Atlas Copco CLAWVAC CP65 User manual

6996 0229 87 Issue A –05/2017 –© Leybold
CLAWVAC
CP65 - CP150 - CP300 - OP150 - OP300
Dry claw vacuum & overpressure pumps
Original Operating Instructions 300676782_002_C0
Part Numbers :
178065 V01 / 10
178150 V01 /10
178300 V01 / 10
178150 P01 / 10
178300 P01 / 10

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Contents
Section Page
Safety precautions 5
1.1 Safety icons 5
1.2 Safety precautions, general 5
1.3 Safety precautions during installation 6
1.4 Safety precautions during operation 7
1.5 Safety precautions during maintenance or repair 8
General description 10
2.1 What is vacuum and how is flow rate understood 10
2.2 Introduction 11
2.3 Flow diagram 16
2.4 Condensate system 19
Installation 20
3.1 Dimension drawings 20
3.2 Installation proposal 25
3.3 Electrical connections 31
3.4 Pictographs 31
Operating instructions 32
4.1 Initial start-up 32
4.2 Starting 33
4.3 During operation 33
4.4 Stopping 34
4.5 Taking out of operation 34
Maintenance 35
5.1 Preventive maintenance schedule 35
5.2 Oil specifications 37
5.3 Storage 37
5.4 Disposal of used material 37
Adjustments and servicing procedures 38
6.1 Air filter 38
6.2 Oil top-up 39
6.3 Cleaning motor fan and vent holes 39
Problem solving 40
Technical data 42
8.1 Reference conditions and limitations 42
8.2 Pump data 42
8.3 Motor data 44
8.4 Electric cable size and fuses 45
Instructions for use 51
Declaration of conformity 52

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Illustrations
Illustration Page
Figure 1 –CP65, CP150, CP300 Dry claw vacuum pumps back view 13
Figure 2 –CP65, CP150, CP300 Dry claw vacuum pumps front view 13
Figure 3 –OP150, OP300 Dry claw overpressure pumps back view 14
Figure 4 –OP150, OP300 Dry claw overpressure pumps front view 15
Figure 5 –Flow diagram - CP65, CP150, CP300 Dry claw vacuum pumps 16
Figure 6 –Flow diagram - OP150, OP300 Dry claw overpressure pumps 17
Figure 7 –Pump cooling 18
Figure 8 –Position of Drain port 19
Figure 9 –Dimension drawing, CP65, CP150 20
Figure 10 –Dimension drawing, CP300 21
Figure 11 –Dimension drawing, OP150 22
Figure 12 –Dimension drawing, OP300 23
Figure 13 –Installation proposal, CP65, CP150, CP300 Dry claw vacuum pumps 25
Figure 14 –Installation proposal, OP150, OP300 Dry claw overpressure pumps 26
Figure 15 –Pictographs and labels 31
Tables
Table Page
Table 1 –Dimensions and weight 24
Table 2 –Preventive maintenance schedule 36
Table 3 –Faults and remedies 40
Table 4 –Reference conditions 42
Table 5 –Limitations 42
Table 6 –Common pump data 42
Table 7 –Motor data 44
Table 8 –Currents and fuses 46

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Safety precautions
1.1 Safety icons
This manual provides installation, operation and maintenance instructions for the Leybold dry claw
pump. Leybold takes no responsibility for damage or injury caused by improper use of the equipment.
Read this manual before you attempt to install, operate or maintain the dry claw pump.
Important safety information is highlighted as WARNING and CAUTION instructions; you must obey
these instructions. The use of WARNINGS and CAUTIONS is defined below.
WARNING
Warnings are given where failure to observe the instruction could result in injury or
death to people.
CAUTION
Cautions are given where failure to observe the instruction could result in damage to the equipment,
associated equipment or process.
The units used throughout this manual conform to the SI international system of units of measurement;
where appropriate, US equivalent units of measurement are also given.
The following IEC warning labels appear on the Leybold dry claw pump:
Warning –Refer to accompanying documentation.
1.2 Safety precautions, general
1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
4. This claw pump is primarily designed for the handing of clean and dry air but inevitably it may be
subjected to dirty and wet applications. If operating in aggressive, toxic, explosive and possibly
dangerous conditions for the pump and operators, consult Leybold.
5. Before any maintenance, repair work, adjustment or any other non-routine checks,
Stop the pump.
Press the emergency stop button.
Switch off the voltage.
Make sure that the pump system is at atmospheric pressure level.
Lock Out - Tag Out (LOTO):
Open the power isolating switch and lock it with a personal lock.
Tag the power isolating switch with the name of the service technician.

