BOC DP180 User manual

A500-03-880
Issue D
Manor Royal, Crawley, West Sussex, RH10 9LW, UK
Telephone: [phone] Fax: [phone]
http://www.bocedwards.com
DP180 Dry Vacuum Pump
Description Item Number
DP180 pump, 200 V, 3-phase, 50 Hz A403-02-934
DP180 pump, 200 V, 3-phase, 60 Hz A403-12-934
DP180 pump, 220-240/380-415 V, 3-phase, 50 Hz A403-02-935
DP180 pump, 208-230/380/460 V, 3-phase, 60 Hz A403-12-995
Instruction Manual

CONTENTS
Section Title Page
1 INTRODUCTION 1
1.1 Scope and definitions 1
1.2 The DP180 pump 1
1.3 Gas-ballast boost 2
1.4 Temperature control system 2
1.5 Accessories 2
2 TECHNICAL DATA 3
2.1 General 3
2.2 Performance data 3
2.3 Service 6
2.4 Temperature control system 6
2.5 Lubrication system 6
2.7 Noise data 6
3 INSTALLATION 7
3.1 Safety 7
3.2 Unpack and inspect 7
3.3 Fill the pump with oil 8
3.4 Locate the pump 8
3.5 Electrical installation 10
3.5.1 Select high or low voltage operation 10
3.5.2 Connect the pump-motor electrical supply 12
3.5.3 Check the direction of pump rotation 12
3.5.4 Connect the thermal snap-switch 12
3.5.5 Connect the solenoid-valve 13
3.6 Connect the cooling-water supply 14
3.6.1 Supply quality requirements 14
3.6.2 Connect the supply to the DP180 14
3.7 Connect the DP180 to your vacuum system 16
3.8 Connect the DP180 to your exhaust-extraction system 17
3.9 Gas-ballast boost system 17
3.9.1 Gas-ballast boost not in use 17
3.9.2 Standard air gas-ballast boost 17
3.9.3 Connect the nitrogen supply (if required) 18
3.10 Evacuation of the bearing end-cover (optional) 18
3.11 Leak-test the installation 19
3.12 Commission the installation 19
3.12.1 Adjust the thermostatic control-valve (TCV) 19
3.12.2 Prime the cooling system 20
3.12.3 Commissioning procedure 20
DP180 Dry Vacuum Pump i
Ipsitech 8091-03

Section Title Page
4 OPERATION 21
4.1 Start-up
21
4.2 Shut-down 21
5 MAINTENANCE 22
5.1 Safety 22
5.2 Maintenance plan 22
5.3 Check the gearbox oil-level 23
5.4 Inspect the pipelines and connections 23
5.5 Change the gearbox oil 24
5.6 Relubricate the rotor bearings 24
5.7 Change the head-plate felt filter 25
5.8 Change the gas-ballast air filter element 26
5.9 Clean the inlet-stage sump 27
5.10 Clean the cooling-jacket 27
6 STORAGE AND DISPOSAL 28
6.1 Storage 28
6.2 Disposal 28
7 SERVICE, SPARES AND ACCESSORIES 29
7.1 Introduction 29
7.2 Service 29
7.3 Spares 29
7.4 Accessories 30
RETURN OF BOC EDWARDS EQUIPMENT
Illustrations
Figure Title Page
1 Dimensions (mm) 4
2 Pumping speed curves 5
3 Power curves 5
4 Lubrication and gas-ballast boost components 9
5 Motor low voltage configuration (200 V, 50/60 Hz; 220-240 V, 50 Hz) 11
6 Motor high voltage configuration (380/415 V, 50 Hz; 380 V, 60 Hz) 11
7 Motor low voltage configuration (208-230 V, 60 Hz) 11
8 Motor high voltage configuration (460 V, 60 Hz) 11
9 Thermal snap-switch connections 13
10 Cooling system and bearing end-cover evacuation components 15
11 Rotor bearing re-lubrication 25
12 Exploded view of the gas-ballast air filter 26
ii DP180 Dry Vacuum Pump

Tables
Table Title Page
1 Full load current ratings 3
2 Checklist of components 8
3 Pump-motor terminal-box wiring configurations 10
4 Maintenance plan 23
Associated publications
Publication title Publication Number
Vacuum pump and vacuum system safety P300-20-000
DP180 Dry Vacuum Pump iii

