Dekker VMAX SERIES Installation, Operation & Maintenance Manual

VMAX SERIES
Brand
Dekker
Model
VMAX SERIES
Type
Installation, Operation & Maintenance Manual
Installation
Operation
&
Maintenance
Manual
Oil-Sealed Liquid Ring Vacuum Pump Systems
SERIAL NO.:___________________________ July 2016
TM
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
2
OIL-SEALED LIQUID RING VACUUM PUMP SYSTEMS
TABLE OF CONTENTS
CUSTOMER SERVICE ................................................................................................................................ 5
CONTACT INFORMATION ........................................................................................................................................................................ 5
ORDER INFORMATION .............................................................................................................................................................................. 5
INTRODUCTION ....................................................................................................................................... 6
SAFETY........................................................................................................................................................ 6
THEORY OF OPERATION ........................................................................................................................ 7
STORAGE .................................................................................................................................................... 7
INITIAL FREIGHT RECEIPT AND INSPECTION .................................................................................. 8
INSTALLATION ......................................................................................................................................... 8
UNPACKING ............................................................................................................................................................................................... 8
LIFTING ........................................................................................................................................................................................................ 8
LOCATION .................................................................................................................................................................................................. 8
MOUNTING................................................................................................................................................................................................. 8
VENTILATION ............................................................................................................................................................................................. 9
ELECTRICAL PREPARATION ..................................................................................................................................................................... 10
PIPE CONNECTIONS AND SIZING .......................................................................................................................................................... 11
COOLING WATER PIPING (WATER COOLED SYSTEMS ONLY) ............................................................................................................. 12
ELECTRICAL CONTROLS (IF INCLUDED) ......................................................................................... 13
DEKKER CONTROLLER .......................................................................................................................... 13
DEKKER CONTROLLER OVERVIEW ..................................................................................................................................................... 13
DEKKER CONTROLLER KEYPAD .......................................................................................................................................................... 14
SECURITY ACCESS LEVELS ....................................................................................................................................................................... 16
START UP PROCEDURES ...................................................................................................................... 22
SHUT DOWN PROCEDURE .................................................................................................................. 27
SEQUENCE OF OPERATION ................................................................................................................. 27
SYSTEM ALARM CONDITIONS ............................................................................................................ 28
MAINTENANCE ....................................................................................................................................... 30
PUMP BEARING LUBRICATION ................................................................................................................................................................ 30
PUMP BEARING LUBRICATING SCHEDULE ............................................................................................................................................. 30
MOTOR BEARING LUBRICATION (WHERE REQUIRED) ........................................................................................................................ 31
MOTOR BEARING LUBRICATION SCHEDULE ........................................................................................................................................ 31
INLET FILTER (IF INSTALLED) ................................................................................................................................................................... 32
SEAL FLUID ................................................................................................................................................................................................ 32
MATERIAL SAFETY DATA SHEETS AVAILABLE UPON REQUEST ............................................................................................................ 32
OIL CHANGE PROCEDURE ..................................................................................................................................................................... 33
STANDARD SYSTEM CAPACITIES ............................................................................................................................................................ 35
PRIMING THE PUMP .................................................................................................................................................................................. 35
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
3
COMPLIMENTARY OIL ANALYSIS ........................................................................................................................................................... 35
SEAL FLUID STRAINER .............................................................................................................................................................................. 36
SEPARATOR ELEMENT .............................................................................................................................................................................. 36
SEPARATOR ELEMENT OIL RETURN LINE .............................................................................................................................................. 36
MECHANICAL SHAFT SEALS .................................................................................................................................................................... 36
MAINTENANCE SCHEDULE ................................................................................................................. 37
FIRST 8 HOURS OF OPERATION ............................................................................................................................................................. 37
500 HOURS OF OPERATION .................................................................................................................................................................. 37
1000 HOURS OF OPERATION ................................................................................................................................................................ 37
1,000-3,000 HOURS OF OPERATION ................................................................................................................................................... 37
10,000 HOURS OF OPERATION ............................................................................................................................................................. 37
30,000 HOURS OF OPERATION ............................................................................................................................................................. 37
ACCESSORIES AND PROTECTIVE DEVICES (IF INCLUDED) ......................................................... 38
ACCESSORIES (OPTIONAL) ..................................................................................................................................................................... 38
PROTECTIVE DEVICES .............................................................................................................................................................................. 38
TROUBLESHOOTING ............................................................................................................................. 40
START-STOP PROBLEMS: ......................................................................................................................................................................... 40
VACUUM PROBLEMS: ............................................................................................................................................................................... 41
OVERHEATING PROBLEMS:...................................................................................................................................................................... 41
NOISE AND VIBRATION PROBLEMS:....................................................................................................................................................... 42
OIL PROBLEMS: ......................................................................................................................................................................................... 42
TROUBLESHOOTING QUICK REFERENCE GUIDE ................................................................................................................................. 43
WARRANTY, REPLACEMENT & RETURN POLICIES ........................................................................ 44
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
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THIS INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL MUST STAY WITH
EQUIPMENT.
