BOC Edwards XDS Series User manual

A726-01-880 Issue H Original
A72X-YY-ZZZ
Pump Type Variant Motor Description
X YY ZZZ
6 = XDS10 01 to 99 903 = Voltage set to 220 - 240 V, 50/60 Hz, single-phase
4 = XDS5 904 = Voltage set to 100/200 V, 50/60 Hz, single-phase
905 = Voltage set to 200 - 230/380 - 460 V, 50/60 Hz, three-phase
906 = Voltage set to 110 - 120 V, 50/60 Hz, single-phase
Instruction Manual
XDS Dry Pump
98/37/EC
94/9/EC
89/336/EEC
73/023/EEC

Jul 05 Issue H
XDS Dry Pump
i
PAGE
i
1 INTRODUCTION 1
1.1 Scope and definitions 1
1.2 ATEX directive implications 1
1.3 Description 3
1.4 Gas-ballast control 3
1.5 Construction 4
2 TECHNICAL DATA 5
2.1 Operating and storage conditions 5
2.2 Performance 5
2.2.1 General 5
2.2.2 Performance characteristics 5
2.3 Mechanical data 8
2.3.1 General 8
2.3.2 Noise and vibration data 8
2.4 Electrical data 8
2.4.1 Single-phase pumps 8
2.4.2 Three-phase pumps 8
2.5 Legislation and standards 8
3 INSTALLATION 11
3.1 Safety 11
3.2 System design considerations 11
3.3 Unpack and inspect 11
3.4 Locate the pump 11
3.5 Electrical installation: single-phase pumps 12
3.5.1 Check and configure the motor 12
3.5.2 Connect the pump to your electrical supply 12
3.5.3 Check the direction of rotation 13
3.6 Electrical installation: three-phase pumps 13
3.6.1 Check and configure the motor 13
3.6.2 Connect the pump to your electrical supply 14
3.6.3 Check the direction of rotation 15
3.7 Inlet and outlet connections 15
3.8 Leak test the system 16
4OPERATION 17
4.1 Gas-ballast control 17
4.2 Start up procedure 17
4.3 To achieve ultimate vacuum 17
4.4 To pump condensable vapours 17
4.5 Implication of ATEX directive 18
4.5.1 Introduction 18
4.5.2 Flammable/pyrophoric materials 18
4.5.3 Gas purges 18
4.6 Shut down 19
CONTENTS
Section Page
DJD 0258

Issue H Jul 05
XDS Dry Pump
ii
PAGE
ii
5 MAINTENANCE 21
5.1 Safety information 21
5.2 Maintenance plan 21
5.3 Inspect and clean the inlet strainer 22
5.4 Inspect and clean the gas-ballast control 22
5.5 Clean the external fan cover 22
5.6 Replace the tip seals 23
5.7 Test the motor condition 25
5.8 Fault-finding 25
5.8.1 The pump has failed to start 25
5.8.2 The pump has failed to achieve the specified performance 26
5.8.3 The pump is noisy 26
5.8.4 The pump surface temperature is above 100 °C 26
5.8.5 The pumping speed is poor 26
6 STORAGE AND DISPOSAL 27
6.1 Storage 27
6.2 Disposal 27
7 SPARES AND ACCESSORIES 29
7.1 Introduction 29
7.2 Spares 29
7.3 Accessories 29
7.3.1 Solenoid operated pipeline valve 29
7.3.2 Gas-ballast adaptor 29
7.3.3 Vibration isolators 29
7.3.4 Exhaust nozzle kit 29
7.3.5 XDS silencer 29
INDEX 31
RETURN OF BOC EDWARDS EQUIPMENT
CONTENTS (continued)
Section Page