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iv DP180 Dry Vacuum Pump

1 INTRODUCTION
1.1 Scope and definitions
This manual provides installation, operation and maintenance instructions for the BOC
Edwards DP180 Dry Vacuum Pump (abbreviated to DP180 in the remainder of this manual).
You must use the DP180 as specified in this manual.
Read this manual before you install and operate your DP180. Important safety information is
highlighted as WARNING and CAUTION instructions; you must obey these instructions. The
use of WARNINGS and CAUTIONS is defined below.
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 or process.
The units used throughout this manual conform to the SI international system of units of
measurement.
1.2 The DP180 pump
The DP180 dry pump operates at pressures between atmospheric and ultimate vacuum without
any lubricating or sealing fluid in the pumping chamber. This ensures a clean pumping system
without back-migration of oil into the system being evacuated. The pump is mounted on steel
runners.
The DP180 is a three-stage, positive-displacement rotary pump in which pairs of intermeshing
rotors (of different profiles mounted on common shafts) are held in correct phase relation by a
pair of timing-gears. The timing-gears and the adjacent double-row angular contact
ball-bearings are oil lubricated.
The pump casing material is cast-iron, the shafts and rotors are made from SG iron. The internal
and external shaft-seals on the pump shafts and the motor drive-shaft are made from
polytetrafluoroethylene (PTFE).
Bearings are located on the high vacuum end of the shaft, near to the pump-inlet. These bearings
are packed with perfluoropolyether (PFPE) grease. As supplied, the bearing end-cover is
connected internally to the pump-inlet and is evacuated when the DP180 pump is operating. If
required, you can use your own external evacuation pump to evacuate the bearing end-cover.
DP180 Dry Vacuum Pump 1

1.3 Gas-ballast boost
The DP180 has a gas-ballast boost system which delivers air to the pump gas-ballast boost inlet.
The flow of air is filtered and is controlled by a solenoid-valve. You can connect the
solenoid-valve to your control equipment to operate the solenoid-valve.
If you wish, you can connect a nitrogen supply to the system in order to deliver nitrogen to the
pump instead of air.
1.4 Temperature control system
The pump is cooled by water which flows through an integral cooling-jacket. The pump is
maintained at a constant operating temperature by a thermostatic control-valve (TCV) which
controls the supply of cooling-water to the pump.
The pump-motor is air-cooled by a cooling-fan which is integral to the motor.
A thermal snap-switch is fitted to the pump-body. This switch shuts down the pump if the pump
is too hot. The switch (which is normally-closed) is connected to the overload control loop of the
pump-motor starter. When the temperature of the pump-body rises to 71 oC, the switch opens
and the pump-motor is switched off.
1.5 Accessories
If the DP180 pump is to be used on clean applications, the pump-outlet can be fitted with a
stainless steel flap-valve accessory. On dirty applications, if the use of an outlet-valve is
necessary, we recommend that you fit a fluoroelastomer flap-valve accessory.
A full list of the accessories available for the DP180 pump is given in Section 7.
2DP180 Dry Vacuum Pump

2 TECHNICAL DATA
2.1 General
Overall dimensions See Figure 1
Mass 230 kg
Nominal motor rating 7.5 kW
Rotational speed 2000 r min-1
Warm-up time 15 min
Vacuum connections
Inlet ISO63
Outlet NW40
Vacuum system maximum leak-rate 1 x 10-3 mbar l s-1, 1 x 10-1 Pa l s-1
Ambient operating temperature range 5 to 40 oC
Maximum ambient operating humidity 90% RH
Maximum exhaust pressure 2 psig, 1150 mbar absolute,
1.15 x 105Pa
2.2 Performance data
Pumping speed range See Figure 2
Power curves See Figure 3
Peak pumping speed 180 m3h-1
Displacement (swept volume) 200 m3h-1
Ultimate vacuum (without outlet flap-valve)
without gas-ballast boost 1 x 10-1 mbar, 10 Pa
with full gas-ballast boost 2.5 x 10-1 mbar, 25 Pa
Water vapour pumping speed at 80 mbar (8 x 103Pa) 5 kg h-1
Full load current ratings See Table 1
Electrical supply Rating (kW) Full load (A)
Voltage (V) Frequency (Hz)
200 50/60 7.5 31.0
208 60 7.0 25.2
220-240 50 7.5 26.8
380-415 50 7.5 15.5
230 60 8.5 25.4
380 60 7.5 19.5
460 60 8.5 14.2
Table 1 - Full load current ratings
DP180 Dry Vacuum Pump 3

