Atlas Copco GLS 250 User manual

Instruction Book
6996 0222 40
Issue A
Atlas Copco
Oil-sealed rotary piston pumps
GLS 250, GLS 500

Atlas Copco Airpower n.v. Part of the Atlas Copco Group
Postal address Visitors address Phone: +0032 (0)3 - 870 2111
P.O. Box 100 Boomsesteenweg 957 Fax: +0032 (0)3 - 870 2443
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp Email: [email protected]
Belgium Belgium Registration no: BE0403.992.231
www.atlascopco.com For info, please contact your local Atlas Copco representative
Form 5009 0513 03 ed. 00, 2014-06-01
EC DECLARATION OF CONFORMITY
We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
Machine name: VACUUM PUMP
Machine type: GLS250, GLS500
Serial number: This declaration covers all product serial numbers from the date this Declaration
was signed onwards.
Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation
of the laws of the Member States relating to machinery, is in conformity with the relevant Essential
Health and Safety Requirements of this directive.
The machinery complies also with the requirements of the following directives and their amendments
as indicated.
Directive on the approximation of laws of the
Member States relating to Harmonised and/or Technical Standards used
Machinery safety 2006/42/EC EN 1012-2
Low voltage equipment 2006/95/EC EN 60034-1
Atlas Copco Airpower n.v. is authorised to compile the technical file.
Conformity of the product to the
specification and by implication to the
directives
Issued by:
Engineering
Name:
Andries Desiron
Signature:
Date:
01/06/2014

GLS 250/GLS 500
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.
Atlas Copco
Oil-sealed rotary piston pumps
6996 0222 40 Issue A
www.atlascopco.com

16996 0222 40 Issue A
Instruction Book
Table of Contents
1 Introduction ...................................................................................................................6
1.1 Scope .............................................................................................................................6
1.2 Description ......................................................................................................................7
2 Technical data .............................................................................................................14
2.1 Operating and storage conditions .................................................................................14
2.2 Pump specifications ......................................................................................................14
2.3 Materials in contact with process gases .......................................................................15
2.4 Electrical data ...............................................................................................................15
3 Installation ...................................................................................................................18
3.1 Safety ...........................................................................................................................18
3.2 System design considerations ......................................................................................19
3.3 Unpack and inspect ......................................................................................................19
3.4 Locate the pump ...........................................................................................................20
3.5 Inlet piping ....................................................................................................................20
3.6 Exhaust piping ..............................................................................................................23
3.7 Electrical connections ...................................................................................................25
3.8 Cooling ..........................................................................................................................27
3.9 Pump lubrication ...........................................................................................................27
4 Operation .....................................................................................................................29
4.1 Pre-start check ..............................................................................................................29
4.2 Pump start ....................................................................................................................29
4.3 Gas ballast operation ....................................................................................................30
4.4 Pump stop .....................................................................................................................31

6996 0222 40 Issue A 2
Instruction Book
4.5 Operating notes ............................................................................................................32
5 Maintenance ................................................................................................................33
5.1 Safety information .........................................................................................................33
5.2 Leak detection ..............................................................................................................33
5.3 Maintenance plan .........................................................................................................34
5.4 Oil change .....................................................................................................................35
5.5 Oil level check ...............................................................................................................35
5.6 Valve deck maintenance ...............................................................................................36
5.7 Belt maintenance ..........................................................................................................36
5.8 Drive belt tension ..........................................................................................................37
5.9 Gas ballast check valve replacement ...........................................................................37
5.10 Fitment or replacement of the motor (GLS 500 models only) .......................................38
5.11 Fault finding ..................................................................................................................40
6 Storage and disposal .................................................................................................43
6.1 Storage .........................................................................................................................43
6.2 Disposal ........................................................................................................................43
7 Spares and accessories .............................................................................................44
7.1 Introduction ...................................................................................................................44
7.2 Service ..........................................................................................................................44
7.3 Spares ..........................................................................................................................44
7.4 Accessories ..................................................................................................................44