Jul 05 Issue H
XDS Dry Pump
iii
PAGE
iii
1 The single-phase XDS dry pump 2
2 Performance characteristics 6
3Dimensions 7
4 Electrical interface: single-phase pumps 12
5 Underside of the pump 13
6 Three-phase electrical connections: 200-230 V 14
7 Three-phase electrical connections: 380-460 V 14
8 Inlet strainer assembly 22
9 Gas-ballast control assembly 23
10 Trimming the tip seals 24
11 Replacing the tip seals 26
TABLES
Table Page
1 General characteristics 5
2 Performance characteristics 6
3 Dimensions (mm) 7
4 Electrical Data (single-phase pumps with item numbers
-903 or -906) 9
5 Electrical Data (single-phase pumps with item numbers -904) 9
6 Electrical Data (three-phase pumps with item numbers -905) 9
7 Wire colour codes 13
8 Maintenance plan 21
9 Solenoid operated pipeline valve 29
ILLUSTRATIONS
Figure Page

Issue H Jul 05
XDS Dry Pump
iv
This page intentionally blank.
PAGE
iv

Jul 05 Issue H
XDS Dry Pump
INTRODUCTION
1
PAGE
1
1INTRODUCTION
1.1 Scope and definitions
This manual provides installation, operation and
maintenance instructions for the BOC Edwards
XDS5 and XDS10 dry pumps. You must use the
XDS pump as specified in this manual. Read this
manual before you install, operate and maintain the
XDS 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.
Throughout this manual, page, figure and table
numbers are sequential.
The units used throughout this manual conform to
the SI international system of units of measurement.
Pressures are stated as absolute pressures
throughout this manual, unless otherwise stated.
The following IEC warning labels appear on the
pump:
Warning - refer to accompanying
documentation.
Warning - risk of electric shock.
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 - hot surfaces.
1.2 ATEX directive implications
• This equipment is designed to meet the
requirements of Group II Category 3
equipment in accordance with Directive 94/9/
EC of the European Parliament and the
Council of 23rd March 1994 on the
approximation of the laws of the Member
States concerning equipment and protective
systems intended for use in potentially
explosive atmospheres. (The ATEX Directive)
The ATEX Category 3 applies in respect of
potential ignition sources internal to the
equipment. An ATEX Category has not been
assigned in respect of potential ignition
sources on the outside of the equipment as
the equipment has not been designed for use
where there is an external potentially
explosive atmosphere.
There is no potential source of ignition within
the pump during normal operation but there
may be potential sources of ignition under
conditions of predicted and rare malfunction
as defined in the Directive. Accordingly,
although the pump is designed to pump
flammable materials and mixtures, operating
procedures should ensure that under all
normal and reasonably predicted conditions,
these materials and mixtures are not within
explosive limits. Category 3 is considered
appropriate for the avoidance of ignition in the
case of a rare malfunction which allows
flammable materials or mixtures to pass
through the pump while within their explosive
limits.

Issue H Jul 05
XDS Dry Pump
INTRODUCTION
2
PAGE
2
Figure 1 - The single-phase XDS dry pump
1. NW25 inlet port
2. Gas-ballast control
3. Cooling fan
4. DN25NW/3/4” BSP exhaust
5. Baseplate
6. Voltage indicator
7. On / off switch
8. Hour counter

