LEYBOLD SCREWLINE SP 250 Operating Instructions Manual

Dry compressing screw vacuum pump atex category 2 inside (i) and 3 outside (o)

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SCREWLINE SP 250

Dry Compressing Screw Vacuum Pump

ATEX category 2 inside (i) and 3 outside (o)

Operating Instructions 300701216_002_C0

P/N

115012V11

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Summary of Contents for LEYBOLD SCREWLINE SP 250

Page 1 SCREWLINE SP 250 Dry Compressing Screw Vacuum Pump ATEX category 2 inside (i) and 3 outside (o) Operating Instructions 300701216_002_C0 115012V11...
Page 2 Connections at the Delivery Side (Exhaust Electrical Connection 3.4.1 Motor Protection 3.4.2 Star/Delta Start-up Circuit 3.4.3 Soft Start 3.4.4 Mains Connection 3.4.5 Power Failure 3.4.6 Operation with a Frequency Converter (FC Operation) Oil Temperature Sensor Pt 100 300701216_002_C0 - 03/2018 - © Leybold...
Page 3 5.13 Empty the Collecting Vessel of the Purge Vent Kit 5.14 Full Service 5.15 Service at Leybold 5.16 Maintenance Schedule Troubleshooting Waste Disposal EU Declaration of Conformity These Operating Instructions are the original instructions. 300701216_002_C0 - 03/2018 - © Leybold...
Page 4 Operating Instructions and follow the information so as to ensure optimum and safe working right from the start. The Leybold SCREWLINE SP 250 have been designed for safe and efficient operation when used properly and in accordance with these Operating Instructions.
Page 5 Hot surface Do not touch. Allow this area to cool before servicing Burn hazard Hot surface inside. Do not touch. Wear protective equipment. Reactive or corrosive media must not be pumped with this pump. 300701216_002_C0 - 03/2018 - © Leybold...
Page 6 Connect the pump so that it not will restart automatically after a mains power failure, once the power returns. Overhead load Transport the pump only at the two crane eyes or with a forklift secured on a suitable palette. 300701216_002_C0 - 03/2018 - © Leybold...
Page 7 Lay the electric feed lines so that there is no risk of tripping over these. The warning information on the pump must not be covered. When changing the oil remove any escaped oil as otherwise there is the risk of slipping. 300701216_002_C0 - 03/2018 - © Leybold...
Page 8 After having connected the motor and each time after having made changes to the wiring, check the direction of rotation. If the direction of rotation is wrong, the pressure can increase on the intake side. Moreover, the pump can suffer severe damage. 300701216_002_C0 - 03/2018 - © Leybold...
Page 9 When nitrogen is used as the purge gas or as the gas ballast, small quantities of nitrogen can escape to the surroundings. Ensure sufficient ventilation for the room in which to pump has been installed. 300701216_002_C0 - 03/2018 - © Leybold...
Page 10 When pump- ing harmful gases, the operator must ensure that such a malfunction cannot occur, respectively that leaks at the pump will not be a hazard. 300701216_002_C0 - 03/2018 - © Leybold...
Page 11 Safety Information Leybold is not in a position to perform servicing (repairs) and waste disposal of radioactively contaminated pumps. Both needs to be ensured from the side of the user. When disposing the pump, used lubricants and used oil filters observe the applicable environment regulations.
Page 12 For proper connection, a suitable motor protection switch must be used. Set this motor protection switch in agreement with the informa- tion provided on the motor nameplate. Connect the pump to the correct mains voltage and mains frequency. 300701216_002_C0 - 03/2018 - © Leybold...
Page 13 Pressures given in bar or mbar are absolute values. If exceptionally a gauge pressure is meant, a “g” is added (bar(g) = bar (gauge) = bar overpressure) 300701216_002_C0 - 03/2018 - © Leybold...
Page 14 For the purpose of removing deposits in the pump housing Leybold offers a flushing kit. DANGER The pump is not suited for pumping of: reactive or corrosive media ■...
Page 15 The IP degree of protection must be maintained. Modifying the supplied screw pump, voids the CE Declaration of Conformity Classification and Marking of the SP-Guard II 3G Ex nA IIC T4 Gc (10°C<Ta<40°C) II 3D Ex tc IIIB 120°C Dc (10°C<Ta<40°C) 300701216_002_C0 - 03/2018 - © Leybold...
Page 16 Equipment group Equipment category Zones Not applicable Protection by housing Classification of dusts Symbol Zone Adequate safety IIIA Flammable fluff for rare errors IIIB Non-conductive dust for predictable errors IIIC Conductive dust for normal operation 300701216_002_C0 - 03/2018 - © Leybold...