36996 0222 40 Issue A
Instruction Book
Illustrations
1 Theory of operation .........................................................................................................8
2 GLS 250 pump general arrangement ...........................................................................10
3 GLS 500 pump general arrangement ...........................................................................11
4 GLS 250 pump dimensions ..........................................................................................16
5 GLS 500 pump dimensions ..........................................................................................17
6 Inlet piping configurations .............................................................................................22
7 Exhaust piping ..............................................................................................................24
8 Electrical schematic ......................................................................................................26
9 Gas ballast setting ........................................................................................................31
10 Typical vacuum system piping ......................................................................................34
11 Collar bolt positions and motor frame sizes ..................................................................39
Tables
1 General data .................................................................................................................14
2 Pump technical specifications .......................................................................................14
3 Motor specifications, IEC motors (CE pumps) ..............................................................16
4 Motor specifications, NEMA motors ..............................................................................17
5 Maintenance plan .........................................................................................................34
6 Belt tension ...................................................................................................................37
7 Motors that can be fitted to GLS 500 pump models .....................................................38
8 Fault finding guide ........................................................................................................40
9 Accessories ..................................................................................................................44

6996 0222 40 Issue A 4
Instruction Book
Associated Publications
Publication title Publication number
Vacuum Pump and Vacuum System Safety.............................................................................6996 0222 10
V Lube F SDS...........................................................................................................................0017 5202 31

56996 0222 40 Issue A
Instruction Book

6996 0222 40 Issue A 6
Instruction Book
1 Introduction
1.1 Scope
This manual provides installation, operation and maintenance instructions for GLS 250 and
GLS 500 pumps (referenced as ‘GLS pump’ throughout the remainder of the manual). The GLS
pump must be used as specified in this manual. Read this manual before installing and operating
the pump.
Important safety information is highlighted as WARNING and/or CAUTION instructions
which must be followed. The use of WARNINGS and/or CAUTIONS is defined below.
The units used throughout this manual conform to SI international system of measurement
followed by imperial units in parenthesis; SI (imperial).
The following warning symbols are on the pump:
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 and process.
WARNING
refer to accompanying documentation.
WARNING
risk of electric shock.
WARNING
hot surfaces.
WARNING
risk of explosion

76996 0222 40 Issue A
Instruction Book
1.2 Description
The GLS pumps are self-contained, rotary, oil sealed piston type units. An eccentric mounted
onthedriveshaft drivesthe piston.Two free-oscillatingfloating hingebars inthe pumphousing
guide the piston slide. The piston assembly rotates clockwise when facing the drive end. Air
enters the pump through the intake and passes through the piston slide as the piston performs its
intake stroke. As the piston nears the top center position the intake port is closed, separating the
system from the pump (see Figure 1). The air is entrapped on the front side of the piston as it
begins the next stroke. As the piston continues to rotate, the entrapped air is compressed and
discharged through the exhaust valves and out the reservoir exhaust outlet. The exhaust valves
are a corrosion-resistant, heavy duty, poppet type.
WARNING
use protective equipment.
WARNING
moving parts.
WARNING
do not block the pump exhaust.

6996 0222 40 Issue A 8
Instruction Book
Figure 1 – Theory of operation
When the pump is in operation, lubrication of the internal parts is completely automatic. Oil is
forced by atmospheric pressure from the reservoir through internal oil passages to the shaft
bearings. The oil is then fed into the pump to provide the necessary piston-to-cylinder oil seal.
The oil in the pumping chamber is forced out through the exhaust valves with the compressed
air and returns to the reservoir. A solenoid valve prevents oil from flooding the pump in the
event of a power failure or when the pump is shutdown without vacuum being broken.
The pump general arrangements are provided in Figures 2and 3.
1.2.1 Gas ballast
To pump high vapour loads, gas ballast is delivered into the pump to prevent condensation of
the vapour carried by the pump gases.
Air can be introduced to the low vacuum stage. Alternatively, an inert gas such as nitrogen can
be supplied through a suitable external valve.

