A705-61-880 Issue H Original Instruction Manual GV Dry Vacuum Pumps Description Item Number GV250 Dry Vacuum Pump, 380/400/415 V, 50 Hz GV250 Dry Vacuum Pump, 230/460 V, 60 Hz A705-61-900 A705-61-908 GV400 Dry Vacuum Pump, 380/400/415 V, 50 Hz GV400 Dry Vacuum Pump, 230/460 V, 60 Hz A706-61-900 A707-61-908
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GV Dry Vacuum Pumps CONTENTS PAGE Section 1 INTRODUCTION 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Scope and definitions The GV pumps Gas system Cooling system Interstage relief valve Drive operation Liquid pumping capability Safe area operation Accessories 1 1 1 2 2 4 4 4 4 2 TECHNICAL DATA 5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.
GV Dry Vacuum Pumps CONTENTS (CONTINUED) PAGE Section 4 OPERATION 23 4.1 4.2 4.3 4.4 Start the pump Allow the pump to warm up Check the purge pressures and flows Shut down the pump 23 23 24 24 5 MAINTENANCE 25 5.1 5.2 5.3 25 25 5.8 5.9 5.10 5.11 5.11.1 5.11.2 5.12 5.13 5.13.1 5.13.2 5.14 5.15 5.
GV Dry Vacuum Pumps PAGE iii ILLUSTRATIONS Figure 1 2 3 4 5 6 7 8 9 10 11 12 Page The GV pump Pump dimensions Schematic diagram of the recommended electrical connections Electrical connections: 380/400/415 V, 50 Hz electrical supplies Electrical connections: 230/460 V, 60 Hz electrical supplies Connect to the thermal snap-switches Exploded view of the gas-ballast assembly Exploded view of the gas-ballast air filter Exploded view of the interstage relief valve Oil-level sight-glass and oil filler and dra
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GV Dry Vacuum Pumps PAGE vi Issue H vi Oct 04
GV Dry Vacuum Pumps 1 INTRODUCTION 1.2 1.1 Scope and definitions Refer to Figure 1. The GV pumps are rugged, reliable dry vacuum pumps designed for general vacuum use. The pump is a three-stage, positive displacement rotary pump in which pairs of intermeshing rotors (mounted on common shafts) are held in correct phase relation by a pair of timing-gears. The timinggears and the adjacent double-row angular contact ball bearings are oil lubricated.
GV Dry Vacuum Pumps PAGE 2 INTRODUCTION 1.4 Cooling system 1.5 Interstage relief valve Note: The direct cooling system fitted to the pump is suitable for pump operating temperatures (measured at the position shown in Figure 1, item 3) of up to 45 oC, (113 oF). If your application requires pump operating o temperatures of 45 to 90 C (113 to 194 oF), we recommend that you fit an Indirect Cooling Kit accessory: refer to Section 7.4.4.
GV Dry Vacuum Pumps PAGE 3 INTRODUCTION Figure 1 - The GV pump Oct 04 3 Issue H
GV Dry Vacuum Pumps 1.6 PAGE 4 1.9 Drive operation Accessories INTRODUCTION A number of accessories are available for the GV pumps; use these to configure the pump for specific applications. These accessories are listed in Section 7.4. The pump has a flexible drive coupling which transmits the drive from the pump-motor (16) to the pump rotors. Refer to Figure 12. A coupling hub (14) is fitted to the pump shaft (9) and a drive hub (16) is fitted to the motor shaft (18).
GV Dry Vacuum Pumps 2 TECHNICAL DATA 2.1 Operating and storage conditions PAGE 5 0 to 40 oC, 32 to 104 oF 90% RH Warm-up time to pump operating temperature of 40 oC (104 oF), with a cooling-water flow rate of 150 l h-1 (33 US gal h-1) * 30 min Area classification in accordance with BS 5345 (standard pumps) Safe Area designation only * Pump operating temperature is measured at the point shown in Figure 1, item 3.
GV Dry Vacuum Pumps 2.4 PAGE 6 Electrical data TECHNICAL DATA Electrical supply 380/400/415 V, 50 Hz or 230/460 V, 60 Hz Thermal snap-switch contact ratings Maximum voltage Maximum load (inductive) Maximum current (resistive load) 240 V 120 VA 12 A GV250 GV400 Pump motor rating 50 Hz electrical supply 60 Hz electrical supply 11.0 kW 20 h. p. 18.5 kW 30 h. p.