Page 17 Chemical reactions ■ The aforementioned ignition sources can occur in connection with malfunc- tions which are to be expected. For safe usage, the screw pump has been equipped with an ignition source monitoring system (SP-Guard). 300701216_002_C0 - 03/2018 - © Leybold...
Page 18 Chapter 3.4.1. In order to avoid static charging, plastic parts must only be cleaned moist. The permissible gas admission temperature (see Technical Data) must not be exceeded. See also Chapters 4.2.5 and 4.2.6. 300701216_002_C0 - 03/2018 - © Leybold...
Page 19 The exhaust gas temperatures will not exceed the stated maximum surface temperatures of the screw pump. The exhaust gases need to be discharged through a suitable exhaust gas sys- tem. 300701216_002_C0 - 03/2018 - © Leybold...
Page 20 Operating Instructions of the filter. Chemical Reactions Without the introduction of special measures the screw pump must not be used in connection with reactive or corrosive gases which may cause an exo- thermal chemical reaction. 300701216_002_C0 - 03/2018 - © Leybold...
Page 21 Description Description Design and Function The SCREWLINE SP 250 is a dry compressing screw-type vacuum pump capable of a maximum pumping speed of 270 m · h at 50 Hz and 330 m · h at 60 Hz. It has been developed specifically for the special requirements of industrial applications.
Page 22 (fig. 1.2) so that the chamber volume is already reduced at low pressures (fig. 1.3c). In this way a power consumption can be attained which is comparable to that of rotary vane pumps. 300701216_002_C0 - 03/2018 - © Leybold...
Page 23 Fig. 1.2 Compression principle and the direction of pumping action within a screw pump without inner compression with inner compression against with inner compression the face side of the pump along the rotor chamber (SCREWLINE) Fig. 1.3 pV diagrams of screw pumps 300701216_002_C0 - 03/2018 - © Leybold...
Page 24 Temperature sensor in the motor coil PTC 160 °C - 5 °C PTC 160 °C - 5 °C Operating mode S1 (continuous operation) S1 (continuous operation) Operating agents Cooling Approved type of oil: LVO 210 300701216_002_C0 - 03/2018 - © Leybold...
Page 25 1) at ultimate pressure with connected discharge line without silencer, in accordance with ISO 4871 (acc. to DIN EN ISO 2151), KpA=3dB 2) in accordance with EN 61800-5-1 3) in accordance with EN 60721-3-3 300701216_002_C0 - 03/2018 - © Leybold...
Page 26 5 to 6,5 mm Electrical connector Festo Connection thread/gas supply G 1/8” - inside thread resp. 6 mm plug connection Purge gas pressure to be set up 2.5 bar Purge gas volume flow 26 Std. l/min 300701216_002_C0 - 03/2018 - © Leybold...
Page 27 SP 250/50 Hz mbar Intake pressure Pressure Fig. 1.4 Pumping speed curves > 500 68-75 1348 > 500 > 500 (Dimensions in mm) Serviceabstand > 900 Clearance for maintenance work > 900 Fig. 1.5 Dimensional drawing 300701216_002_C0 - 03/2018 - © Leybold...
Page 28 For the purpose of shipping the pump, the pump has been affixed to a spe- cial pallet. Retain this pallet in case the pump needs to be returned. 300701216_002_C0 - 03/2018 - © Leybold...
Page 29 SP-Guard may then be reset to the monitoring mode using the reset key. The service technician has the option of reading the most recently saved measured values from the internal memory of the SP-Guard. This information will help to analyse the reasons for the specific failure. 300701216_002_C0 - 03/2018 - © Leybold...
Page 30 Purge gas pressure reducer Purge gas pressure switch Exhaust pressure switch Gas temperature sensor Oil temperature sensor Oil level switch Vibration sensor Fig. 1.7 Components of the monitoring system on the screw pump (covers removed) 300701216_002_C0 - 03/2018 - © Leybold...
Page 31 With the purge vent kit installed, the oil collects in an aluminium collecting vessel. Available Pump Versions: Overview Part No. Pump versions mains frequency 115012V11 50/60 Hz with SP-Guard, electro-pneumatic gas ballast, purge gas for sealing and Purge Vent Kit Special seals (FFPM) 300701216_002_C0 - 03/2018 - © Leybold...
Page 32 ■ Use accessories with special gaskets only. NOTICE Stability of the pump when using Leybold accessories is ensured. If other accessories are fitted then the user himself will be responsible for maintaining pump stability. If other accessories are used, the operator himself will be responsible for ensuring explosion protection of the screw pump.
