A500-03-880 Issue D Instruction Manual DP180 Dry Vacuum Pump Description Item Number DP180 pump, 200 V, 3-phase, 50 Hz DP180 pump, 200 V, 3-phase, 60 Hz DP180 pump, 220-240/380-415 V, 3-phase, 50 Hz DP180 pump, 208-230/380/460 V, 3-phase, 60 Hz A403-02-934 A403-12-934 A403-02-935 A403-12-995 Manor Royal, Crawley, West Sussex, RH10 9LW, UK Telephone: +44 (0) 1293 528844 Fax: +44 (0) 1293 533453 http://www.bocedwards.
CONTENTS Section Title Page 1 1.1 1.2 1.3 1.4 1.5 INTRODUCTION Scope and definitions The DP180 pump Gas-ballast boost Temperature control system Accessories 1 1 1 2 2 2 2 2.1 2.2 2.3 2.4 2.5 2.7 TECHNICAL DATA General Performance data Service Temperature control system Lubrication system Noise data 3 3 3 6 6 6 6 3 3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.6.1 3.6.2 3.7 3.8 3.9 3.9.1 3.9.2 3.9.3 3.10 3.11 3.12 3.12.1 3.12.2 3.12.
Section 4 4.1 Title Page OPERATION Start-up 21 4.2 21 Shut-down 21 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 MAINTENANCE Safety Maintenance plan Check the gearbox oil-level Inspect the pipelines and connections Change the gearbox oil Relubricate the rotor bearings Change the head-plate felt filter Change the gas-ballast air filter element Clean the inlet-stage sump Clean the cooling-jacket 22 22 22 23 23 24 24 25 26 27 27 6 6.1 6.2 STORAGE AND DISPOSAL Storage Disposal 28 28 28 7 7.1 7.2 7.
Tables Table 1 2 3 4 Title Full load current ratings Checklist of components Pump-motor terminal-box wiring configurations Maintenance plan Page 3 8 10 23 Associated publications Publication title Vacuum pump and vacuum system safety DP180 Dry Vacuum Pump Publication Number P300-20-000 iii
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1 INTRODUCTION 1.1 Scope and definitions This manual provides installation, operation and maintenance instructions for the BOC Edwards DP180 Dry Vacuum Pump (abbreviated to DP180 in the remainder of this manual). You must use the DP180 as specified in this manual. Read this manual before you install and operate your DP180. Important safety information is highlighted as WARNING and CAUTION instructions; you must obey these instructions. The use of WARNINGS and CAUTIONS is defined below.
1.3 Gas-ballast boost The DP180 has a gas-ballast boost system which delivers air to the pump gas-ballast boost inlet. The flow of air is filtered and is controlled by a solenoid-valve. You can connect the solenoid-valve to your control equipment to operate the solenoid-valve. If you wish, you can connect a nitrogen supply to the system in order to deliver nitrogen to the pump instead of air. 1.4 Temperature control system The pump is cooled by water which flows through an integral cooling-jacket.
2 TECHNICAL DATA 2.1 General Overall dimensions Mass Nominal motor rating Rotational speed Warm-up time Vacuum connections Inlet Outlet Vacuum system maximum leak-rate Ambient operating temperature range Maximum ambient operating humidity Maximum exhaust pressure 2.2 See Figure 1 230 kg 7.5 kW 2000 r min-1 15 min ISO63 NW40 1 x 10-3 mbar l s-1, 1 x 10-1 Pa l s-1 5 to 40 oC 90% RH 2 psig, 1150 mbar absolute, 1.
Figure 1 - Dimensions (mm) 4 DP180 Dry Vacuum Pump
1. 2. With stainless steel flap-valve Without flap-valve Figure 2- Pumping speed curves 1. 2.
2.3 Services Electrical supply Number of phases Supply voltage Voltage tolerance Cooling-water supply Ryznar Stability Index (RSI) Water consumption at 20 oC (TCV setting: 3 to 3.5) Maximum supply pressure Minimum required pressure differential across supply and return Nitrogen supply (if fitted) Supply pressure Maximum flow rate 2.4 30 psi 5 to 10 psig 100 l min-1 Danfoss AVTA 130 oC 90 oC Microtherm 71 ± 3 oC 240 V/2.
3 INSTALLATION 3.1 Safety WARNING Obey the safety instructions given below and take note of appropriate precautions. If you do not, you can cause injury to people and damage to equipment. 3.2 • A suitably trained and supervised technician must install the DP180. • Ensure that the installation technician is familiar with the safety precautions which relate to the products pumped. Wear the appropriate safety-clothing when you come into contact with contaminated components.
4. Inspect the pump. If the pump or any other item is damaged, notify your supplier and the carrier in writing within three days; state the Item Number of the pump together with your order number and your suppliers invoice number. Retain all packing materials for inspection. Do not use the pump if it is damaged. 5. Check that the pallet contains the items listed in Table 2. If any of these items is missing, notify your supplier in writing within three days. 6.
