BOC DP180 Instruction Manual

Dry vacuum pump

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Instruction Manual

DP180 Dry Vacuum Pump

Description

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

Manor Royal, Crawley, West Sussex, RH10 9LW, UK

Telephone: +44 (0) 1293 528844 Fax: +44 (0) 1293 533453

http://www.bocedwards.com

A500-03-880

Item Number

A403-02-934

A403-12-934

A403-02-935

A403-12-995

Issue D

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Page 1 A500-03-880 Issue D Instruction Manual 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...
Page 2: Table Of Contents
Connect the solenoid-valve Connect the cooling-water supply 3.6.1 Supply quality requirements 3.6.2 Connect the supply to the DP180 Connect the DP180 to your vacuum system Connect the DP180 to your exhaust-extraction system Gas-ballast boost system 3.9.1 Gas-ballast boost not in use 3.9.2 Standard air gas-ballast boost 3.9.3...
Page 3 Clean the cooling-jacket STORAGE AND DISPOSAL Storage Disposal SERVICE, SPARES AND ACCESSORIES Introduction Service Spares Accessories RETURN OF BOC EDWARDS EQUIPMENT Illustrations Figure Title Page Dimensions (mm) Pumping speed curves Power curves Lubrication and gas-ballast boost components Motor low voltage configuration (200 V, 50/60 Hz; 220-240 V, 50 Hz) Motor high voltage configuration (380/415 V, 50 Hz;...
Page 4 Tables Table Title Page Full load current ratings Checklist of components Pump-motor terminal-box wiring configurations Maintenance plan Associated publications Publication title Publication Number Vacuum pump and vacuum system safety P300-20-000 DP180 Dry Vacuum Pump...
Page 5 (This page deliberately left blank) DP180 Dry Vacuum Pump...
Page 6: Introduction
(PFPE) grease. As supplied, the bearing end-cover is connected internally to the pump-inlet and is evacuated when the DP180 pump is operating. If required, you can use your own external evacuation pump to evacuate the bearing end-cover.
Page 7: Gas-Ballast Boost
Accessories If the DP180 pump is to be used on clean applications, the pump-outlet can be fitted with a stainless steel flap-valve accessory. On dirty applications, if the use of an outlet-valve is necessary, we recommend that you fit a fluoroelastomer flap-valve accessory.
Page 8: Technical Data
5 kg h Full load current ratings See Table 1 Electrical supply Rating (kW) Full load (A) Voltage (V) Frequency (Hz) 50/60 31.0 25.2 220-240 26.8 380-415 15.5 25.4 19.5 14.2 Table 1 - Full load current ratings DP180 Dry Vacuum Pump...
Page 9 Figure 1 - Dimensions (mm) DP180 Dry Vacuum Pump...
Page 10: Pumping Speed Curves
With stainless steel flap-valve Without flap-valve Figure 2- Pumping speed curves Without flap-valve With stainless steel flap-valve Figure 3- Power curves DP180 Dry Vacuum Pump...
Page 11: Service
71 ± 3 Opening temperature Contact rating Maximum voltage/current 240 V/2.9 A 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: Installation
Use the following procedure to unpack and inspect the pump: 1. Use a fork-lift truck or a pallet truck to move the DP180 on the pallet into a convenient position . 2. Open the cardboard box and remove the packing material from around the pump.
Page 13: Fill The Pump With Oil
Use the following procedure to locate the DP180; the DP180 must be located on a firm, level surface. 1. Use suitable lifting-gear attached to the lifting bolts (see Figure 1) to locate the DP180 in its final operating position. 2. If required, fit four bolts through the 12 mm fixing-holes in the runners to secure the DP180 in place.
Page 14: Lubrication And Gas-Ballast Boost Components
Pump-motor terminal-box Oil drain-plug Oil filler-plug Solenoid-valve Inlet-flange Clamping-ring Oil-level sight-glass Gas-ballast air filter Figure 4 - Lubrication and gas-ballast boost components DP180 Dry Vacuum Pump...
Page 15: Electrical Installation
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 Select high or low voltage operation...
Page 16: Motor Low Voltage Configuration (200 V, 50/60 Hz; 220-240 V, 50 Hz)
(200 V, 50/60 Hz; 220-240 V, 50 Hz) (380/415 V, 50 Hz; 380 V, 60 Hz) Electrical supply Electrical supply Figure 7 - Motor low voltage configuration Figure 8 - Motor high voltage configuration (208-230 V, 60 Hz) (460 V, 60 Hz) DP180 Dry Vacuum Pump...
Page 17: Connect The Pump-Motor Electrical Supply
You must connect the thermal snap-switch to the motor-starter overload-control loop so that, if the DP180 overheats and the switch operates (that is, the switch contacts open), it will trip the contactor and the DP180 will be switched off. When the pump cools and the switch contacts close again, the DP180 will not then automatically restart;...
Page 18: Connect The Solenoid-Valve
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;...
