BOC Edwards 18B4B User manual

B065-10-880 Issue A Original
Instruction Manual
18B4B Vapour Booster Pumps

This page intentionally blank.

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
i
i
1 INTRODUCTION 1
1.1 Scope and definitions 1
1.2 Description 1
1.3 Construction 1
1.4 Principle of operation 2
1.5 Over-temperature protection 2
1.5.1 Cooling-fail thermal snap-switches 2
1.5.2 Boiler-protection thermal snap-switch 3
1.6 Low fluid level protection (optional) 3
1.7 Temperature indication (optional) 3
1.8 Operation with high ambient humidity 3
2 TECHNICAL DATA 7
2.1 Operating and storage conditions 7
2.2 Performance 7
2.3 Mechanical data 8
2.4 Pump fluid data 8
2.5 Cooling-water data 8
2.6 Electrical data 9
2.7 Construction materials 9
2.8 Pump Item Numbers 10
3INSTALLATION 15
3.1 Safety 15
3.2 Unpack and inspect 15
3.3 Locate the pump 16
3.3.1 General requirements 16
3.3.2 Installation on a vacuum system 16
3.3.3 Free-standing installation 17
3.4 Vacuum connections 17
3.4.1 System design 17
3.4.2 Connect the pump inlet 18
3.4.3 Connect the pump outlet 18
3.5 Cooling-water connections 18
3.6 Pump fluid drain connection (optional) 19
3.7 Connect the electrical supply 20
3.7.1 Electrical safety 20
3.7.2 Connect the supply to the pump 20
3.8 Connect the thermal snap-switches 24
3.8.1 Connect the cooling-fail thermal snap-switches 24
3.8.2 Connect the boiler protection thermal snap-switch 24
3.9 Connect the optional Pt100 temperature probe (if fitted) 24
3.10 Leak test the system 25
3.11 Fill the pump with fluid 25
3.11.1 Safety of vapour pump fluids 25
3.11.2 Recommended pump fluids 25
CONTENTS
Section Page
djd/0240

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
ii
ii
3.12 Filling procedure 26
3.12.1 Introduction 26
3.12.2 General filling procedure 26
3.12.3 Filling procedure for adjustment of the fluid low
level switch 28
3.13 Connect the optional fluid low level switch (if fitted) 28
4 OPERATION 29
4.1 Introduction 29
4.2 Check the insulation resistance of the heaters 29
4.3 Start-up 30
4.4 Rough pumping 30
4.5 Adjust the boiler protection thermal snap-switch
(if necessary) 30
4.6 Re-admission of air to your vacuum system 32
4.7 Re-evacuation of your vacuum system 32
4.8 Shut-down 32
5MAINTENANCE 35
5.1 Safety 35
5.2 Tools and equipment required 35
5.3 Maintenance plan 36
5.4 Check the pump fluid-level 36
5.5 Inspect the pump fluid (and drain if necessary) 37
5.6 Clean and inspect the pump 37
5.6.1 Introduction 37
5.6.2 Dismantle the pump 37
5.6.3 Clean the main pump components 39
5.6.4 Clean the interior components 39
5.6.5 Clean the boiler and fluid return pipes 39
5.6.6 Reassemble the pump 40
5.6.7 Prepare the pump for operation 41
5.7 Clean the radiation shield 41
5.8 Replace a pump heater 42
5.8.1 Prepare the pump 42
5.8.2 Identify and remove the defective heater 42
5.8.3 Assemble and fit the new heater 44
5.8.4 Reassemble the pump 44
5.9 Check the heater clamp plate and retaining nuts 45
5.10 Clean the cooling-coil 45
5.11 Fault finding 45
6 STORAGE AND DISPOSAL 49
6.1 Storage 49
6.2 Disposal 49
CONTENTS (CONTINUED)
Section Page

