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Vacmobile SVM 2S Series Instructions - Operation & Service

svm-2s-service-notes-pdf-iconThis instruction manual provides general instructions for the Vacmobile SVM 2S series of vacuum systems.  This series of machines accommodates a number of vacuum pump models.  Service information specific to a pump model should be obtained from the pump maker’s information. 
NOTE: For easiest reading and the latest update, please download the PDF.


General informationservice-instructions-SVM2S1-i01

Vacuum pump Refer to model plate on pump.
Pumping capacity Refer to model plate on pump.
Maximum vacuum Refer to model plate on pump, typically better than 20 mbar,
98% vacuum, 15 Torr, 29.3” Hg,
-14.4 psi, -99.3 kPa.
Resin catchpot 12 litres (3.1 US gallons)
Trap lid connections With pressed steel lid - up to 4.
With aluminium lid - up to 8.
Connections are available in 4 optional sizes to suit the following outside diameter extruded tubes: 3/8” to
10 mm, 1/2” to 13 mm, 5/8” to 16 mm, or 19 mm to 3/4”.
Power supply Refer to model plate for machine. Typically 230 V, 50/60 Hz,
or 110 V/60 Hz.
Dimensions Assembled as shown:
Length   465 mm (18.3”)
Width    440 mm (17.3”)
Height   1,125 mm (44.3”)
(Varies slightly with trap options)
With trap and handles removed
for transport:

Length   465 mm (18.3”)
Width    345 mm (13.6”)
Height   615 mm (24.2”)
Weight Varies with pump model, from approximately 43 kg (95 lbs) to
56 kg (123.5 lbs)

Main parts - viewed from manifold sideservice-instructions-SVM2S1-i02

(Typical parts shown, not necessarily fitted to all machines)

Key:

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
Resin trap lid (optional aluminium lid shown)
Vacuum tubing gland on trap lid
Resin trap handle (for optional aluminium lid)
Vacuum gauge
Regulation valve (optional & position may vary)
Isolation valve for vacuum regulator (if fitted)
Manifold block
Absolute pressure gauge connection
Pump isolation valve
Oil filler plug
Oil level indicator
Oil drain plug
Pump model plate
Pump exhaust
Machine serial number plate & power details
Spare parts box holder
Switch

Main parts - viewed from handle sideservice-instructions-SVM2S1-i03

Key:

R
S
Pump inlet filter
Power cord retainer

Safety

Any damaged electrical components on the machine should be repaired or replaced by a qualified electrician before the machine is used.

Disconnect the power supply before servicing the pump or its motor.  If the power cord is damaged replace it immediately.

A high level of vacuum is generated.  Hoses from the machine should not be applied to any part of the body, especially sensitive tissue such as the eyes or ears.

When used for clamping or lifting, large forces can be generated.  Care should be taken to avoid trapping any part of the body between clamping surfaces.

Vacuum may be lost in the event of power or mechanical failure.  Vacmobiles must not be used for any lifting operation where loss of vacuum could be dangerous.

This machine is intended for use in dry environments.  Do not use in wet conditions and do not clean by washing with a liquid spray.

The electrical components of this machine are not explosion proof.  Do not use in a potentially explosive atmosphere.


Limitations & cautions

The vacuum pump must not be allowed to ingest resin or other liquids.

The system must not be operated without a resin catchpot in the resin trap.

The vacuum pump must be filled with oil before start-up.

The machine must only be transported and operated with its base panel horizontal.

The Vacmobile must not be used as a vacuum cleaner.  It is designed for use in composite manufacturing processes such as vacuum infusion, vacuum bagging over wet laminate, vacuum bagging over pre-preg and similar applications.

Do not lift machine by its pipe work, or attempt to re-tighten any internal joints.  Lift from the machine panels or the handles only.

Ambient temperature limits.
MINIMUM allowable operating temperature = 10°C (50°F)
MAXIMUM allowable operating temperature = 40°C (100°F)


Preparing for useservice-instructions-SVM2S1-i04

Lock the castors prior to working on machine

Lock castors before doing any work on the machine.


Fit handles to the top panelservice-instructions-SVM2S1-i05

Fit handles using the bolts supplied.  Note that the shorter bolt fits over the corner post.


Slide pump out one notch before oil filling (excluding EM12/B pump)service-instructions-SVM2S1-i06

To prepare for adding oil to the pump, unlatch the panel locking spring and slide the pump out one notch, about 75 mm (3”).