GV Dry Vacuum Pumps 2.6 Lubrication data Note: BOC Edwards Material Safety Data Sheets for the recommended oil and grease specified in Table 6 are available on request. Mobil SHC629 Antiwear Synthetic Gear Oil 150 cst Gearbox oil capacity Minimum Maximum 1.4 litres, 0.37 US gal 1.6 litres, 0.42 US gal High vacuum bearings Grease type Recommended grease Perfluoropolyether Fomblin RT15 Table 6 - Lubrication data 2.
GV Dry Vacuum Pumps PAGE 8 TECHNICAL DATA A Side view B Front view A 3. Port tappings: 1/2 inch BSP 4. Fixing holes: Ø22 mm (0.9 inch) 1. Outlet 2. Inlet B C D E F G H J K L M 380/400/415 V, 50 Hz pump dimensions (mm) GV250 911 366 148 580 315 1000 640 180 377 460 632 13 GV400 955 414 148 580 315 1000 640 180 377 460 632 13 230/460 V, 60 Hz pump dimensions (inches) GV250 37.59 14.41 5.83 22.83 12.4 34.37 26.22 7.09 14.84 18.11 24.88 0.52 GV400 39.
GV Dry Vacuum Pumps 3 INSTALLATION 3.1 Safety 3.2 System design PAGE WARNING 9 Obey the safety instructions listed below and take note of appropriate precautions. If you do not, you can cause injury to people and damage to equipment. WARNING • A suitably trained and supervised technician must install the pump. When the pump is switched off, gas will flow in reverse direction through the pump and there will be a rapid pressure rise in the inlet pipeline and your process system.
GV Dry Vacuum Pumps • Your exhaust pipeline system must be designed so that the pressure in the pipeline during pump operation is less than 1.15 bar absolute (1.15 x 105 Pa, 862 torr). If the pressure in the pipeline is higher than this pressure, the pump will operate at a high temperature and may trip because of excessive electrical current consumption. PAGE 10 INSTALLATION 4. Check that you have received the items listed in Table 10.
GV Dry Vacuum Pumps 3.5 3.6.2 Check the gearbox oil-level Connect the electrical supply to the pump: 380/400/415 V, 50 Hz supplies PAGE Refer to Figure 1. The pump is supplied filled with oil. Before you operate the pump, check that the gearbox oil-level is correct: the oil-level must be between the MIN and MAX marks on the bezel of the oil-level sight-glass (14): see detail C. 11 WARNING If necessary, pour more oil into the gearbox: refer to Section 5.3. 3.6 Electrical connections 3.6.
GV Dry Vacuum Pumps PAGE 12 INSTALLATION 1. To your electrical supply 2. Earth (ground) points 3. Auxiliary contacts (2 off, normally closed) 4. Fuse or circuit breaker 5. Control voltage 6. Stop control 7. Start control 8. Shut-down thermal snap-switch 9. Inlet-valve control solenoid (optional) 10.
GV Dry Vacuum Pumps 3.6.3 Connect the electrical supply to the WARNING Ensure that the electrical installation of the pump 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. CAUTION 1. Remove the cover from the pump-motor terminal-box (Figure 1, item 17). 2. Remove the plug from one of the electrical supply cable entry holes on the terminal-box. 3.
GV Dry Vacuum Pumps PAGE 14 INSTALLATION A Wiring configuration: 230 V supply B Wiring configuration: 460 V supply C Schematic wiring diagram Electrical supply Links 230 V (detail A) T1-T6-T7, T2-T4-T8, T3-T5-T9 460 V (detail B) T4-T7, T5-T8, T6-T9 1. 2. 3. 4. 5. 6.
GV Dry Vacuum Pumps Connect the phase conductors (L1, L2, L3) of the supply cable (1) to terminals T1, T2 and T3. 6. Connect the earth (ground) wire to the earth (ground) terminal (5). 7. Tighten the cable-gland nut strain-relief screws and refit the terminal-box cover. 3.6.4 The thermal snap-switches will reset (that is, close again) when the pump cools down to a preset temperature (see Section 2.5).
