Edwards HV8000 aftercooler Mk4 User manual

HV8000 Aercooler (Mk4)
INSTRUCTION MANUAL
A71213880_A Original instrucons
edwardsvacuum.com

Copyright noce
©Edwards Limited 2020. All rights reserved.
Trademark credit
Edwards and the Edwards logo are trademarks of Edwards Limited, Innovaon Drive,
Burgess Hill, West Sussex RH15 9TW.
Disclaimer
The content of this manual may change from me to me without noce. We accept
no liability for any errors that may appear in this manual nor do we make any
expressed or implied warranes regarding the content. As far as praccal we have
ensured that the products have been designed and constructed to be safe and without
risks when properly installed and used in accordance with their operang instrucons.
We accept no liability for loss of prot, loss of market or any other indirect or
consequenal loss whatsoever.
Product warranty and limit of liability are dealt with in our standard terms and
condions of sale or negoated contract under which this document is supplied.
You must use this product as described in this manual. Read the manual before you
install, operate, or maintain the product.
Associated publicaons
Publicaon tle Publicaon number
HV8000 Instrucon Manual A31103880

Contents
1. Safety and compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Denion of Warnings and Cauons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Introducon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Product overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Aercooler kit components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Installaon safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Unpack and inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Install the aercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.1 Removal of exisng aercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.2 Fing the aercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Steel degassing systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Return the equipment or components for service . . . . . . . . . . . . . . . . . . . . . 21
9. Appendix A1 - Tube ngs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1 Correct use of tube ngs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1.1 Connect a tube ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1.2 Reconnect a tube ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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List of Figures
Figure 1: Aercooler components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2: Aercooler dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 3: Compression ngs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 4: Aercooler orientaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 5: Cooling water connecon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 6: System without ow transmier on aercooler outlet line. . . . . . . . . . . . . . . . . 16
Figure 7: System with ow transmier on aercooler outlet line. . . . . . . . . . . . . . . . . . . . 17
Figure 8: Install a tube ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 9: Reconnect a tube ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1. Safety and compliance
1.1 Denion of Warnings and Cauons
NOTICE:
For safe operaon from the start, read these instrucons carefully before you install
or commission the equipment.
Read all the safety instrucons in this secon and the rest of this manual carefully
and make sure that you obey these instrucons. The equipment must only be
operated and maintained by trained personnel in the proper condion and as
described in this instrucon manual.
Obey local and state requirements and regulaons. If you have any quesons about
safety, operaon or maintenance of the device, please contact our nearest subsidiary.
Important safety informaon is highlighted as warning and cauon instrucons. Obey
these instrucons.
WARNING:
If you do not obey a warning, there is a risk of injury or death. Dierent symbols are
used according to the type of hazard.
CAUTION:
If you do not obey a cauon, there is a risk of minor injury, damage to equipment,
related equipment or process.
NOTICE:
Informaon about properes or instrucons for an acon which, if ignored, will
cause damage to the pump or the system.
We reserve the right to change the design and the stated data. The illustraons are not
binding.
Keep the instrucons for future use.
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A71213880_A - Safety and compliance

1.2 Safety symbols
The safety symbols on the products shows the areas where care and aenon is
necessary.
The safety symbols that follow are used on the product or in the product
documentaon.
Warning/Cauon
An appropriate safety instrucon must be followed or cauon to a po-
tenal hazard exists.
Warning - Heavy object
Idenes a possible hazard from a heavy object.
Warning - Pressurised
The equipment contains pressurised gases/liquids.
Warning - Use protecve equipment
Use appropriate protecve equipment for the task.
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A71213880_A - Safety and compliance

2. Introducon
2.1 Scope
This manual provides installaon, operaon and maintenance instrucons for the
HV8000 aercooler (Mk4) - referred to as aercooler in this manual. Use the aercooler
as described in this manual. Use this manual together with the HV8000 manual
(Publicaon number A31103880).
The Mk4 aercooler is available in two variants:
1. Standard - A71213015
2. Retrot kit with exible water connecon pipes - A71213024
2.2 Product overview
The aercooler is used to remove heat from the process gas passed through the HV8000
pump. It helps to keep the exhaust of the pump in the correct operang range and
lowers the temperature of the process gas for pumps installed aer the HV8000 pump.
The aercooler is installed in a 10” ange and consists of a central cooling block
connected to the cooling aluminium heat sinks. Cooling water enters the cooling block
from one end, passes through the coiled path inside the block and exits the cooling
block on the opposite side.
The aercooler weighs around 25 kg. Obey all safety precauons when you move the
aercooler.
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A71213880_A - Introducon

