Idex Corken Coro-Vac CPS1X Installationsanleitung

CPS1V

CPS4V

CPS6R

IMPORTANT

INSTRUCTIONS

OILLESS SERIES CORO-VAC

MODEL CYLINDER/TANK

PURGING SYSTEMS

IG100

This is the hazard alert symbol: When you see this symbol, be aware that personal injury or

property damage is possible. The hazard is explained in the text following the symbol. Read the

information carefully before proceeding.

The following is an explanation of the three different types of hazards:

DANGER Severe personal injury or death will occur if hazard is ignored.

WARNING Severe personal injury or death can occur it hazard is ignored.

CAUTION Minor injury or property damage can occur if hazard is ignored.

ASSEMBLY INSTRUCTIONS

1. Carefully remove the Corken Coro-Vac Cylinder Purge System from the shipping container

and inspect for any damaged components. Any loose or damaged components should be

reported to Corken, Inc. immediately.

2. Your Corken Coro-Vac Cylinder Purge System includes one vacuum pump. One inlet

hose assembly with fittings and vacuum gauge will be included loose with the vacuum

pump assembly.

3. Install inlet filter and muffler assemblies on CPS6R models only. Refer to exploded view.

4. Apply pipe thread sealant to the male pipe threads on the inlet hose assembly. Remove the

plastic plug over the inlet and install the inlet hose.

5. If necessary, install motor and coupling guard on CPS6R models only. Ensure that the unit

operates satisfactorily. If the unit does not operate properly, see the troubleshooting guide.

CYLINDER PURGING INSTRUCTIONS

This Corken Coro-Vac Cylinder Purge System may be used on multiple cylinders. The following

instructions apply regardless of the number of cylinders being purged. However, the inlet hose of

the Coro-Vac should be connected to a cylinder manifold instead of a single cylinder valve for

multiple cylinder purging.

1. Do not attach to any cylinder that contains LP Gas. This unit is to be used to purge air only.

2. Carefully read all instructions contained in this booklet before use. All warnings should be fully

understood before operation of this unit. Failure to comply with these warnings could result in

severe injury or death.

3. Vent any positive pressure through the cylinder outage or bleed valve before connection of

inlet hose. Retighten after pressure is vented.

4. Connect the inlet hose to the cylinder valve and tighten securely by hand.

5. Open the cylinder valve and switch on the Coro-Vac and allow the unit to pull 2 psia (see chart).

6. Close the cylinder valve and switch off the Coro-Vac.

7. Disconnect the inlet hose from the cylinder valve. The cylinder in now ready to be filled by

authorized personnel.

The following guide can be used to estimate required purge times for multiple cylinders:

*Purge times may vary depending upon cylinder valve manufacturer and

other restrictive fittings.

Number of Cylinders Coro-Vac Model Estimated Purge Time*

1-3 CPS1V/1X 2- 6 minutes

1-15 CPS4V/CPS4X 1 -15 minutes

500 Gallon Tank CPS6R 20 minutes

ATMOSPHERIC PRESSURE BY ALTITUDE

FOR CYLINDER PURGING

Altitude Above Atmospheric Barometer Gauge Reading Gauge Reading

Reference City Sea Level (ft) Pressure (psia) Reading (in. Hg) at 2 psia at 5 psia

Boston, PA 0 14.69 29.92 25.85 19.74

500 14.43 29.38 25.31 19.20

1000 14.17 28.86 24.78 18.68

1500 13.91 28.34 24.26 18.16

2000 13.66 27.82 23.75 17.64

Tucson, AZ 2500 13.41 27.32 23.24 17.13

3000 13.17 26.82 22.74 16.64

3500 12.92 26.32 22.25 16.14

4000 12.69 25.84 21.77 15.66

4500 12.45 25.36 21.29 15.18

Albuquerque, NM 5000 12.22 24.89 20.82 14.71

5500 11.99 24.43 20.35 14.25

6000 11.77 23.97 19.90 13.79

6500 11.55 23.52 19.45 13.34

7000 11.33 23.08 19.01 12.90

Mexico City, Mex 7500 11.12 22.65 18.57 12.46

8000 10.91 22.22 18.15 12.04

8500 10.70 21.80 17.73 11.62

9000 10.50 21.38 17.31 11.20

9500 10.30 20.98 16.91 10.80

Kenosha Pass, CO 10000 10.10 20.58 16.51 10.40

AIR CONTENT

Container Evacuated to 2 psia Conatiner Evacuated to 5 psia

Container Pressure Percentage Air Content Percentage Air Content

psig % %

0 13.3% 34.2%

25 4.9% 12.7%

50 3.0% 7.8%

60 2.6% 6.7%

75 2.2% 5.6%

100 1.7% 4.4%

125 1.4% 3.6%

150 1.2% 3.1%

175 1.0% 2.7%

200 0.9% 2.3%

The approximate container air content as a percentage of the total gas vapor mixture at standard

conditions using Dalton’s andAmagat’s Laws at two points with the empty container’s air volume

evacuated to 2 and 5 psia before being filled with propane vapor to gauge pressure is as follows:

*Dalton’s Law states that the total pressure of a mixture of gases is equal to the sum of the partial

pressures and each component of the mixture at its partial pressure occupies the total volume.