Page 33 When doing so note the risk of slipping and toppling. If required secure the pump. For transporting, the silencer must be disassem- bled as otherwise there is the risk of toppling. 300701216_002_C0 - 03/2018 - © Leybold...
Page 34 When shelving the pump for prolonged periods, drain out of the oil from the pump. Package in the pump air-tight in polyethylene foil. Storage conditions Temperature -20 °C to + 60 °C Storage site Maximum atmospheric humidity 95 %, non-condensing 300701216_002_C0 - 03/2018 - © Leybold...
Page 35 Technical Data. In all other operating modes and with other equipment, higher values may be attained. Suitable hearing protection measures must be intro- duced. 300701216_002_C0 - 03/2018 - © Leybold...
Page 36 From this side all maintenance and installation work can be done. For installation locations over 3000 m above sea level please consult us. Conforming Utilisation See section “Impact of the ATEX Directive” on page 14 ff. 300701216_002_C0 - 03/2018 - © Leybold...
Page 37 Otherwise the screw pump may suffer damage or the pump housing may be contaminated by reverse venting through the shaft seal. 300701216_002_C0 - 03/2018 - © Leybold...
Page 38 Remove protection foil and desiccant from the discharge flange. The pressure in the discharge line must not exceed 200 mbar are above CAUTION the ambient pressure. The discharge line must not be blocked or constrict- 300701216_002_C0 - 03/2018 - © Leybold...
Page 39 The number of operating hours of the pump is acquired through the SP-Guard. The local connection conditions will possibly necessitate means for the pur- pose of reducing the surge currents upon switching the pump on. 300701216_002_C0 - 03/2018 - © Leybold...
Page 40 The line cross-section for the mains power supply needs to be calculated in consideration of the cable length and the available mains circuit breaker. Using a mains power supply line having a cross-section of at least 4 x 6 mm is recommended. 300701216_002_C0 - 03/2018 - © Leybold...
Page 41 I / A I / A ∆ ∆∆ ∆ ∆∆ ∆ ∆ ∆∆ ∆∆ U / V U / V Diagram 3.1.1 Characteristic of the motor protection switch for delta circuit (Symbol ∆ respectively ∆∆ ) 300701216_002_C0 - 03/2018 - © Leybold...
Page 42 3~ / 210 V 60 Hz For continuous operation! For starting only! Temperature sensor integrated in the coil. Caution Do not apply voltages in excess of 2.5 V Fig. 3.4 Mains connection (connection diagrams in the junction box) 300701216_002_C0 - 03/2018 - © Leybold...
Page 43 Observe the direction of rotation of the running down fan. The correct direc- tion of rotation is indicated by an arrow in the junction box. In the case of a wrong connection, rewire. Close the housing again. 300701216_002_C0 - 03/2018 - © Leybold...
Page 44 This prevents an uncontrolled flow through the pump. 3.4.6 Operation with a Frequency Converter (FC Operation) FC operation is not allowed. 300701216_002_C0 - 03/2018 - © Leybold...
Page 45 If the temperature of the oil deviates during normal loads and ambient con- NOTICE ditions from the process dependent standard values, the oil cooler should be checked to see if it has accumulated any dirt. 300701216_002_C0 - 03/2018 - © Leybold...
Page 46 SCREWLINE SP 250 24 V DC Exhaust 4.5 W pressure switch Oil tempera - Gas tempera- Oil level ture sensor ture sensor switch Fig. 3.6 Block diagram for the screw pump ATEX Category 2i/3o 300701216_002_C0 - 03/2018 - © Leybold...
Page 47 Switching output S1 (warning) red/blue Switching output S2 (error) white/green Switching output S3 (watchdog) brown/green Switching output S4 (pump on) yellow/brown 0 V (GND for PLC controller) Not connected Shield For connection, see fig. 3.8 300701216_002_C0 - 03/2018 - © Leybold...
Page 48 1 V below the power supply voltage level and the low level is at approximately 1 V. The maximum current rating is 40 mA. The outputs are protected by means of semiconductor fuses. 300701216_002_C0 - 03/2018 - © Leybold...
Page 49 Failure limit, vibrations 0,2 s Hysteresis Vibration measurement 30 to 60 °C Warning limit, oil temperature °C Failure limit, oil temperature up to 110 °C Warning limit, gas temperature °C Failure limit, gas temperature 300701216_002_C0 - 03/2018 - © Leybold...
Page 50 In the case of an ATEX connection, Union nut comply with IP 65 requirements. Fig. 3.11 Fitting the connector Bürkert for the gas ballast valve 24 V DC Valve Fig. 3.12 Electrical connection at the gas ballast valve 300701216_002_C0 - 03/2018 - © Leybold...
