LEYBOLD Sogevac NEO D 16 User guide

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Sogevac Neo D
NEO D 16
NEO D 25
NEO D 40
NEO D 65
Oil sealed rotary vane pump.
Original Instruction manual
P/N
970100V to 970103V
970200V to 970202V
970300V to 970302V
970400V to 970402V
970102A33
970202A33
970302A33
970402A33
And their variants.
Document Y26/300731504/002/C4

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Contents
Page
Important Safety Information
3
1
Description
6
1.1
Principle of operation
6
1.2
Technical characteristics
8
1.3
Ordering Information
21
1.4
Accessories
22
1.5
Spare parts
23
1.6
Lubricants
23
2
Transport and Storing
24
2.1
Transport and packaging
24
2.2
Mounting orientation
26
2.3
Storage
26
3
Installation
27
3.1
Installation
27
3.2
Connection to system
28
3.3
Electrical connections
29
3.4
Start-up
32
4
Operation
33
4.1
Operation
33
4.2
Shutdown
35
4.3
Ultimate pump pressure
35
4.4
Taking out of use
35
5
Maintenance
36
5.1
Safety Information
36
5.2
Maintenance Intervals
37
5.3
Service at Leybold facilities
37
5.4
Maintenance Work
39
6
Troubleshooting
44
7
Spare parts
46
EC Conformance Declaration
48
Declaration of Contamination of Compressors
49
Vacuum Pumps and Components
Contents

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Important Safety Information
Indicates procedures that must be strictly observed to prevent hazards to
persons. Indicates procedures that must be strictly observed to prevent damage
to, or destruction of the product. Emphasizes additional application information
and other useful information provided within these Operating Instructions.
The Leybold SOGEVAC Neo D have been designed for safe and efficient
operation when used properly and in accordance with these Operating
Instructions. It is the responsibility of the user to carefully read and strictly observe
all safety precautions described in this section and throughout the Operating
Instructions. The SOGEVAC Neo D must only be operated in the proper
condition and under the conditions described in the Operating Instructions.
ATEX Cat 3 vacuum pumps have been specifically designed and manufactured to
meet the requirements for Equipment-group II Category 3 of the "ATEX" Directive"
i.e. Directive 2014/34/EU concerning equipment and protective systems intended
for use in potentially explosive atmospheres. Pumps are designed for indoor use
without condensation. Do not step on the pumps.
SOGEVAC pumps are not designed:
•for pumping of dusty, aggressive, corrosive, flammable, explosive or
pyrophoric gases or gases mixtures
•for pumping of oxygen or other highly reactive gases with a greater
concentration than atmospheric concentration (>20%) unless specific P/N and
PFPE fluid are used
•for working in flammable, explosive (unless ATEX pumps are used) or dusty
environment.
•For continuous duty above 800 mbar abs
For all these cases, special materials must be used. In case of doubt, please
contact Leybold.
See also the limits of use indicated in the CE declaration of conformity.
Never expose part of the body to the vacuum. There is a danger of injury. Never
operate the pump with an open and thus accessible inlet. Vacuum connections as
well as oil filling and oil draining openings must not be opened during operation of
the pump. When operating pump is hot and some surfaces could reach a
temperature higher than 80°C (176°F). There is a risk of burn by touching.
Depending on the process involved, dangerous substances and oil may escape
from the pump. Take the necessary safety precautions!
When working on the pump system always observe the Operating Instructions.
Disconnect the unit from the power supply before starting any work.
Pump must not be operated above 2000 m sea level
Warning
Caution
Note
Warning
Caution
High electric voltages! When touching parts at high electric voltages, there is the
risk of suffering severe injuries by an electric shock! Covers marked with this
symbol must only be opened by trained electricians after having reliably
deenergized (lockout/tagout) the equipment. Always operate the pump with a
properly connected protective earth conductor and make sure that the motor & FC
connection box are closed.
Use only the Leybold frequency converter for the pumps equipped with one.
Lay the connecting lines so that these cannot be damaged. Protect the lines
against humidity and contact with fluids. Avoid thermally stressing the lines by
unfavorable laying. Provide strain relief for the connecting lines so that the plugs
and the line connectors are not subjected to excessively high mechanical
stresses.
Lay electric feed lines so that there is no risk of tripping over these.
Important Safety Information