4DP180 Dry Vacuum Pump
Figure 1 - Dimensions (mm)

DP180 Dry Vacuum Pump 5
Figure 2- Pumping speed curves
1. With stainless steel flap-valve
2. Without flap-valve
1. Without flap-valve
2. With stainless steel flap-valve
Figure 3- Power curves

2.3 Services
Electrical supply
Number of phases 3
Supply voltage 200/220-240/380-415 V at 50 Hz,
200/208-230/380/460 V at 60 Hz
Voltage tolerance ±6% except for 200 V at 50/60 Hz
and 380 V at 60 Hz which are ±10%
Cooling-water supply
Ryznar Stability Index (RSI) 6.5 to 7.0
Water consumption at 20 oC (TCV setting: 3 to 3.5) 100 l h-1
Maximum supply pressure 100 psi
Minimum required pressure differential
across supply and return 30 psi
Nitrogen supply (if fitted)
Supply pressure 5 to 10 psig
Maximum flow rate 100 l min-1
2.4 Temperature control system
Thermostatic control-valve
Type Danfoss AVTA
Maximum operating temperature 130 oC
Maximum sensor temperature 90 oC
Thermal snap-switch
Manufacturer Microtherm
Opening temperature 71 ±3oC
Contact rating
Maximum voltage/current 240 V/2.9 A
2.5 Lubrication system
Note: BOC Edwards Material Safety Data Sheets for the oils and greases referenced below are available
on request.
Gearbox
Fluid capacity (timing gearbox) 1.2 litres
Grade of oil SAE 40
ISO viscosity grade 150
Recommended perfluoropolyether oils Fomblin Y25 or Krytox 1525
High vacuum bearings
Grease type Perfluoropolyether
Recommended grease Fomblin RT15, Krytox 240AD
2.6 Noise data
If the DP180 is not fitted inside an acoustic enclosure, under certain pumping conditions the
continuous A-weighted sound pressure level can reach 90 dB(A).
6DP180 Dry Vacuum Pump

3 INSTALLATION
3.1 Safety
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.
•A suitably trained and supervised technician must install the DP180.
•Ensure that the installation technician is familiar with the safety precautions which relate to
the products pumped. Wear the appropriate safety-clothing when you come into contact
with contaminated components. Dismantle and clean contaminated components inside a
fume-cupboard.
•If the DP180 is to replace an existing pump, vent and purge the pumping system before you
start any installation work.
•Disconnect the other components in the pumping system from the electrical supply so that
they cannot be operated accidentally.
•Do not re-use 'O' rings and Co-Seals and do not allow debris to get into the DP180 during
installation.
•Before you use the DP180 to pump dangerous substances, refer to the associated publication
referred to at the end of the contents list. You must take all necessary precautions to dilute
flammable gases with nitrogen to a safe level.
•Leak-test the system after installation and seal any leaks found.
3.2 Unpack and inspect
WARNING
Use suitable lifting equipment to move the DP180. Refer to Section 2 for the mass of the
pump.
Use the following procedure to unpack and inspect the pump:
1. Use a fork-lift truck or a pallet truck to move the DP180 on the pallet into a convenient
position .
2. Open the cardboard box and remove the packing material from around the pump.
3. Use suitable lifting-gear attached to the lifting-eyes provided to remove the pump from its
pallet.
DP180 Dry Vacuum Pump 7