Figure 1 Aercooler components
1. Water inlet connecon 2. Heat sink
3. Cooling block 4. Mounng/support ange
5. Water outlet connecon 6. Connecon for oponal temperature
gauge
1. Water inlet connecon 2. Heat sink
3. Cooling block 4. Mounng/support ange
5. Water outlet connecon 6. Connecon for oponal temperature
gauge
Note:
The an tamper sleeves are installed next to the water inlet and outlet connecons to
prevent accidental loosening of the ng inside the aercooler. Make sure that it is not
removed.
Coolant water ow direcon can be reversed if necessary.
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A71213880_A - Introducon

2.3 Aercooler kit components
Refer to Figure: Aercooler components for the aercooler components. A ow
restrictor (A24802232) is supplied separately with the aercooler kit.
Table 1 Retrot kit (A71213024) components
Quanty Descripon Check
1 Mk4 aercooler q
2 Gasket q
12 M20 x 145 stud bolt q
24 M20 nut q
24 M20 plain washer q
24 M20 S-coil washer q
2 Con 12 mm OD tube q
2 Water pipe DN10, length 800 mm q
2 Male 12 mm tube to 3/8" BSPP male q
Table 2 Standard kit (A71213015) components
Quanty Descripon Check
1 Mk4 aercooler q
2 Gasket q
12 M20 x 145 stud bolt q
24 M20 nut q
24 M20 plain washer q
24 M20 S-coil washer q
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A71213880_A - Introducon

3. Technical data
Table 3
Technical data
Parameter Value
Mass (including ange) 25 kg (approximate)
Flow rate 8 – 10 l/m
(2.1 – 2.6 US gallon/minute)
Cooling water operang tempera-
ture range +5 °C ‑ +35 °C
Maximum working pressure 5 barg (7.25 psig)
Mounng/support ange 10" ASME B16.5, Class150
Cooling water specicaon*
▪ Ryznar Stability Index (RSI) 6.5 - 7.0
▪ Acidity pH 6.5 to 8.0
▪Resisvity > 1 kΩ cm-1
▪ Hardness < 100 ppm
▪ Solids (turbidity) < 100 ppm
*For steel degassing applicaons, refer to system manual P60100910
Figure 2 Aercooler dimensions
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A71213880_A - Technical data

4. Installaon
4.1 Installaon safety
WARNING: BLOCKED COOLING WATER SUPPLY
Risk of damage to equipment. If the cooling waterlines are closed or blocked when
the aercooler is in operaon, there will be high pressure and temperature inside the
aercooler. If this situaon occurs, you must stop the booster pump and leave the
aercooler for 1 hour to cool.
WARNING: INSTALLATION SAFETY
Risk of injury or damage to equipment. Obey the safety instrucons and take note of
appropriate precauons. Only suitably trained and supervised technicians must
install the equipment.
▪ Purge and shut down the booster pump and disconnect the nitrogen supply before
you start installaon.
▪ Disconnect the booster pump and other components in the system from the
electrical supply so that they cannot be operated accidentally.
▪If the booster pump is on, shut it down and allow it to cool to a safe temperature
before you start installaon.
▪ Do not allow debris to get into the booster pump during installaon.
▪ Do a leak test of the system aer installaon is complete. Seal the leaks to prevent
further leakage. Leakage rate must be less than 1 x 10-5 mbar l s-1.
▪ Make sure that you connect, disconnect and ghten all tube connecon
components correctly (Refer to Figure: Connect a tube ng and Figure:
Reconnect a tube ng).
▪ Obey all naonal and local rules and safety regulaons when you install the
equipment.
4.2 Unpack and inspect
1. Remove all packing materials and protecve covers and inspect the equipment.
2. If the equipment is damaged, nofy your supplier and the carrier in wring within
three days. Give the supplier and the carrier the informaon that follows:
▪item number of the damaged item
▪order number
▪supplier's invoice number
3. Retain all packing materials for inspecon.
4. Do not use the equipment if it is damaged.
5. Check that your package contains the items listed in Aercooler kit components on
page 9. If any of these items are missing, nofy your supplier in wring within
three days.
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A71213880_A - Installaon

If the equipment is not to be used immediately, ret the protecve packaging and store
in suitable condions as described in Storage on page 20.
4.3 Install the aercooler
Note:
The aercooler will physically t to either ange (port) of the HV8000, but you must
install it at the discharge (outlet) side of the pump.
Before you install the aercooler, visually inspect the compression ngs. If required,
ghten the ngs. Refer to Appendix A1 - Tube ngs on page 22.
Figure 3 Compression ngs
1. Visually inspect the compression ngs1. Visually inspect the compression ngs
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A71213880_A - Installaon