THIS STEP NOT REQUIRED FOR EM12/B VACUUM PUMP.  THIS PUMP MAY BE FILLED IN PLACE.


Add oil to the vacuum pump!service-instructions-SVM2S1-i07

The pump must be filled with the correct grade of oil before use.  For the pump models fitted to the SVM 2S, the correct grade will be an ISO 68 (SAE 20) vacuum pump oil.  Approximate fill volumes are:

Pump Model      Amount ml/pints
PVR EM12/B      330 ml/0.7 pint
PVR EM20/B      450 ml/0.9 pint
Becker U4.20     450 ml/0.9 pint
PVR EM28/B      750 ml/1.5 pints

DO NOT OVERFILL!  Fill to ¾ level on the sight glass maximum.

 


Fit the resin trapservice-instructions-SVM2S1-i08

Slide the resin trap into the top docking position.  The trap control manifold can face the handle side or face away from the handles as preferred.  Push the trap in until its base panel latches in place.

 


Removing the resin trap lid (aluminium lid only)service-instructions-SVM2S1-i09

To remove the aluminium resin trap lid, push down on the handles and rotate them until the cap screw below the handle disengages from the trap body.  With both cap screws disengaged, the lid may be lifted off.  

If the lid gasket is stuck, “bump” the lid with the palm of your hand.


Check there is a catchpot in the trap!service-instructions-SVM2S1-i10

The machine must not be used without a catchpot in the resin trap!

For resin degassing, a polyethylene bucket is available as an option.  The polyethylene bucket must not be used for catching large volumes of exothermic resin, as there is a risk it will melt.


Fitting the resin trap lid (aluminium lid only)service-instructions-SVM2S1-i11

Before fitting the lid, check that the cap screws below the handles face away from the resin trap body.

Position the lid on the trap and rotate the two handles until the two cap screws lock underneath the lip on the trap body.

 


Connect the resin trap to the vacuum pumpservice-instructions-SVM2S1-i12

  1. Check that the hollow aluminium gland nuts are slightly loose on the connection points below the resin trap control manifold and on the pump’s inlet filter.  
  2. Insert the black plastic ends of the silicone rubber hose into the 2 connections as shown.
  3. Tighten the aluminium gland nuts hand tight only.  Excessive torque will not be required.

 


Fit the vacuum gauge and vent itservice-instructions-SVM2S1-i13

  1. The vacuum gauge will have been packed in protective padding for transport.  Unpack it and insert the gauge stem into the orange coloured socket on top of the control manifold.
  2. When ready to use the machine, flip the yellow lever on top of the gauge to the OPEN position.  This allows the gauge to vent to atmosphere.

Note: To remove the gauge for future transport, push down on the orange socket to release the lock.

 


Connect and retain the power cordservice-instructions-SVM2S1-i14

Connect the power cord and retain as shown.

 


Blanking plugs and vacuum tubing connectionsservice-instructions-SVM2S1-i15

The vacuum tubing connections are designed for smooth walled extruded vacuum tubing, usually translucent polyethylene. To fit a tube:

  1. Unscrew the knurled aluminium nut approx half a turn  
  2. Pull out the blanking plug and store safely for re-use
  3. Cut tube end square with a tubing cutter and push through the hollow gland nut until it comes to a firm stop
  4. Tighten the gland nut finger tight only.

 


Cold start-up (less than 15°C/60°F)service-instructions-SVM2S1-i16

To ease the motor starting load when the pump is cold:

  1. Open the valve below the vacuum regulation valve
  2. Open the valve above the pump
  3. Depress the brass knob on the vacuum regulation valve and release all vacuum
  4. Operate the start switch

If ambient temperature is above 15°C (60°F), the pump may be started with the valves in any position.


Adjusting the vacuum levelservice-instructions-SVM2S1-i17

For a regulated level of vacuum, open the valve below the vacuum regulation valve.  Adjust the vacuum level by rotating the aluminium cap on the vacuum regulation valve.

Some resin systems such as polyester and vinyl ester may require a reduced level of vacuum to avoid resin “boil-off”.  Check with your resin supplier, or set the vacuum to -75 kPa (22.5” Hg).

For maximum vacuum, close the valve below the vacuum regulator.


Fitting of absolute pressure gauge (optional accessory)service-instructions-SVM2S1-i18

An absolute gauge is useful for precision vacuum measurement, faster detection of vacuum leaks and the detection of water vapour.  Plug the gauge into accessory socket provided underneath the aluminium manifold block.