1. 2. 3. 4. Pump-motor terminal-box Oil filler-plug Inlet-flange Oil-level sight-glass 5. 6. 7. 8.
3.5 Electrical installation WARNING Ensure that the electrical installation of the DP180 conforms with your local and national safety requirements. It must be connected to a suitably fused and protected electrical supply and a suitable earth (ground) point. 3.5.
1. 2. Links Electrical supply 1. 2. Figure 5 - Motor low voltage configuration (200 V, 50/60 Hz; 220-240 V, 50 Hz) 1. Electrical supply Figure 7 - Motor low voltage configuration (208-230 V, 60 Hz) DP180 Dry Vacuum Pump Links Electrical supply Figure 6 - Motor high voltage configuration (380/415 V, 50 Hz; 380 V, 60 Hz) 1.
3.5.2 Connect the pump-motor electrical supply Notes: Wiring instructions for the pump-motor are also shown on a label inside the terminal-box cover. The following procedure will ensure that the pump will rotate in the correct direction if phase 1 of your electrical supply corresponds to line L1 in Figures 5 to 8, phase 2 corresponds to line L2 and phase 3 corresponds to line L3. However, we recommend that you check the direction of rotation of the pump as described in Section 3.5.3.
3.5.5 Connect the solenoid-valve Connect the gas-ballast boost solenoid-valve (Figure 4, item 6) to your control equipment so that the valve closes when the DP180 is shut down. Use a suitably rated fused electrical supply (refer to Section 2). If the solenoid-valve is left open after the DP180 is shutdown, the pressure in your vacuum system could rise to the pressure of your nitrogen supply; see Section 3.9.3. 1. 2. 3. 4.
3.6 Connect the cooling-water supply CAUTION If your pump is installed in an area where the ambient temperature falls close to or below freezing point, ensure that the cooling-water cannot freeze inside the pump cooling-jacket or TCV. If the cooling-water freezes, the pump or TCV can be damaged. 3.6.1 Supply quality requirements Your cooling-water must meet the requirements of Section 2.3. If it does not, you may get a build-up of deposits inside the pump cooling-jacket.
1. 2. 3. 4. Bearing end-cover evacuation plug Cooling-water outlet Exhaust outlet Thermostatic control-valve 5. 6. 7. 8.
3.7 Connect the DP180 to your vacuum system WARNING Do not operate the DP180 with the exhaust-pipeline blocked. If the exhaust-pipeline is blocked, the DP180 can generate exhaust-pipeline pressures up to 7 bar. When you connect the DP180 to your vacuum system, take note of the following: • To get the best pumping speed, ensure that the pipeline which connects the vacuum system to the DP180 inlet is as short as possible and has an internal diameter not less than that of the DP180 inlet port.
3.8 Connect the DP180 to your exhaust-extraction system WARNING Pipe the exhaust to a suitable treatment plant to prevent the discharge of dangerous gases or vapours to the surrounding atmosphere. WARNING Use a catchpot to prevent the drainage of condensate back into the DP180. Condensate which drains back into the DP180 could damage it.
The gas-ballast boost pipe has a non-return valve, however some of the process gas pumped can leak through the valve if you are rough pumping (above an inlet pressure of 650 mbar, 6.5 x 104 Pa). If you will pump dangerous substances, we therefore recommend that you use a bottled nitrogen supply or a closed system; refer to Section 3.9.3 to connect the nitrogen supply. 3.9.
8. 3.11 Use 3/8 inch BSP fittings to connect a suitable pipeline to the end-cover. Connect the other end of the pipeline to your evacuation pump. Leak-test the installation WARNING Leak-test the system after installation and seal any leaks found to prevent the leakage of dangerous substances from the system and leakage of air into the system. Leak-test the system after installation and seal any leaks found.
3.12.2 3.12.3 20 Prime the cooling system 1. Isolate the DP180 from your vacuum system. 2. Turn the TCV to the '0' setting and turn on the cooling-water supply. 3. Allow the cooling-water to flow for five to six minutes to ensure that the cooling-jacket is full of water. 4. Check all of the water connections and pipelines for leaks. Seal any leaks found. 5. Turn the TCV to the required setting. Commissioning procedure 1.
4 OPERATION WARNING Take all appropriate safety precautions when you pump oxidants or pyrophoric or flammable gases. 4.1 Start-up Use the following procedure below to start up the pump. 4.2 1. Check the gearbox oil-level in the sight-glass on the side of the pump (Figure 4, item 4). The oil-level must be between the MIN and MAX marks when the pump is cold and at rest. If necessary, pour more oil into the pump (refer to Section 3.3) or drain oil from the pump (refer to Section 5.5). 2.
5 MAINTENANCE 5.1 Safety WARNING Obey the safety instructions given below and take note of appropriate precautions. If you do not, you can cause injury to people and damage to equipment. 5.2 • A suitably trained and supervised technician must maintain the DP180. • Ensure that the maintenance technician is familiar with the safety procedures which relate to the products pumped. Wear the appropriate safety-clothing when you come into contact with contaminated components.