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
iii
iii
7 SERVICE, SPARES AND ACCESSORIES 51
7.1 Introduction 51
7.2 Service 51
7.3 Spares 51
7.4 Accessories 51
RETURN OF BOC EDWARDS EQUIPMENT
ILLUSTRATIONS
Figure Page
1 Part-sectional view of the 18B4B pump 5
2 Typical performance curves 11
3 Dimensions (mm) 13
4 Heater wiring connections 21
5Terminalblock 21
6 Terminal block links for Star connections 22
7 Star connection wiring diagram 22
8 Terminal block links for Delta connections 22
9 Delta connection wiring diagram 22
10 Recommended control circuit 23
11 Adjust the boiler protection thermal snap-switch 31
12 Typical pumping system 33
13 Replace a heater 43
TABLES
Table Page
1 Operating and storage conditions 7
2Performancedata 7
3Mechanicaldata 8
4 Pump fluid data 8
5 Cooling-water data 8
6 Electrical data 9
7 Construction materials 9
8 Pump Item Numbers 10
9Checklistofitems 15
10 Vapour pump fluid thermal breakdown 27
11 Maintenance plan 36
12 Fault finding 46
13 18B4B accessories 51
14 18B4B pump spares 52
Section Page

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
iv
iv
SUPPLEMENTARY PUBLICATIONS
Publication title Publication Number
iTEMP PCP TMT 181 Temperature
head transmitter
KA 141R/09/a3/07.02 51004624
liquiphant S FTL70, FTL71 Level Limit Switch KA 172F/00/a6/04.03 52009621
liquiphant M FTL 51 High Pressure Sliding Sleeve KA 153F/00/a6/12.99 52004587
Note: The above manufacturer’s instructions will only be provided with pumps supplied
fitted with the corresponding option(s).
ASSOCIATED PUBLICATIONS
Publication title Publication Number
Application Note: Operation of diffusion
pumps in environments with high ambient
humidity P400-50-000

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
1
1
INTRODUCTION
1INTRODUCTION
1.1 Scope and definitions
This manual provides installation, operation and
maintenance instructions for the BOC Edwards
18B4B Vapour Booster Pumps. You must use the
pumps as specified in this manual.
Read this manual before you install and operate your
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.
In accordance with the recommendations of
IEC1010, the following warning symbols may appear
on the pump or its accessories:
The units used throughout this manual conform to
the SI international system of units of measurement.
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.
The pump identification and rating plate (Figure 3,
item 12) provides specific details about the pump,
including: pump type; part number and serial
number; name and address of manufacturer; and so
on.
1.2 Description
The 18B4B pumps are high performance vapour
booster pumps, and have pumping speeds of up to
4000 l s-1.
The pumps are rugged and reliable and have high
performance even with relatively high backing
pressures.
Three versions of 18B4B pumps are available, with
different inlet and outlet flanges: refer to
Section 2.8.
1.3 Construction
Refer to Figure 1 which shows a part-sectional view
of the 18B4B pump. The pump has:
• A vertical top cone assembly (45) which
incorporates the three diffusion pump stages
(42, 6 and 5).
• A horizontal side cone assembly (14).
• A boiler (33), which forms part of the base of
the pump.
• A ‘T’ piece (38), which connects the top cone
(45), the side cone (14) and the boiler (33).
• A vertical backing condenser (17), which
incorporates a baffle assembly (18).
The diffusion pumping jet stages have top (5),
second stage (6) and lower (42) vapour tubes, each
of which has a jet cap (47, 44, 43). The top jet cap is
covered by a guard ring (2), which minimises the
backstreaming of pump fluid.
The lower vapour tube is bolted to the ejector stage
‘T’ piece (38), and the ‘T’ piece is bolted to the
boiler assembly (33), through flanges to allow easy
access for cleaning.