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Take appropriate precautions to ensure that the pump cannot start.
If the pump has pumped hazardous gases it will be necessary to determine
the nature of the hazard involved and take the appropriate safety precautions.
Observe all safety regulations!
Take adequate safety precautions prior to opening the intake or exhaust port.
Failure to observe the following precautions could result in damage to
the equipment or people!
Liquid and solid particles or dust must not enter the pump. Install the
adequate filters, separators and/or condensers. In case of doubt consult
Leybold.
The intake line of the pump must never be connected to a device with over
atmospheric pressure. Design the exhaust line so that no pressure higher
than 1,15 bar abs. (0,15 bar rel.) can occur. The pressure regulation device is
to be installed by the end-user. We recommend also to collect the pump
exhaust and to treat the gases in function of their nature.
Operating of the pump without oil or operating with incorrect direction of
rotation can destroy the pump.
Never use discarded seals. Always assemble using new seals.
Respect the instructions concerning environment protection when discarding
used oil or exhaust filters!
The pump must be packaged in such a way that it will not be damaged during
shipping, and so that no harmful substances can escape from the package.
We reserve the right to alter the design or any data given in these Operating
Instructions. The illustrations are not binding.
It is mandatory that these operating instructions be read and
understood prior to the vacuum pump installation and start-up.
We reserve the right to alter the design or any data given in these Operating
Instructions. The illustrations are not binding.
Caution: hot surface! In normal operation, the pump surface temperature can
reach 85°C. There is a risk of burning. Switch off the pump and let it cool
down before any intervention or take appropriate precautions. It is
recommended to use an oil casing or pump touching protection at high
ambient temperatures.
As a touching protection, you can use the “Noise enclosure” P/N
960331NENC or 960560NENC. The noise enclosure is an accessory not
included in the pump delivery.
All work on a pump which is “still warm from operation” should be done only
whilst wearing protective gloves.
Handle the pump only while vented and after having let it cool down.
Never remove the oil-fill or oil-drain plugs while the pump is running. There
exists the risk of suffering burns. Always wear protective gloves and protec-
tive goggles also for protection against the oil.
Warning
Caution
Note
Important Safety Information

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Some pumps use perfluoropolyether (PFPE) as lubricant.
When handling PFPE you should observe the following: During thermal
decomposition at temperatures over 290 °C toxic and corrosive gases are
released. This is not likely to happen in a Sogevacpump. When handling
PFPE keep it way from open fires. Do not smoke with PFPE on your fingers.
Touch the inner sections of the pumps only while wearing clean gloves and
use clean tools; do the necessary work in clean and dry rooms.
Do not allow the ingestion of any objects (screws, welding beads, nuts,
washers, pieces of wire, fittings etc.) through the intake port of the pump.
Objects falling into the pump can cause severe damage.
Some variants are equipped with a frequency converter giving a constant
pumping speed independently of the mains frequency and regulating the
pump power consumption. At high inlet pressures, the pump speed is
decreased.
The pump speed can be reduced to 1200 rpm (idle mode) to reduce the
power consumption w/o loss of end pressure on some pump variants. In this
idle mode, the pump inlet pressure must remain below 10 mbar
Information to user
The user's manual or instruction manual for an intentional or unintentional
radiator shall caution the user that changes, or modifications not expressly
approved by the party responsible for compliance could void the user's
authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for
a Class B, group 1 digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction manual, may
cause harmful interference to radio communications Operation of this equip-
ment in a residential area is likely to cause harmful interference in which case
the user will be required to correct the interference at his own expense.
Important Safety Information

