Installation and Operating Instructions
Automatic Purge System
Busch, Inc. 516 Viking Drive Va. Beach, VA 23452 Phone: (757) 463-7800 Fax: (757) 463-7407 P/N 872.011.01 /
0806
TABLE OF CONTENTS
Page
1.0
DESCRIPTION
2
2.0
OPERATION
2
3.0
INSTALLATION
2
4.0 4.1
AUTO PURGE SEQUENCE Safety Switches
3 3
5.0 5.1 5.2 5.3
MODULATION PROCESS VALVE Installation (Air Controller) Setup (Air Controller) Installation (Electronic Controller)
3 3 3 3
6.0
Flow Diagrams
4
We reserve the right to change the product at any time without any form of notification. The information in this publication is accurate to the best of our ability at the time of printing. Busch, Inc. will not be responsible for errors encountered when attempting to perform tasks outlined in this publication which is copyright protected. 1
1.0
DECSCRIPTION
The second and more obvious benefit is the purge cycle clearing the pump of process material at shut down. The gas used to purge the pump would in most cases be atmospheric; however, when the process vapors are highly flammable or explosive, it might be desirable to use nitrogen.
A typical auto-purge system will contain the following: •
Emergency stop switch - push to stop/pull to reset.
•
Purge start pushbutton - single-pole momentary contact - normally open.
•
Purge stop pushbutton - single pole momentary contact - normally closed.
•
Power on light - white (NEMA 4 only).
•
Purging light - amber (NEMA 4 only).
•
Process valve air solenoid - 120 volt electrically operated.
•
Process valve - "closed" during purging/"open" on process.
•
Purge solenoid - "open" during purging/"closed" on process.
•
Programmable Logic Relay - This controls all tim ing functions and safety interlocks as well as start and stop controls.
•
Electrical components are housed inside a NEMA 4 or 7 enclosure.
Note: All the information within this manual is based upon using an atmospheric gas purge. Contact the factory for additional equipment recommendations when using a purge gas other than atmosphere. When the process vapor is corrosive or acidic, the inclination might be to introduce a neutralizing gas as a purging agent; however, this could cause solids to form inside the pump. The best solution is to use an inert gas to sweep through the pump, purging it of the process vapor. When setting up the purge system, be sure to consider the effect of the process on the pump lubrication. Make allowances that will protect the pump. 3.0
CAUTION: All electrical connections should be made by a qualified, competent electrician in accordance with all local and national codes. Note: The following installation procedure makes the assumption that the auto-purge panel was shipped unmounted, the purge and process valves were not provided, and the air solenoid was prewired and mounted to the purge panel. Therefore, the following instructions must be applied when appropriate and altered when required to fit the situation:
In many cases, the above components are supplied by Busch; but in some cases, these components are supplied by others. For that reason, we can only make recommendations on components we would supply. When alternate designs or suppliers are used, it is the responsibility of the party in charge of the design to make his design compatible with the Busch supplied components. 2.0
INSTALLATION
Mount the auto-purge panel at a convenient location as near as possible to the pump. Mount a normally open air-operated purge valve on a "T" connection off the pump inlet piping. Install a normally closed air-operated process valve in the inlet piping on the process side of the purge "T" connection.
OPERATION
The benefit of using an auto-purge system is twofold; first and least obvious is the heat of compression warming the pump during the start-up purge cycle. The start-purge time delay relay should be set (normal factory setting 15 minutes) to allow the pump to reach operating temperature before opening the process valve. This warm-up period is especially necessary when dealing with a process stream carrying condensable vapors. Pumps with a Danfoss valve should be set to keep the pump temperature in the range between polymerization and condensation of the process gas (if your process gas will polymerize). If your process gas will not polymerize, you will only need to keep it from condensing in the pump. The purge cycle must be set to allow the pump to reach the desired range before the process stream reaches the pump.