Issue A Feb 04
PAGE
2
18B4B Vapour Booster Pumps
INTRODUCTION
2
The ejector nozzle (8) is housed in the ‘T’ piece (38),
which is bolted to the side cone (14) into which the
ejector discharges. The side cone ends in a vertical
backing condenser (17).
The pump fluid is heated and vaporised by electric
heaters (27). There are three heaters in the pump,
rated the same for all voltage variants. The boiler
(33) has a dipstick/fluid filler connection (21) and a
fluid drain connection (29).
The electrical supply cables from the heaters are
connected into a terminal box (31) on the base of
the pump, for ease of connection to your electrical
supply.
The pump boiler assembly (33) has a cleaning port
cover (10). You can remove this cover and use the
cleaning port to remove any residue build up from
the inside of the boiler. You should regularly clean
the boiler, to maintain the pump performance at its
optimum level. A radiation shield (22) underneath
the heaters reflects heat from the underside of the
heaters (27) to the boiler, and so increases the
efficiency of the pump.
The pump is cooled by water, which flows through
copper cooling-coils (13, 19, 41) wound around the
top cone, the side cone and the backing condenser.
The cooling couplings (36, 40) connect these coils
together, to form a single cooling circuit around the
pump.
The pump can be supplied with one or both of the
following optional items:
• A fluid low level switch (12): see Section 1.6.
• A Pt100 temperature probe (30): see
Section 1.7.
1.4 Principle of operation
Refer to Figure 1. Pump fluid is heated in the boiler
(33) to produce a vapour, which passes up through
the interior of the diffusion pumping stages (42, 6, 5)
and emerges from the gaps in the jet caps (43, 44,
47) as high velocity vapour streams. The vapour
streams condense on the cooled walls of the top
cone (45) and the side (ejector) cone (11), then
drain into the boiler (33) for recirculation.
A portion of system gas which arrives at the pump
inlet (1), is trapped in the vapour stream from the
first stage jet cap (47) The gases are compressed and
transferred to the next stage. The gases then pass
through the ejector nozzle (8) and into the backing
condenser (17) where they are removed (through
the outlet, 16) by your backing pump.
The cooled surface of the guard ring (2) above the
top jet cap (47) traps and condenses pump fluid
vapour and minimises any backstreaming of pump
fluid vapour into your vacuum system.
1.5 Over-temperature protection
1.5.1 Cooling-fail thermal snap-switches
Refer to Figure 1. The pump has two cooling-fail
thermal snap-switches (7, 9) on the cooling-coils.
These snap-switches protect the pump against
damage due to failure of the cooling-water supply.
Both snap-switches have normally closed contacts
that will open if the temperature of the cooling coils
increases above 46 oC. The snap-switches will reset
automatically when the pump cools down.
You must configure the snap-switches to switch off
the electrical supply to the pump heaters when the
snap-switch contacts open. You must also interlock
the snap-switches so that the pump cannot
automatically restart after the snap-switch contacts
have opened and the pump has then cooled again,
until the problem has been rectified.

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
3
3
INTRODUCTION
1.5.2 Boiler-protection thermal snap-
switch
The pump has a boiler protection thermal snap-
switch (Figure 3, item 20) fitted to the wall of the
boiler. The snap-switch protects the pump against
damage due to a low level of pump fluid, which
causes the boiler temperature to rise.
As supplied, the snap-switch contacts will open
when the boiler wall temperature reaches 250 oC.
You must configure the snap-switch to switch off
the electrical supply to the pump heaters when the
snap-switch contacts open. You must also interlock
the snap-switch so that the pump cannot
automatically restart after the snap-switch contacts
have opened and the pump has then cooled again,
until the problem has been rectified.
1.6 Low fluid level protection (optional)
Your pump may be supplied with an optional fluid
low level switch (Figure 1, item 12).
If fitted, this level switch will provide a warning that
the fluid level in the pump boiler is low, and that
more fluid needs to be added.
As supplied, the level switch is preset to operate
when the fluid level in the boiler has fallen to 6 litres.
1.7 Temperature indication (optional)
Your pump may be supplied with an optional Pt100
temperature probe (Figure 1, item 30), fitted to the
fluid drain connection.
If fitted, this probe will provide an indication of the
temperature of the pump fluid.
1.8 Operation with high ambient
humidity
When the pump is switched off, the heaters in the
pump will absorb moisture: this will cause a
decrease in the insulation resistance of the heaters.
If you operate the pump in an environment with high
ambient humidity, this may cause the heaters to fail.
The rate of moisture absorption (and therefore the
time taken for the insulation resistance of the
heaters to fall below the recommended value)
depends on the ambient humidity and temperature
and the length of time that the pump is switched off.
In addition to the recommendations made in later
sections of this manual, you can overcome the effect
of high ambient humidity if you:
• Configure the electrical installation of the
pump for ‘soft-start’ operation, when the
pump is operated with typically 20 to 25% of
the nominal supply voltage.
• Install an anti-moisture heater under the base
of the pump. Switch on this heater when you
switch off the pump.
Detailed information about these recommendations
is outside the scope of this manual. If you need more
information about the operation of the pump with
high ambient humidity, request a copy of our
Application Note P400-50-000 from your supplier
or BOC Edwards.