PLEASE REGISTER YOUR EQUIPMENT
WARRANTY AND START-UP RECORD ONLINE
AT WWW.DEKKERVACUUM.COM
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
5
CUSTOMER SERVICE
Contact information
935 SOUTH WOODLAND AVENUE, MICHIGAN CITY, IN 46360-5672
TEL.: 219-861-0661 – FAX: 219-861-0662 – TOLL-FREE: 888-925-5444
Business hours: 7.30 a.m. – 4.30 p.m. CST
Website: www.DEKKERvacuum.com
E-mail: AfterSales_Support@DEKKERvacuum.com
Order information
When calling for service, parts or system information always have the pump or system model number and
serial number(s) ready. Refer to the bill of lading or the gold-colored system information plate attached to
the system.
Parts should be purchased from the nearest authorized DEKKER representative or from the vacuum pump
system supplier. If for any reason parts cannot be obtained in this manner, contact the factory directly.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
6
INTRODUCTION
The Vmax oil-sealed liquid ring vacuum pump system has been designed to give you safe, reliable trouble-
free service, provided some of the basic maintenance guidelines as set out in this manual are followed.
Compared to other vacuum pump systems, the Vmax oil-sealed liquid ring vacuum pump system offers the
advantages of no metal-to-metal contact between the impeller and casing. Grease lubricated bearings are
mounted external to the pumping chamber, isolated by mechanical shaft seals. This means that the pump
requires no internal lubrication. However, a vacuum pump is a rotating piece of equipment and operators
must exercise good judgment and follow proper safety procedures to avoid damage to the equipment or
personal injury. Please review and follow all instructions in this manual before attempting to install, start or
operate equipment.
The Vmax oil-sealed liquid ring vacuum pump system is equipped with a standard DEKKER Controller. The
DEKKER Controller is a microprocessor-based digital controller for use with DEKKER vacuum systems.
The controller is designed for flexibility and can be used on one system or multiple systems interacting
together. The DEKKER Controller provides for system control as well as monitoring of system status.
Service functions include display of spare parts list, maintenance schedules, and service history, along with
logging of fault conditions.
The DEKKER Controller includes a 4-line large-font liquid crystal display, a durable Lexan membrane
keypad, and multiple status LEDs. Communication between controllers is via RS-485 for multi-machine
systems. An Ethernet port provides for remote monitoring and control via TCP/IP protocols and can be
enhanced with the use of DEKKER’s OnDek Software. Input and output (I/O) includes 9 digital (24VDC)
inputs and 7 dry relay contact outputs. Analog I/O includes two Resistance Temperature Detectors (RTD)
inputs, four 0-10VDC/4-20mA inputs, one 0-10VDC output, and one 4-20mA output. Power input to the
controller is 24VDC.
SAFETY
All products offered by DEKKER have been designed and manufactured for safe operation. However, the
responsibility for safe operation rests with those who use and maintain these products. Your safety
department should establish a safety program based on OSHA, federal, state and local codes. It is important
that due consideration be given to hazards which arise from the presence of electrical power, hot liquids,
harmful gases and rotating equipment. Proper installation and care of protective devices is essential to safe
system operation. These safety procedures are to be used in conjunction with the instructions contained in
this manual.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
7
THEORY OF OPERATION
The DEKKER Vmax oil-sealed liquid ring vacuum pump system includes our high efficiency liquid ring
vacuum pump. Minimal maintenance is required due to the absence of wearing parts such as pistons, sliding
vanes and internal bearings. The impeller assembly is the only moving part which rotates freely in the casing
without metal-to-metal contact. This means that no additional lubrication is required. The function of the
sealing liquid is to create a liquid piston action used to produce vacuum and to remove the heat of
compression. The seal fluid in the system circulates in a closed loop passing through an air- or water-
cooled heat exchanger that removes the heat of compression. The discharge separator/reservoir holds the
seal fluid and incorporates the DEKKER DX-5 or DX-7 patented high-efficiency separator arrangement to
separate the seal fluid from the air or gases discharged by the pump. See “Piping and Instrument Diagram”
of the Vmax oil-sealed liquid ring vacuum pump system below.
STORAGE
Keep the system in a cool dry environment and close the seal fluid isolation valve as shown on page 21.
Plug all open ports to keep out dirt and foreign objects. Every 2 - 3 months rotate the impeller by rotating
the shaft by hand 2 ¼ turns.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
8
INITIAL FREIGHT RECEIPT AND INSPECTION
Before a system ships from DEKKER, it is thoroughly tested, and will not be released unless it passes our
Quality Control standards. Once the system is received and signed for in Good Condition, DEKKER cannot
be held accountable for undiscovered, unclaimed damage that is a result of freight transit. It is the
responsibility of the receiver to thoroughly inspect and test the system for functionality upon delivery. The
customer should take photos of the system as it arrives and send to DEKKER if there are any issues. Failure
to report these issues within the freight carriers’ undiscovered damage window can result in non-
acceptance of warranty claims. DEKKER does keep photos of all systems, as shipped, to assist in freight
claims. Report any damage immediately to AfterSales_Support@DEKKERvacuum.com
Key items to check:
Is system received as requested? Are all parts, accessories, and components delivered?
