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Vacuum Systems

From the simplest pump to elaborate computer-controlled systems, Hope Air Systems provides for its customer’s complete vacuum system requirements. This includes pumps, compressors, filtration, instrumentation, controls, monitors, computer hardware and software and complete installation and training for a total package installation.

Industrial Vacuum Applications
Industrial vacuum applications range from food processing to pharmaceutical, plastics, pneumatic conveying, laboratories, medical, printing, semiconductor and many other industries. To meet these varying requirements, Hope Air Systems distributes vacuum systems using a variety of pump types including:

• oil-recirculating
• dry vane
• once-through-sealing
• claw-type
• rotary lobe
• liquid ring
• dry screw pumps

Through use of centralized vacuum systems, manufacturers are finding a more manageable and cost-effective system for running the shop floor. Costs are less, noise is less, maintenance down-time is less, over-heating is less; in general everything is less – except profits, which are up.

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Types of Systems
There are three basic types of vacuum systems:

• oil-sealed
• water-sealed
• oil-less systems

Depending on the customer’s requirements and budget, Hope Air Systems can help select components and design a system to meet specific manufacturing requirements. There are even applications where a variable speed design may be appropriate.

Custom/Centralized Vacuum Systems
Hope Air Systems has over 40 years experience in designing custom skid-mounted systems to meet specific requirements. Its team of experienced in-house engineers can direct the fabrication of a system customized to each customer’s unique requirements. There are many design criteria taken into consideration for each system. Some of these are:

• Energy efficiency
• Low noise
• Easy access for servicing
• Modular design accommodates expansion
• Built-in back-ups
• Reliable components for durability
• ISO 9001:2000 certified facility
• CE and UL certified facility

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Some additional features and advantages:

• Many different pump technologies
• Condenser, scrubber, separator options
• Construction material resists process vapors
• Variable frequency drive option
• Explosion proof unit available

The installation of a custom central vacuum system eliminates the need for multiple single pumps in certain applications. This reduces energy costs and reduces maintenance as well. A central vacuum system can be arranged in a vertical or horizontal configuration and can be expanded up to a quadruplex system. Skids can be pre-drilled and the inlet manifold pre-piped to accept expansion modules.

A duplex design is perfect for applications where future growth is expected but budget constrains limit initial expenses. Typical applications include:

• Hospital surgical vacuum systems
• Vacuum thermoforming
• ATE central systems
• Robotic applications
• Rubber molding
• Many more

Some important design features are:

• Programmable controller
• Space saving design
• Automatic alternation evens pump wear
• High ultimate vacuum level
• Displacement from 40 CFM to 2260 CFM

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Rotary Screw Vacuum Systems
The rotary screw vacuum packages from Kaeser Compressors range from 10 HP to 40 HP with 99 percent vacuum achievable as a result of the proprietary Sigma Control system. Sigma Control is an innovative controller designed and developed based on an industrial computer. Hope Air Systems’ customers benefit from energy savings, less maintenance, more reliability, enhanced performance and simplified operation. The Kaeser ASV (10-15HP), BSV (20-25HP) and CSV (30-40HP) models are ideal for applications ranging from:

• dust suction
• packaging
• inspection instruments
• bottle and tube filling
• drying
• degassing
• filtration

Kaeser rotary screw vacuum packages feature a solid steel floor with anti-vibration mounts, eliminating the need for special foundations. A powder-coated, sound-dampening enclosure is standard on all models, ensuring low noise levels. The enclosure has wide opening doors and removable panels, providing easy access to all maintenance points. These units include replaceable, cleanable cabinet pre-filter mats to prevent particles larger than 40 microns from entering the enclosure.

Among the standard features on Kaeser vacuum systems are:

• Vacuum airend
  • The rotary vacuum airend with Sigma Profile has oversized bearings to ensure long service life.
• Sigma Control
  • The Sigma Control system is a PC-based control system with Intel processor that monitors all control functions and maintenance items.
• Motor and Starter
  • A TEFC electric motor is EPAct compliant and features class F insulation and a 1.15 service factor.
• Air/coolant system
  • The Kaeser vacuum package is equipped with an air-cooled cooler. A package cooling fan in mounted on the motor drive shaft.