*Amagat’s Law states that if each component in a mixture of gases could be segregated at the

same temperature and pressure as the mixture, the sum of the separate volumes would equal

that of the original, and the partial pressure of each component would equal the total pressure.

GENERAL INFORMATION

This pump is only to be used for the purpose

of pumping air and under no circumstances

be used with any other gases. The pump

must not be used for the pumping of fluids,

particles, solids or any substance mixed

with air, particularly combustible substances

likely to cause explosions.

DANGER Do not pump flammable or

explosive gases, or operate

the unit in an atmosphere

containing them without

appropriate motor and

electrical connection.

CAUTION The exhaust air of this pump

can become very hot. Do

not direct exhaust air

towards property that is

temperature sensitive.

CAUTION This pump is designed for air

only. Do not allow corrosive

gases or particulate material

to enter the pump. Water

vapor, oil-based contaminants,

or other liquids must be

filtered out.

Ambient temperature should not exceed

40°C (104°F). For operation at higher

temperatures, consult the factory.

Performance is reduced by lower

atmospheric pressure found at high

altitudes. Consult a Corken distributor

for details (see chart).

Never lubricate this oil-less air pump.

The sealed bearings are grease packed,

and the service life of the rings or vanes

will be reduced by petroleum or

hydrocarbon products.

INSTALLATION

WARNING To avoid risk of

electrocution do not use

this product in an area

where it could come in

contact with water or other

liquids. If exposed to the

elements it must be

weather protected.

WARNING Beware of any exposed

moveable parts. Proper

guards should be in place

to prevent personal injury

or death.

CAUTION Do not block the flow of

cooling air over the pump in

any way.

CAUTION Do not lift the unit by the fan

shroud, filters or mufflers.

MOUNTING

This pump may be installed in any

orientation as long as the flow of cool,

ambient air over the pump is not blocked.

To reduce noise and vibration, mount to a

stable, rigid operating surface. If mounted

outside, cover or shield from the elements.

PLUMBING

To prevent air flow restriction, use pipe

and fittings that are the same size or

larger than the threaded ports of the

pump. The ports are marked "IN" and

"OUT”. Be sure to remove port plugs

before operating unit.

ACCESSORIES

Intake and exhaust filters are external to

the pump and will provide adequate

filtration for most applications. Check

filters periodically and replace when

necessary. Consult a Corken

representative for additional filter

recommendations. Install relief valves

and gauges at the inlet or outlet, or both,

to monitor performance. Check valves

may be required to prevent

backstreaming through the pump.

WIRING

WARNING Incorrect wiring can result in

electric shock. Wiring must

conform to all required safety

codes and be installed by a

qualified person. Grounding

is required. All power to the

motor must be de-energized

and disconnected when

servicing.

ELECTRIC MOTOR CONTROL

The motor must be protected against

short circuit, overload and excessive

temperature rise. Fuses, motor protective

switches and thermal protective switches

provide the necessary protection in these

circumstances. Fuses only serve as a

short circuit protection of the motor (wiring

fault). Fuses in the incoming line should be

chosen so as to be able to withstand the

starting current of the motor, not as a

protection against overload. Motor starters,

incorporating thermal magnetic overload,

or circuit breakers protect the motor from

overload or reduced voltage conditions.

Selection of the correct overload setting is

required to provide the best possible

protection. Refer to the motor starter

manufacturer's recommendations.

GROUNDING INSTRUCTIONS

Check with a qualified electrician or

serviceman if the grounding instructions are

not completely understood, or if in doubt as

to whether the product is properly grounded.

FOR ALL GROUNDED, CORD-

CONNECTED PRODUCTS: This product

should be grounded. In the event of an

electrical short circuit, grounding reduces

the risk of electric shock by providing an

escape wire for the electric current. Some

units are equipped with a cord having a

grounding wire with an appropriate

grounding plug. The plug must be

plugged into an outlet that is property

installed and grounded in accordance

with all local codes and ordinances.