Check the skid and crating for cosmetic damage. Was the skid or crating received in good condition?
Is there any cosmetic damage to the vacuum system or control panel?
Wiring inside of control panel. All wires should be terminated and connections tight.
Control panel components should be tight on DIN rail or other mounts/fasteners.
Are there any leaks or puddles around the pump? Specify hose, piping or housing leak.
System must be given an initial startup test as soon as possible after delivery. This is to check and make sure
that the pump has not shifted out of alignment during transit as well as to verify that electrical components
are functioning without fault (VFD, DEKKER Controller, PLC’s, panel cooling fans, transducers)
INSTALLATION
The design of the piping system, foundation layout and plant location are the responsibility of the purchaser.
DEKKER Vacuum Technologies, Inc. and its representatives may offer advice but cannot assume
responsibility for operation and installation design.
Please consult an authorized dealer or a specialist skilled in the design of plant layout, system piping design
and foundation design. The installer should carefully read this manual before installing the equipment.
DEKKER or your local dealer can provide start up assistance in most instances at reasonable cost.
Unpacking
Upon receipt of pump or system, immediately inspect for signs of damage. Carefully remove
packing or crating from around pump or system. Be sure to keep equipment in upright position.
Lifting
Lift the equipment carefully and with weight evenly distributed. DEKKER is not responsible for equipment
that has been damaged through mishandling or dropping. Use of DEKKER provided lifting points will ensure
proper handling.
Location
Install the unit in a well ventilated and dust free area. The pump or system should be a minimum distance of
3 feet from surrounding walls to allow for checking fluid level, temperatures, pressures and general
servicing.
Mounting
The pump or system must be installed on a level surface in a horizontal position. The foundation must be
designed to support the total unit weight, without any settlement or crushing, be rigid and substantial
enough to absorb any equipment vibration, maintain true alignment with any drive mechanism, and must
permanently support the system baseplate at all points. The vacuum system must be leveled and secured
with foundation bolts. Foundation bolts must be of adequate size to withstand the mechanical stresses
exerted on it.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
9
Systems 50 HP and larger should also be grouted into position per local codes. The foundation should be
constructed to allow for ¾ to 1-½ inch of grout. The baseplate is set on shims and the grout is poured
between the foundation and the baseplate. To have the required body to support the baseplate, grout
should be at least ¾ inch thick.
The number and location of shims will be determined by the design of the baseplate. Firm support should
be provided at points where weight will be concentrated at the anchor bolt locations. Use enough, and
large enough shims to provide rigid support. Baseplates are usually designed with openings to allow pouring
grout. When the baseplate has been shimmed and leveled and the anchor bolts have been snugly tightened,
a dam is constructed around the foundation to contain the grout. The dam level should be at least ½ inch
above the top surface of the shims. Grout should be poured inside and around the outside of the baseplate
and leveled. Allow the grout to dry for a minimum of 48 hours before tightening the anchor bolts.
Please note that the pump/motor coupling and V-belt units will need to be realigned
prior to start-up, with the exception of monoblock units.
Ventilation
Locate the vacuum system in an area with sufficient airflow and accessibility. To prevent excessive ambient
temperature rise it is imperative to provide adequate ventilation. Cooling is an important aspect of reliable
equipment operation and it is therefore important to install the unit in a reasonably cool area where the
temperature does not exceed 104°F (40°C). For higher ambient temperatures contact the factory.
For water-cooled vacuum systems it is necessary to check cooling water supply. A proper, consistent
water flow must be maintained for adequate cooling.
Normal system operating temperature is between 140° - 185° F. Minimum oil temperature should not be
below 45°F.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
10
Electrical Preparation
Wire Size Chart (AWG) by Vmax Horsepower
Recommended Wire Size and Disconnect Size for Vmax Systems
Vmax
FLC NEC Tables
Volt.
Copper AWG (kcmil)
Recommended Conduit
Size in Inches
Recommended Class J
Fuse
System
Serv.
Model No.
HP
Fact.
200V
230V
460V
Tol.
