BOC DP180 Instruction Manual Download Page 1

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A500-03-880

Issue D

Manor Royal, Crawley, West Sussex, RH10 9LW, UK
Telephone: +44 (0) 1293 528844 Fax: +44 (0) 1293 533453
http://www.bocedwards.com

DP180 Dry Vacuum Pump

Description

Item Number

DP180 pump, 200 V, 3-phase, 50 Hz

A403-02-934

DP180 pump, 200 V, 3-phase, 60 Hz

A403-12-934

DP180 pump, 220-240/380-415 V, 3-phase, 50 Hz

A403-02-935

DP180 pump, 208-230/380/460 V, 3-phase, 60 Hz

A403-12-995

Instruction Manual

Summary of Contents for DP180

Page 1: ... 0 1293 533453 http www bocedwards com DP180 Dry Vacuum Pump Description Item Number DP180 pump 200 V 3 phase 50 Hz A403 02 934 DP180 pump 200 V 3 phase 60 Hz A403 12 934 DP180 pump 220 240 380 415 V 3 phase 50 Hz A403 02 935 DP180 pump 208 230 380 460 V 3 phase 60 Hz A403 12 995 Instruction Manual ...

Page 2: ...tion of pump rotation 12 3 5 4 Connect the thermal snap switch 12 3 5 5 Connect the solenoid valve 13 3 6 Connect the cooling water supply 14 3 6 1 Supply quality requirements 14 3 6 2 Connect the supply to the DP180 14 3 7 Connect the DP180 to your vacuum system 16 3 8 Connect the DP180 to your exhaust extraction system 17 3 9 Gas ballast boost system 17 3 9 1 Gas ballast boost not in use 17 3 9 ...

Page 3: ... ACCESSORIES 29 7 1 Introduction 29 7 2 Service 29 7 3 Spares 29 7 4 Accessories 30 RETURN OF BOC EDWARDS EQUIPMENT Illustrations Figure Title Page 1 Dimensions mm 4 2 Pumping speed curves 5 3 Power curves 5 4 Lubrication and gas ballast boost components 9 5 Motor low voltage configuration 200 V 50 60 Hz 220 240 V 50 Hz 11 6 Motor high voltage configuration 380 415 V 50 Hz 380 V 60 Hz 11 7 Motor l...

Page 4: ...ratings 3 2 Checklist of components 8 3 Pump motor terminal box wiring configurations 10 4 Maintenance plan 23 Associated publications Publication title Publication Number Vacuum pump and vacuum system safety P300 20 000 DP180 Dry Vacuum Pump iii ...

Page 5: ... This page deliberately left blank iv DP180 Dry Vacuum Pump ...

Page 6: ...c and ultimate vacuum without any lubricating or sealing fluid in the pumping chamber This ensures a clean pumping system without back migration of oil into the system being evacuated The pump is mounted on steel runners The DP180 is a three stage positive displacement rotary pump in which pairs of intermeshing rotors of different profiles mounted on common shafts are held in correct phase relatio...

Page 7: ...he supply of cooling water to the pump The pump motor is air cooled by a cooling fan which is integral to the motor A thermal snap switch is fitted to the pump body This switch shuts down the pump if the pump is too hot The switch which is normally closed is connected to the overload control loop of the pump motor starter When the temperature of the pump body rises to 71 o C the switch opens and t...

Page 8: ...2 Performance data Pumping speed range See Figure 2 Power curves See Figure 3 Peak pumping speed 180 m3 h 1 Displacement swept volume 200 m3 h 1 Ultimate vacuum without outlet flap valve without gas ballast boost 1 x 10 1 mbar 10 Pa with full gas ballast boost 2 5 x 10 1 mbar 25 Pa Water vapour pumping speed at 80 mbar 8 x 103 Pa 5 kg h 1 Full load current ratings See Table 1 Electrical supply Rat...

Page 9: ...4 DP180 Dry Vacuum Pump Figure 1 Dimensions mm ...

Page 10: ...DP180 Dry Vacuum Pump 5 Figure 2 Pumping speed curves 1 With stainless steel flap valve 2 Without flap valve 1 Without flap valve 2 With stainless steel flap valve Figure 3 Power curves ...

Page 11: ...ss AVTA Maximum operating temperature 130 o C Maximum sensor temperature 90 o C Thermal snap switch Manufacturer Microtherm Opening temperature 71 3 o C Contact rating Maximum voltage current 240 V 2 9 A 2 5 Lubrication system Note BOC Edwards Material Safety Data Sheets for the oils and greases referenced below are available on request Gearbox Fluid capacity timing gearbox 1 2 litres Grade of oil...

Page 12: ... so that they cannot be operated accidentally Do not re use O rings and Co Seals and do not allow debris to get into the DP180 during installation Before you use the DP180 to pump dangerous substances refer to the associated publication referred to at the end of the contents list You must take all necessary precautions to dilute flammable gases with nitrogen to a safe level Leak test the system af...