Operation Frequency Refer to Section Monthly 5.3 Inspect the pipelines and connections 6 Monthly 5.4 Change the gearbox oil 6 Monthly 5.5 Relubricate the rotor bearings 6 Monthly 5.6 Change the head-plate felt filter Yearly 5.7 Change the gas-ballast air filter element Yearly 5.8 Clean the inlet-stage sump As required 5.9 Clean the cooling-jacket As required 5.10 Check the gearbox oil-level Table 4 - Maintenance plan 5.3 Check the gearbox oil-level Refer to Figure 4.
5.5 5.6 Change the gearbox oil 1. Refer to Figure 4. Remove the oil filler-plug (4). 2. Place a suitable container under the oil drain-plug (5). 3. Remove the oil drain-plug (5) and allow the oil to drain out of the gearbox. 4. Refit the oil drain-plug (5). 5. Dispose of the old rubber bonded seal on the oil filler-plug (4) and replace it with a new one from the pump maintenance kit. 6. Fill the gearbox through the filler-hole, with the correct grade and quantity of oil.
1. 2. 3. Bearing end-cover Screw 'O' ring 4. 5. 6. Felt filter Bearing End-cover cavity Figure 11 - Rotor bearing relubrication 5.7 Change the head-plate felt filter If you have not connected an external pump to evacuate the bearing end-cover (see Section 3.10), you must change the felt filter in the head-plate annually. As you must remove the bearing end-cover to replace the felt filter, it is convenient to carry out this maintenance when you relubricate the rotor bearings (see Section 5.6).
5.8 Change the gas-ballast air filter element If you have not connected a nitrogen gas-ballast supply to the pump, use the following procedure to replace the gas-ballast air filter element: 1. Refer to Figure 12. Turn the top-cap (1) clockwise (when viewed from the top-cap end of the gas-ballast air filter) to release it from the filter body (4), then remove the top-cap. 2. Remove and dispose of the used filter element (3). 3. Fit the new filter element (3) into the filter body (4). 4.
5.9 Clean the inlet-stage sump Clean the inlet-stage sump regularly if you use the DP180 to pump dusty or tarry vapours. Use the following procedure: 5.10 1. Remove the two screws on the clamp which secures the inlet-stage sump blanking-plate to the pump (see Figure 10). 2. Remove the clamp, the blanking-plate and the sealing 'O' ring. Dispose of the 'O' ring. 3. Use a suitable tool (for example, a flexible handled, large diameter bottle-brush) to clean the sump.
6 STORAGE AND DISPOSAL 6.1 Storage Store the DP180 as follows : 6.2 1. If applicable, ensure that the DP180 has been shut down as described in Section 4.2 and disconnect all services, process and exhaust connections. 2. Drain the water from the cooling-jacket as described in Section 5.10. 3. Fit blanking-plates to all vacuum inlets and outlets. Place protective covers over the pump services connection points. 4. Store the pump in clean dry conditions until required. 5.
7 SERVICE, SPARES AND ACCESSORIES 7.1 Introduction BOC Edwards products, spares and accessories are available from BOC Edwards companies in Belgium, Brazil, China, France, Germany, Israel, Italy, Japan, Korea, Singapore, United Kingdom, U.S.A and a world-wide network of distributors. The majority of these centres employ Service Engineers who have undergone comprehensive BOC Edwards training courses. Order spare parts and accessories from your nearest BOC Edwards company or distributor.
7.4 Accessories The accessories listed below are available for the DP180. Each accessory contains all the necessary components for assembly and installation of the accessory. Full functional descriptions and fitting details are included in the instruction manual supplied with the accessory.
Form HS1 Return of BOC Edwards Equipment - Procedure INTRODUCTION Before returning your equipment, you must warn BOC Edwards if substances you used (and produced) in the equipment can be hazardous. This information is fundamental to the safety of our Service Centre employees and will determine the procedures employed to service your equipment. Complete the Declaration (HS2) and send it to BOC Edwards before you dispatch the equipment.
Form HS2 Return of BOC Edwards Equipment - Declaration Return Authorisation Number: You must: • Know about all of the substances which have been used and produced in the equipment before you complete this Declaration • Read the Return of BOC Edwards Equipment - Procedure (HS1) before you complete this Declaration • Contact BOC Edwards to obtain a Return Authorisation Number and to obtain advice if you have any questions • Send this form to BOC Edwards before you return your equipment SECTION 1: EQ
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UNITED KINGDOM CANADA ISRAEL CORPORATE HEADQUARTERS BOC EDWARDS Manor Royal Crawley West Sussex RH10 9LW Tel +(44) 1293 528844 Fax +(44) 1293 533453 BOC EDWARDS 5975 Falbourne Street Mississauga, Ontario L5R3W6 Canada Tel +(1) 905 501 2558 Fax +(1) 905 501 1632 EDWARDS ISRAEL VACUUM LTD.