200V
230V
460V
200V
230V
460V
200V
230V
460V
200V
230V
460V
VMX0023MA1
1.5
1.15
6.9
6
3
±10%
14
14
14
1/2"
15
15
15
12
10.5
5.25
VMX0023KA1
1.5
1.15
6.9
6
3
±10%
14
14
14
15
15
15
12
10.5
5.25
VMX0036MA1
3
1
11
9.6
3.7
±10%
14
14
14
20
20
15
19.2
16.8
8.4
VMX0036KA1
3
1.15
11
9.6
4.8
±10%
14
14
14
20
20
15
19.2
16.8
8.4
VMX0063MA1
5
1.15
17.5
15.2
7.6
±10%
12
12
14
40
30
15
30.6
26.6
13.3
VMX0063KA1
5
1.4
17.5
15.2
7.6
±10%
12
12
14
40
30
15
30.6
26.6
13.3
VMX0083MA1
5
1.15
17.5
15.2
7.6
±10%
12
12
14
40
30
15
30.6
26.6
13.3
VMX0083KA1
5
1.4
17.5
15.2
7.6
±10%
12
12
14
40
30
15
30.6
26.6
13.3
VMX0103MA1
7.5
1
25.3
22
11
±10%
10
10
14
50
40
20
44.2
38.5
19.2
VMX0103KA1
7.5
1.3
25.3
22
11
±10%
10
10
14
50
40
20
44.2
38.5
19.2
VMX0153MA1
10
1
32.2
28
14
±10%
8
10
14
60
50
30
56.3
49
24.5
VMX0153KA1
10
1.28
32.2
28
14
±10%
8
10
14
60
50
30
56.3
49
24.5
VMX0203KA1
15
1.3
48.3
42
21
±10%
6
6
10
3/4"
3/4"
1/2"
90
80
40
84.5
73.5
36.7
VMX0303KA1
20
1.25
62.1
54
27
±10%
4
6
10
1”
3/4"
1/2"
110
100
50
109
94.5
47.2
VMX0303KA1-20
20XP
1.15
62.1
54
27
±10%
4
6
10
1”
3/4"
1/2"
110
100
50
109
94.5
47.2
VMX0453KA1
25
1.3
78.2
68
34
±10%
3
4
8
1”
1”
1/2"
140
120
60
137
119
59.5
VMX0453KA1-20
25XP
1.15
78.2
68
34
±10%
3
4
8
1”
1”
1/2"
140
120
60
137
119
59.5
VMX0553KA1
40
1.3
120
104
52
±10%
0
1
6
1.25
1.25
3/4"
220
190
100
210
182
91
VMX0553KA1-20
40XP
1.15
120
104
52
±10%
0
1
6
1.25
1.25
3/4"
220
190
100
210
182
91
VMX0753KA1
50
1.28
150
130
65
±10%
0
0
4
1.5
1.5
1”
270
230
115
262
227
114
VMX1003KA1
60
1.15
177
154
77
±10%
0
0
3
2
1.5
1”
320
270
140
310
269
135
VMX1103KA1
75
1.15
221
192
96
±10%
300
0
1
2
2
1.25
390
340
180
387
336
168
VMX1203KA1
100
1.15
285
248
124
±10%
500
350
0
2.5
2.5
1.25
510
440
230
499
434
217
NOTES: 1. Based on no more than three single insulated conductors rated 0-2000 volts. 6. If fuse is not a standard size, choose the next higher standard size.
2. Conduit sizes shown at 9.6% Fill does include ground conductor if required (over 60 amperes). 7. If disconnect is not a standard size, choose the next higher standard size.
3. Wire sizes are based on NEC Table 310.15.b.16 @ 75 deg. C rated conductors.
4. Approved trade size conduit or metal tubing.
5. Above information is general information. Per NEC tables please confirm motor FLA does not exceed FLC
Note: Fuse and disconnect sizes are for vacuum pump only. For main disconnect and fuse sizes for systems
with a circulation pump and fan, multiply the FLC of the vacuum pump motor by 175% then add the FLC for
the circulation pump and fan to get the fuse size. Disconnect must be sized to fit fuse.
All system wiring is performed at the factory if a control panel is supplied. Check area classification to ensure
all electrical enclosures comply with code. Required customer wiring is minimal, but should be done by a
qualified electrician in compliance with OSHA, National Electric Code and any other applicable local electrical
code concerning switches, fused disconnects, etc. DEKKER includes a wiring diagram in the control panel for
use by the installer. DEKKER recommends a main disconnect switch be fitted between the vacuum system and
the incoming power.
After the electrical wiring connections are completed check the incoming voltage to make sure the incoming
voltage is the same as the vacuum system voltage. Line voltage should be within the voltage tolerance as
specified on the motor or to local code. Check the system for proper motor rotation. The direction of
rotation is always clockwise when looking at the shaft of the pump and is marked by an arrow on the motor or
pump housing. Jog the motor by pressing the ON button and then the OFF button. If the rotation is incorrect
switch any two of the three main power leads on the contactor inside the control panel. Failure to do so could
result in serious equipment damage.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
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WARNING: Install, ground, and maintain equipment in accordance with the National Electrical
Code and all applicable federal, state and local codes.
WARNING: For NFPA 99 hospital and generator applications, please shut down the vacuum
pumps prior to generator testing. The rapid stop and restart may cause damage to the pump
and/or motor and cause damage to electrical panel and related components.
