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Defender 500 | 1www.natvac.com | 800.253.5500

Defender 500

Owner’s Record Date of Purchase: _________________________ Purchased from: __________________________ Serial Number: ____________________________

National Vacuum Equipment, Inc.

2 | Defender 500 www.natvac.com | 800.253.5500

C O N T E N T SLimited Warranty .................................................................3 Warranty ........................................................................................3

Defender 500........................................................................7 General Suggestions .....................................................................7 Technical Data and Performances ................................................7 PumpSpecifications ......................................................................8 Drive System .................................................................................9 Factory Settings .............................................................................9

Operating Instructions .....................................................11 Recommended Lubricant ............................................................ 11 Maintenance ................................................................................12 Check Vane Wear ........................................................................12 Cold Weather Operation ..............................................................12

Troubleshooting ............................................................... 13 Pump overheats ..........................................................................13 Pump doesn’t turn .......................................................................13 No vacuum...................................................................................14 Vacuum/Pressure Changeover Valve .........................................15

Pump Layout ....................................................................16 Vacuum Lines .............................................................................16 Technical Dimensions ..................................................................17

Parts Diagram ...................................................................18 Parts List ......................................................................................19


Warranty

National Vacuum Equipment, Inc.

Guarantees that the product it provides is free of manufacturer’s defects, including materials and workmanship. Properly installed and maintained product is warranted for a period of one (1) year subject to the following conditions:

1. A properly completed warranty registration card must be received by us within 30 days of sale to end user for pump sales to be considered warrantable. All pumps received for warranty consideration must retain the original NVE serial number tag.

2. The one (1) year period shall begin the day the product is shipped from our warehouse, unless we are provided with an authentic copy of the original resale invoice, in which case the one (1) year period shall begin at such invoice date.

3. The covered product must be used in an application for which it was intended. We do not recommend our product for particular uses or applications.

4. Vane breakage, or damage caused by vane breakage, is not warrantable.

5. Damage caused by improper use or lack of proper maintenance is not warrantable.

6. Manufacturer’s liability under this or any other warranty, whether express or implied, is limited to repair of or, at the manufacturer’s option, replacement of parts which are shown to have been defective when shipped.

NVE Defender 500

L I M I T E D W A R R A N T Y


7. Manufacturer’s liability shall not be enforceable for any product until National Vacuum Equipment, Inc. has been paid in full for such product.

8. Except to the extent expressly stated herein, manufacturer’s liability for incidental and consequential damage is hereby excluded to the full extent permitted by law.

9. Manufacturer’s liability as stated herein cannot be altered except in writingsignedbyanofficerofNationalVacuumEquipment,Inc.

10. Certain products provided by National Vacuum Equipment, Inc. are covered by their respective manufacturer’s warranties (e.g., engines used in the NVE engine drive packages). These products are not covered by the National Vacuum Equipment, Inc. Manufacturer’s Warranty.

11. Final assemblers responsibility. NVE goes to great lengths to ensure the quality and proper functionality of the products it sup-plies. Many products we supply are purchased for resale or are impossible or impractical to test prior to the installation of the item inavacuumsystem.Itisthereforetheresponsibilityofthefinalassembler to thoroughly test the vacuum system and components suppliedtotheassemblerbyNVEpriortothedeliveryofthefinalproduct to the end user.

12. Not responsible for pump coupling tightness or alignment. Customer needs to inspect periodically to ensure proper alignment and to check tightness of set screws.

Any items found to be defective after delivery to the end user that should have been discovered prior to deliver will qualify replacement of the defective part only with absolutely no compensation for outside labor or travel expenses. Any subsequent damage to other compo-nents caused by the defective part will be the sole responsibility of the assembler.


W A R R A N T Y P R O C E D U R E S

Should a potential warranty situation arise, the following Procedures must be followed:

• Contact your dealer or NVE immediately upon the occurrence of the event and within the warranty period.

• Customer must receive a return goods authorization (RGA) before returning product.

• All serial-numbered products must retain the NVE serial number tagtobequalifiedforwarranty.

• Product must be returned to NVE intact for inspection before warranty will be honored.

• Product must be returned to NVE freight prepaid in the most economical way.

• Credit will be issued for material found to be defective upon our inspection, based upon prices at the time of purchase.