GV Dry Vacuum Pumps 3.7 3.8 Check the direction of rotation PAGE Fit a mechanical booster pump (optional) WARNING 16 INSTALLATION If you want to use a mechanical booster pump with the GV pump, fit it now. Details of the connection kits available from BOC Edwards are given in Section 7.4. Refer to the installation procedures in the instruction manual supplied with the connection kit. You must ensure that the direction of rotation of the pump is correct before you operate the pump.
GV Dry Vacuum Pumps PAGE 17 INSTALLATION 1. Bolts (4 off) 2. Cover 3. Thermal snap-switch box 4. Four-core cable 5. Cable-gland 6. Warning wires 7. Spade terminals 8. Warning thermal snap-switch 9. Shut-down thermal snap-switch 10. Spade terminals 11.
GV Dry Vacuum Pumps PAGE 18 3.10.2 Connect the shaft-seals purge air or nitrogen supply Connect the cooling-water supply as described below; you must use 1/2 inch outside diameter pipes for the cooling-water supply and return pipelines. WARNING 1. INSTALLATION 2. Refer to Figure 1. Remove the red blanking caps from the cooling-water inlet (6) and outlet compression connections (2).
GV Dry Vacuum Pumps 2. 3.11 Connect the pump-inlet When you connect the pump to the process system: • Support process pipelines to stop the transmission of stress to pipeline joints. Fit the end of your air or nitrogen supply pipeline to the shaft-seals purge inlet connection (22), then tighten the nut to secure the pipeline in place. • Use a flexible connection in the pipeline from the process system to the pump to reduce vibration and stress in the system pipelines. 3.10.
GV Dry Vacuum Pumps 3.12 PAGE 20 Connect the pump outlet 3.13 INSTALLATION WARNING WARNING Connect the pump outlet to a suitable treatment plant to prevent the discharge of dangerous gases and vapours to the surrounding atmosphere. Leak-test the system after installation and seal any leaks found to prevent the leakage of dangerous substances out of the system and leakage of air into the system. CAUTION Leak-test the system after installation and seal any leaks found.
GV Dry Vacuum Pumps PAGE 21 INSTALLATION 1. 2. 3. 4. 5. 6. 7. Adaptor: 16 to 25 mm 8. Co-Seal 9. Clamp 10. Flap valve 11.
GV Dry Vacuum Pumps 7. Leave the pump to operate for approximately 30 minutes to allow the pump operating temperature to stabilise. 8. Check that the pump operating temperature is between 30 and 45 oC (86 and 113 oF). 9. Turn off the pump, the cooling-water supply, the shaft-seals air or nitrogen purge supply and the gas-ballast nitrogen supply (if fitted).
GV Dry Vacuum Pumps 4 OPERATION 2. WARNING 3. Switch on the pump. 4. Continue at Section 4.2 to allow the pump to warm up. 4.2 Allow the pump to warm up WARNING CAUTION During operation, some parts of the pump become hot; these areas are identified by ‘hot surface’ labels (see Section 1.1). Do not touch these areas of the pump, and avoid accidental contact between these areas of the pump and electrical cables and wires, and so forth.
GV Dry Vacuum Pumps 4.3 Check the purge pressures and flows PAGE 24 4.4 Shut down the pump OPERATION WARNING CAUTION Ensure that you do not touch the pump-body when you adjust the gasballast flow valve. During operation, parts of the pump can become hot. Purge the pump before you shut it down. If you do not, process vapours may condense in the pump and corrode or damage it. Note: Do the following checks immediately after pump start and regularly during pump operation: 1.
GV Dry Vacuum Pumps 5 MAINTENANCE 5.1 Safety information 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. • A suitably trained and supervised technician must maintain the pump. 5.2 • Ensure that the maintenance technician is familiar with the safety procedures which relate to the synthetic oils and greases used and the products pumped.
GV Dry Vacuum Pumps PAGE Frequency Refer to Section Check the gearbox oil level and fill the gearbox with oil (if necessary) Weekly 5.3 Inspect the gas-ballast system Monthly 5.4 3 Monthly 5.5 Yearly or when necessary 5.6 When you relubricate the high vacuum bearings or when contaminated ‡, whichever occurs first 5.7 When necessary Ø 5.8 Yearly or when necessary 5.9 Replace the interstage relief valve When necessary 5.10 Replace the pump-motor # When necessary 5.11 Yearly 5.