Page 19: Connect The Cooling-Water Supply
RSI and advise on treatments which you can carry out to make your supply suitable for use with the DP180. If you use a treated closed-circuit cooling system, we recommend that you fill it (and refill it) with de-ionised or reverse-osmosis treated water.
Page 20: Cooling System And Bearing End-Cover Evacuation Components
Bearing end-cover evacuation plug Inlet-stage sump clamp-plate Cooling-water outlet Cooling-water inlet Exhaust outlet Bearing end-cover Thermostatic control-valve Pump body cooling-water inlet Figure 10 - Cooling system and bearing end-cover evacuation components DP180 Dry Vacuum Pump...
Page 21: Connect The Dp180 To Your Vacuum System
• 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. •...
Page 22: Connect The Dp180 To Your Exhaust-Extraction System
3.9.2 Standard air gas-ballast boost As supplied, the DP180 has a gas-ballast boost system which delivers air to the gas-ballast boost inlet of the pump. To use this system, connect the solenoid-valve to the electrical supply as described in Section 3.5.5.
Page 23: Connect The Nitrogen Supply (If Required)
When necessary, you can connect a nitrogen supply to the gas-ballast boost system so that nitrogen is delivered to the DP180 instead of air. Use the following procedure to connect your nitrogen supply. 1. Refer to Figure 3. Undo and remove the NW10 clamp (7) which secures the air-filter (8) to the gas-ballast boost pipe.
Page 24: Leak-Test The Installation
Adjust the thermostatic control-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.
Page 25: Prime The Cooling System
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 (that is, that the DP180 is at the correct operating temperature). 5. Turn off the electrical supply to the DP180 and the services.
Page 26: Operation
Shut-down Use the following procedure to shut down the DP180. 1. Isolate the pump-inlet from your vacuum system and operate the DP180 for 15 minutes with the gas-ballast boost solenoid-valve open. 2. Close the gas-ballast boost solenoid-valve and switch off your nitrogen supply (if fitted).
Page 27: Maintenance
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 fluorinated materials used in the DP180 are available on request: contact your supplier or BOC Edwards.
Page 28: Check The Gearbox Oil-Level
Refer to Figure 4. Check the pump gearbox oil-level on the sight-glass (4). The level of oil must be between the MIN and MAX marks when the pump is off and is cold: • If the oil-level is below the MIN mark, pour more oil into the DP180 until the oil-level is correct: refer to Section 3.3. •...
Page 29: Change The Gearbox Oil
Do not over-pack the bearings or the DP180 will run hot. 6. If you have not fitted a pump to evacuate the bearing end-cover (see Section 3.10) and you have reached the planned time to replace the head-plate felt filter (this is carried out annually), replace the filter as described in Section 5.7.
Page 30: Change The Head-Plate Felt Filter
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 in Step 7 of Section 5.6. DP180 Dry Vacuum Pump...
Page 31: Change The Gas-Ballast Air Filter Element
(2) on the top-cap does not point upwards, otherwise debris, dust or liquids may enter the filter body. Top-cap Inlet Filter element Filter body Figure 12 - Exploded view of the gas-ballast air filter DP180 Dry Vacuum Pump...
Page 32: Clean The Inlet-Stage Sump
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: 1. Remove the two screws on the clamp which secures the inlet-stage sump blanking-plate to the pump (see Figure 10).
Page 33: Storage And Disposal
Storage Store the DP180 as follows : 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.
Page 34: Service, Spares And Accessories
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 repair of your equipment. For more information about service options, contact your nearest Service Centre or other BOC Edwards company. Spares...
Page 35: Accessories
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.
Page 36: Return Of Boc Edwards Equipment
7. If the equipment is large, strap the equipment and its accessories to a wooden pallet. If the equipment is too small to be strapped to a pallet, pack it in a suitable strong box. 8. Fax or post a copy of the Declaration (HS2) to BOC Edwards. The Declaration must arrive before the equipment.
Page 37 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...
Page 38 This page intentionally blank.
Page 39 PLEASE CONTACT ANY OF THESE COMPANIES FOR DETAILS OF OTHER SALES AND SERVICE CENTRES IN YOUR AREA. BOC Edwards is part of BOC Limited. BOC Edwards and the stripe symbol are trade marks of The BOC Group. © BOC Edwards 2003 Produced by Technical Publicity Techpublicity@edwards.boc.com...