Page 13: ...oil drain plug 5 is tight 2 Unscrew and remove the oil filler plug 2 3 Fill the gearbox with oil until the oil level is at the MAX level mark on the oil level sight glass 4 4 Check that the rubber bonded seal on the oil filler plug is in place then refit the oil filler plug 2 and tighten to finger tight Use a spanner to tighten the plug an additional 1 16 th of a turn 3 4 Locate the pump WARNING U...

Page 14: ...Pump 9 Figure 4 Lubrication and gas ballast boost components 1 Pump motor terminal box 2 Oil filler plug 3 Inlet flange 4 Oil level sight glass 5 Oil drain plug 6 Solenoid valve 7 Clamping ring 8 Gas ballast air filter ...

Page 15: ... supply voltages and frequencies as shown in Table 3 Electrical supply Refer to Figure Voltage V Frequency Hz 200 50 5 200 60 5 220 240 50 5 380 415 50 6 208 230 60 7 380 60 6 460 60 8 Table 3 Pump motor terminal box wiring configurations Use the following procedure to configure the pump for use with your electrical supply 1 Check the information on the pump motor data plate to make sure that the ...

Page 16: ...40 V 50 Hz Figure 6 Motor high voltage configuration 380 415 V 50 Hz 380 V 60 Hz Figure 7 Motor low voltage configuration 208 230 V 60 Hz Figure 8 Motor high voltage configuration 460 V 60 Hz 1 Electrical supply 1 Electrical supply 1 Links 2 Electrical supply 1 Links 2 Electrical supply ...

Page 17: ... pump motor terminal box 3 5 3 Check the direction of pump rotation 1 Look at the pump motor cooling fan switch on the DP180 for one or two seconds then switch the DP180 off again 2 If the fan rotated anticlockwise when viewed from the motor end of the pump the direction of rotation is incorrect If the direction of rotation is incorrect Isolate the DP180 from the electrical supply Remove the cover...

Page 18: ...d 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 DP180 Dry Vacuum Pump 13 1 Pump motor terminal box 2 2 way terminal block 3 Thermal snap switch 4 To the motor starter overload control loop Figure 9 Thermal snap switch connections ...

Page 19: ...our supply suitable for use with the DP180 If you use a treatedclosed circuit cooling system we recommend that you fill it and refill it with de ionised or reverse osmosis treated water 3 6 2 Connect the supply to the DP180 CAUTION Make sure you connect the cooling water supply and return hoses to the correct connectors on the DP180 If the hoses are incorrectly fitted the DP180 may overheat and ma...

Page 20: ...nd bearing end cover evacuation components 1 Bearing end cover evacuation plug 2 Cooling water outlet 3 Exhaust outlet 4 Thermostatic control valve 5 Inlet stage sump clamp plate 6 Cooling water inlet 7 Bearing end cover 8 Pump body cooling water inlet ...

Page 21: ...lines On very dusty applications use an inlet filter to minimise damage to the DP180 You must be able to isolate the pump inlet from the atmosphere and from your vacuum system if you have pumped or produced corrosive chemicals Adequately support vacuum pipelines to stop the transmission of stress to the coupling joints Use the following procedure to connect the DP180 inlet flange to your vacuum sy...

Page 22: ...able to isolate the pump exhaust from the atmosphere if you have pumped or produced corrosive chemicals You must adequately support exhaust pipelines to prevent the transmission of stress to the coupling joints Use NW40fittingstoconnecttheoutlet flangeof theDP180toyourexhaust extractionsystem 3 9 Gas ballast boost system 3 9 1 Gas ballast boost not in use When the gas ballast boost is not in use t...

Page 23: ...ures the air filter 8 to the gas ballast boost pipe Remove the air filter 2 Connect your nitrogen supply to the gas ballast boost pipe through an NW10 adaptor Your nitrogen supply must meet the specification given in Section 2 3 Fit the NW10 clamp removed in Step 1 to secure the adaptor 3 10 Evacuation of the bearing end cover optional If you want to use an external evacuation pump to evacuate the...

Page 24: ...ntrol valve TCV CAUTION Do not adjust the TCV to a lower setting that is towards 0 when the DP180 is hot This will increase the flow of cooling water which may damage the DP180 because of the differential contraction of the pump rotor and case The TCV regulates the flow of water through the pump cooling jacket to maintain the DP180 at the required operating temperature The TCV can be adjusted betw...

Page 25: ...CV to the required setting 3 12 3 Commissioning procedure 1 Turn on the electrical supply the nitrogen supply and your exhaust extraction system if fitted 2 Check all of the nitrogen system exhaust extraction system and vacuum system connections 3 Switch on the DP180 4 Wait for approximately 15 minutes to allow the pump operating temperature to stabilise then check that the TCV operates correctly ...