GV Dry Vacuum Pumps 5.3 Check the gearbox oil-level and fill 3. the gearbox with oil (if necessary) Refit the oil filler-plug (12) and bonded seal (13) to the oil-filler port (1). PAGE 5.4 WARNING Note: Use the following procedure to inspect the gasballast system. Note that if you have not connected a nitrogen gasballast supply, the gas-ballast air filter element must be replaced every three years as part of the pump overhaul (see Section 5.15).
GV Dry Vacuum Pumps 5.5 PAGE 28 1. MAINTENANCE 2. 3. 4. 5.6 Inspect the pipelines and connections Inspect all cooling-water pipelines and connections; check that they are not corroded or damaged. Replace any of the pipelines and connections that are corroded or damaged. Check that all cooling-water connections are secure. Tighten any connections that are loose. If you think that the interstage relief valve does not operate correctly, use the following procedure to inspect it. Refer to Figure 9.
GV Dry Vacuum Pumps PAGE 29 MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Valve flap 8. 'O' ring 9. Retainer 10. Jacking hole 11.
GV Dry Vacuum Pumps 5. PAGE 30 MAINTENANCE Clean the inside of the exhaust manifold (3) to remove any deposits; if necessary, use a suitable cleaning solution. If you use a cleaning solution, ensure that all of the solution is removed before you fit the new interstage relief valve componentts. 6. Inspect the 'O' rings (8, 5, 4) and, if necessary, fit new 'O' rings. 7. If necessary, refit the two hinge bushes (1) to the valve flap (7), then fit the valve flap to the valve body (2). 8.
GV Dry Vacuum Pumps PAGE 31 MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Sight-glass 9. ‘O’ ring 10. Bezel 11. Screws (4 off) 12. Oil filler-plug 13.
GV Dry Vacuum Pumps 6. PAGE 32 MAINTENANCE 7. Refit the compression ring (6) in the sight-glass recess in the gearbox (2). 8. Fit two new ‘O’ rings (7, 9) and the sight-glass (8), then fit the bezel (10) and secure with the four M5 screws (11). 9. 5.8 Clean all of the sight-glass components and the sight-glass recess in the gearbox (2) with a soft lint-free cloth.
GV Dry Vacuum Pumps PAGE 33 MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8.
GV Dry Vacuum Pumps 1. Switch off your cooling-water supply. 2. Refer to Figure 1. Disconnect the cooling-water supply and return pipelines from the water inlet (7) and outlet (2) connections. 3. Fit a suitable water supply pipeline to the water outlet connection (2), and fit a suitable water return pipeline to the water inlet connection (7). 4. Turn on the water supply to flush the cooling jacket in the reverse direction, and wash out any deposits from the cooling jacket. 5.
GV Dry Vacuum Pumps 5.10 Replace the interstage relief valve The masses of the pump-motors are as shown below: PAGE You must replace the interstage relief valve if it is damaged. The interstage relief valve is available as a spare: refer to Section 7.3. 2. GV250: 380/400/415 V, 50 Hz 104 kg Refer to Figure 9. Undo and remove the four M8 bolts (11) which secure the valve retainer (9) to the exhaust manifold (3).
GV Dry Vacuum Pumps 5.11.2 Fit the new pump-motor PAGE WARNING 36 MAINTENANCE Ensure that the pump-motor does not fall when you move it. The pumpmotor is heavy (see Section 5.11.1) and can cause injury to people if it falls. 2. Inspect the motor shaft (18) of the new pumpmotor (19). The motor shaft must be free of burrs and dirt. If necessary, clean or refinish the motor shaft. 3. Inspect the motor shaft bore of the drive hub (16). The bore must be free of burrs and dirt.
37 Issue H Figure 12 - Exploded view of the pump-motor, coupling drive and coupling housing 11. Shaft bearing nut 12. Coupling cover 13. Bolt 14. Coupling hub 15. Coupling insert 16. Drive hub 17. Holding ring 18. Motor shaft 19. Pump-motor 20. Gap MAINTENANCE Oct 04 1. Bolt 2. Key 3. Set screws 4. Set screw 5. Set screw 6. Bolt 7. Coupling housing 8. Key 9. Pump shaft 10.
