BOC Edwards XDS35i User manual

A730-01-880 Issue A Original
Instruction Manual
XDS Dry Pump
Description Electrical Supply Item Number
XDS35i Scroll Pump 100-120 V, 200-230 V, A730-01-983
50/60 Hz, Single Phase
98/37/EC
89/336/EEC
73/023/EEC

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XDS Dry Pump
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1 INTRODUCTION 1
1.1 Scope of this manual 1
1.2 Description 1
1.3 Gas ballast control 3
1.4 Construction 3
2TECHNICALDATA 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 6
2.3.1 General 6
2.3.2 Vibration data 7
2.4 Electrical data 7
3 INSTALLATION 9
3.1 Safety 9
3.2 System design considerations 9
3.3 Unpack and inspect 11
3.4 Locate the pump 11
3.5 Electrical installation 11
3.5.1 Check and configure the pump 11
3.5.2 Connect the pump to your electrical supply 12
3.6 Inlet and outlet connections 12
3.7 Leak test the system 13
4OPERATION 15
4.1 Use of gas ballast control 15
4.1.1 Gas ballast control 15
4.2 Start up procedure 15
4.3 To achieve ultimate vacuum 15
4.4 To pump condensable vapours 16
4.5 To pump flammable gases 16
4.6 Remote operation using 15 way D connector 16
4.7 Shut down 18
5 MAINTENANCE 19
5.1 Safety information 19
5.2 Maintenance plan 19
5.3 Inspect and clean the inlet strainer 20
5.4 Inspect and clean the gas ballast control 20
5.5 Clean the external fan cover 21
5.6 Replace the tip seals 22
5.7 Test the motor condition 26
CONTENTS
Section Title Page
dcs/0129/1102

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5.8 Fault-finding 26
5.8.1 The pump has failed to start or has stopped 26
5.8.2 The pump has failed to achieve the specified performance 27
5.8.3 The pump is noisy 27
5.8.4 The pump surface temperature is high 27
5.8.5 The pumping speed is poor or if pump down time is too long 27
6 STORAGE AND DISPOSAL 29
6.1 Storage 29
6.2 Disposal 29
7 SERVICE, SPARES AND ACCESSORIES 31
7.1 Introduction 31
7.2 Service 31
7.3 Accessories 31
7.3.1 Electrical cables 31
7.3.2 Silencer 31
7.3.3 Gas ballast adaptor 31
7.3.4 Solenoid operated pipeline valves 31
7.3.5 Tip seal service kit 31
INDEX 33
RETURN OF BOC EDWARDS EQUIPMENT
ILLUSTRATIONS
Figure Title Page
1 XDS35i scroll pump 2
2 Performance characteristics 6
3 Installation drawing 10
4 Logic interface schematic 17
5 Inlet strainer assembly 20
6 Gas ballast control assembly 21
7 Fan connector / fixed scroll retaining screws 22
8 Fixed scroll lever slot 23
9 Fitting tip seals 24
10 Tip seal length adjustment 25
CONTENTS (continued)
Section Title Page

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1 Operating and storage conditions 5
2 General characteristics 5
3 Performance characteristics 5
4 Generalmechanicaldata 6
5 Vibrationdata 7
6 Electrical data 7
7 Recommended fuses 12
8 Pin status on the logic interface connector 17
9 Maintenance plan 20
10 Electrical cables 31
11 Solenoid operated pipeline valves 32
ASSOCIATED PUBLICATIONS
Publication Title Publication Number
Vacuum pump and vacuum system safety P300-20-000
TABLES
Table Title Page

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Nov 02 Issue A
XDS Dry Pump
INTRODUCTION
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1INTRODUCTION
1.1 Scope of this manual
This manual provides installation, operation and
maintenance instructions for the BOC Edwards
XDS35i Scroll pump. You must use your pump as
specified in this manual. Read this manual before you
attempt to 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.
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.
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 Description
The XDS35i 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 controlled 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 that 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 is a truly dry vacuum pump, as all the
bearings, with their hydrocarbon lubricant, are
isolated from the vacuum space.
The inlet of the pump has a NW40 (1) inlet and inlet
strainer.