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1. Description
SOGEVACpumps are designed for pumping of inert gases in the range of
medium vacuum, between atmospheric pressure and end pressure of the
pump. When removing condensable vapors, a gas ballast valve must be
installed or opened.
1.1 Principle of operation
The SOGEVAC Neo D are oil-sealed rotary vane pumps. The anti-suckback
valve, gas ballast valve, exhaust filter, oil return circuit and oil cooling oil are
integrated functional elements. The pumps are driven by a directly flanged
motor.
The rotor mounted eccentrically in the pump cylinder has three vanes which
divide the pump chamber into several compartments. The volume of each
changes periodically with the rotation of the rotor. As the rotor rotates, the
intake portion of the pumping chamber expands and sucks gas thru the intake
port. The gas passes through the dirt trap and the open anti-suckback valve
and enters the pump chamber. As the rotor rotates further, the vane
separates part of the pump chamber from the intake port. This part of the
pump chamber is reduced, and the gas is compressed. At slightly above
atmospheric pressure the gas is expelled from the chamber via the exhaust
valve.
Oil injected into the pump chamber serves to seal, lubricate and cool the
pump. The oil entrained with the compressed gas is coarsely trapped in the oil
case by deflection. Then fine filtering occurs in the exhaust filter elements.
The proportion of oil in the exhaust gas is thus reduced below the visibility
threshold (over 99 % entrapment rate).
Oil trapped in the exhaust filters is returned to the inlet chamber via an oil
return line.
To prevent gas flowing at atmospheric pressure from the oil reservoir into the
intake port, the oil return line is controlled by a float valve.
The oil cycle is maintained by the pressure difference existing between the oil
casing (pressure above or equal atmospheric pressure) and the intake port
(pressure below atmospheric pressure) and by an oil pump. On part of the oil
is taken from the oil casing and flows via the oil filter to the bearing points of
the rotor and to the pump chamber. The other part of oil injected in the pump
does not run through the oil filter.
A fan running on the motor shaft generates the necessary cooling air.
Pumps depending of their P/N are equipped with a gas ballast device. If
opened, a controlled amount of air so called "gas ballast" is admitted into the
pump chamber. This gas ballast prevents condensation (up to the limit of
water vapor tolerance specified in the Technical Data) when pumping
condensable gases or vapors. There are different types of gas ballast:
- standard manual gas ballast closed, small flow & standard flow,
- EM 24 V DC gas ballast available upon request,
- permanent, available upon request,
Note
Description