Page 51 Pressure connection for purge gas - G 1/8" inside thread, respectively 6 mm plug-in connector. Manual drain for condensate Fig. 3.13 Purge gas connection and condensate drain at the supply unit 300701216_002_C0 - 03/2018 - © Leybold...
Page 52 IP pump and in line with IP 65 requirements. The valve is of the normally closed type. In the control arrangement needs to be implemented such that before switch ing on the screw pump, the purge gas valve opens as otherwise the SP-Guard will output an error message. 300701216_002_C0 - 03/2018 - © Leybold...
Page 53 When doing so make sure that all aids used are clean so as to avoid con- taminating the oil. Use only lubricating oil which has been approved by Leybold. The gear oil should be filled in at room temperature. At lower temperatures, the oil is thicker so that there then is the risk of overfilling gear chamber with oil.
Page 54 Minimum mark at the oil sight glass Float ■ during standstill Minimum mark at the oil sight glass ■ during operation Oil drain plug Fig. 4.2 Oil level at the oil sight glass after the SP 250 300701216_002_C0 - 03/2018 - © Leybold...
Page 55 The gear housing is vented in the vicinity of fan wheel through two channels on the side opposite the exhaust. By design, small amounts of gear oil may escape through this vent. This will not adversely affect operation of the pump. 300701216_002_C0 - 03/2018 - © Leybold...
Page 56 Press the pushbutton - long (3 seconds), and then short twice. A confirmation of the resetting pro- cess will be indicated on the display for approximately 5 seconds. 300701216_002_C0 - 03/2018 - © Leybold...
Page 57 It must be ensured that the pressure does not exceed p + 200 mbar CAUTION and that the temperature does not exceed 60 °C. Max. gas ballast con- sumption is at approximately 14 Std. m 300701216_002_C0 - 03/2018 - © Leybold...
Page 58 RUVAC pump. In such a case, the output from the temperature sensor at the RUVAC needs to be processed additionally. 300701216_002_C0 - 03/2018 - © Leybold...
Page 59 If much condensate is col- lected, the condensate separator will have to be checked regularly. 300701216_002_C0 - 03/2018 - © Leybold...
Page 60 Section 2 “Transport and Storing”. For this please contact Leybold for advice. Switch off power supply for the SP-Guard ■...
Page 61 All work within the pump should be left to suitably trained staff. In this con- text we would like to inform you about practical seminars offered by Leybold in which maintenance, repair and testing of the SP 250 are cov- ered by qualified instructors. Improperly performed maintenance or repair work will void the CE and ATEX conformity and void any warranty claims.
Page 62 Thus proper seat- ing of the cover halves is ensured. The cables for the potential equalisation must be reconnected and checked as to proper functioning (see Chapter 5.12). 300701216_002_C0 - 03/2018 - © Leybold...
Page 63 Maintenance V4/5 V3/7 V4/6 V2/3 (Inside) (innen) Fig. 5.2 Cables for potential equalisation 300701216_002_C0 - 03/2018 - © Leybold...
Page 64 Place a sufficiently large collecting vessel (about 20 litres) under the pump. When disposing of the waste oil observe the applicable environment pro- tection regulations. Use only lubricants approved by Leybold. NOTICE To change the oil, the cover section on the discharge side needs to be disas- sembled, see fig.
Page 65 Pull the filter insert out. Push the new filter insert on until it positively engages. Replace the O-ring of the filter housing. Screw the filter housing on up to the stop and tighten. 300701216_002_C0 - 03/2018 - © Leybold...
Page 66 A dirty cooler may cause increased oil and pump temperatures and impair operation and reduce the service life of the pump. The oil cooler can be cleaned with an industrial vacuum cleaner after having removed one cover section. 300701216_002_C0 - 03/2018 - © Leybold...
Page 67 Cleaning the Dust Filter in the Intake Line (optional) The dust filters which are installed upstream of the pump need to be checked regularly for contamination and cleaned as required. 300701216_002_C0 - 03/2018 - © Leybold...
Page 68 When blowing out with compressed air, protect your eyes and wear pro- CAUTION tective goggles. Fit the dust cap again and affix it with the locking clips. The cover is fitted in the reverse order as described in Section 5.1. 300701216_002_C0 - 03/2018 - © Leybold...