Issue A Feb 04
PAGE
4
18B4B Vapour Booster Pumps
INTRODUCTION
4
Figure 1 - Part sectional view of the 18B4B pump: key
1. Inlet
2. Guard ring
3. Inlet ‘O’ ring
4. Cooling-water inlet
5. Top vapour tube
6. Second stage vapour tube
7. Cooling-fail thermal snap-switch
8. Ejector nozzle
9. Cooling-fail thermal snap-switch
10. Cleaning port cover and gasket
11. Cleaning port access lid
12. Fluid low level switch (optional)
13. Cooling-coil
14. Side cone assembly
15. Cooling-water outlet
16. Outlet (backing connection)
17. Backing condenser
18. Baffle
19. Cooling-coil
20. Condenser fluid return pipe
21. Dipstick
22. Heater radiation shield
23. Mounting feet
24. Clamp plate
25. Heater retaining nut
26. Heater cover
27. Heater
28. Earth (ground) stud
29. Fluid drain plug
30. Pt100 temperature probe (optional)
31. Terminal box
32. Boiler base
33. Boiler
34. Jet stack fluid return pipe
35. Tie-rod
36. Cooling coupling
37. ‘T’ piece ‘O’ ring
38. ‘T’ piece
39. Jet gasket
40. Cooling coupling
41. Cooling-coil
42. Lower vapour tube
43. Lower jet cap
44. Second stage jet cap
45. Top cone assembly
46. Locating pin
47. Top jet cap
48. Setting dimension: 1.6 mm *
* This is the setting dimension for AP201 fluid.
This dimension may differ if you use a different
fluid: refer to Section 5.6.6.

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
5
5
INTRODUCTION
Figure 1 - Part-sectional view of the 18B4B pump

Issue A Feb 04
18B4B Vapour Booster Pumps
PAGE
6
6
This page intentionally blank.

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
7
7
TECHNICAL DATA
2TECHNICALDATA
2.1 Operating and storage conditions
2.2 Performance
Notes: The performance data in Table 2 and in Figure 2 is for use of the pump with Apiezon AP201 fluid.
The pumping speeds and throughput specified below and shown in Figure 2 were calculated from
measurements made with partial pressure gauges. If total pressure gauges are used, the calculated
values for pumping speeds are approximately 10% lower. This is because partial pressure gauges do
not measure the pressure added to the system by condensable gases.
We do not give absolute values for the ultimate pressure of the pump. The ultimate pressure depends
on the fluid used in the pump, the leak tightness of the system, outgassing from surfaces, and the use
of cold traps.
Maximum ambient operating temperature
Typical surface temperature during operation
Jet stage cone
Boiler
Maximum surface temperature during operation
Jet stage cone
Under covers/below the pump
Minimum backing pump displacement
Recommended BOC Edwards backing pump
40 oC
30 oC
200 oC
55 oC
250 oC
190 m3h-1
GV260M, E1M275
Table 1 - Operating and storage conditions
Performance curves
Maximum system pressure (absolute)
Critical backing pressure
Pumping speed (ISO)
Air
Hydrogen
Maximum throughput (air)
Backstreaming rate at ultimate vacuum
Fluid loss at 1 x 10-1 mbar, 10 Pa
Warm-up time to maximum throughput
Cool-down time (to approximately 100 oC)
See Figure 2
1.3 bar absolute, 1.3 x 105Pa
2 to 2.6 mbar, 2 to 2.6 x 102Pa
4000 l s-1
6000 l s-1
100 mbar l s-1, 1 x 104Pa l s-1
0.7 mg cm-2 min-1
10 g h-1
60 min
120 min
Table 2 - Performance data