4.3.1 Removal of exisng aercooler
CAUTION: WATER SPILL
Risk of damage to equipment. The aercooler being replaced may contain water aer
it is removed from the pump. Make sure that no water enters the booster pump
system.
CAUTION: HEAVY OBJECT
Risk of injury. The aercooler weighs 25 kg. Make sure that two persons li the
aercooler together.
If you replace an earlier version of the aercooler (Mk1 to Mk3), rotate the posion of
the Mk4 aercooler by 90 degrees for cooling water lines connecon. Refer to Figure:
Aercooler orientaon. It shows the removal of the discharge bellows and the
aercooler.
Figure 4 Aercooler orientaon
4.3.2 Fing the aercooler
The aercooler will t in the HV8000 in all four orientaons. Any other orientaon will
prevent the booster pump from turning and may cause damage to the pump or
aercooler.
We recommend that you install the aercooler in a way that the cooling block and water
connecons are parallel to the rotors. This orientaon will result in the water inlet
connecon at either the drive or the none drive end.
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A71213880_A - Installaon

The aercooler requires two gaskets, one below and one above the ange. You must
replace both the gaskets.
To ghten the aercooler, you must ghten the opposite bolts one by one.
Cooling water supply connecons
The cooling water inlet connecon is on the opposite side to the temperature sensor
connecon. The water outlet connecon is beside the temperature probe connecon.
To ghten the cooling water connecons, hold the ng at both ends rmly in its place
with an applicable wrench and rotate the ng next to the aercooler ange.
Flexible cooling water pipes
If you install the retrot kit then the 800 mm exible pipes can be used to connect the
aercooler to the exisng water supply and return pipework.
Figure 5 Cooling water connecon
1. Visually inspect the compression ngs1. Visually inspect the compression ngs
Flow restrictor
The ow restrictor (A24802232) is required to limit the maximum ow through the
aercooler. It can be ed at any locaon up-stream or down-stream of the aercooler.
We recommend that you install the ow restrictor within 1 m of the aercooler.
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A71213880_A - Installaon

Control or alarm limits
If there is a control system (for example a PLC) used to control the pumping system, you
must set an alarm limit for the aercooler.
Acon System response Value
Alarm Stop pump 6 l/m (1.59 US gallon/minute)
Temperature sensor
If the HV8000 has a temperature transmier ed to the exisng aercooler, remove
and t it to the port on the Mk4 aercooler. Make sure the temperature sensor has the
correct inseron length. The ng is a 1/4" BSPT type.
If the HV8000 has a temperature sensor ed to the body (stator) of the pump it must
not be moved.
4.4 Steel degassing systems
The HV8000 mechanical seal cooling works best when the cooling water ow is
connected in series with the aercooler. The cooling water should ow through the
mechanical seal and then through the aercooler.
The aercooler will funcon correctly in either serial or parallel ow connecons. We
recommend that you change the cooling water pipework to funcon in series with the
mechanical sea for improved reliability.
To change the ow connecon you can use the serial ow kit (NZA010A48). Contact us
for details. Refer to Figure: System without transmier on aercooler outlet line and
Figure: System with transmier on aercooler outlet line for the ow changes aer the
seal is installed.
Note:
All ball valves on the steel degasser system water lines, connecng to the aercooler
must be locked in the open posion with a cable e. The ball valves may be closed when
the system is not in operaon, if needed for maintenance. A ball valve does not need to
be ed downstream from the ow restrictor if there is no space.
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Figure 6 System without ow transmier on aercooler outlet line
A. Before change B. Aer changeA. Before change B. Aer change
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A71213880_A - Installaon

Figure 7 System with ow transmier on aercooler outlet line
A. Before change B. Aer changeA. Before change B. Aer change
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A71213880_A - Installaon

5. Maintenance
Table 4
Maintenance schedule
Check Interval
Check that the HV8000 aercooler is not damaged.
Weekly
Check that there are no external leaks.
Check that the water ow is between 8 ‑ 10 l/m
(2.1 ‑ 2.6 US gallon/min)
Visually inspect the aercooler heat sinks for product build up.
Clean the heat sink if required. 12 month
Check internal pipe connecons for leaks.
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A71213880_A - Maintenance

6. Disposal
Dispose of the equipment safely in accordance with all local and naonal safety and
environmental requirements.
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A71213880_A - Disposal

7. Storage
If the equipment is not used immediately, replace it in its packaging and store it in a cool
and dry place unl necessary.
When required for use, refer to Installaon to install the equipment.
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A71213880_A - Storage