Connect an 80 psig filtered, dry, and regulated air supply line to port No. 2 of the solenoid valve. Run a line from port No. 1 on the solenoid valve to the actuator port on the process valve. Install a "T" in the actuator port and run a line to the actuator port on the purge valve. Port No. 3 on the solenoid is used to exhaust the system and requires no piping. The purge panel is prewired (see Schematic supplied in control panel box) and will require field installation of the interconnecting wires between it and the starter panel (see the appropriate diagram Fig. 1 or 2 for connections). The interconnecting 120 volt control circuit wire should be AWG-14 (minimum), THHN red (hot), 2
white is (neutral), and green is (ground). 4.0
a 1/4" line from 80 psig shop air to the inlet port of the regulator. Make sure the air is clean, dry, and moisture free.
AUTO PURGE SEQUENCE
1. After ensuring that the Emergency Stop switch is pulled out and power is available to the system, the operator pushes the Start Purge push button. The pump will run with the Purge Valve open and the Process Valve closed.
CAUTION: Do not apply more than 15 psig air pressure to the controller. 3. Run 80 psig shop air to the purge valve actuator supply port. 4. Connect a 1/4" line to the controller "control" port and run it to the piping up stream of the process valve when controlling the process pressure and down stream of the process valve when controlling the pump inlet pressure.
2. After Start Purge timer times out (factory set at 15 minutes), the Process Valve will open, the Purge Valve will close, and the pump will start evacuating the entire system. 3. To initiate a stop purge, the operator pushes the Stop Purge push button. The Process Valve will close and the Purge Valve will open. The pump will remain running until Stop Purge timer times out (factory set at 15 minutes). Once Stop Purge timer times out, the pump will shut down and the timers will reset.
5. Assemble a 1/4" line to the "output" port on the controller, and run it to the instrument port on the process valve positioned. Note: See Section "3.0 INSTALLATION" for installation of the balance of the components.
CAUTION: The stop purge is necessary to purge the pump of all contaminants before shutdown. Failure to do so could cause serious damage to the pump and may void the warranty.
5.2
1. Adjust the air regulator to 15 psig, and set the controller for the desired vacuum system pressure.
4. The pump may be shut down in an emergency by depressing the Emergency Stop push button. T h e pump will immediately shut down, the Process Valve will close, and the Purge Valve will open. 4.1
2. Start the vacuum pump and allow the vacuum level to stabilize. Open and close a valve in the vacuum process line to simulate operating conditions. Experiment with the proportional band and reset adjustments while changing the vacuum load to arrive at the most desirable control setting.
Safety Switches
When any of the safety switches reach their set point, power is discontinued to the Motor Starter coil circuit stopping the pump without a purge cycle. The malfunction must be corrected to allow the affected switch to return to normal before the pump can be restarted. See the individual pump manual for the safety switches. 5.0
MODULATING PROCESS VALVE
5.1
Installation (Air Controller)
5.3
Installation (Electronic Controller)
Mount the transmitter (on a vacuum line between the pump and process valve, to control pressure at the pump or on the process side of the process valve to control the process pressure), vacuum controller, purge valve, process valve and positioner as required (see Fig. 2). 1. Run power supply (120 V) to the 24vDC power supply on the controller. Run control circuit wires from the transmitter to the controller and from the controller to the positioner.
Note: The following procedure is written as an aid when installing a modulating purge system; any operation that is required in the installation of a non-modulating system (3.0 INSTALLATION) will not be duplicated in this write-up.
2. Adjust the transmitter range, calibration, etc., if required. Refer to the manufacturer's manual for the procedure.
Mount the air regulator, vacuum controller, purge valve, process valve, and positioner as required (see Fig. 1).
3. Start the vacuum pump and allow the vacuum level to stabilize. Open and close a valve in the vacuum process line to simulate operating conditions. Experiment with the proportional band and reset adjustments while changing the vacuum load, to arrive at the most desirable control.
1. Connect the "outlet" port of the air pressure regulator to the "supply" port on the back side of the controller. 2.
Setup (Air Controller)
Set the air regulator at "0" output pressure. Run 3
6.0
FLOW DIAGRAMS
Fig. 1 - Typical Pneumatic Modulating Auto Purge Flow Diagram
Fig. 2 - Typical Electronic Modulating Auto Purge Flow Diagram 4
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5
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