Pipe Connections and Sizing
DEKKER recommends CPVC piping as discharge temps may exceed +170°F. CPVC is rated for 200°F max,
and PVC is only rated for 140°F max. Schedule 40 PVC piping is OK for the inlet connections
Before installation, remove all protective inserts on the pump suction and discharge. Piping connected to
the system must be installed without imposing any strain on the system components. Improperly installed
piping can result in misalignment, general operating problems and pump failure. Use flexible connectors
where necessary. Piping must be cleaned of debris before installation.
Inlet and Discharge
Pipe Diameter
(Inches)
Maximum Number of Systems Running, based on SCFM at 15"
HgV
1
2
3
4
5
6
7
8
9
10
11
12
PUMP MODEL
DV0020B
1
1
1.25
1.25
1.25
1.5
1.5
2
2
2
2
2.5
DV0035B
1
1.25
1.5
1.5
2
2
2.5
2.5
2.5
3
3
3
DV0060B
1.25
1.5
2
2.5
2.5
3
3
3
4
4
4
4
DV0080B
1.25
2
2
2.5
3
3
4
4
4
4
4
6
DV0100B
1.25
2
2.5
3
3
4
4
4
4
6
6
6
DV0150B
1.5
2.5
3
4
4
4
6
6
6
6
6
6
DV0200B
2
3
4
4
6
6
6
6
6
6
8
8
DV0300B
2.5
4
6
6
6
6
8
8
8
8
8
8
DV0450B
3
4
6
6
6
8
8
8
8
10
10
10
DV0550B
4
6
6
8
8
8
10
10
10
10
12
12
DV0650B
4
6
6
8
8
10
10
10
10
12
12
12
DV0750B
4
6
8
8
8
10
10
12
12
12
12
14
DV1000B
6
6
8
10
10
10
12
12
14
14
16
16
DV1100B
6
8
8
10
10
12
12
14
14
16
16
16
DV1200B
6
8
8
10
10
12
12
14
16
16
16
18
Inlet Piping
Note: Install a temporary screen at the pump inlet flange at first start-up to protect the unit against
carryover of pipe debris and welding slag. The screen must be removed after the initial run in period.
Inlet piping should be at least the size of the pump inlet. Install the system as close as possible to the
process to minimize losses due to the length of the suction line. If the system has to be installed further
away from the process, be sure the inlet piping is properly sized to minimize the overall line pressure drop.
For more information consult your dealer or call the factory.
Pump systems operating in parallel on a common manifold must each have a manual or automatic shut-off
valve and a suitable check valve installed in the suction line close to the pump suction flange. This allows
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
12
each individual system to be isolated when it is not in operation. The line size of the manifold should be a
minimum equal to the sum of the individual system pipe areas.
Vmax systems are supplied with an inlet check valve as standard. This valve provides a minimum of
resistance close to the pump suction flange to prevent back flow of process gas and seal fluid when the
pump is stopped.
If the inlet gas pumped contains dust or foreign particles, a suitable 10 micron (or finer) inlet filter should be
installed at the inlet port. For more information consult your dealer or factory.
If the possibility exists that the pump inlet can become closed during operation it will be essential to install
some type of vacuum relief valve (anti-cavitation valve) so that air can enter the pump inlet. Never run a
pump with a closed suction. This causes hydraulic knock / cavitation and can damage the
pump.
Discharge Piping
Discharge piping must be at least the size of the separator discharge. Do not discharge the exhaust gases
from the pump system into the area where the system is installed. Vapors pulled over from the process
could be hazardous. Install an exhaust line of at least the same diameter as the discharge connection on top
of the separator reservoir leading outside. Install a drip leg with tee on the discharge line to prevent
condensables from draining back into the separator reservoir. See the “Discharge piping diagram” as shown
below.
For pump systems operating in parallel on a common discharge we recommend the installation of a suitable
check valve close to the separator discharge flange of each unit. Discharge check valves should be a low
differential pressure type with positive shutoff. For more information contact the factory. When
discharging more than one pump in a common discharge line and/or over a long distance, oversize pipe
accordingly.
Discharge piping diagrams
Cooling water piping (water cooled systems only)
Water-cooled systems require an adequate supply of cooling water at a maximum of 85°F and a minimum
supply pressure of 20 psig. If the cooling water temperature is higher or available pressure lower, consult
your dealer or call the factory.
The cooling water outlet connection of the heat exchanger may be fitted with an optional automatic
temperature control valve, which regulates the cooling water flow rate depending on pump operating
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
13
temperature. The valve is preset at the factory. To raise the system operating temperature, turn the valve-
adjusting screw counter-clockwise. To lower operating temperature, turn clockwise. Normal system
operating temperature is between 140° - 185° F. Minimum oil temperature should not be below 45°F. The
valve will only open when the system operating temperature is reached.
Electrical Controls (if included)
Disconnect Handles:Disconnect handles must be turned on to energize the system. The handles
must be turned off to open control panel.
o CAUTION: High voltage, main disconnect must be off when servicing panel.