96996 0222 40 Issue A
Instruction Book
1.2.2 Water system
A cooling water supply rated at 30 °C (85 °F) and 5.7 litres per minute (1.5 GPM) for the GLS
250, and 7.6 litres per minute (2 GPM) for the GLS 500 maximum isrequired for efficient pump
performance. Internal pump water pressure should not exceed 2.41 bar(g) (35 psig) (Refer to
Section 3.8 for information).
WARNING
Cooling lines must be installed as to not create a trip hazard which
can result in injury to personnel.
Reference Designation Reference Designation
(1) Motor lift eye-bolt (10) Reservoir cover
(2) Belt guard (11) 1/4 inch vacuum access port
(3) Exhaust connection 2 inch ANSI (12) Gas ballast adjustment
(4) Solenoid valve (13) Gas ballast purge connection
(5) Oil flow indicator (14) Water inlet connection 1/2 inch
NPT (water miser fitted)
(6) Oil drain valve (15) Motor
(7) Oil fill port (16) Vacuum inlet connection 3 inch
ANSI
(8 Oil level sight glass (17) 1/2 inch vacuum access port
(9) System lift eye-bolt (x2) (18) Water outlet connection 1/2 inch
NPT

6996 0222 40 Issue A 10
Instruction Book
Figure 2 – GLS 250 pump general arrangement

11 6996 0222 40 Issue A
Instruction Book
Figure 3 – GLS 500 pump general arrangement

6996 0222 40 Issue A 12
Instruction Book
1.2.3 Electrical system
The main power supply is either 415 V 50 Hz, 380 - 400 V 50 Hz or 230/460 V 60 Hz and should
be wired through a suitable fused motor starter. Power for the oilsolenoid is taken from anytwo
motor leads. Check both motor and solenoid nameplates to insure proper voltage (Refer to
Section 3.7 for information).
1.2.4 Lubricants
Refer to Section 3.9 for recommended pump fluids.
1.2.5 Guards
The motor pulley, pump pulley, belts andflywheel are enclosed by guards to prevent accidental
contact with these parts. The pump should never be operated with guards removed.
Reference Designation Reference Designation
(1) Motor lift eye-bolt (12) Oil fill port/pressure relief
(2) System lift eye-bolt (13) Oil temperature sensor port
(3) Reservoir cover (14) Oil temperature heater port
(4) Oil level sight glass (15) Oil drain valve
(5) Oil flow indicator (16) Gas ballast adjustment
(6) Motor (17) Gas ballast purge connection
(7) Exhaust connection 3 inch NPT/
ANSI flange (18) Water inlet connection 1/2 inch NPT (water miser mounted)
(8 Belt guard (19) System lift eye-bolt
(9) 1/2 inch vacuum access port (20) 1/4 inch vacuum access port
(10) Oil drain port, dead end (21) Vacuum inlet connection 4”
ANSI
(11) Water outlet connection 1/2 inch
NPT
WARNING
Electrical lines must be installed as to not create a trip hazard
which can result in injury to personnel.

13 6996 0222 40 Issue A
Instruction Book
1.2.6 Vacuum access ports
The pump is provided with 1/4 inch and 1/2 inch NPT vacuum access ports. These ports are
provided for customer convenience. The ports can be used for gauges to monitor the pump
performance or access for introducing purge gases to the pump.
1.2.7 Oil drain port (GLS 500 pump only)
A 1/4 inch oil drain access port has been added to provide a means of removing oil that pools
above the valve decks (Refer to Figure 3 Item 10).
CAUTION
When connecting a gauge to one of the ports, it is necessary to provide a 90°
elbow and a minimum of 305 mm (12 inches) of vertical pipe to the gauge
sensor to reduce the chance of contaminating the gauge with pump
lubricants.