4. Inspect the pump. If the pump or any other item is damaged, notify your supplier and the
carrier in writing within three days; state the Item Number of the pump together with your
order number and your suppliers invoice number. Retain all packing materials for
inspection. Do not use the pump if it is damaged.
5. Check that the pallet contains the items listed in Table 2. If any of these items is missing,
notify your supplier in writing within three days.
6. If the pump is not to be used immediately, replace the packing materials and store the pump
in suitable conditions as described in Section 6.
Qty Description Check (✓)
1 DP180 pump ❏
1 General fitting-kit ❏
Table 2 - Checklist of components
3.3 Fill the pump with oil
Use the following procedure to fill the pump with oil.
1. Refer to Figure 4. Ensure that the oil drain-plug (5) is tight.
2. Unscrew and remove the oil filler-plug (2).
3. Fill the gearbox with oil until the oil-level is at the MAX level mark on the oil-level sight-glass
(4).
4. Check that the rubber bonded seal on the oil filler-plug is in place, then refit the oil filler-plug
(2) and tighten to finger tight. Use a spanner to tighten the plug an additional 1/16 th of a
turn.
3.4 Locate the pump
WARNING
Use suitable lifting equipment to move the DP180. Refer to Section 2 for the mass of the
pump.
Use the following procedure to locate the DP180; the DP180 must be located on a firm, level
surface.
1. Use suitable lifting-gear attached to the lifting bolts (see Figure 1) to locate the DP180 in its
final operating position.
2. If required, fit four bolts through the 12 mm fixing-holes in the runners to secure the DP180
in place. If you do not fit bolts and leave the pump free-standing, we recommend that you fit
vibration isolators; these are available as optional accessories (see Section 7).
8DP180 Dry Vacuum Pump

DP180 Dry Vacuum Pump 9
Figure 4 - Lubrication and gas-ballast boost components
1. Pump-motor terminal-box
2. Oil filler-plug
3. Inlet-flange
4. Oil-level sight-glass
5. Oil drain-plug
6. Solenoid-valve
7. Clamping-ring
8. Gas-ballast air filter

3.5 Electrical installation
WARNING
Ensure that the electrical installation of the DP180 conforms with your local and national
safety requirements. It must be connected to a suitably fused and protected electrical
supply and a suitable earth (ground) point.
3.5.1 Select high or low voltage operation
The universal voltage and frequency motor can be configured for low voltage operation
(200/220-240 V at 50 Hz or 208-230 V at 60 Hz) or for high voltage operation (415 V at 50 Hz, 380 V
at 50/60 Hz, or 460 V at 60 Hz).
Figures 5 to 8 show the required wiring configurations for the electrical supply voltages and
frequencies as shown in Table 3.
Electrical supply Refer to
Figure
Voltage (V) Frequency (Hz)
200 50 5
200 60 5
220-240 50 5
380/415 50 6
208-230 60 7
380 60 6
460 60 8
Table 3 - Pump-motor terminal-box wiring configurations
Use the following procedure to configure the pump for use with your electrical supply:
1. Check the information on the pump-motor data plate to make sure that the pump is suitable
for use with your electrical supply voltage and frequency. If the pump is not suitable, do not
continue to install it.
2. Remove the cover from the pump-motor terminal-box.
3. Check the configuration of the links in the motor terminal-box. If necessary, change the
configuration to suit your electrical supply voltage and frequency (see Figures 5 to 8).
10 DP180 Dry Vacuum Pump

DP180 Dry Vacuum Pump 11
Figure 5 - Motor low voltage configuration
(200 V, 50/60 Hz; 220-240 V, 50 Hz)
Figure 6 - Motor high voltage configuration
(380/415 V, 50 Hz; 380 V, 60 Hz)
Figure 7 - Motor low voltage configuration
(208-230 V, 60 Hz)
Figure 8 - Motor high voltage configuration
(460 V, 60 Hz)
1. Electrical supply 1. Electrical supply
1. Links
2. Electrical supply
1. Links
2. Electrical supply