HOA (Hand-Off-Auto) Pushbutton: Pump units will start in HAND mode (unless units are in a
shutdown alarm condition). The pumps will bypass vacuum setpoints. AUTO mode, allows units to
start based on vacuum setpoints.
HOA (Hand-Off-Auto) LED: The HOA LED indicates run mode of system (Orange indicates
hand/manual operation while green indicates auto operation).
Power On LED: The power on LED indicates that power is on in panel (Red indicates controller
power is on).
On LED: The on LED indicates system is on. (Green indicates system is running or in standby
mode).
Off LED: The off LEDindicates system is off. (Red indicates system is off).
Run Status LED: The run status LED indicates system status (Green indicates system running, orange
indicates system is in standby / auto mode, and red indicates system is stopped).
Reset Button: The rest button is used to reset the starter overloads (this is the reset button on
panel door not DEKKER Controller.
Lag Pump In Operation Light: When the lag pump in operation light illuminates,the lag pump is in
operation.
Audible Alarm: The audible signals that the lag pump is in operation. The alarm can be silenced by
pressing the RESET pushbutton. The audible alarm may also be used to signal other alarm conditions,
such as high temperature, low oil level or high back pressure.
Alarm Silence Button: The alarm silence button is used to silence the audible alarm, but the light
will remain on unless alarm condition has been corrected.
Alarm Reset Pushbutton: The alarm reset pushbutton is used to reset an alarm condition when
the condition has been rectified. The RESET pushbutton will remove displayed fault on the DEKKER
Controller LCD and alarm if alarm condition has been corrected.
DEKKER Controller
DEKKER Controller Overview
DEKKER’s Controller is standard on the Vmax models. The DEKKER Controller provides for system
control as well as monitoring of system status. Service functions include display of spare parts list,
maintenance schedules, and service history, along with logging of fault conditions.
The DEKKER Controller includes a 4-line large-font liquid crystal display, a durable Lexan membrane
keypad, and multiple status LEDs. Communication between controllers is via RS-485 for multi-machine
systems. An Ethernet port provides for remote monitoring and control via TCP/IP protocols and can be
enhanced with the use of DEKKER’s OnDek Software (optional and purchased separately). Input and
output (I/O) includes 9 digital (24VDC) inputs and 7 dry relay contact outputs. Analog I/O includes 2 RTD
(Resistance Temperature Detectors) inputs, four 0-10VDC/4-20mA inputs, one 0-10VDC output, and one
4-20mA output. Power input to the controller is 24VDC.
Refer to the most current DEKKER Controller Manual for more detailed information.
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
14
DEKKER Controller Keypad
The DEKKER Controller text display, buttons, and LEDs are described below. Refer to the diagram below that
shows this information.
The Lexan overlay on the controller is durable and scratch resistant. Buttons should be actuated with fingers
avoiding use of tools or sharp objects. The overlay may be cleaned by gently wiping with a damp cloth. Avoid
solvents or vigorous rubbing. Isopropyl alcohol wipes may be used on difficult areas.
1) 4-LINE LCD DISPLAY
2) UP – ARROW/ + BUTTON
NAVIGATE MENUS AND
CHANGE VALUES
3) DOWN – ARROW/ - BUTTON
NAVIGATE MENUS AND CHANGE VALUES
4) ENTER BUTTON
SELECT MENU ITEMS MENUS
AND VALUES
5) HAND/AUTO LED
ORANGE=HAND
GREEN=AUTO
6) HAND/AUTO BUTTON
ALTERNATES BETWEEN HAND AND
AUTO MODES
7) POWER ON LED
RED=CONTROLLER POWER ON
8) POWER ON BUTTON
TURNS CONTROLLER
ON AND OFF
9) ON LED
GREEN= SYSTEM
RUNNING OR IN
STANDBY
10) ON BUTTON
STARTS SYSTEM
11) OFF BUTTON
STOPS SYSTEM
12) OFF LED
RED = SYSTEM STOPPED
13) RUN STATUS LED
GREEN = SYSTEM RUNNING
ORANGE = STANDBY/AUTO MODE
RED = SYSTEM STOPPED
14) RESET BUTTON
RESETS FAULTS
15) LOG BUTTON
FAULT HISTORY LOG MENU
16) MAINT BUTTON
MENU FOR:
SPARE PARTS LIST
MAINTENANCE SCHEDULES
SERVICE HISTORY
17) PROGRAM BUTTON
PROGRAM MENU FOR
SETPOINTS, CLOCK, UNITS
18) ESCAPE BUTTON
RETURNS TO
RUN/STANDBY/STOPPED SCREEN
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
15
1) 4-LINE LIQUID CRYSTAL DISPLAY
2) UP ARROW /+ BUTTON
o Navigate menus and change values for setpoints, real-time clock, vacuum units, and
temperature units
3) DOWN ARROW / - BUTTON
o Navigate menus and change values for setpoints, real-time clock, vacuum units, and
temperature units
4) ENTER BUTTON
o Select menu items and values
5) HAND / AUTO LED
o Orange = Hand (manual operation)
o Green = Auto
6) HAND / AUTO BUTTON
o Alternates between Hand (manual operation) and Auto mode
7) POWER ON LED
o Red = Controller power is ON
8) POWER BUTTON
o Turns controller ON and OFF
9) ON LED
o Green = System is running or in Standby mode
10) ON BUTTON
o Starts system
11) OFF BUTTON
o Stops system
12) OFF LED
o Red = System stopped
13) RUN STATUS LED
o Green = System running
o Orange = Standby / Auto mode
o Red = System stopped
14) RESET BUTTON
o Resets Faults
15) LOG BUTTON (For details, see page 20)
o Fault history log menu
16) MAINTENANCE BUTTON (For details, see page 18)
o Menu for:
Spare Parts List
Maintenance Schedule
Service History
17) PROGRAM BUTTON
o Programming menu for Setpoints, Clock, Vacuum Units, Temperature Units, and after
purchase options
18) ESCAPE BUTTON
o Returns to Run / Standby / Stopped screen
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
16
Security Access Levels
The DEKKER Controller is protected against unauthorized access to system parameter changes. Security
codes can be entered as follows to access functionality of the DEKKER Controller.