_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes


The sliding vane vacuum pump, cooled by ballast air induction, are supplied complete with:

• High temperature asbestos-free vanes

• Forced lubrication, oil pump with a remote oil tank

• 4-way vacuum/pressure changeover valve

• Non-return check valve

• Aluminum inlet/outlet connections

• “Ballast Port” cooling

General Suggestions ____________________________________________

• Designedforextendedoperation

• Ordinary and extraordinary maintenance has to be done while the unit is stopped and the drive disconnected.

• Repairs on plumbing have to be done after disconnecting pressure/vacuum from the same.

• Never start the pump if adequate safety devices are not installed. Damaged safety equipment must be immediately replaced.

• Be aware that the pump’s body can reach temperature of over 280o Fahrenheit.

• Maximumspeedshowninthetechnicalspecificationstablesmustnotbeexceeded.

N V E D E F E N D E R 5 0 0Model-SpecificInformation

Technical Data and Performances ____________________________


Pump Specifications _____________________________________________

PERFORMANCE AT 1200 R.P.M. - MAX SPEED

Normal Use _______________________________________________________ • The Defender 500 used for the suction of air for the movement of

liquids. Should be run at a max pressure of 21.8 PSI and a max vacuum rate of 92%.

• As cooling is given by atmospheric air through the ballast system pumps used to pressurize are for non-continuous duty.

• Overheating the pump will cause serious damage to the pump and/or rotor seizure.

• Inordertomaximizeefficiencyoftheballastaircoolingsystem,thefiltersmustbekeptclean.

Air Flow - CFM free air 310

Air Flow - CFM 60% vacuum 257

Max vacuum - % 92

Max absolute pressure-PSI 21.8

Weight-LBS 397

Oil consumption g/h=(drops / min) total 135 (80)

Remote Oil tank capacity - QT 5

Sound level at 60% vac. 7 m, dist - db(A) - with silencer

84

108-500-DCLOCKWISE SHOWN

SCALE 1 / 4

SECTION F-FSCALE 1 / 2SECTION G-G

SCALE 1 / 2

108-500-SCCW SHOWNSCALE 1 / 4

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

NVE NationalVacuum

Equipment, Inc.2670 Aero Park Drive, Traverse City, MI 49686Phone: (231) 941-0215 Fax: (231) 941-2354

TOLERANCES UNLESS OTHER WISE SPECIFIED

One place (.X) ±.1Two places (.XX) ±.01Three places (.XXX) ±.005Angles ±1°

All machined surfaces 125 RMS max.Remove all burrs and sharp edges.CAD drawing - NO manual changes.All dimensions in inches unless specified.

This document may contain confidential tradesecret information which is the exclusive

property of National Vacuum Equipment. Anyinformation on this drawing is not to be

disclosed to anyone not having a "Need toKnow." The information contained herein is to

be used only in accordance with the bestinterests of National Vacuum Equipment.

PART NAME:

MATERIAL:

DRAWN BY:

SCALE:

CHECKED BY:

DATE:

BOB

PART NO.SHEET

2 108-500-D OR S2 of

SEE BOM

APPROX. WT.CAD FILE LOCATION: P:\Data\CAD - Production\108-500-D OR S.idw

SHEET SIZE D

DEFENDER 500, CW OR CCW

F

F

G

G(6.890)

(9.815)(4.908)

(.752)

(11.170)(11.417)

(5.275)

(31.617)

(8.751)

(3.000)

(3.150)

(16.879)(8.195)

(21.726)

(1.499) (1.375)

(1.289)

(.375) SQ(.3125) SQ

(1.201)

13.000

REVISION HISTORYREV DATE DESCRIPTION APPROVED ZONE

A 4/27/10 COMPLETE REDESIGN OF ASSEMBLY ECN 1126 -

B 6/9/2010ITEM 22 802-063-500 WAS

120-063-500, CORRECT OILPUMP

ECN 1132 C2

Filter

Valve

Figure 1


• The pump must be installed so that it is easily accessible for inspection and maintenance.

• The vacuum pump must be installed on a rigid base or stand. The drive can be by shaft, belts and pulley, or hydraulic motor.