Jul 05 Issue H
XDS Dry Pump
INTRODUCTION
3
PAGE
3
• When flammable or pyrophoric materials are
present within the equipment you must:
• Not allow air to enter the equipment.
• Ensure the system is leak tight.
• Use an inert gas purge (for example, a
nitrogen purge) to dilute any flammable
gases or vapours entering the pump inlet,
and/or use an inert gas purge to reduce the
concentration of flammable gases or
vapours in the pump and in the exhaust
pipeline to less than one quarter of the
gases' published Lower Explosive Limits
(LEL).
For further information, please refer to the back
page of this instruction manual for the contact de-
tails of your nearest BOC Edwards.
1.3 Description
The XDS pump is shown in Figure 1. Refer to
Figure 1 for item numbers in brackets in the
following descriptions.
The XDS pump is a compact, reliable vacuum pump
which is suitable for use on vapour handling
processes. The XDS pump may be used for some
pumping applications involving corrosive substances
and particulates; for information
on pumping flammable gases, please
refer to Section 4.5 and contact BOC Edwards for
any further assistance.
The body of the pump includes a fixed scroll and an
orbiting scroll. The orbiting scroll is driven by the
electric motor through an eccentric cam on the
motor drive shaft. The movement of the orbiting
scroll, meshed with the fixed scroll, forms
successive crescent shaped volumes in the pump.
Gas which enters the pump through the inlet is
compressed by the movement of the orbiting scroll
and swept towards the centre of the fixed scroll.
The compressed gas enters the exhaust port near
the centre of the stationary scroll and is exhausted
from the pump through the outlet.
The XDS pump is a dry vacuum pump, as all the
bearings, with their hydrocarbon lubricant, are
isolated from the vacuum space.
The inlet of the pump is fitted with a removable inlet
strainer which prevents the entry of debris into the
pump.
The pump mechanism is driven directly by a single-
phase or three-phase electric motor. Single-phase
motors are fitted with an on/off switch (7) and a
thermal overload device. When the motor is too
hot, the thermal overload device switches off the
pump. The thermal overload device has an
automatic reset; when the motor cools down, the
device resets and (unless you have incorporated
suitable control equipment which must be manually
reset), the motor will restart.
The pump is air-cooled by a fan mounted at the
opposite end to the motor.
The pump is mounted on a baseplate on rubber feet.
Details of suitable vibration isolators and other
accessories are provided in Section 7.
1.4 Gas-ballast control
To pump high vapour loads, gas-ballast is delivered
into the pump to prevent condensation of the
vapour carried by the pumped gases.
Air can be introduced to the low vacuum stages
through the gas-ballast valve. Alternatively, an inert
gas such as nitrogen can be supplied through a
suitable external valve.
The gas-ballast control has three-positions:
• Closed (position '0')
• Low flow (position 'I')
• High flow (position 'II')

Issue H Jul 05
XDS Dry Pump
INTRODUCTION
4
PAGE
4
1.5 Construction
The pump scrolls are made from anodised
aluminium and the motor housing made from
aluminium only. All surfaces of the pump which are
exposed to the pumped gases are free from copper,
zinc and cadmium.

Jul 05 Issue H
XDS Dry Pump
TECHNICAL DATA
5
PAGE
5
2 TECHNICAL DATA
2.1 Operating and storage conditions
Ambient temperature:
Operating range 10 °C to 40 °C
Storage range -30 °C to 70 °C
Surface temperature of pump above ambient (when
operating at ultimate) typically 45 °C
Maximum humidity (operation) 90%
Altitude up to 2000 m
2.2 Performance
2.2.1 General
Suckback on pump switch off typically 30 mbar ls-1
(leak tightness 1x10-6 mbar ls-1).
2.2.2 Performance characteristics
The position of the gas-ballast control defines the
performance characteristics of the pump.
These performance characteristics are
listed fully in Table 2.
The curves shown in Figure 2 show the relationship
between inlet pressure and pumping speed for the
pump.
XDS 10 XDS 5
Maximum displacement (m3/hr)
50 Hz electrical supply
60 Hz electrical supply
11.3
13.4
5.7
6.7
Maximum pumping speed (m3/hr)
Pneurop 6602 (1979)
50 Hz electrical supply
60 Hz electrical supply
9.3
11.1
4.8
6.0
Maximum permitted inlet pressure
and gas-ballast inlet pressure
Maximum permitted outlet pressure
0.5 bar gauge
1 bar gauge
0.5 bar gauge
1 bar gauge
Table 1 - General characteristics