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The units may be powered by a frequency converter. Wait 10 minutes after power down before
starting any electrical repair.
Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
WARNING
If the machine is equipped with an automatic restart after voltage failure function is
active, be aware that the machines will restart automatically when the power is
restored if it was running when the power was interrupted!
CAUTION
In a domestic environment, this product may cause radio interference in which case supplementary
mitigation measures are required.
6. Avoid contact with pump intake during operation.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the unit or on its components.
9. Never block the outlet in case the pump is used as a vacuum pump.
1.3 Safety precautions during installation
WARNING
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will be
disclaimed by the manufacturer.
1. The machine must only be lifted using suitable lifting equipment in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly
forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration
must be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting
equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be
taken; consult Leybold.
3. Place the machine where the ambient air is as cool and clean as possible. Never obstruct the cooling
air inlet. Water handling capacity is limited. For operating in such applications, consult Leybold.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the
pipes.
5. All connections must be of correct size and suitable for working pressure and temperature. Never
use frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct size
and suitable for the working pressure and temperature.
6. The aspirated air must be free of flammable fumes, vapors and particles, for example, paint solvents
that can lead to internal fire or explosion. Follow the material safety.
7. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
8. Ensure no external force exerted on the inlet and outlet connection. The connection pipes must be
free of strain. No supports may be fixed to the canopy of the machine.

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9. If remote control is installed, the machine must bear a clear sign stating:
DANGER: This machine is remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that isolating switch is open and
locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or
working on the machine. To this end, a suitable notice shall be affixed to the starting equipment.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the vacuum/over-pressure pump air inlet of the
vacuum relief valve or cooling air inlet.
11. The electrical connectionsmust correspond to the applicable codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch must
be installed near the vacuum/over-pressure pump.
12. On machines with automatic start/stop system or if the automatic restart function after voltage failure
is activated, a sign stating “This machine may start without warning” must be affixed near the
instrument panel.
13. In multiple vacuum/over-pressure pump systems, manual valves must be installed to isolate each
pump. Non-return valves (check valves) must not be relied upon for isolating multiple systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
15. Piping or other parts with a temperature that exceeds 70°C (158°F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
16. If the ground is not leveled or can be subject to variable inclination, consult the manufacturer.
17. Whenever air containing hazardous substances are sucked in (that is, biological or microbiological
agents), use abatement systems placed upstream of the vacuum/over-pressure pump.
18. Any pump placed in an application with inlet gas stream temperatures above the published
maximum temperature should be approved by Leybold prior to start-up.
CAUTION
Also consult following safety precautions: Safety precautions during operation and Safety precautions
during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.
1.4 Safety precautions during operation
WARNING
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will be
disclaimed by the manufacturer.
1. Never touch any piping or components of the pump during operation.
2. Use only the correct type and size of hose end fittings and connections. Make sure that a hose is
fully depressurized before disconnecting it.

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3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed
to the remote start equipment.
4. Never operate the machine when there is a possibility of taking inflammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork panels shut during operation. The panels may be opened for short periods only,
for example, to carry out routine checks. Wear ear protectors when opening a panel. On
vacuum/over-pressure pumps without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80
dB(A) shall wear ear protectors.
8. Periodically check that:
All guards are in place and securely fastened
All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
There are no leaks
All fasteners are tight
All electrical leads are secure and in good order
Air inlet valve and air net, that is pipes, couplings, manifolds, valves, hoses, and so on are in
good repair, free of wear or abuse
9. If warm cooling air from vacuum pumps is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound-damping material.
11. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
12. Do not change the purpose of the pump. If the pump is configured to be used as a vacuum pump,
do not use the pump as an over-pressure pump. If the pump has been configured to be used as an
over-pressure pump, do not use the pump as a vacuum pump.
13. Never run the over-pressure pump without the air intake filter mounted. For the vacuum pump,
Leybold recommends to install an air intake filter to safeguard the pump. Consult Leybold to check
whether the application for the vacuum pump requires and air intake filter.
CAUTION
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
WARNING
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated, will be
disclaimed by the manufacturer.