GV Dry Vacuum Pumps 25. Use the four bolts (13) to secure the other coupling covers (12) to the coupling housing (7). Tighten the bolts to a torque between 3 and 5 Nm (2.2 and 3.7 lbf ft). 17. Check that the gap (detail A, item 20) is as shown below. PAGE 38 Pump Gap setting MAINTENANCE GV250, 50 Hz -1.5 mm * GV250, 60 Hz -1.5 mm * GV400, 50 Hz 7.0 mm Use the following procedure to replace the coupling insert: GV400, 60 Hz 26.0 mm 1. Refer to Figure 12.
GV Dry Vacuum Pumps 5.13 Relubricate the motor bearings • We recommend that you use Esso Unirex N3 grease to relubricate 50 Hz motor bearings, and Chevron SRI No. 2 or Shell Oil Dolium-R to relubricate the 60 Hz motor bearings. 5.13.1 General requirements WARNING Do not relubricate the motor bearings unless you have been suitably trained in the necessary procedures. If you are not suitably trained, you may damage the motor and it may not operate correctly or safely. 5.13.
GV Dry Vacuum Pumps 5.14 PAGE 5.16 Replace the motor bearings Refer to Table 15 for fault finding. WARNING 40 Fault finding MAINTENANCE Do not replace the motor bearings unless you have been suitably trained in the necessary procedures. If you are not suitably trained, you may damage the motor and it may not operate correctly or safely.
GV Dry Vacuum Pumps Symptom Check Actions The pump suddenly stops. Is there a hydraulic lock in the pump ? Switch off and drain the fluid from the pump. If necessary, turn the pump by hand. Has the shut-down thermal snap-switch operated to stop the pump because the pump is operating at too high a temperature ? Check that there is a sufficient flow of cooling-water through the pump: check that the cooling-water supply is on, is at the correct pressure and is of the correct temperature.
GV Dry Vacuum Pumps PAGE 42 MAINTENANCE Symptom Check Actions The pump-motor trips out due to excessive electrical current consumption when the GV250 pump is operating with pumpinlet pressure in the range 300 to 1000 mbar (3.0 x 104 to 1 x 105 Pa, 225 to 750 torr), or when the GV400 pump is operating with pump-inlet pressure in the range 200 to 1000 mbar (2.
GV Dry Vacuum Pumps 6 STORAGE AND DISPOSAL Storage Note: If you will store the pump in an environment with an ambient temperature below -14 oC (7 oF), you must also drain the oil from the pump: use the procedure in Section 5.7, then refit the oil drain-plug to the pump before you store it. Disposal PAGE WARNING 43 Ensure that you wear the appropriate Personal Protective Equipment (PPE) when you handle contaminated oils or contaminated components.
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GV Dry Vacuum Pumps 7 SPARES, SERVICE AND ACCESSORIES Spares and maintenance kits Refer to Table 16 (page 47) for the spares and maintenance kits for the pumps. PAGE 7.4 SPARES, SERVICE AND ACCESSORIES 7.1 7.3 45 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.
GV Dry Vacuum Pumps 7.4.5 PAGE 46 Other accessories A number of other accessories are available for the GV pumps, as listed below; contact your supplier or BOC Edwards for details of these accessories: SPARES, SERVICE AND ACCESSORIES • Acoustic enclosure for the GV pump. • Acoustic enclosure for the GV pump with mechanical booster pump. • Pump motor acoustic jacket. • Gas control system. • Motor control module. • Cooling-water control panel.
GV Dry Vacuum Pumps R Spare/Kit Item Number H110-23-010 H110-23-011 Interstage (Pressure) Relief Valve (complete valve assembly) Routine Maintenance Kit Motor Fitment Kit A705-11-832 A705-01-825 A705-01-805 Inlet End (Upper) Bearing Kit Air filter Swing PRV Overhaul Kit Motor Coupling Insert A705-01-826 A506-16-000 A705-11-833 A705-73-758 Motor Bearing Kits: GV 250 or GV400, 380/400/415 V, 50 Hz GV 250, 230/460 V, 60 Hz GV 400, 230/460 V, 60 Hz A071-99-065 A071-99-069 A071-99-076 PAGE 47 SPARES,
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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.