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Figure 1 - XDS35i scroll pump
1. NW40 inlet port
2. Gas ballast control
3. Cooling fan
4. NW25 exhaust port
5. Fan connector
6. Rubber feet
7. Electrical connector
8. Voltage changeover switch cover
9. On/Off switch
10. 15 way connector
11. Hour counter
The pump mechanism is driven directly by a three
phase electric motor. The motor is controlled by an
inverter, which manages the supply of current to the
motor in accordance with operating conditions, and
allows the pump to be connected to a single phase
supply. The voltage changeover switch (beneath the
voltage changeover switch cover, refer to Figure 1,
item 8) must be set to the correct position in
accordance with the power supply being used, refer
to Section 3.5.2.
The XDS35i is designed to run from atmospheric
pressure however, if the inlet pressure exceeds
100 mbar for an extended period, the inverter may
reduce the motor speed. The pump will speed up
again after the pressure is reduced.
The pump is air-cooled by a fan (3) mounted at the
opposite end to the motor. The fan will run on for
one minute after the pump is switched off. The
XDS35i incorporates a thermal protection device
that will stop the motor in the event of thermal
overload e.g. high ambient temperature. The pump
will restart after it has cooled down.
The pump is mounted on rubber feet (6).
The pump is fitted with an hours counter (11), which
indicates the total time that the pump has run.

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INTRODUCTION
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1.3 Gas ballast control
To pump high vapour loads, gas ballast can be
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 control (2). Alternatively, an
inert gas such as nitrogen can be supplied through a
suitable external valve and by using the appropriate
adaptor, available as an accessory, refer to
Section 7.3.3.
The gas ballast control has three positions:
• Closed (position '0')
• Low flow (position 'I')
• High flow (position 'II')
1.4 Construction
The pump scrolls are made of anodised aluminium.
The motor housing is aluminium. All surfaces of the
pump which are exposed to the pumped gases are
free from copper, zinc and cadmium.
Other materials of construction include
fluorocarbon elastomer, nitrile, chemically resistant
polymers, nickel and stainless steel.
The tip seal is a PTFE composite material.

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TECHNICAL DATA
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2 TECHNICAL DATA
2.1 Operating and storage conditions
General XDS35i
Suckback protection (no solenoid valve on inlet) By exhaust valve
Maximum initial pressure rise with no gas ballast flow (mbar l) 5
Maximum displacement (m3/hr) 44
Maximum pumping speed (m3/hr) 35
Maximum permitted inlet pressure and gas ballast inlet pressure (barg) 0.5
Maximum permitted outlet pressure (barg) 1
Leak tightness (mbar l s-1) <1 x 10-6
Table 2 - General characteristics
Operating and storage conditions XDS35i
Ambient temperature range (operation) +10 °C to +40 °C
Maximum surface temperature of pump body at ultimate vacuum.
(Depending on ambient temperature)
+40 °C to +70 °C
Maximum humidity (operation) 90% RH
Ambient temperature range (storage) -30 °C to +70 °C
Table 1 - Operating and storage conditions
2.2 Performance
2.2.1 General
2.2.2 Performance characteristics
The position of the gas ballast control defines the
performance characteristics of the pump. These
performance characteristics are listed in Table 3.
Pump Gas ballast
control position
Ultimate total
pressure (mbar)
Gas ballast
flow (l min-1)
XDS35i 0 <0.01 -
1 <0.02 3
2 <0.03 12
Table 3 - Performance characteristics

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TECHNICAL DATA
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Figure 2 - Performance characteristics
1. Speed 2. Power
2.3 Mechanical data
2.3.1 General
Parameter Units XDS35i
Overall dimensions (L x W x H) mm 476 x 333 x 396
Maximum tilt angle degree 10
Nominal rotational speed rpm 1750
Mass kg 48
Inlet connection NW40
Outlet connection NW25
Degree of protection (IEC60529) IP44
Table 4 - General mechanical data

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TECHNICAL DATA
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Parameter XDS35i
Sound pressure, measured at ultimate vacuum 1 metre from the end of the pump
to ISO 11201
61.5 dB (A)
Vibration: measured at the inlet port (ISO3744) Class 1C…< 4.5 mms-1
(rms)
Table 5 - Vibration data
2.3.2 Vibration data
2.4 Electrical data
Pump Supply (V) Phase Frequency
(Hz) Power (W) Current (A)
XDS35i 200/230 Single 50/60 520 5
100/120 Single 50/60 520 8.5
Table 6 - Electrical data

