET 06/26/03 06:30 LSL TOTAL TRIPS 00000004 TOTAL WATER RUN TIME 00000072 (MIN) LSL-1 OPEN 06/26/03 06:32 (15) Vacuum Information Key (a) When the Vacuum Information Key is pressed, the time and date of the last low vacuum will be displayed. The arrow keys can be used to scroll through the last 15 alarms. If there has not been a low vacuum, the time and date will be blank. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Alarm number (1-15) LOW VACUUM 1 06/26/03 06:34 OPERATION Page 49 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (16) LAG Run Information Key (a) OPERATION Page 50 When the LAG Run Information Key is pressed, the option of alarms or counts is displayed. When the left arrow key is pressed, an option to view LAG1 alarms or LAG2 alarms is displayed. Press the left arrow key for LAG1 or the right arrow key for LAG2. The screen will display the most recent alarm and the time and date it occurred. If no date is present, the alarm has not been activated. Use the arrow keys to scroll through the 15 alarms. (b) If the count option is selected, the LAG1 run time will be displayed. This counter can be reset using the Reset key when in service mode. Use the arrow keys to view the LAG1 start counter. (c) Press the arrow keys again and the LAG2 hour meter and start counter will be displayed. Press the Enter key to exit this mode any time. LAG PUMP RUN INFO <> LAG PUMP ALARMS << LAG 1 | LAG2>> LAG1-1 STARTED 06/26/03 06:45 LAG1 TIME 00000004 RSET 06/26/03 06:49 LAG1 starts 00000035 RSET 06/26/03 06:49 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. Manual Operations The following procedures manually initiate operations that can also be performed from the OIT on the control panel. Whenever possible, these actions should be performed from the OIT. If these actions cannot be accomplished from the OIT, then these procedures serve as alternatives. A. Manually Initiated Discharge (1) If a discharge operation cannot be completed successfully from the OIT, open the ¼ inch vent valves on the top of the waste collection tanks to initiate manual discharge of the tank. This action works regardless of the status of the vacuum control solenoid valves, but will reduce overall system vacuum in the process. (2) To reduce the vacuum volume loss experienced when venting the tanks for discharge, close the isolation valve between the vacuum volume tank and the control solenoid valve for the desired waste tank. This cuts down the amount of air ingested when initiating a waste tank discharge. When done, close the vent valve and open the isolation valve to restore vacuum to the waste tank. B. Manually Initiated Pump Start (1) C. To manually start a pump, vent the Vacuum Central using any of the three vent valves. Two of the vent valves are located on the waste collection tanks, and a third is located on the inlet header to the vacuum volume tank. When enough atmospheric air has entered the tanks to drop the system vacuum to 15 inches Hg, then a vacuum pump will start. Reservoir Tank Drain Note: This action can only be performed manually. No function is available on the OIT to discharge this tank. (1) 4. To manually drain the reservoir tank, the power disconnect switch on the control panel must be in the OFF position. Turning the power off prevents the float switch from filling the reservoir. To drain the reservoir, open the drain valve until the tank empties. Shutdown Procedure A. Normal Shutdown (1) Press all three of the Pump Off-Line Keys. (2) Press the Waste Tank 1 Key, then the Reset Key, and then Discharge Tank 1. (3) Repeat for tank 2. (4) Enter the service mode and hold the Help Key and the Reset Key for 10 seconds. When you are prompted to reset all memories, select YES and follow the onscreen instructions. (5) Verify that Pump 3 is set to ON or OFF as required, and then shut off power to system and Drain the cooling tank with the shut-off valve on the side of the tank. (6) Bleed all vacuums out of all tanks by opening all tank relief valves. (7) Turn all valves to the OFF position. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS OPERATION Page 51 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 B. Extended Shutdown (1) OPERATION Page 52 If for any reason the vacuum central is to be out-of-use for an extended period of time beyond typical maintenance or repair operations, there are several steps to be followed for shutdown. (a) Isolate the vacuum system by closing the inlet header isolation ball valves. (b) Manually discharge the waste collection tanks. Repeat the discharge cycle until no effluent flows from the tanks or open and leave the waste tank vent valves open. (c) Turn off power at the main breaker to the vacuum central, if possible. (d) Turn the power disconnect switch on the control panel to the OFF position. (e) Open the drain valve for the reservoir. Allow reservoir to drain completely and then flush with clean water. Close the drain valve. (f) If shutdown period is to extend beyond 2 weeks, a water-soluble rust inhibitor should be added to the pumps. This should preserve the pumps for 2 to 3 months. For longer periods of preservation, please contact Evac. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 TROUBLESHOOTING 1. General A. This section provides the information necessary to test and troubleshoot the system. 2. Fault Isolation A. If the Evac Vacuum Collection System is not operating or is operating unsatisfactorily, determine if the problem is a system, electrical, or mechanical malfunction by consulting Table 106, Fault Isolation. B. In the event the system cannot be restored to operating condition, Evac can provide technical assistance through its Customer Service Department. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS TROUBLESHOOTING Page 53 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 106 Fault Isolation Fault Pump(s) will not run. Probable Cause Vacuum level is above 15 in. Hg. The motor protector is in the STOP position. The input light on the PLC corresponding to the motor protector must be off. The contactor corresponding to the pump must be energized. The corresponding PLC output light is not lit. Vacuum Level reads 30.00 in. Hg. Proper voltage across A1 and A2 of corresponding coil not present. PLC power light is not lit. PLC error light is lit. The analog module ribbon cable is not connected to the PLC. The transducer output is not 4 – 20mA. The vacuum transducer wires are not connected. Motor protector tripped. The transducer output is not 4 – 20mA. The trip point is set too low. Motor protector contact tripped and the motor protector is set to START. The motor protector trips to STOP immediately after being reset. PLC power light is not lit. PLC error light is lit. The wires are connected to the N/C contacts. No power to PLC. The corresponding PLC input light is on and the motor protector is not tripped. The fuses are blown. Vacuum level reads 00.00 in. Hg. TROUBLESHOOTING Page 54 Remedy Pump run is not needed at this time. Set all Motor protectors to the START position. Motor Protector is tripped. Reset by setting to START position. Verify that corresponding PLC output light is lit per schematic inside panel door. Verify that corresponding contactor coil is receiving 120VAC +/- 10% across A1 and A2. Verify connections to PLC and replace contactor. Replace fuse. Replace PLC. With power off connect cable. Replace transducer. Connect wires to the transducer and proper terminal blocks. Replace transducer. Reset per schematic label inside control panel. Replace the motor protector. Replace fuse. Replace PLC. The wires must be connected to the N/O contacts. Replace the auxiliary contacts. Check and replace the fuses. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 106 Fault Isolation Fault PLC error light is on. OIT is off. OIT is flashing not connected. Contactors will not energize. Solenoid valve will not energize. (SV1 & SV2). Probable Cause The transformer output voltage is not 120VAC +/- 10%. The light is blinking. The light is solid. Power wires are disconnected or shorted at OIT. PLC power light is not lit. Voltage is not present across power terminals. The RS-232 cable is not connected. The cable is damaged. The corresponding motor protector is tripped. The corresponding PLC output light is not lit. The corresponding PLC light is not lit. 120VAC +/- 10% is not measured across connection points of terminal blocks when corresponding PLC output light is lit. The vacuum pilot is disconnected. LSL alarm is on. Low vacuum alarm is on. Vacuum is below 8 in. Hg. The valve is energized, but will not move. The water supply is off. The drain valve is open. SV3 is not energizing. The pumps have been running continuously. The vacuum is below 12 in. Hg. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Remedy Verify incoming power is correct. The errors will self correct over time and operation is not affected. Replace PLC Correct wiring. Replace fuse. Replace PLC. Connect cable to the OIT and PLC. Replace cable. Reset the motor protector. Verify that corresponding contactor coil is receiving 120VAC +/- 10% across A1 and A2. Verify that corresponding solenoid coil is receiving 120VAC +/- 10%. Solenoid valve will not energize if power is not available. Valve will energize but not shift if pilot is removed. Reconnect pilot. Replenish vacuum. Valve is plugged up. Clean or replace. Water must be on. Close valve. Replace coil. Excessive water use may have occurred. Check for vacuum leaks. Check for vacuum leaks. TROUBLESHOOTING Page 55 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 106 Fault Isolation Fault Probable Cause Vacuum is below 12 in. Hg. A leak has occurred on the vacuum central or the overhead piping. A pinch valve is stuck open. A wire is not connected to the junction box correctly. The cable connecting the junction box to the control panel is disconnected. The floats are wired to the N/C terminal. The LSB alarm for the same tank is also on. A wire is not connected to the junction box correctly. The cable connecting the junction box to the control panel is disconnected. The floats are wired to the N/O terminal. The discharge check valve corresponding to the failed float is plugged. Solenoid valve is not operating. LSH1 or LSH2 alarm is on. LSB1 or LSB2 alarm is on. There is a vacuum leak. A pinch valve will not open. A pinch valve will not close. The activator will not activate the pinch valve. TROUBLESHOOTING Page 56 Remedy Correct leak. Replace valve. Connect wires per schematic inside panel door. Connect wires per schematic inside panel door. LSH floats must be wired to the N/O terminals. Replace the LSH float. Connect wires per schematic inside panel door. Connect wires per schematic inside panel door. LSB floats must be wired to the N/C terminals. Clean or replace check valve. Replace solenoid valve corresponding to failed float. A hose is disconnected from the pinch Reconnect hose. valve or activator. A glue joint is broke loose or never Prime and glue joint back glued. together. Pinch valve is stuck open. Replace pinch valve. A hose connecting to the buffer box, Reconnect hose and correct activator, or pinch valve is any hose kinks. disconnected or kinked. The valve body is cracked or the inner Replace the valve and brace tube is torn. properly around valve. The valve will not open when the Replace the activator. activator is manually pressed. A large object is stuck in the valve. Clean or replace valve. A continuous high flow of waste is Split flow to multiple boxes. entering buffer box. Manual button is stuck on the Replace activator. activator. A hose connecting to the buffer box, Reconnect hose and correct activator, or pinch valve is any hose kinks. disconnected or kinked. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 Table 106 Fault Isolation Fault There is water on the floor. Probable Cause Remedy The valve will not open when the activator is manually pressed. Replace the activator. The low vacuum alarm is ON. The low vacuum alarm is ON. There is a vacuum leak. A pinch valve is not opening. Replenish vacuum. Replenish vacuum. Correct leak. Check activator and pinch valve for failure. Check activator for failure. Reconnect hose and correct any hose kinks. The activator is not activating. A hose connecting to the buffer box, activator, or pinch valve is disconnected or kinked. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS TROUBLESHOOTING Page 57 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INTENTIONALLY LEFT BLANK TROUBLESHOOTING Page 58 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. Diagnostic Procedures A. B. C. Pump Rotation (1) Verify that the pump is wired correctly per wiring diagram on pump body. (2) Manually bump Contactor 1 and verify that Vacuum Pump 1 rotates in the direction indicated by the arrow on the pump housing. (3) Repeat for Pumps 2 and 3. Pump Performance Test (1) Make sure the power is OFF. (2) Verify that power is properly connected and turn the MMP switches (located inside the control panel) to the ON position. (3) Turn the power to the system ON. (4) Turn on Pump 1 by pressing pump 1 On-Line. The