• The drive shaft must be mounted so that it does not create any axial thrust; the inclination of the shaft must not exceed 15 degrees (seefig.2)

• When using belts and pulley, the pulley can be mounted directly on the rotor shaft on the larger diameter inboard portion of the shaft. The alignment between the pulley of the pump and the driving pulley must be thoroughly checked. The tension must be adjusted sothebeltsflexforabout1/16th between pulleys. • The direction of rotation and RPM are marked on the front of the pump.

• The direction of rotation required by your drive system should be determined prior to ordering the pump.

Drive System ______________________________________________________

Direction of Rotation ___________________________________________

7

4. Installation

4.1 Checking at arrival

- upon receipt check that the pump and related accessories arenot damaged.

4.2 Pump mounting / Drive connection

- The pump must be installed so that it is easely accessible forinspection and maintenance.

- The vacuum pump must be installed on a rigid base or stand.The drive can be by cardan shaft, belts and pulley or by hydraulicmotor.

- The cardan shaft must be mounted so that it does not create anyaxial thrust; the inclination of the shaft must not exceed 15° (seefig. 2).

- When using the belts and pulley, the pulley can be mounteddirectly on the rotor shaft eccept for R 430 .For model R 430 pumps the pulley must be mounted with thesuitable support, supplied by JUROP.The alignment between the pulley of the pump and the drivingpulley must be thoroughly checked.The V-belts tension must be normal, that means the belts mustflex for about 2 cm. under the thumb pressure.

- With the hydraulic transmission the motor must be connected bymeans of a support and a flexible joint.

The transmission must be protected accordingto current safety standards (for Europe 89/392 CEE standards).

Check that the actual shaft rotationdirection matches that of the arrow onthe label fixed on the front of the pump.

Fig. 2

15°

Transmission driveVacuum pump axle

axles must be parallel

16 -

20

mm

Flange must beperfectly parallel

V-belts must beexactly in line

- Check that the rotor/shaft is not blocked.

Figure 2


Before starting-up the pump, check oil level in translucent tank. Ifrefillisneeded,usetherecommendedoilsshowninthenextsection.

Verifyoilisflowingthrougheachlineatareasonablerate. Oil lines are translucent to allow viewing oil.

Oil Usage Checking ______________________________________________

• The automatic lubrication pumps are set at the factory during pump testing and should require no further adjustment during pump installation. The pump should consume 12oz - 15oz of oil per hour. Please contact us if oil usage is outside of these parameters.

• It is the responsibility of the installer to ensure proper vacuum relief settings, pressure relief settings and RPM.

Factory Settings _________________________________________________


Recommended Lubricant ______________________________________

• We recommend that non-synthetic turbine oil be used in our pumps. Turbine oil is much more resistant to breakdown due to heat than normal motor oil, thereby avoiding the problems associated with motor oil such as lacquering and excessive wear. Acceptable oils include:

1. *NVE ISO 68 Oil

2. Penzoil Penzabell 68 T.O.

3. Shell Turbo 68

4. Mobil D.T.E. Heavy - Medium

5. Texaco Regal R & O 68

* NVE ISO 68 Oil is our recommended pump oil for the Challenger series vacuum pumps. Challenger Vacuum Pump Oil is sold by the case, six-1 gallon containers of oil per case.

O P E R AT I N G I N S T RU C T I O N S


Ordinary maintenance•Re-fillthelubricationoiltankperiodically

•Checkthatthedriveprotectionsareproperlyfixed

•Cleanthefiltersoftheinjectionvalves(ballastports)

Checking Vane Wear• We recommend checking vane wear at least every 12 months.

• Anewvaneisflushwiththeoutsidediameteroftherotor.

• Unscrewtheplug(fig.3)andinsertarodofdia.1/4”andturntheshaft by hand. With the checking rod touching the outside diam-eteroftherotor,markitafirsttimewithascribe.Continueturningthe shaft until the checking rod falls inside a vane groove touching the vane. Mark the rod a second time. If the distance between the two marks exceeds 3/16” the vanes must be replaced. Once finishedthecheckingprocedurereplacetheplugof(fig.3).

• Vanes should be replaced in sets and it is always a good idea to have an extra set of vanes on hand for emergencies.