 


Oil changing - every 500 hours, or when oil is noticeably discoloured

Regular pump oil changes and dust removal from the motor and pump services will prolong pump life.  While 500 hours is the maximum recommended service interval, the pump should be serviced as soon as the oil becomes noticeably discoloured.

 

Draining the oilservice-instructions-SVM2S1-i19

Make sure the old oil is hot before draining it – after the pump has been running for at least 1 hour.

  1. Lock castors
  2. Unlatch base panel of pump and slide pump out 1 notch (about 75 mm, or 3”)
  3. Place an oil collection container tray of at least 1litre (2 US pints) capacity under the oil drain outlet
  4. Undo the oil drain plug with the appropriate wrench:
    For PVR EM12 pump –17 mm (11/16”) AF socket
    For PVR 20/28 pumps – 22 mm (7/8”) AF socket
    For Becker pumps – 8 mm (5/16”) Allen wrench
    A sharp anti-clockwise tap on the wrench with a soft hammer will help release the plug.
  5. To speed oil drainage, also remove the oil filler plug.
  6. Dispose of old oil carefully; bearing in mind that it will be hot.

Add new oilservice-instructions-SVM2S1-i20

Refill the pump with the correct grade of oil.  For the pump models fitted to the SVM 2S, the correct grade will be an ISO 68 (SAE 20) vacuum pump oil.  Approximate fill volumes are:

Pump Model      Amount ml/pints
PVR EM12/B      330 ml/0.7 pint
PVR EM20/B      450 ml/0.9 pint
Becker U4.20     450 ml/0.9 pint
PVR EM28/B      750 ml/1.5 pints

DO NOT OVERFILL!  Fill to ¾ level on the sight glass maximum.


Remove surface dust at each oil changeservice-instructions-SVM2S1-i21

Use a compressed air nozzle to remove dust from pump and motor surfaces whenever the oil is changed.  This is most effective when the pump is running but do not insert nozzle into moving motor fan!

 


Inspect the inlet filter element at each oil changeservice-instructions-SVM2S1-i22

Unclip the filter cap and inspect the inlet filter element.  Replace if badly contaminated.

Make sure that loose dust does not fall into the inlet of the pump!  If badly contaminated, remove the complete filter unit before removing the filter element.


Replace exhaust oil mist filter - every 2,000 hours, or when motor overload trips

A very fine filter is fitted inside the exhaust cavity of the vacuum pump.  (Refer to pump maker’s exploded parts drawing).  In heavy use, with insufficient oil changes, or with contamination in the incoming air stream this filter will become blocked.  Blockage of the filter may show up in the following ways:

  • Electric motor overload tripping out (especially on start-up)
  • Oil becoming black and replacement oil discolouring rapidly

The filter should be replaced whenever these problems occur, or as routine maintenance at approximately 2,000 operating hours.

 

Parts required for exhaust oil mist filter changeservice-instructions-SVM2S1-i23

The illustrated parts are required for this service.  Also have access to the exploded parts drawing for the appropriate pump model.  Refer to pump section of this manual.

 


Procedure for replacing the exhaust oil mist filterservice-instructions-SVM2S1-i24

  1. If the pump oil is dirty, first run the pump until hot - ideally about 1 hour.  Stop the pump and drain the oil as previously described.  If the oil is very dirty, replace the drain plug and run the pump briefly (less than 5 seconds).  This will remove oil from the pumping chamber.  After stopping the pump, remove the drain plug and drain the remaining oil.  Do not run the pump with the drain plug removed!
  2. Replacement of the exhaust oil mist filter may be performed with the pump in the docking cart, or with the pump removed and placed on a workbench.  If performed in the docking cart, unlatch the pump and slide it out until all of the exhaust cover bolts become accessible.
  3. Barely loosen the cap screws using a 5 mm AF Allen wrench.
  4. Give the cover a sharp sideways tap with a soft faced hammer to break the paint film over the gasket which seals the cover to the exhaust box casting.  This may reduce the risk of breaking the gasket when the cover plate is removed.  Completely remove the cap screws holding the cover in place.service-instructions-SVM2S1-i25
  5. Once the exhaust cover plate is removed, the exhaust oil mist filter will be accessible.  Depending on pump model, remove the filter with either an Allen wrench or by removing the fixing knob by hand
  6. The filter cannot be cleaned and must be replaced with a new one
  7. Inspect the gasket and replace if necessary
  8. Refit the cover plate, noting that the lowest cap screw on some pump models may have a copper washer to prevent oil leakage.  If a copper washer is present make sure it is fitted to the lowest cap screw.