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1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, and so on).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as “Work in progress; do not start” shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed
to the remote start equipment.
7. Before removing any component, effectively isolate the machine from all sources of under- and/or
overpressure and make sure that the pump system is at atmospheric pressure level.
8. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapors of cleaning liquids.
9. Carefully observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
10. Never weld or perform any operation involving heat near the oil system.
11. Whenever there is an indication or any suspicion that an internal part of a machine is overheated,
the machine shall be stopped but no inspection covers shall be opened before sufficient cooling
time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
12. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel,
and so on.
13. Make sure that no tools, loose parts or rags are left in or on the machine.
14. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
15. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted
and that they function correctly. If removed, check that the coupling guard of the vacuum/over-
pressure pump drive shaft has been reinstalled.
16. Protect the motor, air filter, electrical and regulating components, and so on to prevent moisture
from entering them, for example when steam cleaning.
17. Make sure that all sound-damping material and vibration dampers, for example, damping material
on the bodywork and in the air inlet and outlet systems of the pump, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
18. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
19. Faults or wearing of seals may cause oil lubricant leaks. Avoid dispersion in soil and pollution of
other materials.
CAUTION
Also consult following safety precautions: Safety precautions during operation and Safety precautions
during installation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.

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General description
2.1 What is vacuum and how is flow rate understood
What is vacuum and how to denote
A vacuum is any pressure in a system that is below the ambient atmospheric pressure. It can be denoted
in absolute terms or in effective (gauge) terms:
mbar(a) - Absolute pressure - denotes how much the pressure is above absolute zero vacuum.
(minus) mbar(e) - The Effective or Gauge pressure - denotes how much the pressure is below local
atmospheric pressure
(1)
Pressure
(2)
Absolute vacuum
(3)
Typical CP / OP claw pump working range 600 mbar(a) (450 Torr(a)) –150 mbar(a)
(112.5 Torr(a))
(4)
Atmospheric pressure
Atmospheric pressure at sea level is roughly 1 bar or 1000 mbar (750 Torr). A typical working range for
the CP /OP claw pumps is 600 mbar(a) (450 Torr(a)) to 150 mbar(a) (112.5 Torr(a)). From the
illustration it can be seen clearly that this range is also equivalent to - 400 mbar(e) (-300 Torr(e)) to
- 850 mbar(e) (-637.6 Torr(e)).
It is important to understand which type of reference is required before selecting a pressure instrument
for measuring the vacuum. It must be noted that the distinction doesn't matter for a pressure difference
(delta P; for example, pressure loss), since it is always the result of subtracting 2 pressures (whether
stated as absolute or effective pressures).
Flow rate definitions
There are two common but different ways to denote flow rate in vacuum. The first one is based on the
displacement or volumetric flow rate and the second one is based on the throughput or mass flow rate.
Leybold vacuum pumps use volumetric flow rate to denote performance, the unit being Am³/hr.

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Displacement/volumetric flow rate
For the relevant pressure range, when a CP / OP claw pump operates at quasi constant motor speed
(rotations per minute) and since the compression chambers have fixed dimensions, the same volume
of air is pumped from inlet to outlet with falling pressure level. Over the relevant pressure range, this
makes the volumetric flow rate quasi-independent of the vacuum level. It is the expression of the flow
rate inside the piping at the governing vacuum level (Am³/hr), and always higher than the throughput in
mass flow rate.
Throughput in mass flow rate
Even if the volumetric flow rate is quasi unchanged with falling pressure level, the number of
molecules in that pumped volume is not. By definition: the deeper the vacuum, the lower the amount
of molecules in the same volume of air. This means that the mass flow will decrease with decreasing
(absolute) pressure. It is clear that a flow rate must be stated at a certain vacuum level when using
this denotation.
2.2 Introduction
The CP / OP series claw pumps are single-stage, dry vacuum and over-pressure pumps driven by an
electric motor. The vacuum and over-pressure pumps are air-cooled.
The pump is designed to be run as a vacuum pump or an over-pressure pump dependent upon its
configuration.
The pump is specifically designed to work with clean air, inert gas or small amounts of water vapor. The
ambient temperature must be between 0 °C to 40 °C.
These pumps are enclosed in a sound-insulated bodywork to aid noise reduction, cleanliness and heat
transfer.
The CP / OP claw pump robust design ensures complete flexibility and quick access to all parts. The
claw pump mainly includes dry claw element, gearbox, electric motor and drive train all mounted on a
common base frame.
Element
The pumping chamber consist of duplex set of rotating claws / rotors on cantilevered shafts. The two
claws and the cylinder are all non-touching but have accurate clearances to allow a very efficient
performance.
The main chamber is completely lubrication free and designed with corrosion resistant materials. The
whole assembly is referred to as an element.
Inlet non-return valve
Inlet non-return valve prevents reverse flow of inlet air and thus prevents reverse rotation of the pump.
Gearbox
The element is driven through an oil lubricated gearbox housing synchro-meshing gears which in-turn
is coupled to a direct drive motor.