3.5.2 Connect the pump-motor electrical supply
Notes: Wiring instructions for the pump-motor are also shown on a label inside the terminal-box cover.
The following procedure will ensure that the pump will rotate in the correct direction if phase 1 of
your electrical supply corresponds to line L1 in Figures 5 to 8, phase 2 corresponds to line L2 and
phase 3 corresponds to line L3. However, we recommend that you check the direction of rotation of
the pump as described in Section 3.5.3. You must use the procedure in Section 3.5.3 to check the
direction of rotation if you do not know the phase order of your electrical supply.
Use the following procedure to connect the electrical supply to the pump motor. Connect your
electrical supply to the pump-motor through a suitable contactor which has an overload
protection facility. Use appropriately rated 4-core cable and a suitable cable-gland.
1. Connect the phase-wires of your electrical supply cable to the appropriate terminals inside
the terminal-box (refer to Section 3.5.1 and to Figures 5 to 8).
2. Connect the earth (ground) wire to the earth (ground) terminal inside the terminal-box.
3. Refit the cover to the pump-motor terminal-box.
3.5.3 Check the direction of pump rotation
1. Look at the pump-motor cooling-fan, switch on the DP180 for one or two seconds, then
switch the DP180 off again.
2. If the fan rotated anticlockwise when viewed from the motor end of the pump, the direction
of rotation is incorrect. If the direction of rotation is incorrect:
•Isolate the DP180 from the electrical supply.
•Remove the cover from the pump-motor terminal-box, reverse any two of the
phase-wires in the terminal-box, then refit the cover to the terminal-box.
•Repeat the check from Step 1 to ensure that the direction of rotation is correct.
3.5.4 Connect the thermal snap-switch
The thermal snap-switch is fitted to the pump cooling-water jacket and is connected to the 2-way
terminal-block in the motor terminal-box.
You must use a suitable cable to connect the 2-way terminal-block to the motor-starter
overload-control loop, as shown in Figure 9.
You must connect the thermal snap-switch to the motor-starter overload-control loop so that, if
the DP180 overheats and the switch operates (that is, the switch contacts open), it will trip the
contactor and the DP180 will be switched off. When the pump cools and the switch contacts close
again, the DP180 will not then automatically restart; you must manually reset the contactor
before you can start the DP180 again.
12 DP180 Dry Vacuum Pump

3.5.5 Connect the solenoid-valve
Connect the gas-ballast boost solenoid-valve (Figure 4, item 6) to your control equipment so that
the valve closes when the DP180 is shut down. Use a suitably rated fused electrical supply (refer
to Section 2).
If the solenoid-valve is left open after the DP180 is shutdown, the pressure in your vacuum
system could rise to the pressure of your nitrogen supply; see Section 3.9.3.
DP180 Dry Vacuum Pump 13
1. Pump-motor terminal-box
2. 2-way terminal-block
3. Thermal snap-switch
4. To the motor starter overload-control loop
Figure 9 - Thermal snap-switch connections

3.6 Connect the cooling-water supply
CAUTION
If your pump is installed in an area where the ambient temperature falls close to or below
freezing point, ensure that the cooling-water cannot freeze inside the pump cooling-jacket
or TCV. If the cooling-water freezes, the pump or TCV can be damaged.
3.6.1 Supply quality requirements
Your cooling-water must meet the requirements of Section 2.3. If it does not, you may get a
build-up of deposits inside the pump cooling-jacket. If you have any doubt about the quality of
your supply, contact your local water authority who can tell you its RSI and advise on treatments
which you can carry out to make your supply suitable for use with the DP180.
If you use a treated closed-circuit cooling system, we recommend that you fill it (and refill it) with
de-ionised or reverse-osmosis treated water.
3.6.2 Connect the supply to the DP180
CAUTION
Make sure you connect the cooling-water supply and return hoses to the correct
connectors on the DP180. If the hoses are incorrectly fitted, the DP180 may overheat and
may be damaged.
The cooling-water connections on the DP180 are suitable for use with hoses with an outside
diameter of 12 mm (1/2inch). If you need to connect more than one DP180 to the cooling-water
supply, you must connect the pumps in parallel and not in series.
1. Connect the cooling-water supply hose to the cooling-water inlet (Figure 10, item 6).
2. Connect the return hose to the pump cooling-water outlet (Figure 10, item 2).
14 DP180 Dry Vacuum Pump

DP180 Dry Vacuum Pump 15
Figure 10 - Cooling system and bearing end-cover evacuation components
1. Bearing end-cover evacuation plug
2. Cooling-water outlet
3. Exhaust outlet
4. Thermostatic control-valve
5. Inlet-stage sump clamp-plate
6. Cooling-water inlet
7. Bearing end-cover
8. Pump body cooling-water inlet