With Basic Access (default), the user is able to clear Faults, but is unable to make any parameter changes.
Operator Access [022] adds the ability to make operating parameter changes (Program>Setpoint menu)
and the ability to transfer data from the controller.
The Security Access Level is changed by entering a Password. To enable Operator Access, first press and
hold the ESCAPE button for two seconds. The screen will display “Password”. Enter the password “22” by
pressing the PROG button twice (See Number Diagram Above) followed by the ENTER BUTTON.
Service Access [033] allows the ability to make operating parameter changes (Programs>Setpoint menu)
add field options (Programs>Programs>Options menu), and update service history (Maint(x5)>Service
History menu).
The Security Access Level is changed by entering a Password. To enable Service Access, first press and
hold the ESCAPE button for two seconds. The screen will display “Password”. Enter the password “33” by
pressing the MAINT button twice (See Number Diagram Above) followed by the ENTER BUTTON.
To restore Basic Access, press and hold the ESCAPE button for two seconds. The screen will display the
words “Access Locked”. Basic Access is also restored upon powering the controller off and on.
Note: Once the DEKKER Controller has no activity for 5 minutes it will default back to Basic Access any
changes after the password times out will required password to be re-entered.
= PROG ‘2’
= MAINT ‘3’
= ESC
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
17
Program Menu
Note: The Security Access level must be changed from Basic (default) to allow changes within the Setpoint
(parameter) menu. Refer to Security Access Levels above for instructions on enabling Operator Access or
Service Access.
Pressing the PROG button once displays the following Setpoint menu:
Vac Cut In
Vac Cut Out
Min Run Time
Temp Warn
Temp Fault
Time
Date
Vacuum Unit
Temp Unit
The UP-ARROW / + button and the DOWN-ARROW / - button can be used to move the right arrow
cursor to the desired parameter. Pressing the ENTER button will select that parameter for change. The
value will begin to flash. Use the ARROW buttons to change the value. Press the ENTER button to save
the new value.
Vac Cut In (Optional)
When in the Auto mode, a vacuum level at or below this value will cause the vacuum system to turn ON.
This value can be displayed in units of Torr (mm HgA) or “HgV (inches of Hg vacuum). See menu item
Vacuum Unit on the next page for changing units.
Vac Cut Out (Optional)
When in the Auto Mode, a vacuum level at, or above (deeper) this value, will cause the vacuum system to
turn OFF. This value can be displayed in units of Torr (mm HgA) or “HgV (inches of Hg vacuum). See
menu item Vacuum Unit on the next page for changing units.
Min Run Time
When in the Auto mode, short cycling is prevented by the minimum run time feature. The setting for this
feature is 10 minutes. At the end of the minimum run time, and if Vac Cut Out has been achieved, the
pump will stop and the Run Status light will change from green to orange indicating STANDBY. The ON
light will remain green during Standby. Run times less than 10 minutes may shorten the life of the motor or
pump from frequent cycling on and off.
Temp Warn
If the pump is running, or in standby mode, and the discharge temperature reaches this value, the warning
message “High Discharge Temp” will be displayed. In addition, the Run Status light will be orange and will
flash on and off. The pump will not be shut down by this warning condition. Standard Warning is 210°F
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
18
Temp Fault
If the pump is running, or in Standby mode, and the discharge temperature reaches this value, the message
“High Discharge Temp” will be displayed. In addition, the Run Status light will be red and will flash on and
off. The system will be shut down and the display will indicate “Shutdown”. Standard Shut-Down is 225°F
This is a Fault condition and must be cleared and then reset before the system can be started. Refer to the
section on resetting faults for details.
Time
The DEKKER Controller real-time clock may be viewed and changed from within this menu. The correct
local time should be entered to insure proper operation time-dependent functions. UP-ARROW / +
button and the DOWN-ARROW / - button can be used to set correct time.