DANGER improper installation of the

grounding plug can result in

a risk of electric shock. If

repair or replacement of the

cord or plug is necessary do

not connect the grounding

wire to either flat blade

terminal. The wire with

insulation having an outer

surface that is green, with or

without yellow stripes, is the

grounding wire.

FOR A GROUNDED, CORD-

CONNECTED PRODUCT RATED LESS

THAN 15 AMPERES AND INTENDED

FOR USE ON A NOMINAL 120v, or 220-

240 VOLT SUPPLY CIRCUIT:

This product is for use on a nominal 120v

or 220-240 volt circuit, and has a

grounding plug, Make sure that the

product is connected to an outlet having

the same configuration as the plug, No

adapter should be used with the product.

FOR PERMANENTLY CONNECTED

PRODUCT:

This product should be connected to a

grounded, metallic, permanent wiring

system, or an equipment grounding

terminal or lead on the product (refer to

wiring diagram). Explosion proof versions

should be installed per code.

EXTENSION CORDS:

Use only a 3-wire extension cord that has

a 3-blade grounding plug, and a 3-slot

receptacle that will accept the plug on the

product, Make sure your extension cord

is in good condition. When using an

extension cord, be sure to use one heavy

enough to carry the current that your

product will draw. For lengths less than

50 feet, 16 AWG extension cords should

be used.An under-sized cord will cause a

drop in line voltage resulting in loss of

power and overheating.

ELECTRIC MOTOR CONNECTION

Refer to the motor nameplate for wiring

diagram. If the motor fails to start or

slows down under load, shut the pump off

and unplug it. Check that the supply

voltage agrees with the motor nameplate.

Be sure the 3-phase motor turns in the

proper direction of rotation after

installation. Turning in the wrong direction

will drastically reduce vane life, result in

overheating and cause unit damage.

OPERATION

Solid or liquid material exiting the unit can

cause eye or skin damage. Keep away

from air stream.

WARNING Some models are equipped

with glass jars. Proper

measures should be taken

to guard against the

fragmenting of breaking

glass if an alternate material

is not used. If hazard is

ignored, severe personal

injury of death can occur.

WARNING Always disconnect the

power before servicing.

The motor may be thermally

protected and will restart

automatically when it cools

if the thermal protection

switch is tripped.

WARNING Pump surfaces can become

very hot during operation.

Do not touch these surfaces

until unit has been shut off

and allowed to cool.

WARNING Do not operate without both

the coupling guard and

shroud in place. Failure to

do so could result in severe

personal injury.

CAUTION Do not operate units above

recommended pressures

or vacuum duties. To do so

will damage the unit.

Starting

If the pump is extremely cold, let it warm

up to room temperature before starting. If

the pump does not operate property, see

the Troubleshooting Guide.

WARNING Some models may exceed

85 dB(A). When in close

proximity to these models,

hearing protection is

required.

INSPECTION AND MAINTENANCE

Regular inspection can prevent

unnecessary damage and repairs. The

intake and exhaust filters require periodic

inspection and replacement. Initial

inspection is suggested at 500 hours,

then the user should determine the

frequency. Keeping filters clean can

prevent most problems. Dirty filters

decrease pump performance and can

diminish pump service life.

FILTER

INSPECTION / REPLACEMENT

The unit may become very hot during

operation. Do not touch until the pump

has been turned off and allowed to cool.

Refer to exploded view drawing during

the following procedure.

Make sure the pump is turned off, isolated

from the power supply, and that all pressure

and/or vacuum is released from the pump.

Remove filter cover and inspect felt. If

the felt is completely contaminated, it

must be replaced. Replace felt and

install cover.

Before putting the pump back into

service, ensure that any external

accessories such as relief valves and

gauges attached to the cover have not

been damaged.

SERVICE KIT INSTALLATION

NOTE: Corken will not guarantee the

performance of a field-rebuilt pump. You

can return the pump to a Corken

authorized service facility, or perform the

following rebuild procedures.

Kits contain most or all of the following.

Head gasket, Valves, Cylinder gasket,

Piston Ring, Piston Seal, Rider Ring,

Felts and Vanes. Kits are used for several

models and may contain extra parts not

applicable for your specific model. Refer

to exploded view.

Disconnect the pump from electrical power.

WARNING You must disconnect the

pump from electrical power

before you service it. Failure

to do so can result in severe

personal injury or death.

Pump Disassembly CPS1V, CPS1X,

CPS4V, CPS4X

Remove the shroud, cylinder head, and

valve components. DO NOT re-arrange

the valve components. Remove the

cylinder and rings. Make sure all parts

are clean before reassembling. DO NOT

use any chlorinated solvents to clean

valves, or any liquids to flush units, THE

STAINLESS STEEL VALVES MAY BE

CLEANED WITH WATER. All parts,

except the valves, can be cleaned with

any industrial, nonflammable, nontoxic,

non-petroleum based cleaning solvent.