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Electric motor
Electric motors are 3 phase ‘multi voltage/multi frequency’. For 60Hz supplies they are cUL/UL
approved. The main motor options are:
200/230V 50/60Hz
400V 50Hz
380V 60Hz
500V 50Hz and 575 60Hz
460V 60Hz
230/460V 60Hz (Optional)
The motors are suited to operate with Variable Speed Drive to have complete controllability and to
reduce power consumption. This efficiency improvement leads to power reduction and consequently a
lower carbon footprint.
Following standard features provided with the pump:
Vacuum relief valve (In case of vacuum pump)
The relief valve is designed to open at a predetermined set pressure to protect the pump from
damage.
When the vacuum level is exceeded, the relief valve opens and allows air to enter the pumping
chamber. This has the effect of internal cooling.
Intake filter (In case of over-pressure pump)
Intake filter prevents foreign material from entering the pump. Abrasive, bulky material will damage
the pump’s internal parts and could cause catastrophic failure.
Silencer (Extra inlet silencer in case of over-pressure pump)
The pump inlet and discharge can be noisy. The pump is equipped with an outlet silencer.
For the over-pressure pump an extra inlet silencer is installed.
Pressure Safety valve (In case of over-pressure pump)
A pressure safety valve automatically releases air from a pump, when the pressure exceeds preset
limits.
The following features are available as an option:
Humid Option (In case of vacuum pump)
‘Standard’ and ‘Humid’ versions are available dependent upon the harshness of the application.
The harsh applications, generally wet application need more protection for the pump. ‘Humid’
version contains advanced corrosion resistant wetted parts.
In addition to this, pump is provided with inlet liquid separator, condensate drain facility and
corrosion resistive coating to the exhaust to withstand the harsh applications.

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General views of Dry claw vacuum and overpressure pumps
Figure 1 –CP65, CP150, CP300 Dry claw vacuum pumps back view
Figure 2 –CP65, CP150, CP300 Dry claw vacuum pumps front view

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Reference
Name
1
Drive motor (Fixed speed or inverter driven)
2
Gearbox
3
Inlet Non Return valve
4
Element
5
Exhaust silencer
6
Air outlet
7
Base frame
8
Oil drain plug
9
Oil sight glass
10
Vacuum relief valve
11
Noise reducing canopy
Figure 3 –OP150, OP300 Dry claw overpressure pumps back view

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Figure 4 –OP150, OP300 Dry claw overpressure pumps front view
Reference
Name
1
Air inlet
2
Air intake filter
3
Inlet silencer
4
Inlet Non Return valve
5
Element
6
Exhaust silencer
7
Pressure Safety valve
8
Air outlet
9
Gearbox
10
Drive motor (Fixed speed or inverter driven)
11
Base frame
12
Oil drain plug
13
Oil sight glass
14
Noise reducing canopy

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2.3 Flow diagram
Figure 5 –Flow diagram - CP65, CP150, CP300 Dry claw vacuum pumps
Vacuum Pump
Air comes in through air intake and non-return valve arrangement and displaced by the vacuum pump
element.
After passing the element, the air enters the discharge silencer before exiting to the atmosphere.

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Figure 6 –Flow diagram - OP150, OP300 Dry claw overpressure pumps
Over pressure Pump
Air comes in through air inlet filter and silencer. The air flows through the non-return valve which
prevents reverse flow of air to the inlet. The air is compressed in the element and exhausted at
pressure through the pressure port.
Ensure that the safety valve at the outlet is correctly installed and adjusted.

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Cooling
Figure 7 –Pump cooling
The pump is cooled by forward curved fan located within the coupling housing. This provides air flow
around the pump to aid cooling. The cooling fins also radiate the heat away and the motor fan cools
the drive motor.
The gearbox oil is cooled down by recirculation and convection from the fan.
In many cases the process gas can also cool the element.

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2.4 Condensate system
Figure 8 –Position of Drain port
Reference
Name
1
Drain port
A port (1) at the base of the exhaust silencing chamber allows draining of the condensate.
Humid versions of this vacuum pump may have a manual drain valve / tap installed to facilitate easy
draining.
From factory this drain point is sealed with a threaded plug, but can be exchanged by a connector with
tube to drain the condensate.
Consult local regulations which are applicable for water drainage.

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Installation
3.1 Dimension drawings
Figure 9 –Dimension drawing, CP65, CP150