Figure 3

Maintenance _____________________________________________________

108-500-DCLOCKWISE SHOWN

SCALE 1 / 4

SECTION F-FSCALE 1 / 2SECTION G-G

SCALE 1 / 2

108-500-SCCW SHOWNSCALE 1 / 4

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

NVE NationalVacuum

Equipment, Inc.2670 Aero Park Drive, Traverse City, MI 49686Phone: (231) 941-0215 Fax: (231) 941-2354

TOLERANCES UNLESS OTHER WISE SPECIFIED

One place (.X) ±.1Two places (.XX) ±.01Three places (.XXX) ±.005Angles ±1°

All machined surfaces 125 RMS max.Remove all burrs and sharp edges.CAD drawing - NO manual changes.All dimensions in inches unless specified.

This document may contain confidential tradesecret information which is the exclusive

property of National Vacuum Equipment. Anyinformation on this drawing is not to be

disclosed to anyone not having a "Need toKnow." The information contained herein is to

be used only in accordance with the bestinterests of National Vacuum Equipment.

PART NAME:

MATERIAL:

DRAWN BY:

SCALE:

CHECKED BY:

DATE:

BOB

PART NO.SHEET

2 108-500-D OR S2 of

SEE BOM

APPROX. WT.CAD FILE LOCATION: P:\Data\CAD - Production\108-500-D OR S.idw

SHEET SIZE D

DEFENDER 500, CW OR CCW

F

F

G

G(6.890)

(9.815)(4.908)

(.752)

(11.170)(11.417)

(5.275)

(31.617)

(8.751)

(3.000)

(3.150)

(16.879)(8.195)

(21.726)

(1.499) (1.375)

(1.289)

(.375) SQ(.3125) SQ

(1.201)

13.000

REVISION HISTORYREV DATE DESCRIPTION APPROVED ZONE

A 4/27/10 COMPLETE REDESIGN OF ASSEMBLY ECN 1126 -

B 6/9/2010ITEM 22 802-063-500 WAS

120-063-500, CORRECT OILPUMP

ECN 1132 C2

Vanes wear control plug


Confirmpumpisnotfrozen.• Priortoengagingthepump,turnbyhandtoconfirmitisnotfrozen.

Ifpumpisfrozen,thawit.• If the pump is frozen, thaw it out by heating the bottom of the pump

with a torch or move the truck into a heated building.

Avoidfreezingproblems• You can avoid freezing problems by putting a small amount of

diesel fuel into the pump at the end of the day.

Cold Weather Operation ________________________________________


Defender 500Vacuum Pump

Cause Correction

Faulty lubrication Check the lubrication

Oilmissing Re-fillthetank

RPM to high Reduce RPM

Operation-time too long at Stop the pump for a while andhigh vacuum let it cool down.

Cloggedfiltersof“ballastport” Thoroughlycleanthefiltersinjection valves.

Cause Correction

Drip-oiler/s badly adjusted Adjustment as described

Oiler’s pin not sealing Clean the related seat.

Cause Correction

Broken vanes due to suction of Dismount the pump and replace damaged parts, foreign objects, damaged parts. Check primary or bad lubrication. shut-off and lubrication system.

Frozen pump Unfreeze the vacuum pump

Damaged drive system Check and replace damaged parts.

Flange bolts too tight Loosen the bolts

TROUBLESHOOTING

Pump overheats ________________________________________________

Pump uses too much oil ________________________________________

Pump doesn’t turn _______________________________________________


Cause Correction

Change-over lever in neutral position Place lever in correct position as shown.

Worn sliding-vanes Replace the vanes

Loose check-valve Replace the valve

Worn lip seals Replace the seals

Blocked vacuum pump See previous instructions

Leaking of the gate-valves on the tank Tighten the valves

Leaking of the seals on the tank Repair or replace the seals

Primary shut-off blocked Dismount and clean the parts

Clogged connecting pipeline Clean the metal pipelines or replace the rubber ones.

No vacuum _______________________________________________________


Layout of vacuum line

1. Primary shutoff 2. Tank 3. Secondary Shutoff 4. SilencerandOilCatchMuffler 5 . Vacuum Pump 6. Safety Relief Valve

• The mounting of a secondary shutoff (pos. 3) is suggested in between the pump and the tank, for protecting the vacuum pump.

• A silencer (pos. 4) is suggested in order to reduce sound level.

6

5

3

6

1 2

66

4

P U M P L A Y O U T


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207


_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes

defender 500 - natvac.com · texaco regal r & o 68 * nve iso 68 oil is our recommended pump oil...

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