Date
The calendar date should be entered in mm/dd/yy format. UP-ARROW / + button and the DOWN-
ARROW / - button can be used to set correct date.
Vacuum Unit
The vacuum level can be displayed with in Torr (mm HgA), or inHgV.
Temp Unit
The discharge temperature level can be displayed in Fahrenheit (F), or Celsius (C) units.
Note: The Security Access level must be changed from Basic (default) to allow changes within the Options
menu. Refer to Security Access Levels above for instructions on enabling Service Access.
To enable any of the following options, you must also enter a 9 digit Keycode, as detailed in the following section.
Pressing the PROG button twice displays the following Options menu:
Inlet Filter
Hi Level Sw
Low Level Sw
Circ Pump
Relief Valve
Temp Valve
Solenoid
Temp Switch
Aux Temp
Differential
Back Pressure
No# of Units
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
19
Key Codes to Add Options
The DEKKER Controller allows for easy to install retrofit options once the product has shipped. To view the
available options press the PROG button twice and using the UP-ARROW / + button and the DOWN-
ARROW / - button scroll through the available options. If the options states YES, the option has already been
chosen and added to the DEKKER Controller control circuit. If the option states N/A, the option must be
selected and a key code must be supplied with the appropriated components from DEKKER Vacuum
Technologies to upgrade this option.
To enter a key code, the user must enable Service Access by entering the appropriate security password as
described on page 15. Once password is entered go to the Options menu under PROG, choose the option to
be enabled and press the ENTER pushbutton on the DEKKER Controller. The key code is a nine digit number
with the first two numbers as zeroes. After the two leading zeroes, enter the seven remaining numbers that
are supplied by DEKKER in the option kit that was sent for the upgrade. After using the UP-ARROW / +
button and the DOWN-ARROW / - button on the DEKKER Controller to scroll to the appropriated digit,
press the ENTER button to accept each digit of the key code. The key code will look similar to the following;
“001234567.” Once the key code is accepted, the N/A changes to YES.
Please contact local dealer or factory with any questions on available options and the benefits of each option.
Maintenance Menu
Pressing the MAINT button once will display information similar to the following:
DEKKER Vacuum Tech
1-888-925-5444
Serial # (of System)
Model # (of System)
Pressing the MAINT button twice will display the following information:
Spare Parts List
The Spare Parts List includes recommended parts and their corresponding DEKKER part numbers. The
UP and DOWN ARROW buttons can be used to navigate through the list. Contact DEKKER After
Sales Support or your local distributor for additional information or to order parts.
Pressing the MAINT button three times will display the following information:
Recommended Maintenance Schedule and Intervals
Run Hours
The Run Hours are the total number of run hours on the vacuum system
Service History
DEKKER Vacuum Technologies, Inc. – Vmax/July 2016
20
Pressing the MAINT button four times will display the following information:
Maintenance Schedules
This list provides a recommended maintenance schedule along with intervals. The time in hours until
the maintenance is due counts down and can be seen on the DEKKER Controller LCD in this area.
Proper maintenance is necessary to provide proper performance and can prolong the life of your
system. The UP and DOWN ARROW buttons can be used to navigate through the list. Proper
response and service of service due message is highly recommended. Contact DEKKER After Sales
Support or your local distributor for additional information.
Pressing the MAINT button five times will display the following information:
Service History
Important details about your DEKKER systems service history can be accessed under this menu.
In order to have the Service History record a service event, Service Access must be enabled via
proper password. Once in the service history menu, when the hours to next service is set to the
appropriate level, the change will be recorded by date and time.
Resetting the 500 Hour Service Maintenance Alarm
1. Hold Escape button until you see “password” at the bottom of the screen
2. Press the maintenance button twice to enter service password “033”
3. Press the enter button
4. Press Maintenance button until you see the Maintenance Schedule
5. Use UP/DOWN Arrows to highlight Hrs To Srv
6. Press Enter
7. Press up arrow to reset to change hours to next maintenance schedule 500 hours this will reset
the 500 hr maintenance period (Note: Do not change this value unless you are getting the warning
screen)
8. Press Enter to save
9. Press escape button to reset
Multi-Machine and Panel Communication
VMX Units that have the Multi-Machine feature enabled, can be networked by ‘daisy chaining’ a Shielded 2
Wire connector at the indicated Terminal Strip Locations. (MFG Date 10/2015 – Current)
Example, Connecting a Triplex: A+B+SH of Unit 1 to A+B+SH of Unit 2 to A+B+SH of Unit 3. Unit 3 will
NOT connect back to Unit 1
For systems with MFG Date PRE 10/2015, use the ports labeled ‘RS485’ to Daisy Chain the units.
Communication cable will be RS485 with RJ45 Jack.
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Dekker VMAX SERIES Installation, Operation & Maintenance Manual

VMAX SERIES
Brand
Dekker
Model
VMAX SERIES
Type
Installation, Operation & Maintenance Manual
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