Issue H Jul 05
XDS Dry Pump
TECHNICAL DATA
6
PAGE
6
Figure 2 - Performance characteristics
Parameter Units XDS 10 XDS 5
Gas-ballast control closed (position '0')
typical ultimate vacuum (total pressure) 50 Hz
typical ultimate vacuum (total pressure) 60 Hz
mbar
Pa
mbar
Pa
< 7 x 10-2
< 7
< 6 x 10-2
< 6
< 7 x 10-2
< 7
< 6 x 10-2
< 6
Gas-ballast control closed (position '1')
typical ultimate vacuum (total pressure) 50 Hz
typical ultimate vacuum (total pressure) 60 Hz
Gas-ballast flow
water vapour pumping capacity
mbar
Pa
mbar
Pa
l / min
g / hr
1.5 x 10-1
15
1.2 x 10-1
12
3
70
1.5 x 10-1
15
1.2 x 10-1
12
3
70
Gas-ballast control closed (position '2')
typical ultimate vacuum (total pressure) 50 Hz
typical ultimate vacuum (total pressure) 60 Hz
Gas-ballast flow
water vapour pumping capacity
water vapour tolerance
mbar
Pa
mbar
Pa
l / min
g / hr
mbar
Pa
3.5 x 10-1
35
3 x 10-1
30
15
> 200
35
5 x 103
3.5 x 10-1
35
3 x 10-1
30
15
> 200
50
3.5 x 103
Table 2 - Performance characteristics
1. 60 Hz performance
2. 50 Hz performance

Jul 05 Issue H
XDS Dry Pump
TECHNICAL DATA
7
PAGE
7
Figure 3 - Dimensions
Dimension Reference
(Refer to Figure 3) XDS5 XDS10
A =
B =
C =
D =
E =
F =
G =
H =
J =
K =
L =
M =
N =
P =
55
135
147
290
288
133
220
249
210
427
297
120
230
275
55
135
147
290
288
133
220
249
210
427
315
120
230
275
Table 3 - Dimensions (mm)

Issue H Jul 05
XDS Dry Pump
TECHNICAL DATA
8
PAGE
8
2.3 Mechanical data
2.3.1 General
Maximum tilt angle 10°
Motor rotational speed
(50 Hz supply) 1440 rpm
Motor rotational speed
(60 Hz supply) 1730 rpm
Mass (kg) XDS5=23
XDS10=24.5
Inlet / outlet connections DN25NW
Overall dimensions (mm) 427x290x249
2.3.2 Noise and vibration data
Sound pressure measured at
ultimate vacuum pump to
ISO 11201 55 dB(A) at 1 m
Vibration: measured at the
inlet port to BS4675 Part1: 1976 Class 1B
<1.5 mms-1 (rms)
2.4 Electrical data
2.4.1 Single-phase pumps
The dual voltage, dual frequency motor is designed
for a single-phase electrical supply and is suitable for
50 Hz or 60 Hz operation (refer to
Tables 4 and 5 for the electrical data). The motor can
be manually switched between nominal supply
voltages of 110-120 V and 220-240 V (refer to
Section 3.5).
2.4.2 Three-phase pumps
The dual voltage, dual frequency motor is designed
for a three-phase electrical supply and is suitable for
50 Hz or 60 Hz operation (refer to Table 6 for the
electrical data). The motor can be manually
switched between nominal supply voltages of 220-
240 V and 380-460 V electrical supplies (refer to
Section 3.6). Pumps are supplied pre-set to 380-
460 V electrical supplies.
2.5 Legislation and standards
The standards and legislation with which the XDS
pump complies are listed in full on the Declaration
of Conformity on the inside cover of this manual.

Jul 05 Issue H
XDS Dry Pump
TECHNICAL DATA
9
PAGE
9
Pump Nominal
Supply (V)
Frequency
(Hz)
Power
(W)
Current
(A)
Recommended
Fuse Rating (A)
220 - 240 50 250 3.6 5
XDS5 and XDS10 230 - 240 60 300 3.2 5
110 50 250 7.2 10
115 - 120 60 300 6.4 10
Table 4 - Electrical Data (single-phase pumps with item numbers -903 or -906)
Pump Nominal
Supply (V)
Frequency
(Hz)
Power
(W)
Current
(A)
Recommended
Fuse Rating (A)
200 50 250 4 5
XDS5 and XDS10 200 60 300 3.7 5
100 50 250 8 10
100 60 300 7.5 10
Table 5 - Electrical Data (single-phase pumps with item numbers -904)
Pump Nominal
Supply (V)
Frequency
(Hz)
Power
(W)
Current
(A)
Recommended
Fuse Rating (A)
XDS5 and XDS10 200 - 230 50 250 1.77 5
200 - 230 60 300 1.80 5
380 - 415 50 250 0.96 3
400 - 460 60 300 1.00 3
Table 6 - Electrical Data (three-phase pumps with item numbers -905)