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3INSTALLATION
3.1 Safety
You must ensure that the XDS35i pump is suitable
for your application. If you have any doubt about the
suitability of the XDS35i 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).
A suitably trained and supervised technician must
perform the installation of the XDS35i pump. 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.
• Mechanical lifting equipment should be
attached to the lifting eye on the pump.
WARNING
Obey the safety instructions given
below and take note of appropriate
precautions. If you do not, you can
cause injury to people and damage to
equipment.
WARNING
The BOC Edwards XDS35i pump is
not recommended for pumping
explosive gases or hazardous
substances.
WARNING
Prevent any part of the human body
coming into contact with the vacuum.
WARNING
Use suitable lifting equipment
to move the XDS35i pump.
The mass of the pump is
approximately 48 kg.
• Loose slings should not be used to lift the
XDS35i.
• 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 that 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.
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 cause the 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 approach 70 ºC and you must
fit suitable guards to prevent contact with hot
surfaces.
WARNING
Take care when moving the pump
into position. The pump's weight
makes it difficult to slide and
movement should be attempted
using two people.

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Figure 3 - Installation drawing

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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.
Provide for a purge of inert gas when you shut down
the pumping system, to dilute dangerous gases to
safe concentrations.
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. Refer to Section 6.2 for disposal of
materials.
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.
WARNING
Use suitable lifting equipment
to move the XDS35i pump.
The mass of the pump is
approximately 48 kg.
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.
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 ºC. There
must be a minimum space of 25 mm between the
pump and the enclosure walls.
3.5 Electrical installation
3.5.1 Check and configure the pump
Ensure that the voltage shown on the voltage
indicator (refer to Figure 1, item 8) 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.
1. Undo the two screws and lift off the voltage
indicator moulding.
2. Rotate the voltage indicator moulding so that
the correct voltage is uppermost.
3. Replace the two screws.
CAUTION
Ensure that the pump is correctly configured for
your electrical supply otherwise you may cause
damage.

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3.5.2 Connect the pump to your electrical
supply
The following fuse ratings should be used (refer to
Table 7).
The pump will automatically restart after
restoration of the power supply following power
failure.
Make the electrical connections to the pump motor
with an IEC60320 cable socket (C19) that satisfies
your local electrical standards.
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 with a suitable earth point.
CAUTION
If using an overload circuit breaker it must be of a
time lag type because of high start up current.
CAUTION
If using an earth leakage device e.g. an RCD, use at
least a 30 mA rated unit to avoid trip during start
up.
3.6 Inlet and outlet connections
Refer to Figure 1. Before you connect the pump to
your vacuum system, remove the plastic cap from
the inlet and the exhaust, and ensure that the inlet
strainer is fitted to the pump inlet port. Use
appropriate NW40 vacuum fittings for connection
to your system.
Take note of the following information when you
connect the pump to your vacuum system.
• To minimise noise and exhaust emissions, it is
recommended that the pump is connected to
an exhaust line or a silencer (refer to
Section 7.3.2).
• For optimum pumping speeds, ensure that the
pipeline connected to the pump inlet is as
short as possible and has a suitable internal
diameter.
• Support the vacuum pipeline to prevent
loading of the coupling joints.
WARNING WARNING
If pumping dangerous gases or
vapours, connect the exhaust to a
suitable treatment plant to prevent
the discharge of dangerous gases and
vapours to the surrounding
atmosphere.
WARNING
If pumping for a prolonged period
above 100 mbar inlet pressure, use
an exhaust silencer (refer to
Section 7.3.2) or connect to an
appropriate exhaust line.
Area Voltage Rating
UK 230 V 13 A
Europe 230 V 16 A
US 110 V 20 A
Japan 100 V 20 A
Table 7 - Recommended fuses

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• If necessary, incorporate flexible bellows in
your system pipelines to reduce the
transmission of vibration and to prevent
loading of the coupling joints. If you use
flexible bellows, you must ensure that you use
bellows that have a maximum pressure rating
which is greater than the highest pressure that
can be generated in your system. We
recommend that you use BOC Edwards
bellows.
• Incorporate an inlet isolation valve in the
pipeline from the vacuum system to the pump,
so that you can isolate the vacuum system
from the pump when it is switched off and
prevent the suckback of process gases and
debris into the vacuum system.
• Ensure that the sealing surfaces are clean and
scratch-free.
We recommend that you use an exhaust extraction
system suitable for use with all of the process gases
you will pump. Ensure that the exhaust extraction
system cannot become blocked or obstructed when
the pump is operating.
A small amount of tip seal wear product may collect
in the exhaust duct of the pump. The dust may be
blown out with the initial burst of air after the pump
has been vented. This is quite common and the
amount of dust seen will reduce over time.
3.7 Leak test the system
After you have installed the XDS pump, leak test the
system and seal any leaks found.

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