Page 69 If these functions of the SP-Guard are not operative, please contact the Leybold Service. If the pump does not shut down as intended, check the control and power circuitry. Switch the pump off and let it cool down for the following work.
Page 70 In the next step slowly reduce the pressure, as soon as the switching thresh- old is attained, a flow of 22 Std. l/min or more must be present. If this is not the case, please contact the Leybold. d) Checking the leak tightness of the piston rings In order to check the leak tightness of the shaft seal (piston rings), the screw pump must be sealed off firmly on its intake side.
Page 71 After the test has been concluded with a positive out- come, screw the cooler back on and check the oil hoses as to the presence of any leaks. Check potential equalisation, see Chapter 5.12. 300701216_002_C0 - 03/2018 - © Leybold...
Page 72 To inspect the rotors and the pump housing, the cover halves must be removed (see Chapter 5.1). NOTICE This work must only be done by personnel trained by Leybold. 5.10 Checking the Connection Lines and the Hoses To check the connection lines and the hoses, the cover halves must be removed (see Chapter 5.3.1).
Page 73 Fig. 5.10). For the measurements a resistance meter is used and the value which is measured must be below 100 Ohm. The electrically conducting parts must be connected to each other. Such connections must be re-established and tested after repair and maintenance work (see Fig. 5.9). 300701216_002_C0 - 03/2018 - © Leybold...
Page 74 Cover half on Copper rivet below the handle recess non-discharge side see figure Bottom trough M 16 hexagon nut, see figure Heat sink Closure screw Fig. 5.10 Potential equalisation measurement points 300701216_002_C0 - 03/2018 - © Leybold...
Page 75 Again install the collecting vessel in the reverse order. 5.14 Full Service Every 40,000 operating hours or every five years (depending which comes first) a full service must be performed. The full service can only be performed by authorised service centres. 300701216_002_C0 - 03/2018 - © Leybold...
Page 76 Maintenance 5.15 Service at Leybold If you send a pump to Leybold indicate whether the pump is free of sub- stances damaging to health or whether it is contaminated. If it is contaminated also indicate the nature of the hazard. To do so, you must use a preprinted form which we shall send to you upon request.
Page 77 Flushing kit (P/N 119 015) Depending on the application KA17200916 shorter maintenance intervals can become necessary. Filter cartridge in the E110000850 Depending on the application pressure reducer shorter maintenance intervals can become necessary. 300701216_002_C0 - 03/2018 - © Leybold...
Page 78 Purge gas flow is too low or too high. Check to see whether the purge gas supply is Operator and flow okay. Check pressure reducer setting 2.5 bar. maintenance Leaky connection line? personnel Exhaust pressure too high or too low. 300701216_002_C0 - 03/2018 - © Leybold...
Page 79 Check if rotors turn freely, measure motor Notice: Do not restart the pump after the resistance, replace motor if required. Service motor protection switch has tripped without having repaired the cause of the tripping. 300701216_002_C0 - 03/2018 - © Leybold...
Page 80 Defective silencer. Repair silencer. High gas throughput with the discharge line Install discharge line or silencer. open, without silencer. Oil film in the Oil ingress after longer operation. No need for action. junction box. 300701216_002_C0 - 03/2018 - © Leybold...
Page 81 Waste oil from vacuum pumps must not be mixed with other substances or materials. Waste oil from vacuum pumps (Leybold oils which are based on mineral oils) which are subject to normal wear and which are contaminated due to the influence of oxygen in the air, high temperatures or mechanical wear must be disposed of through the locally available waste oil disposal system.
Page 83 Person to contact: Calibration: Factory-calibr. Phone : Fax: Quality test certificate DIN 55350-18-4.2.1 End user: A. Description of the Leybold product: Failure description: Material description : Catalog number: Additional parts: Serial number: Application-Tool: Type of oil (ForeVacuum-Pumps) : Application- Process: B.
Page 84 Sales and Service Germany America Great Britain Leybold Japan Co., Ltd. Tsukuba Technical Service Center 1959, Kami-yokoba Leybold UK LTD. Leybold GmbH Tsukuba-shi, Ibaraki-shi 305-0854 Unit 9 Bonner Strasse 498 Japan Silverglade Business Park D-50968 Cologne Leybold USA Inc. Service:...

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