Page 26: ...and the exhaust extraction system if fitted 3 Check all of the water nitrogen system exhaust extraction system if any and vacuum system connections 4 Switch on the DP180 5 If required use your control equipment to open the gas ballast boost solenoid valve Set your nitrogen supply pressure and flows to suit your process conditions 4 2 Shut down Use the following procedure to shut down the DP180 1 I...

Page 27: ...or inhale the thermal breakdown products of fluorinated materials which may be present if the DP180 has been overheated to 260 o C and above These breakdown products are very dangerous Fluorinated materials in the DP180 may include oils greases and seals The DP180 may have overheated if it was misused if it malfunctioned or if it was in a fire BOC Edwards Materials Safety Data Sheets for fluorinat...

Page 28: ...that they are secure tighten any loose connections Inspect all of the cooling water pipelines and connections and check for leaks seal any leaks found Inspect all of the cooling water pipelines and connections and check for corrosion and damage repair or replace any corroded or damaged component 2 Inspect all of the gas ballast boost connections and check that they are secure tighten any loose con...

Page 29: ...d cover 1 and remove the sealing O ring 3 Dispose of the O ring see Section 6 2 3 Use a plastic or wooden spatula to remove as much old grease as possible from the end cover and bearings 5 Do not use your fingers for this operation 4 Inspect the bearings for obvious signs of wear or the presence of debris If the bearings are worn return the pump to a BOC Edwards Service Centre for repair 5 If the ...

Page 30: ... the following procedure to change the filter this procedure assumes that you have already carried out Steps 1 to 5 in Section 5 6 1 Refer to Figure 4 Use a suitable tool to prise out the felt filter 4 from the high vacuum head plate Dispose of the filter see Section 6 2 Place the new felt filter supplied in the maintenance kit into the head plate 3 Refit the end cover 1 to the pump as described i...

Page 31: ...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 Refit the top cap 1 to the filter body 4 and turn it anticlockwise until it clicks to secure it to the filter body ensure that the inlet 2 on the top cap does not point upwards otherwise debris dust or liquids may enter the filter body 26 DP180 Dr...

Page 32: ...ing water supply 2 Refer to Figure 10 Place a suitable container under the pump body cooling water inlet connection 8 and undo the connection Allow the water to drain out of the pump 3 Disconnect the water return hose from the cooling water outlet 2 4 Connect the cleaning water supply to the pump cooling water outlet 2 5 Place a suitable container under the pump body cooling water inlet or connect...

Page 33: ...he pump services connection points 4 Store the pump in clean dry conditions until required 5 When required for use prepare and install the pump as described in Section 3 6 2 Disposal Dispose of the DP180 use oil and grease and any components safely in accordance with all local and national safety and environmental requirements Take particular care with the following Fluoroelastomers which may have...

Page 34: ...ld wide network of BOC Edwards Service Centres Each Service Centre offers a wide range of options including equipment decontamination service exchange repair rebuild and testing to factory specifications Equipment which has been serviced repaired or rebuilt is returned with a full warranty Your local Service Centre can also provide BOC Edwards engineers to support on site maintenance service or re...

Page 35: ...tem Number Acoustic enclosure with vibration isolators A500 65 000 Vibration isolators set of 4 A248 01 414 Exhaust silencer A500 71 000 Exhaust silencer with enclosure A500 83 000 Gas ballast boost assembly manual A500 66 000 Gas ballast boost assembly solenoid valve A500 67 000 Inlet isolation valve B424 03 000 Inlet dust filter A443 03 000 Outlet flap valve pack A500 72 000 The outlet flap valv...

Page 36: ... hazardous materials Note Some contaminated equipment may not be suitable for airfreight PROCEDURE 1 Contact BOC Edwards and obtain a Return Authorisation Number for your equipment 2 Complete the Return of BOC Edwards Equipment Declaration HS2 3 If the equipment is contaminated you must contact your transporter to ensure that you properly classify the hazard mark manifest and ship the equipment in...

Page 37: ...proof of decontamination YOU MUST CONTACT BOC EDWARDS FOR ADVICE BEFORE YOU RETURN SUCH EQUIPMENT Print your name _________________________________Print your job title _________________________ Print your organisation ____________________________________________________________________ Print your address _______________________________________________________________________ ______________________...

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Page 39: ...OC EDWARDS Ammerthalstraße 36 85551 Kirchheim Munich Tel 49 89 99 19 18 0 Fax 49 89 99 19 18 99 HONG KONG S A R BOC EDWARDS ASIA 12 Chun Yat Street Tseung Kwan O Industrial Estate Tseung Kwan O Kowloon Hong Kong S A R Tel 852 2372 2640 Fax 852 2796 9095 INDIA BOC EDWARDS DIVIN OF BOC INDIA LIMITED 203 Surya Kiran Building 19 Kasturba Gandhi Marg New Delhi 110 001 India Tel 91 11 851 0065 Fax 91 11...

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