6996 0222 40 Issue A 14
Instruction Book
2 Technical data
2.1 Operating and storage conditions
2.2 Pump specifications
Technical specifications for GLS pumps are provided in Table 2. Pump dimensions are shown
in Figures 4and 5.
Table 1 – General data
General items Reference data
Ambient temperature range (operation) 12 to 40 °C (54 to 104 °F)
Normal surface temperature of the pump body at ultimate
vacuum (operation), ambient temperature of 20 °C (68 °F) 50 to 70 °C (122 to 158 °F)
Maximum humidity (operation) 90 % RH
Ambient temperature range (storage) -30 to 70 °C (-22 to 158 °F)
Table 2 – Pump technical specifications
Specification Unit GLS 250 GLS 500
Ultimate vacuum mbar(a) < 3.3 x 10-2 mbar(a) < 3.3 x 10-2 mbar(a)
microns Hg < 25 < 25
Displacement m3/h 255 510
cfm 150 300
Pump rotation speed rpm 500 490
Peak pumping speed rpm 234 442
Inlet and outlet connections
Vacuum inlet inch 3 ANSI 4 ANSI
Exhaust inch 2 NPT/ANSI flange 3 NPT/ANSI flange
Noise level at 1 metre*dB(A) 77 83
Vibration severity†mm/sec 7 7
Pipe connections
Water inlet mm 13 13
inch 1/2 NPT 1/2 NPT
Water outlet mm 13 13
inch 1/2 NPT 1/2 NPT
Oil capacity litres 15 45
gal 4 12

15 6996 0222 40 Issue A
Instruction Book
2.3 Materials in contact with process gases
The following material will come in contact with process gases. A safety review should be
performed considering the effect of process gases on the following materials: Aluminum;
Nitrile; Brass; Cast Iron; Ductile Iron; Fluoroelastomer; Steel; Stainless Steel; Hydrocarbon
Oil, and; atmosphere.
2.4 Electrical data
The motor specifications are provided in Table 3 and Table 4.
WeightNet kg 431 850
lb 950 1875
Shipping kg 488 896
lb 1075 1975
Height mm 1171 1395
inch 46 55
Floor space mm 667 x 610 1022 x 651
inch 026-1/4 x 24 40-1/4 x 25-5/8
Cooling water consumption
(maximum) litres per minute 5.7 7.6
gpm 1.5 2
Inlet cooling water
temperature (maximum) °C 30 30
°F 85 85
*The noise level was measured in accordance with ISO2151 and with the pump running
at ultimate pressure. Running at higher inlet pressures will increase the noise level.
†Measured at the inlet port to ISO2372 (1974).
Table 2 – Pump technical specifications (continued)
Specification Unit GLS 250 GLS 500

6996 0222 40 Issue A 16
Instruction Book
Figure 4 – GLS 250 pump dimensions
Table 3 – Motor specifications, IEC motors (CE pumps)
Specification GLS 250 GLS 500
Enclosure IP55 IP55
Ambient temperature 40 °C (104 °F) 40 °C (104 °F)
Frame 132 160
Insulation class F F
Electrical supply 415 V or 380 - 400 V 415 V or 380 - 400 V
Mounting B3 B3
Phase/frequency 3/50 Hz 3/50 Hz
Power 5.5 kW 11.0 kW
NOTE
Refer to motor rating nameplate for weight, efficiency, motor speed, and full load
amperage values.

17 6996 0222 40 Issue A
Instruction Book
Figure 5 – GLS 500 pump dimensions
Table 4 – Motor specifications, NEMA motors
Specification GLS 250 GLS 500
Enclosure TEFC TEFC
Ambient temperature 40 °C (104 °F) 40 °C (104 °F)
Frame 213T 215T
Insulation class F F
Electrical supply 230/460 V 230/460 V
Mounting B3 B3
Phase/frequency 3/60 Hz 3/60 Hz
Power 7.5 HP 10.0 HP
NOTE
Refer to motor rating nameplate for weight, efficiency, motor speed, and full load
amperage values.