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Unintentional venting of the vacuum chamber as well as oil suck back when
shutting down the pump are prevented by the integrated anti suck back valve.
This valve is not a safety device and its correct operation & tightness can only
be assured if the valve plate & sealing zone are kept clean and in good
condition.
If oil returns are to be avoided by all means, it is required to install a vacuum
safety valve on the pump suction flange. Please consult us.
Warning
Inside the pump (process gas) for ATEX pumps
The inside (process gas side) of this vacuum pump is so designed and
constructed so as not to present an ignition source in cases of expected
malfunction. It is therefore suitable for use in situations in which explosive
atmospheres caused by gases, vapors, mists do not occur in normal
operation (i.e. Zone 2).
Outside the pump for ATEX pumps
The outside of this vacuum pump is also so designed and constructed so as
not to present an ignition source in cases of expected malfunction. It is
therefore suitable for use in situations in which explosive atmospheres caused
by gases, vapors, mists cannot occur occasionally in normal operation (i.e.
Zone 2).
Additionally, the outside of this vacuum pump is so designed and constructed
as to prevent foreseeable ignition sources which can occur during normal
operation and can ignite potentially explosive dust clouds. As such, when
operated within the parameters specified within this instruction manual, the
pump will provide a normal level of protection against the ignition of potentially
explosive dust clouds. It is therefore also suitable for use in situations in which
explosive atmospheres caused by gas or dust in air are unlikely to occur (i.e.
Zone 22).
Places where explosive atmospheres in air may occur are classified in terms
of three zones based on the frequency and duration of the occurrence of an
explosive atmosphere. These are designated Zone 0, 1, 2 where gases,
vapors or mists and Zone 20, 21, 22 where the explosive atmosphere is
caused by dusts. The definitions for these Zones are given in Annex I of the
"ATEX-Directive for users" i.e. Directive 99/92/EC on minimum requirements
for improving the safety and health protection of workers potentially at risk
from explosive atmospheres.
Guidance on how to classify a hazardous area is provided in Directive
99/92/EC and its accompanying Guide (COM (2003)515) together with the
European Standard EN 60079-10 (EN 60079-10 Electrical apparatus for
explosive gas atmospheres Part 10 Classification of hazardous areas). In
addition the Directive 99/92/EC and its Guide provide further information on
explosion prevention and protection. They can be downloaded from the EU
web site: www.europa.eu.int under:
www.europa.eu.int/comm/employment_social/health_safety/publicat/com_199
9_92_ce_en.pdf
www.europa.eu.int/comm/employment_social/health_safety/publicat/com_199
9_92_ce_de.pdf
www.europa.eu.int/comm/employment_social/health_safety/publicat/com_199
9_92_ce_fr.pdf
Ignition temperatures of gases / vapors that may be present:
The pump is only suitable for use in situations in which potentially explosive
gas or vapor atmospheres have an ignition temperature greater than 200°C.
Ignition temperatures of gases and vapors can be obtained from the MSDS
(Material Safety Data Sheet).
Description

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Potential Ignition Sources
An Ignition hazard assessment has been carried out according to the
European Standard EN 13463-1. (EN 13463-1 Non-electrical equipment for
potentially explosive atmospheres —Part 1: Basic method and requirements)
This has identified that the following ignition sources may occur during
operation of the pump:
Potential Ignition Sources
Comments
Hot surfaces
Inside and Outside due to:
•Gas compression, vane friction etc.
•Deposits on Stator/ Rotor slots
•Ingress of particles
Hot gases
Produced inside pump and released at the exhaust
Mechanical sparks
Will not occur in normal operation - surfaces covered with oil
inside the pump, sufficient clearance outside the pump
Electrical sparks
Motor, Accessories
Static electricity
Possible if conducting parts of pump are not earthed (Vanes, Lip
seal, Exhaust filter, float valve)
Chemical reaction
Possible with process fluid/gas
Protective measures
Hot surfaces
The compression of gas which occurs during normal operation of a vacuum
pump results in heating and hot surfaces. The SOGEVAC ATEX Cat. 3
vacuum pumps have been specially modified, and tests have shown that
when operated under the conditions specified in this manual, the internal
parts of the pump which could come into contact with a potentially explosive
atmosphere could reach a maximum temperature as marked on the pump.
The maximum temperature is reached after continuously operating the pump
with an inlet pressure of between 300 mbar and 400 mbar. The actual
temperature reached depends on the inlet pressure. Similarly, the outside of
the pump could reach a maximum surface temperature as marked (These
temperatures include the safety allowances specified in EN13463-1).
NOTE: Higher maximum surface temperatures will occur if the pump is filled
and used with other oils than indicated on the pump. This is caused by the
poorer lubricating and cooling characteristics of other oils in particular PFPE
oils.
Hot gases
Hot gases are produced inside the pump due to compression of the gas in
normal operation and are released at the exhaust. These should be ducted to
a safe place. The pump exhaust must be collected.
Mechanical sparks
Mechanical sparks will not occur in normal operation as the internal pump
surfaces are covered with oil. The external cooling fan is designed and
constructed with enough clearance to prevent contact and frictional rubbing.
NOTE: Ingress of particles into the pump must be avoided to prevent
formation of hot spots due to rubbing or friction, where necessary a suitable
ATEX filter should be used.
Description