vacuum level should climb and shut off when vacuum equals 22 inches Hg. turn the pump back to the off-line position. (5) Bleed the vacuum down to 0 inch Hg with the manual relief valve (located below SV1 and SV2 and on top of each collection tank). (6) Repeat steps for remaining pumps, if applicable. (7) If all pumps work properly, turn all pumps to the on-line position. If one or all pumps did not work properly, refer to Fault Isolation, Table 106. Float and Discharge Verification (1) Verify that all pumps are set to the On-Line selection on the touch pad. (2) Turn on a sink that is connected to the vacuum system, or turn on a hose into a buffer box. (3) Open Tank 1 and close Tank 2 to the piping network using the 2” ball valves connected to the inlet of the collection tanks. (4) Disconnect wire number 20 from terminal 20 of the TB2 terminal blocks inside the control panel. (5) Watch PLC light 0CH-02. When the light turns off, Tank 1 will have filled and will begin to discharge. The LSH1 alarm will be displayed. If the light is already off, an LSB1 problem has occurred. Refer to Fault Isolation, Table 106. (6) Reconnect wire 20 to terminal 20 of TB2. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS TROUBLESHOOTING Page 59 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (7) Watch PLC light 0CH-00. When the light turns on, Tank 1 will have filled and will begin to discharge. If the light remains on after the discharge cycle, or the light is already on, the LSH1 alarm will be displayed. Refer to Fault Isolation, Table 106. (8) Open Tank 2 and close Tank 1 to the piping network using the 2” ball valves connected to the inlet of the collection tanks. (9) Disconnect wire number 21 from terminal 21 of the TB2 terminal blocks inside the control panel. (10) Watch PLC light 0CH-03. When the light turns off, Tank 2 will have filled and will begin to discharge. The LSH2 alarm will be displayed. If the light is already off, an LSB2 problem has occurred. Refer to Fault Isolation, Table 106. (11) Reconnect wire 21 to terminal 21 of TB2. (12) Watch PLC light 0CH-01. When the light turns on, Tank 2 will have filled and will begin to discharge. If the light remains on after the discharge cycle, or the light is already on, the LSH2 alarm will be displayed. Refer to Fault Isolation, Table 106. D. E. F. Vacuum Central Leak Test (1) Isolate Tanks 1 and 2 from the piping network by closing the 2 inch valve near the tank inlet. (2) Press the Pump 1 On-Line button for 3 seconds. The pump will start and then shut off when the system reaches 22 inches Hg. (3) Record the vacuum level as displayed on the screen and make note of the time. (4) After 5 minutes, the vacuum level should be no more than 0.5 inches Hg less than it was in step 3. If the change is greater than 0.5 inches Hg, refer to Fault Isolation, Table 106, (check for loose valve unions) correct the leak, and repeat the test Piping and Component Leak Test (1) Verify that the isolation 2 inch valves are open. (2) Press the Pump 1 On-Line button for 3 seconds. The pump will start and then shut off when the system reaches 22 inches Hg. (3) Record the vacuum level as displayed on the screen and make note of the time. (4) After 5 minutes, the vacuum level should be no more than 1 inch Hg less that it was in step 3. If the change is greater than 1 inch Hg, refer to Fault Isolation, Table 106, correct the leak, and repeat the test. Pinch Valve Inspection and Replacement (1) Verify that the pinch valve operates by pressing the manual activation button on the activator. Make sure there is enough hose slack for valve to operate. If the valve does not open, it must be replaced. See GENERAL INFORMATION section for manual activation button location. G. Activator Inspection and Replacement (1) Press the activator manual activation button. The pinch valve should open, and then close. If the pinch valve does not operate correctly, refer to Fault Isolation, Table 106. TROUBLESHOOTING Page 60 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 INTENTIONALLY LEFT BLANK EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS TROUBLESHOOTING Page 61 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 PREVENTATIVE MAINTENANCE WARNING – BE CAREFUL WHEN WORKING WITH ELECTRICAL DEVICES, SPECIFICALLY, AROUND MOISTURE. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID ACCIDENTAL SHOCK OR INJURY. THE POWER SUPPLY TO THE EQUIPMENT MUST BE TURNED OFF WHILE YOU ARE PERFORMING MAINTENANCE. TURN ON THE POWER SUPPLY ONCE THE WORK IS COMPLETE OR TO VERIFY OPERATION AT SPECIFIC STEPS BELOW. 1. General This section details the schedule and performance of preventative maintenance for the vacuum collection system. Procedures outlined for inspection and cleaning may be used in conjunction with diagnostic procedure from the preceding section of this manual. 2. Preventative Maintenance Schedule Table 107 Preventative Maintenance Schedule 6 Months Vacuum Central General inspection Leak test Verify pump performance Replace and clean water treatment cartridge Reservoir flush Control panel inspection Clean and inspect Collection Tanks Replace vacuum pump mechanical seals and bearings Piping & Collection Network General Piping Inspection Leak test Inlet header Riser Inspection Check Valve Inspection 3. Annual 2 Years 5 Years X X X X X X X X X X X X X Inspection and Cleaning Procedures The following general procedures apply to all inspections. All tightening operations should be performed with sufficient torque to tighten a unit according to good mechanical practice and/or produce an effective seal. Do not over tighten because this may strip threads or cause distortion of gaskets. Tightening will always be understood to include the correct installation of lock washers, lock nuts, locking wires, or cotter pins to secure the tightened parts. A. Inspection for good condition is usually based on visual examination to determine if the unit is safe or serviceable. Good condition is explained further as meaning: not bent or twisted, not chafed or burned, not cracked or broken, not bared or frayed, not dented or collapsed, not torn, cut or deteriorated, not corroded or leaking. PREVENTATIVE MAINTENANCE Page 62 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 B. Visually inspect components making sure components are assembled correctly and aligned in the normal position. Be sure all parts are present and in their correct relative positions. C. Inspection of a unit to see if it is secure is usually a visual, hands-free, wrench, or screwdriver inspection for looseness in the unit. This inspection will include any brackets, lock washers, lock nuts, locking wires, and cotter pins, as well as any connecting piping, tubes, hoses, or wires. D. Excessively worn is understood to mean worn beyond serviceable limits or likely to fail if not replaced before the next scheduled inspection. (1) Vacuum Central (a) General Inspection 1. 2. (b) Control Panel • Vacuum Volume Tank • Vacuum Pumps • Waste Collection Tanks • Seal Water Reservoir • Discharge Check Valves • Water Treatment Unit • Foundation Bolts • Vacuum Control Solenoid Valves Observe system for proper operation. Check for unusual noise or visible signs of malfunction or leakage. Annually, perform a leak test of the vacuum central to verify the integrity of all seals and piping joints. Refer to section TROUBLESHOOTING, Vacuum Central Leak Test, for the test procedure. Verify Pump Performance 1. (d) • Leak Test 1. (c) Every six months visually inspect the vacuum system for good condition. This should include, but is not limited to, inspection of the following areas: Regular inspection and preventive maintenance ensure more reliable operation. Annually, each pump should be monitored for appropriate performance. Refer to section TROUBLESHOOTING, Pump Performance Test, for the test procedure. Inspecting and Servicing the Water Treatment Cartridge Over time, the contents of the water treatment cartridge will be consumed. It is recommended that the cartridge be replaced on an annual basis. Consumption rate may vary based on vacuum central utilization or water quality. It is not necessary to replace the cartridge any more frequently than once a year. This schedule should provide adequate scale prevention for the pumps EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS PREVENTATIVE MAINTENANCE Page 63 EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 1. Replace the filter cartridge as follows: CAUTION: EYE IRRITANT. CONTAINS SODIUM CALCIUM HEXAMETAPHOSPHATE. AVOID CONTACT WITH EYES. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 5 MINUTES AND GET MEDICAL ATTENTION. a. Turn off water supply to system. Depress red pressure-relief button. b. Unscrew bottom of housing from cap. Locate and remove large oring, wipe clean of lubricant, and set aside. c. Discard used filter cartridge. Scrub the bottom of housing, cap, and o-ring groove with dish soap and warm water using a nonabrasive sponge or cloth. Rinse thoroughly. d. Lubricate o-ring with clean silicon grease. Insert o-ring in groove and press into place. NOTE: This step is important to ensure a proper housing seal. Make certain the o-ring is seated level in the groove. e. Insert new filter cartridge, making sure it slips over the standpipe in bottom of housing. Make sure cartridge is installed in the correct direction, as indicated by arrows on cartridge insert. f. Screw the bottom of housing onto the cap and hand-tighten. Do not over tighten. Make sure cap standpipe slips into cartridge. g. Turn on water supply slowly to allow system to fill with water. Press pressure-relief button to release trapped air. Check for leaks before leaving installation. (e) Inspecting and Cleaning Seal Water Reservoir 1. Inspect the seal water reservoir for any visible signs of leaks and/or physical damage. Verify that all hose and pipe connections to the tank are secure. 2. The reservoir tank should be flushed at minimum on an annual basis. Flush and clean the tank as follows: a. Turn the power disconnect switch on the control panel OFF to disengage the fill float switch. b. Open the reservoir drain valve. c. Using a hose, flush with clean water. If necessary, remove the tank access cover and scrub the inside tank walls with a soft bristle brush. d. Completely drain the tank. Replace the tank access cover if off. Close the drain valve. e. Turn the power disconnect switch to the ON position. The tank will fill back to the overflow level. PREVENTATIVE MAINTENANCE Page 62 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (f) Inspecting and Cleaning Waste Collection Tanks and Level Floats 1. Annually, inspect the vacuum waste collection tank interior and exterior for any evidence of corrosion. Check for evidence of seepage through seals, and for security of all mounting brackets and flanges. Thoroughly clean any affected area and repair as required. 2. Inspect and clean vacuum waste collection tanks and level sensors as follows: a. Isolate one waste collection tank from the piping network, keeping the other collection tank in service. b. Isolate the control solenoid valve for the isolated tank from the vacuum volume tank by closing the isolation ball valve. Completely empty the isolated waste collection tank by opening the tank vent valve located on the lid. Leave the valve open. d. Disconnect flexible piping from tank lid to the control solenoid valve union. Remove tank lid. e. Thoroughly rinse off the inside of the vacuum collection tank, including the level sensors using a hose connected to a pressurized water supply. Drain tank. f. If any of the level sensors are excessively soiled and cannot be rinsed clean, then remove, clean, re-install and test before continuing. g. Re-install vacuum waste collection tank lid. Replace lid gasket if necessary. h. Reconnect flexible piping to control solenoid valve union. Close tank vent valve. i. Open isolation ball valves between vacuum volume tank and control solenoid valve and between the waste collection tank and system piping. j. Repeat procedure from step 1 with other waste collection tank. k. Vacuum leak test per TROUBLESHOOTING, Vacuum Central Leak Test. (g) Control Panel The control panel assembly is designed to be a moisture tight enclosure. Always keep the control panel assembly door closed so that water and moisture cannot get into the electronics. Check periodically to be sure the interior of the control panel is dry and all the terminal connections are tight. 1. General Cleaning a. Place the power disconnect switch in the OFF position to disconnect electric power to the control panel and tag “OUT OF SERVICE. Open control panel door. b. Clean control panel interior and components using a vacuum cleaner with a nonmetallic nozzle. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS PREVENTATIVE MAINTENANCE Page 63 EVAC NORTH AMERICA OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 2. c. Remove surface dust by wiping with lint-free rags. d. Close and secure control panel door. e. Remove safety tag and restore electric power to the panel. Inspecting Manual Motor Protectors (MMPs) and Contactors Manual motor protectors and contactors are designed to provide years of almost maintenance free operation. MMPs and contactors in service should be inspected annually. WARNING: BEFORE INSPECTING A MANUAL MOTOR PROTECTOR IN AN ELECTRICAL SYSTEM, MAKE SURE THE MANUAL MOTOR PROTECTOR IS SWITCHED TO THE OFF POSITION. FOR BOTH MANUAL MOTOR PROTECTORS AND CONTACTORS, MAKE SURE THAT THERE IS NO VOLTAGE PRESENT WHERE WORK IS TO BE PERFORMED. THE VOLTAGES IN ENERGIZED EQUIPMENT CAN CAUSE DEATH OR SEVERE PERSONAL INJURY. CAUTION: MAKE SURE THAT CLEANING AGENTS OR SOLVENTS USED TO CLEAN THE MANUAL MOTOR PROTECTORS OR CONTACTORS ARE SUITABLE FOR THE JOB. SOME COMMERCIAL CLEANING AGENTS WILL DAMAGE THE NAMEPLATES OR MOLDED PARTS. a. Remove dust, dirt, soot, grease, or moisture from the surface of the device (manual motor protector or contactor) using a lint-free dry cloth, brush, or vacuum cleaner. Do not blow debris into manual motor protector. If contamination is found, look for the source and eliminate the problem. b. ( For MMP’s only.) Switch manual motor protector to ON and OFF several times to be sure that the mechanical linkages are free and do not bind. If mechanical linkages are not free, replace manual motor protector. c. ( For MMP’s only.) Press the PUSH-TO-TRIP button to mechanically trip the manual motor protector. Trip, reset, and switch manual motor protector ON several times. If mechanism does not reset each time the manual motor protector is tripped, replace the manual motor protector. d. Check the base, cover, and operating handle for cracks, chipping, and discoloration. Replace the device if cracks or severe discoloration is found. PREVENTATIVE MAINTENANCE Page 64 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 3. e. Check terminals and connectors for looseness or signs of overheating. Overheating will show as discoloration, melting, or blistering of conductor insulation, or as pitting or melting of conductor surfaces due to arcing. If there is no evidence of overheating or looseness, do not disturb or tighten the connections. If there is evidence of overheating, terminations should be cleaned or replaced. Before re-energizing the device, all terminations and cables should be refurbished to the condition when originally installed. f. Check mounting hardware and tighten if necessary. g. Check area where device is installed for any safety hazards including personal safety and fire hazards. Exposure to certain types of chemicals can cause deterioration of electrical connections. Inspecting Programmable Logic Controller (PLC) a. (h) (2) Once yearly, check all LED’s on the front of the PC. Clean any dust or dirt that has accumulated. Check all terminal wiring. Replacing Vacuum Pump Mechanical Seals and Bearings 1. It is generally recommended that the vacuum pump mechanical seals and bearings be replaced after 5 years of service. The vacuum central is designed with a backup pump in the event one pump fails. Mechanical seals in liquid ring pumps tend to fail gradually over time. This may result in a slight decrease in the overall capacity of the pump. Inspect the pump periodically for any signs of leakage underneath the system. Also, pay attention to the pump performance testing as reduced capacity may also be a symptom of a failing mechanical seal. 2. Should the pump require new seals and/or bearings, this procedure should be performed by an authorized service technician. Please contact Evac for more information. Piping and Collection Network (a) General Piping Inspection 1. (b) Every six months perform a general walk around inspection to verify that the piping network is in good condition. Direct attention to the operation of the piping network should be viewed to determine the quality of bracing and the performance of the interface valve and piping seals. Verify that there is no water on the floor due to the vacuum collection system. Leak Test 1. Annually, perform a leak test of the vacuum piping network to verify the integrity of all seals, vacuum interface valves, and piping joints. Refer to section TROUBLESHOOTING, Piping and Component Leak Test for the test procedure. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS PREVENTATIVE MAINTENANCE Page 65 EVAC NORTH AMERICA OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (c) Inspecting the Inlet Header 1. (d) Inspect the inlet header for proper bracing and any visible signs of damage or leakage. Verify that the isolation ball valves operate freely and that the union couplings are secure. Verify that all connections to the vacuum waste collection tanks are secure. Inspect the inlet check valves as directed in this section. Refer to Check Valve Inspection. Inspecting Risers Inspect the riser for proper bracing and any visible signs of damage or leakage. If the piping is not properly braced, operation could damage the piping and the vacuum components that comprise the riser. 1. 2. 3. Inspecting Activators a. Inspect the activator for physical damage and evidence of paint over spray. Verify that both jets on the side of the activator have blue markings. If this is not the case, contact your Evac representative for assistance. If the activator is damaged, it must be replaced. If paint over spray is found on the activator, please test the activator according to section TROUBLESHOOTING, Activator Inspection and Replacement. b. Verify that all hoses are firmly connected to the sensor, vacuum, and valve ports. If any of the hoses are loose, pinched, or pulled tight, replace with a proper section of hose. Inspecting Pinch Valves a. Pinch valves do not generally require any regular maintenance. However, it is advisable that the rubber parts of the vacuum interface valve be examined yearly. Attention should be given to possible distortions and/or cracks. Bracing should be found within 12 inches of both sides of the valve. If the valve is physically damaged, or evidence of paint over spray is found on the rubber diaphragms, replace the valve. b. Verify that all hoses are firmly connected to the pinch valve and the source port next to the valve. Check for signs of any possible leakage. If any of the hoses are loose, pinched, or pulled tight, they must be replaced. c. Observe the pinch valve for proper operation. To manually activate the pinch valve, refer to section TROUBLESHOOTING, Pinch Valve Inspection and Replacement. Inspecting Buffer Boxes a. Inspect the buffer box and glued joints for physical damage and/or cracks. If any damage is discovered, fix or replace the buffer box. b. Verify that the sensor hose is firmly connected to the buffer box port. If the hose is loose, pinched, or pulled tight, replace with a proper section of hose. PREVENTATIVE MAINTENANCE Page 66 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 (e) Inspecting Check Valves 1. Inspect the vacuum check valves for signs of physical damage or leakage. Verify that there are no cracks in the housing and that the valve lid is properly seated. If the valve is damaged, it must be replaced. EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS PREVENTATIVE MAINTENANCE Page 67 EVAC NORTH AMERICA OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 EVAC NORTH AMERICA INC 1445 Huntwood Drive Cherry Valley, IL 61016-USA Telephone: Toll Free: Fax: Attention: Internet: (815) 654-8300 (U.S. & International) (888) GET-EVAC (438-3822) (815) 654-8306 Customer Service Department www.Evac.com When ordering parts, please specify the following: 1. HORIZON model number 2. Evac or manufacturer's serial number (refer to nameplate) 3. Part description(s) 4. Part number(s) 5. Quantity required 6. Purchaser name 7. Complete address and shipping instructions 8. Supplemental information to aid in expediting the order/inquiry PREVENTATIVE MAINTENANCE Page 68 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS PREVENTATIVE MAINTENANCE Page 69 EVAC NORTH AMERICA OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 PREVENTATIVE MAINTENANCE Page 70 EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS EVAC NORTH AMERICA INC OPERATION AND MAINTENANCE MANUAL PART NUMBERS: 2900418、2900419, 2900420, 2900421, & 2900465 COMMENTS: Item Use item numbers to cross-reference any NO answers from Page 1. Comment ADDITIONAL COMMENTS: Any additional comments regarding the system Item Comment Evac Sales Representative Company Name EVAC NORTH AMERICA INC PROPRIETARY - SEE COVER PAGE FOR DETAILS Address: PREVENTATIVE MAINTENANCE Page 71 : : : : CONTROL PANEL FOR: : L380-40-HV & L280-40-HV CONTROL PANEL FOR: L335-40-HV & L235-40-HV CONTROL PANEL FOR: L380-40-LV & L280-40-LV : CONTROL PANEL FOR: L335-40-LV & L235-40-LV CONTROL PANEL FOR: : L380-40-SV & L280-40-SV CONTROL PANEL FOR: L335-40-SV & L235-40-SV CONTROL PANEL FOR: L335-40-MV & L235-40-MV : : : :