Issue H Jul 05
XDS Dry Pump
10
This page intentionally blank.
PAGE
10

Jul 05 Issue H
XDS Dry Pump
INSTALLATION
11
PAGE
11
3INSTALLATION
3.1 Safety
You must ensure that the XDS pump is suitable for
your application. If you have any doubt about the
suitability of the XDS pump for your application,
refer to the BOC Edwards guidelines on vacuum
pump and vacuum system safety (see associated
publications at the end of the contents list at the
front of this manual).
The installation of the XDS pump must be
performed by a suitably trained and supervised
technician. Obey the safety instructions listed below
when you install the XDS pump, especially when you
connect the pump into an existing system. Details of
the specific safety precautions are given at the
appropriate point in the instructions.
• Wear the appropriate safety clothing when
you come into contact with contaminated
components. Dismantle and clean
contaminated components inside a fume
cupboard.
• Vent and purge your vacuum system before
you start installation work.
• Ensure that the installation technician is
familiar with the safety procedures which
relate to the products handled by the
pumping system.
• Disconnect the other components in the
pumping system from the electrical supply so
that they cannot be operated accidentally.
WARNING
The BOC Edwards XDS dry pump is
not recommended for pumping
hazardous substances.
3.2 System design considerations
Consider the following points when you design your
pumping system:
Use a suitable valve to isolate the pump from your
vacuum system if you need to allow the pump to
warm up before pumping condensable vapours or if
you need to maintain vacuum when the pump is
switched off.
Avoid high levels of heat input into the pump from
the process gases, otherwise the pump may
overheat and seize, and cause the motor thermal
overload device to open.
If you use the pump in a high ambient temperature
and have a high gas throughput, the temperature of
the pump body may exceed 100 °C and you must fit
suitable guards to prevent contact with hot surfaces.
Make sure that the exhaust pipeline cannot become
blocked. If you have an exhaust isolation valve, make
sure that you cannot operate the pump with the
valve closed.
3.3 Unpack and inspect
Remove all packing materials, remove the pump
from its packing box, remove the protective covers
from the inlet and outlet ports and inspect the
pump. If the pump is damaged, notify your supplier
and the carrier in writing; state the item number of
the pump together with your order number and
your supplier's invoice number. Retain all the
packing materials for inspection. Do not use the
pump if it is damaged.
If the pump is not to be used immediately, replace
the protective covers. Store the pump in suitable
conditions, as described in Section 6.1.
3.4 Locate the pump
Provide a firm, level platform for the pump. Locate
the pump so that the gas-ballast control and the on
/ off switch are accessible.

Issue H Jul 05
XDS Dry Pump
INSTALLATION
12
PAGE
12
If your pump will be located inside an enclosure,
make sure that there is adequate ventilation at both
ends of the pump, so that the ambient temperature
around the pump does not exceed 40 °C. There
must be a minimum space of 25 mm between the
pump and the enclosure walls.
3.5 Electrical installation: single-phase
pumps
3.5.1 Check and configure the motor
Refer to Figure 4 for the item numbers in brackets.
Ensure that the voltage shown on the voltage
indicator (5) on the motor cover corresponds with
your electrical supply voltage. If it does not, you
must change the configuration of the pump motor to
match your supply voltage; use the procedure
below.
CAUTION
Ensure that the motor is correctly configured for
your electrical supply. If you operate the pump
when the motor is not correctly configured for the
electrical supply, you will damage the motor.
1. Undo the two screws (4) and lift off the voltage
indicator moulding (2).
2. Rotate the voltage indicator moulding (2) so
that the correct voltage is next to the arrow (5)
on the terminal box cover.
3. Replace the two screws (4).
3.5.2 Connect the pump to your electrical
supply
Make the electrical connections to the pump motor
with an IEC 320 cable socket (cold condition type)
that satisfies your local electrical standards. A range
of suitable cables are available from your supplier or
BOC Edwards.
WARNING
Ensure that the electrical installation
of the XDS pump conforms with
your local and national safety
requirements. It must be connected
to a suitably fused and protected
electrical supply and a suitable earth
point.
Figure 4 - Electrical interface: single-phase pumps
1. On/off switch (I = on, O = off)
2. Voltage indicator moulding
3. Cable socket
4. Voltage selector screws
5. Voltage indicator arrow