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Electrical sparks
The motor and accessories supplied with this pump are certified to the same
classification as the outside of the pump. These should be installed and used
in accordance with the manufacturer's instructions attached to this manual.
Static electricity
The pump should be adequately earthed to prevent the accumulation of static
electricity. This will be achieved if the electrical earth cable to the motor is
properly connected. No hazardous charge generation will occur on the plastic
cooling fan and cowl or on the plastic coupling sleeve in normal operation.
(For further information on hazards from static electricity see CENELEC
report CLC/TR 50404:2003 Electrostatics - Code of practice for the avoidance
of hazards due to static electricity.)
NOTE: Only original Leybold replacement exhaust gas filter cartridges and
gas inlet filter cartridges should be used as these have a special construction
to ensure earthing.
Chemical reactions
The pump should not be used with reactive gases that could produce an
exothermic chemical reaction.
Description

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1.2 Technical characteristics Sogevac NEO D 16
NEO D 16
50 Hz
60 Hz
Nominal speed 1)
m3. h -1 (cfm)
19 (11.2)
23 (13.5)
Pumping speed 1)
m3. h -1 (cfm)
16 (9.4)
19 (11.2)
Ultimate total pressure
without gas ballast 1)
mbar (Torr)
≤ 8 x 10 -3
(≤ 6 x 10 -3)
Ultimate total pressure with
standard gas ballast 1)
mbar (Torr)
≤ 0.1
(≤ 0.075)
Ambient temperature
12 … 40 °C
(54…104 °F)
Inlet gas temperature
-20 … +60 °C
(-4…140 °F)
Water vapor tolerance with
standard gas ballast 1)
mbar (Torr)
10 (7.5)
10 (7.5)
Water vapor capacity with
standard gas ballast
kg.h -1 (qt/h)
0.03 (0.03)
0.04 (0.04)
Noise level 2)
dB (A)
54
55
Leak rate
mbar.l.s-1
≤1.10-3
≤1.10-3
Rated rotational speed
min. -1
1500
1800
Net weight (with oil filling)
kg (lbs)
49 (108)
Protection level
IP55 three phase drives
IP40 single phase drives
Oil capacity
l (qt)
1.5 (1.59)
Intake connection
DN 25 ISO-KF
Exhaust connection
DN 25 ISO-KF
1) to DIN 28400 and following numbers, with standard gas ballast
2) operated at the ultimate pressure without gas ballast, free-field measurement at a distance of 1 m
These values are valid for the standard variants and with the use of the recommended oils acc. § 1.6.
Description

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1.2 Technical characteristics Sogevac NEO D 25
NEO D 25
50 Hz
60 Hz
Nominal speed 1)
m3. h -1 (cfm)
28
34
Pumping speed 1)
m3. h -1 (cfm)
24
29
Ultimate total pressure
without gas ballast 1)
mbar (Torr)
≤ 8 x 10 -3
(≤ 6 x 10 -3)
Ultimate total pressure with
standard gas ballast 1)
mbar (Torr)
≤ 0.1
(≤ 0.075)
Ambient temperature
12 … 40 °C
(54…104 °F)
Inlet gas temperature
-20 … +60 °C
(-4…140 °F)
Water vapor tolerance with
standard gas ballast 1)
mbar (Torr)
10 (7.5)
10 (7.5)
Water vapor capacity with
standard gas ballast
kg.h -1(qt/h)
0.05 (0.05)
0.06 (0.06)
Noise level 2)
dB (A)
54
55
Leak rate
mbar.l.s-1
≤1.10-3
≤1.10-3
Rated rotational speed
min. -1
1500
1800
Protection level
IP55 three phase drives
IP40 single phase drives
Net weight (with oil filling)
kg (lbs)
48 (105)
Oil capacity
l (qt)
1.5 (1.59)
Intake connection
DN 25 ISO-KF
Exhaust connection
DN 25 ISO-KF
1) to DIN 28400 and following numbers, with standard gas ballast
2) operated at the ultimate pressure without gas ballast, free-field measurement at a distance of 1 m
These values are valid for the standard variants and with the use of the recommended oils acc. § 1.6.
Description

