Atlas Copco DZS 065V User manual

Atlas Copco
Dry claw vacuum & overpressure
pumps
DZS 065V, DZS 150V, DZS 300V
DZS 150P, DZS 300P
Instruction Book
6996 0223 70
Issue B

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Atlas Copco
Dry claw vacuum & overpressure pumps
DZS 065V, DZS 150V, DZS 300V
DZS 150P, DZS 300P
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings. This instruction book is valid for CE as well as non-CE labelled machines.
It meets the requirements for instructions specified by the applicable European
directives as identified in the Declaration of Conformity.
2017-11
No. 6996 0223 70 Issue B
www.atlascopco.com

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4 6996 0223 70
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6996 0223 70 5
Table of contents
SAFETY PRECAUTIONS.....................................................................................................................................7
1.1 Safety icons ..................................................................................................................................................7
1.2 Safety precautions, general..........................................................................................................................7
1.3 Safety precautions during installation...........................................................................................................8
1.4 Safety precautions during operation.............................................................................................................9
1.5 Safety precautions during maintenance or repair.......................................................................................10
GENERAL DESCRIPTION.................................................................................................................................11
2.1 What is vacuum and how is flow rate understood ......................................................................................11
2.2 Introduction .................................................................................................................................................12
2.3 Flow diagram ..............................................................................................................................................17
2.4 Condensate system ....................................................................................................................................20
INSTALLATION..................................................................................................................................................21
3.1 Dimension drawings....................................................................................................................................21
3.2 Installation proposal....................................................................................................................................26
3.3 Electrical connections.................................................................................................................................31
3.4 Pictographs.................................................................................................................................................32
OPERATING INSTRUCTIONS ..........................................................................................................................33
4.1 Initial start-up ..............................................................................................................................................33
4.2 Starting .....................................................................................................................................................34
4.3 During operation .........................................................................................................................................34
4.4 Stopping .....................................................................................................................................................35
4.5 Taking out of operation...............................................................................................................................35
MAINTENANCE .................................................................................................................................................36
5.1 Preventive maintenance schedule..............................................................................................................36
5.2 Oil specifications.........................................................................................................................................38
5.3 Storage .....................................................................................................................................................38
5.4 Disposal of used material............................................................................................................................38
ADJUSTMENTS AND SERVICING PROCEDURES.........................................................................................39
6.1 Air filter .....................................................................................................................................................39
6.2 Oil top-up.....................................................................................................................................................40
6.3 Cleaning motor fan and vent holes.............................................................................................................40
PROBLEM SOLVING.........................................................................................................................................41
TECHNICAL DATA............................................................................................................................................43
8.1 Reference conditions and limitations..........................................................................................................43

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8.2 Pump data...................................................................................................................................................44
8.3 Motor data...................................................................................................................................................45
8.4 Electric cable size and fuses ......................................................................................................................46
INSTRUCTIONS FOR USE................................................................................................................................52
DECLARATION OF CONFORMITY ..................................................................................................................53

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Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
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 Atlas Copco.
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.
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.
In a domestic environment, this product may cause radio interference in which case
supplementary mitigation measures are required.
If the machine is equipped with an automatic restart after voltage failure function and if this
function is active, be aware that the machine will restart automatically when the power is
restored if it was running when the power was interrupted!
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.

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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
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
Atlas Copco.
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 Atlas Copco.
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.
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 connections must 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 Atlas Copco prior to start-up.

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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
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.
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, Atlas Copco
recommends to install an air intake filter to safeguard the pump. Consult Atlas Copco to check whether the
application for the vacuum pump requires and air intake filter.
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.

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1.5 Safety precautions during maintenance or repair
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. 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.
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 DZS 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 DZS
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. Atlas Copco vacuum
pumps use volumetric flow rate to denote performance, the unit being Am³/hr.
Displacement/volumetric flow rate
For the relevant pressure range, when a DZS 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.

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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 DZS 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 DZS 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.
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.

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6996 0223 70 13
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.
General views of Dry claw vacuum and overpressure pumps
DZS 065V, DZS 150V, DZS 300V Dry claw vacuum pumps back view

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14 6996 0223 70
DZS 065V, DZS 150V, DZS 300V Dry claw vacuum pumps front view
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

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DZS 150P, DZS 300P Dry claw overpressure pumps back view
DZS 150P, DZS 300P Dry claw overpressure pumps front view

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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
Flow diagram - DZS 065V, DZS 150V, DZS 300V 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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Flow diagram - DZS 150P, DZS 300P 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
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
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.