Clean the gas ballast filter – annually and whenever oil mist is replacedservice-instructions-SVM2S1-i26

Mounted on top of the pump is a small external filter.  Its purpose is to introduce a small flow of filtered air into the pump to help discharge contaminants such as water vapour and styrene vapour from the pump.  In dusty atmospheres, this external filter may block.  When the gas ballast filter becomes blocked the pump oil will contaminate more quickly.  In most environments, the gas ballast filter should be cleaned annually.  In very dusty atmospheres, more frequent cleaning may be necessary.

To clean the filter:

  1. Using compressed air, first blow all loose dust from all external surfaces of the vacuum pump – including around the gas ballast filter
  2. Unscrew the gas ballast filter by hand
  3. Blow the filter clean with compressed air from the inside and check that air passes freely through the filter
  4. Replace the filter

Resin trap maintenance (perform as required)

Remove hardened resin from connection glandsservice-instructions-SVM2S1-i27

Remove aluminium gland nuts. Remove and inspect O-rings. Inspect internals of gland fitting and clean out accumulated resin. If necessary, drill out resin from UNDERSIDE of the fitting using the appropriate drill bit.  Twisting the bit by hand will usually suffice. 

Tubing gland size
10 mm (3/8”) OD tube
13 mm (1/2”) OD tube
16 mm (5/8”) OD tube
19 mm (3/4”) OD tube
Drill bit size
8.5 mm (21/64”)
10.5 mm (13/32”)
14 mm (17/32”)
17.5 mm (11/16”

DO NOT DRILL OUT THE TUBE STOP!


Apply liquid mould release to connection glandsservice-instructions-SVM2S1-i28

After removing hardened resin, coat all internal surfaces with liquid mould release.

Refit O-rings, replacing any damaged ones.

Replace aluminium gland nuts, but do not tighten.

Fit tube or plugs as required and hand tighten gland nuts.


Apply liquid mould release to resin trap bodyservice-instructions-SVM2S1-i29

Apply liquid mould release to all internal surfaces (and external surfaces if you wish).

Apply a minimum of 2 wiped on coats or as recommended by the mould release supplier.


 

 

 


Replacement of spatter shield on the underside of the resin trap lidservice-instructions-SVM2S1-i30

If the PVC spatter shield underside of the lid become obscured, replace it as follows:

  1. Pull off silicone rubber tubes and break off any adhering resin by deforming the tube a few times
  2. Fit a new spatter shield
  3. Push the silicone tubes back over the projecting ends of the gland nipples until the shield is in firm contact with the underside of the lid.

 


Instructions for preparing collapsible catchpot for use

While our rigid cardboard catchpot is very effective for catching resin that may reach a high temperature during exotherm, the rigid catchpots are expensive to freight. We are experimenting with a collapsible catchpot which will freight more cost effectively.    This seems to work well up to about 200 0C (400 0F) but may weep slightly when subject to higher temperature. To provide security against resin leakage, we are providing a high temperature nylon outer bag for added protection. The collapsible catchpot will need to be discarded when full, but the nylon outer bag should be reusable. To prepare the collapsible catchpot for use, proceed as follows:

Extend the collapsible catchpotservice-instructions-SVM2S1-i31

Extend the bag and note the marks on both end rings at right angles to the handle axis.










Fit one end of the extender rib 

service-instructions-SVM2S1-i32 service-instructions-SVM2S1-i33
Hook one of the extender ribs over one of the plastic bucket rings approximately at the marked position. Exact positioning is not critical.
Push down on the rib until clips tight over the plastic ring.






Clip on the other end of the extender rib

service-instructions-SVM2S1-i34

service-instructions-SVM2S1-i35
Clip the other end of the extender rib to the opposite plastic ring.  Bow the rib out wards slightly to make it easier to fit, then push down.

Repeat process for the second extender rib.






Assembled catchpot | Assembled catchpot with nylon outer bag

                                                          service-instructions-SVM2S1-i36

Positioning the collapsible catchpot inside the RT19 trapservice-instructions-SVM2S1-i37

Position one of the extenders so that it touches one side of the hollow vacuum pump connection port. This will prevent the collapsible catchpot material being sucked into the vacuum port.

MAKE SURE THE CATCHPOT EXTENDER DOES NOT OBSCURE THE VACUUM PORT.











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