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1.2 Technical characteristics Sogevac NEO D 40
NEO D 40
50 Hz
60 Hz
Nominal speed 1)
m3. h -1 (cfm)
47
56
Pumping speed 1)
m3. h -1 (cfm)
40
48
Ultimate total pressure
without gas ballast 1)
mbar (Torr)
≤ 8 x 10 -3
(≤ 6 x 10 -3)
Ultimate total pressure with
standard gas ballast 1)
mbar (Torr)
≤ 0.1
(≤ 0.075)
Ambient temperature
12 … 40 °C
(54…104 °F)
Inlet gas temperature
-20 … +60 °C
(-4…140 °F)
Water vapor tolerance with
standard gas ballast 1)
mbar (Torr)
10 (7.5)
10 (7.5)
Water vapor capacity with
standard gas ballast
kg.h -1 (qt/h)
0.28 (0.30)
0.34 (0.36)
Noise level 2)
dB (A)
57
58
Leak rate
mbar.l.s-1
≤1.10-3
≤1.10-3
Rated rotational speed
min. -1
1500
1800
Protection level
IP55 three phase drives
IP40 single phase drives
Net weight (with oil filling)
kg (lbs)
80 (176)
Oil capacity
l (qt)
3 (3.2)
Intake connection
DN 40 ISO-KF
Exhaust connection
DN 40 ISO-KF
1) to DIN 28400 and following numbers, with standard gas ballast
2) operated at the ultimate pressure without gas ballast, free-field measurement at a distance of 1 m
These values are valid for the standard variants and with the use of the recommended oils acc. § 1.6.
Description

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1.2 Technical characteristics Sogevac NEO D 65
NEO D 65
50 Hz
60 Hz
Nominal speed 1)
m3. h -1 (cfm)
74
89
Pumping speed 1)
m3. h -1 (cfm)
63
76
Ultimate total pressure
without gas ballast 1)
mbar (Torr)
≤ 8 x 10 -3
(≤ 6 x 10 -3)
Ultimate total pressure with
standard gas ballast 1)
mbar (Torr)
≤ 0.1
(≤ 0.075)
Ambient temperature
12 … 40 °C
(54…104 °F)
Inlet gas temperature
-20 … +60 °C
(-4…140 °F)
Water vapor tolerance with
standard gas ballast 1)
mbar (Torr)
10 (7.5)
10 (7.5)
Water vapor capacity with
standard gas ballast
kg.h -1 (qt/h)
0.36 (0.38)
0.42 (0.44)
Noise level 2)
dB (A)
57
58
Leak rate
mbar.l.s-1
≤1.10-3
≤1.10-3
Rated rotational speed
min. -1
1500
1800
Protection level
IP55 three phase drives
IP40 single phase drives
Net weight (with oil filling)
kg (lbs)
88 (193)
Oil capacity
l (qt)
3 (3.2)
Intake connection
DN 40 ISO-KF
Exhaust connection
DN 40 ISO-KF
1) to DIN 28400 and following numbers, with standard gas ballast
2) operated at the ultimate pressure without gas ballast, free-field measurement at a distance of 1 m
These values are valid for the standard variants and with the use of the recommended oils acc. § 1.6.
Description

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Dimensional drawing NEO D 16
Fig 1.1
Description

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Dimensional drawing NEO D 25
Fig 1.2
Description

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Installation drawing NEO D 16 & 25
Fig 1.3
Description

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Dimensional drawing NEO D 40
Fig 1.4
Description

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Dimensional drawing NEO D 65
Fig 1.5
Description

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Installation drawing NEO D 40
Installation drawing NEO D 65
Fig 1.6

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NEO D 16 Pumping speed curve 50 Hz
NEO D 16 Pumping speed curve 60 Hz
Description