Assembly:

• Install piston seals, piston rings, and

rider rings on the piston.

• Locate ring joints approximately opposite

each other.

• Attach cylinder to bracket with the

cylinder screws and washers.

• Tighten screws finger tight. Move

pistons to top dead center position.

• Adjust each cylinder flush with top of

piston and Torque cylinder screws to

150-160 inch lbs.. Retorque second time.

• Stack the valve components in order as

originally assembled.

• Install the cylinder head and head screws.

NOTE: The exhaust ports in the cylinder

heads have been marked by

omitting the ends of two of the fins.

• Do not tighten head screws at this time,

Install manifold nuts and seals on the

manifold and assemble into the other

cylinder head and manifold.

• Torque all head screws to 150-160

inch lbs.

• Turn fan by hand at this point to

ensure that the rod assembly is not

hitting the head.

NOTE: If rod assembly does hit head,

loosen cylinders and re-adjust.

• Position manifold and tighten Manifold

nut 1/2 to 3/4 turns beyond hand tight.

• Retorque head screws again after

running for 10 minutes.

CPS6R

3. Remove the shroud and fan.

4. Use a wheel puller to remove the

dead-end plate and bearing from the

pump body; note the direction of the

bevel edge on the vane. Do not

damage the dowel pins between the

end plate and the body. Save the

bearing spacer on the dead-end of

the shaft for reassembly. Remove

the snap ring from the end plate.

Save the snap ring, belleville

springs, and washer for reassembly.

5. Remove the bearing from the dead-

end plate.

6. Check the exposed surfaces of the

rotor, body, and end plate for scoring.

If you find no scoring, you can perform a

Minor Rebuild to replace only the vanes

and the deadend bearing.

If you find severe damage, perform the

Major Rebuild.

Minor Rebuild

7. Install the new vanes supplied with

the kit. Be careful to face the vane

bevels in the proper direction (as

noted in step 4).

8. Place end plate over the shaft with

dowel pins aligned. Place bearing

spacer on dead end of shaft. Place

the new bearing in its bore in the

dead end plate. Be careful to press

only on the inner bearing race.

9. Install and tighten the pump body

bolts. Install the belleville springs

with the washer between them, and

the snap ring.

Major Rebuild

7. Remove the drive end cap, Use a

wheel puller to remove the drive-end

plate and bearing from the body. Do

not remove or damage the dowel

pins in the body. Save the deflector

and endplate gasket for reassembly.

8. Place one of the new bearings in its

seat in the drive-end plate, then

place one of the shoulder rings on

the drive-end of the shaft. Using an

arbor press, press the bearing onto

the shaft. Be careful to press only on

the inner bearing race. Tighten the

pump body bolts.

9. Install the new vanes supplied with

the kit. Be careful to face the vane

bevels in the proper direction (as

noted in step 4).

10. Perform step #8 from Minor Rebuild.

11. Install the belleville springs with the

washer between them, and the snap

ring. Install and tighten the pump

body bolts.

12. Apply a thread-lock adhesive and

start the drive-end cap into its thread

in the drive-end plate, but do not

tighten it.

13. Place a dial indicator against the

dead-end of the shaft to measure axial

movement. Tighten the drive-end cap

until the indicator shows .002”.

14. Clean and reinstall filters.

Vacuum Motor Excessive Won’t

Possible Reason Low High Overheating Overload Noise Start

Dirty Filter X at pump X X X

Dirty Muffler X X X

Plugged Vacuum Line X at pump X X

Vanes Sticking X X

Running at Too High RPM X X X X

Rings / Vanes Worn X X

Shaft Seal Worn (Replace) X

Particulate Material in Pump X X X X

Motor Not Wired Correctly X X X

Damaged / Dirty Valves X X

Improper Cylinder Alignment X X

TROUBLESHOOTING GUIDE

NO. DESCRIPTION QTY.

1 Muffler Assembly 1

• 2 Felt 1

3 Inline Filter (not shown) 1

4 Cylinder Head 1

• 5 Head Gasket 1

• 6 Valve, Outlet 1

7 Valve Plate 1

• 8 Valve, Inlet 1

• 9 Cylinder Gasket 1

10 Cylinder 1

• 11 Piston Ring 2

• 12 Piston Seal 2

• 13 Rider Ring 1

14 Piston Rod Assembly 1

15 Counter Weight 1

16 Flat Key 1

17 Fan 1

18 Shroud 1

• Denotes parts included in the Service Kit #5217.

CPS1V, CPS1X EXPLODED VIEW AND PARTS ORDERING INFORMATION

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