Issue A Feb 04
PAGE
8
18B4B Vapour Booster Pumps
TECHNICAL DATA
8
2.3 Mechanical data
2.4 Pump fluid data
Note: A BOC Edwards Material Safety Data Sheet for the fluid specified below is available on request.
2.5 Cooling-water data
Dimensions
Mass
Complete pump (without fluid)
Complete pump (with full fluid charge)
Jet stage cone
Side cone assembly
Cleaning port cover *
Heater assembly and terminal box *
Boiler assembly (jncluding * items above)
Maximum stability angle
See Figure 3
165 kg
175 kg
40 kg
20 kg
8 kg
10 kg
105 kg
10o
Inlet flange
Outlet flange
Cooling-water connections
EHVI, ANSI12 or ISO320: see Figure 3
2 inch union, ANSI14 or ISO160: see Figure 3
1/2inch BSP female (with 1/2inch NPT
male adaptors)
Table 3 - Mechanical data
Recommended fluid type
Fluid charge
Nominal
Minimum
Fluid data (for AP201)
Flash point
Auto-ignition point
Molecular weight
Apiezon AP201
10 l
6 l
196 oC
305 oC
310
Table 4 - Pump fluid data
Maximum allowed water outlet temperature
Minimum cooling-water flow rate (at 25 oC)
Pressure differential across supply and return
(with minimum recommended flow rate)
35 oC
375 l h-1
1.3 bar gauge, 2.3 x 105Pa
Table 5 - Cooling-water data

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
9
9
TECHNICAL DATA
2.6 Electrical data
2.7 Construction materials
Heater rating
Nominal heater power (3 heaters)
Electrical supply
Nominal 200 V supply
Nominal 220 V supply
Nominal 240 V supply
Nominal 380 V supply
Nominal 415 V supply
Nominal 460 V supply
Over-current protection settings (on full heat)
200 V, 50/60 Hz
220 V, 50/60 Hz
240 V, 50/60 Hz
380 V, 50/60 Hz
415 V, 50/60 Hz
460 V, 50/60 Hz
Cooling-fail thermal snap-switch rating
Boiler protection thermal snap-switch rating
Maximum interlock control voltage
Recommended control voltage
Pt100 temperature probe (optional)
Output (proportional to measurement range)
Measurement range
Power supply voltage
Fluid low level switch (optional)
Power supply voltage
Relay contacts maximum voltage
Relay contacts maximum current
2 kW
6 kW
200 - 210 V, 50/60 Hz, three-phase
220 - 230 V, 50/60 Hz, three-phase
240 - 250 V, 50/60 Hz, three-phase
380 - 400 V, 50/60 Hz, three-phase
415 - 440 V, 50/60 Hz, three-phase
460 - 480 V, 50/60 Hz, three-phase
20 A
18 A
16 A
11 A
10 A
9 A
6.3 A at 250 V a.c.
5 A at 240 V a.c.
277 Vac
24 Vac
4 to 20 mA
0 to 300 oC
8 to 35 V d.c.
19 to 253 V a.c. or 19 to 55 V d.c.
253 V a.c., 30 V d.c.
6 A
Table 6 - Electrical data
Pump body
Covers
Water cooling coils
Inlet and backing ‘O’ rings
Internal pump ‘O’ rings
Jet stack gasket
Boiler port gasket
Nickel plated/painted mild steel
Anodised aluminium
High conductivity copper
Fluoroelastomer
Fluoroelastomer
Aramid fibre in nitrile rubber binder
Carbon fibre in nitrile rubber binder
Table 7 - Construction materials