Jul 05 Issue H
XDS Dry Pump
INSTALLATION
13
PAGE
13
The pump must be connected to a suitable fused and
protected electrical supply and a suitable earth
point.
If your XDS pump was supplied with an electrical
supply cable, the cable will be fitted with a moulded
IEC connector at one end. The other end of the
cable may be fitted with a plug suitable for your local
electrical supply. A cable without a plug will contain
wires colour coded as follows:
1. Ensure that the on /off switch on the motor is
in the 'off' position.
2. Insert the moulded IEC connector at the end of
the cable into the electrical inlet connector on
the motor.
3. Check that the screw on the back of the motor
rotates in the correct direction, shown by the
arrow on the motor. If the direction of rotation
is incorrect, switch off the electrical supply
immediately and contact your supplier or BOC
Edwards for advice.
Convention Earth Neutral Live
Europe green and
yellow
blue brown
USA green white black
Table 7 - Wire colour codes
3. Connect the plug (if fitted) at the other end of
the cable to your electrical supply. If a plug is not
fitted, connect the wires in the cable to the
correct terminals of your electrical supply.
3.5.3 Check the direction of rotation
1. Remove the plastic cover over the screw in the
centre of the motor back plate.
2. Use the on / off switch to switch on the electrical
supply to the motor for a few seconds.
CAUTION
Ensure that the pump motor rotates in the correct
direction. If it does not, turn the pump and your
vacuum system can become pressurised.
Figure 5 - Underside of the pump
1. Screws
2. Access plate
3.6 Electrical installation: three-phase
pumps
3.6.1 Check and configure the motor
1. Place the pump on its back, exposing the
underside of the pump (refer to Figure 5). Undo
the 3 screws securing the access plate and
remove it.
CAUTION
Ensure that the motor is configured correctly for
your electrical supply. If you operate the pump
when the motor is not configured correctly for the
electrical supply, you will damage the motor.

Issue H Jul 05
XDS Dry Pump
INSTALLATION
14
PAGE
14
2. Ensure that the motor is correctly configured
for your electrical supply. If necessary
reconfigure the links (refer to Figures 6 and 7)
to suit your electrical supply.
• For 200 - 230 V electrical
supplies the links must be configured as
shown in Figure 6.
• For 380 - 460 V electrical
supplies the links must be configured as
shown in Figure 7.
3.6.2 Connect the pump to your electrical
supply
Note: To prevent automatic restart of the pump-
motor if the electrical supply is restored after
an electrical supply failure, connect the pump
to the electrical supply through suitable control
equipment which must be reset manually after
an electrical supply failure.
Note: To maintain compliance with CSA (Canadian
Standards Association) standards, you must
incorporate a switch or circuit breaker in the
pump electrical supply. The switch or circuit
breaker must be close to the pump and easily
accessible, and must be clearly marked to
identify that it is the electrical supply
disconnection device for the pump.
WARNING
Ensure that the electrical installation
of the XDS pump conforms with
your local and national safety
requirements. It must be connected
to a suitably fused and protected
electrical supply and a suitable earth
point.
WARNING
If the pump is to be used on the floor
of a work area, position the power
lead and the exhaust and inlet hoses
with care. Ensure that personnel in
the area are aware of any
obstructions around the pump.
The electrical supply cable to the
3-phase pump is permanently
attached to the pump. Ensure that it
is routed such that it cannot be
snagged or become a tripping hazard.
Figure 6 - Three-phase electrical connections: 200-
230 V
Figure 7 - Three-phase electrical connections: 380-
460 V