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Rotary Vane Vacuum Systems
Among the modular designed rotary vane vacuum pumps from Busch are the Single-Stage, air-cooled and direct driven style. This oil-recirculating design is one of the simplest and most reliable vacuum pumps available anywhere. These rugged pumps are used in a variety of industries such as:

• packaging
• food processing
• rubber molding
• thermoforming
• printed circuit board testing
• medical
• laboratories
• robotics vacuum lamination
• printing
• woodworking

The operating principle for a rotary vane system is the rotation of the vacuum pump rotor traps entering vapor between rotor vane segments where it is compressed, then discharged into the exhaust box. Exhaust vapors pass through several stages of internal oil and mist eliminators. Oil is then returned to the oil reservoir. Some key design features include:

• Easy installation design
• Air-cooled, requiring no water
• Direct drive, eliminating belts, gears
• Oil mist eliminator for 99.9 percent oil-free exhaust
• No special oil required
• Quiet operation
• Water-cooled version optional

Hope Air Systems recommends the Busch Two-Stage Once-Through-Sealing rotary vane design for certain applications. This design allows engineers the flexibility and performance needed for specific processes, including the choice of several sealing fluids with different vapor pressures.

A small amount of sealant from an external reservoir is continuously metered into the pump cavity for vacuum sealing and lubrication. The sealant washes the internal surfaces, preventing contaminate buildup. It is then discharged with the process vapor into the exhaust system where it is separated and removed. Some features of this system are:

• Coolant temperature control system
• Graphite PTFE exhaust and bypass valves
• Adjustable sealant metering pump
• Grease-lubricated bearings
• Sealant reservoir
• Optional flushing tank
• Protective instrumentation
• Wide selection of sealing fluids

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Liquid Ring Vacuum Systems
A Single-Stage, compact and direct driven pump, such as the liquid ring Busch Dolphin, is able to pump gases, vapors and handle entrained liquids in a continuous operation. The impeller rotates in the cylinder partially filled with water or another liquid medium. The rotation forces the liquid to the outside of the cylinder to form a liquid ring. The entering vapors are trapped within the vane slots between the rotor shaft and the liquid ring where they are compressed and discharged to atmosphere. Some of its key features are:

• Compact design
• Cost effective
• Direct drive
• Single-stage
• Oil-free
• Low maintenance

Rotary Lobe Vacuum Systems
Using an air-cooled, positive displacement design, the rotary lobe vacuum blowers are intended for use in conjunction with a backing pump. They are designed for vertical flow, preventing material buildup within the booster during periods of shutdown and are quiet, vibration-free and non-polluting.

An integral bypass valve permits continuous operation of the booster from atmospheric pressure and protects the motor and pump from overloading. The Busch Panda boosters yield a faster pump downtime than is possible with conventional rotary lobe booster systems and are more reliable because operation is not dependent on pressure or temperature switches. A splash lubrication system in both ends of the booster assures positive lubrication of the bearings and timing gears. Some key features include:

• Vertical flow – self draining
• Horizontal discharge available
• Integral bypass valve
• Continuous operation
• Sealing rings prevent oil from entering chamber
• Gauge parts for auxiliary instrumentation
• Double shaft seals prevent air leakage
• Direct drive motor
• Modular design permits easy service
• Temperature switch optional

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Medical/Laboratory Vacuum Systems
The specialized requirements of medical vacuum systems are well met by Busch vacuum systems, which meet or exceed NFPA 99C guidelines. These systems are engineered and manufactured to provide hospitals and surgical centers with high quality, reliable and low maintenance equipment. Some of the advantages of the Busch medical vacuum systems are:

• Choice of design
  • Oil-lubricated rotary vane
  • Rotary dry-claw
  • Oil-less
• Modular designs
• Expandable designs
• Convenient service points
• Single point service connections
• Vibration-free
• Air-Cooled
• High efficiency motors
• Inlet filters
• Redundant transformers

Normal industrial vacuum systems may not be able to adequately deal with the variety of gases that may enter a laboratory vacuum system. The Busch laboratory vacuum systems are equipped with a manual or automatic purge assembly to remove condensable vapors from the pump prior to shutdown. They also feature special seal materials; corrosion resistant components in the exhaust box; and an exhaust flange adapter to permit remote exhausting of gases.

Some key features include:

• Space saving compact design
• Single point connections
• Exhaust flange adapters
• Venting of gas to remote location
• Automatic purging of gas prior to shutdown
• Lead/Lag operation

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