Issue A Feb 04
PAGE
10
18B4B Vapour Booster Pumps
TECHNICAL DATA
10
2.8 Pump Item Numbers
Pump voltage and options
Inlet
EHVI ANSI ISO
18B4B pump
200 V
220 V
240 V
380 V
415 V
460 V
B065-10-200
B065-10-220
B065-10-240
B065-10-380
B065-10-415
B065-10-460
B065-20-200
B065-20-220
B065-20-240
B065-20-380
B065-20-415
B065-20-460
B065-30-200
B065-30-220
B065-30-240
B065-30-380
B065-30-415
B065-30-460
18B4B pump, with Pt100 temperature probe
200 V
220 V
240 V
380 V
415 V
460 V
B065-11-200
B065-11-220
B065-11-240
B065-11-380
B065-11-415
B065-11-460
B065-21-200
B065-21-220
B065-21-240
B065-21-380
B065-21-415
B065-21-460
B065-31-200
B065-31-220
B065-31-240
B065-31-380
B065-31-415
B065-31-460
18B4B pump, with fluid low level switch
200 V
220 V
240 V
380 V
415 V
460 V
B065-12-200
B065-12-220
B065-12-240
B065-12-380
B065-12-415
B065-12-460
B065-22-200
B065-22-220
B065-22-240
B065-22-380
B065-22-415
B065-22-460
B065-32-200
B065-32-220
B065-32-240
B065-32-380
B065-32-415
B065-32-460
18B4B pump, with Pt100 and fluid low level switch
200 V
220 V
240 V
380 V
415 V
460 V
B065-13-200
B065-13-220
B065-13-240
B065-13-380
B065-13-415
B065-13-460
B065-23-200
B065-23-220
B065-23-240
B065-23-380
B065-23-415
B065-23-460
B065-33-200
B065-33-220
B065-33-240
B065-33-380
B065-33-415
B065-33-460
Table 8 - Pump Item Numbers

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
11
11
TECHNICAL DATA
1. Pumping speed (l s-1) against inlet pressure (mbar/Pa) for nitrogen
2. Throughput (mbar l s-1) against inlet pressure (mbar/Pa) for nitrogen
Figure 2 - Typical performance curves

Issue A Feb 04
PAGE
12
18B4B Vapour Booster Pumps
TECHNICAL DATA
12
Figure 3 - Dimensions (mm): key
1. Inlet
2. Cooling-water inlet
3. Outlet
4. Cooling-water outlet
5. Cooling-fail thermal snap-switches
6. Clearance required to remove heaters
7. Fluid low level switch (optional)
8. Electrical box
9. Earth (ground) stud
10. Pt100 temperature probe (optional)
11. Fluid drain connection
12. Identification and rating plate
13. Hot surfaces: temperatures below this line can reach 250 oC
14. Fixing holes (3 off): Ø17.5 on 549 PCD
15. ISO inlet
16. EHVI inlet
17. ANSI inlet
18. ANSI outlet (8 holes Ø19.2 on 190.5 PCD)
19. ISO outlet (8 holes Ø11.2 on 200 PCD)
20. EHVI outlet (2 inch union nut and tailpiece, counter-bored
Ø54.1-54.18 x 19.4, 20.2 deep)
21. Boiler protection thermal snap-switch
22. Fixing holes:
12 holes Ø14 on 395 PCD (ISO inlet)
12 holes Ø25.4 on 431.8 PCD (ANSI inlet)
8 holes Ø11 on 387.4 PCD (EHVI inlet)
ØA ØB C
ANSI 482.6 228.6 807
ISO 425 225 807
EHVI 406 178 810

Feb 04 Issue A
18B4B Vapour Booster Pumps
PAGE
13
13
TECHNICAL DATA
Figure 3 - Dimensions (mm)

Issue A Feb 04
18B4B Vapour Booster Pumps
PAGE
14
14
This page intentionally blank.