LEYBOLD SOGEVAC SV25 FP User manual

SOGEVAC®
SV25 FP
Single-stage, oil-sealed rotary vane pump
Original Operating Instructions 300419811_002_C2
and spare parts list
Ref :
960251FP
960256FP
960257FP
960261FP

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0 Important Safety Information
1 Description
1.1 Principle of operation
1.2 Standard specification
1.3 Technical characteristics
1.4 Connection fittings
1.5 Lubricants
2 Transport and Storing
2.1 Transport and Packing
2.2 Storing
3 Installation
3.1 Setting up
3.2 Conforming Use
3.3 Connection to system
3.4 Oil filling
3.5 Electrical connections
4 Operation
4.1 Shutdown
5 Maintenance
5.1 Safety Information
5.2 Maintenance Intervals
5.3 Leybold Service
5.4 Oil level
5.5 Oil changing
5.6 Exhaust filter replacement
5.7 Gas ballast cleaning
5.8 Inlet flange sifter cleaning
5.9 Anti-suck back valve cleaning
5.10 Fan cover cleaning
5.11 Checking the oil recovery system
6 Problem analysis
7 Spare parts
8 Waste Disposal
EU Declaration of Conformity
Contents
4
6
6
6
7
10
10
12
12
12
13
13
13
14
14
15
16
16
17
17
17
18
18
18
19
19
19
19
19
19
20
22
26
27

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Obligation to Provide Information
Before installing and commissioning the pumps, carefully read these Op-
erating Instructions and follow the information so as to ensure optimum
and safe working right from the start.
The Leybold SOGEVAC® has 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 Instruc-
tions. The SOGEVAC® must only be operated in the proper condition and un-
der the conditions described in the Operating Instructions. It must be operated
and maintained by trained personnel only.
Consult local, state, and national agencies regarding specific requirements
and regulations. Address any further safety, operation and/or maintenance
questions to our nearest office.
DANGER indicates an imminently hazardous situation which, if not avoid-
ed, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoid-
ed, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoid-
ed, could result in minor or moderate injury.
NOTICE is used to notify users of installation, operation, programming or
maintenance information that is important, but not hazard related.
We reserve the right to modify the design and the specified data. The illustra-
tions are not binding.
Retain the Operating Instructions for further use.
This Manual is valid for standard products. If the delivered pump is a special
version, then the pump will be delivered with an additive document which is to
be understood as a part of the Instruction Manual.
NOTICE
DANGER
WARNING
CAUTION
NOTICE
Safety Information

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Safety Information
0Important Safety Information
0.1 Mechanical Hazards
1Never expose part of the body to the vacuum. There is a danger of inju-
ry. Never operate the pump with an open and thus accessible inlet. Vac-
uum connections as well as oil filling and oil draining openings must not
be opened during operation of the pump.
0.2 Electrical Hazards
1 The electrical connection must only be provided by a trained person.
Please observe the national regulations in the country of use like EN
50110-1 for Europe, for example.
2 Disconnect the unit from the power supply before starting any work.
0.3 Thermal Hazards
1When operating pump is hot and some surfaces could reach a tem-
perature higher than 80 °C (176 °F). There is a risk of burn by touching.
0.4 Hazards Caused by Materials and Substances
1 SOGEVAC® pumps are not designed:
■ for pumping of dusty, aggressive, corrosive, flammable or explosive
gases or gases mixtures;
■ for pumping of oxygen or other highly reactive gases with a greater
concentration than atmospheric concentration (>20%);
■ for pumping liquids;
■ for working in flammable, explosive or dusty environment.
In case of doubt, please contact Leybold.
2 Depending on the process involved, dangerous substances and oil may
escape from the pump. Take the necessary safety precautions!
3 Take appropriate precautions to insure that the pump cannot start.
4If the pump has pumped hazardous gases it will be absolutely necessary
to determine the nature of the hazard involved and take the appropriate
safety precautions.
5Observe all safety regulations!
6Take adequate safety precautions prior to opening the intake or exhaust
port.
7 Respect the instructions concerning environment protection when discard-
ing used oil or exhaust filters!
WARNING
DANGER
CAUTION
DANGER

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Safety Information
0.5 Danger of Pump Damage
1Liquid and solid particles must not enter the pump. Install the adequate
filters, separators and/or condensers. In case of doubt consult Leybold.
2The 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. Never work with
closed or restricted pump exhaust.
3Operating of the pump without oil or operating with incorrect direction of
rotation can destroy the pump or lead to oil backstreaming.
4Never use discarded seals. Always assemble using new seals.
5 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.
NOTICE

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1 Description
SOGEVAC® pumps are designed for pumping of inert gases in the range of rough
vacuum, between atmospheric pressure and ultimate pressure of the pump.
When removing condensable vapours, a gas ballast valve must be used.
1.1 Principle of operation
The SOGEVAC® pumps are single stage oil sealed rotary vane vacuum pumps.
The rotor, having three slots in which the vanes are sliding, is eccentrically in-
stalled in a pump cylinder (stator). The vanes separate the interior space into 3
chambers. The volume of these chambers varies with the rotation of the rotor.
The gas sucked into the inlet chamber is compressed and then pushed out at the
exhaust valve.
The oil injected in the inlet chamber guarantees the air-tightness, the lubrication
and cooling of the pump. It is dragged off by the compressed gases and roughly
separated by gravity when entering in the oil sump. A fine separation is then oper-
ated in the exhaust filter. The proportion of oil in the exhaust gas is thus reduced
below the visibility threshold (over 99% entrapment rate). The collected oil is flow-
ing back to the generator through an internal transfer. A non-return valve is in-
cluded in the oil return screw system to avoid an oil flow from the generator to the
oil casing when the pump works at inlet pressures greater than 150mbar. There-
fore, continuous operation above 150mbar is not recommended and can lead to
oil spilling from the exhaust.
The pumps are equipped with a permanent gas ballast for pumping condensable
vapors.
The anti suck back valve at the inlet flange avoids oil coming back into the inlet
line when the pump is stopped, in condition that the valve is clean and in good
condition.
1.2 Standard specification
The amount of oil needed for the first filling is supplied next to the pump.
The intake port is blanked off by a protective cap.
When ordering spare parts, please always state the serial and catalog numbers of
the pump.
Description

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1.3 Technical characteristics
Technical data 50Hz 60Hz
Nominal pumping speed 1) m
3
/h 26 31
Pumping speed 1) m
3
/h 22.5 25
Ultimate partial pressure without gas ballast 1) mbar ≤0.5 ≤0.5
Ultimate total pressure with small gas ballast 1) mbar ≤0.8 ≤0.8
Water vapour tolerance 1) mbar 10 10
Water vapour tolerable load 1)3) g/h 85 100
Noise level 2) dB(A) 64 67
Motor power - Rated rotational speed kW– min-10.9-3000 1.1-3600
Protection - Isolation IP55 - F IP55 - F
Leak rate mbar.l.s-11X10-31X10-3
Oil type / capacity LLVO 140 / 1 LVO 140 / 1
Weight with mineral oil 26(3φ)-27(1φ)26(3φ)-27(1φ)
Intake connection G 3/4 + G1/2 G 3/4 + G1/2
Exhaust connection G 3/4 G 3/4
1) to DIN 28400 and following numbers
2) operated at the ultimate pressure without gas-ballast, free-field measurement at a distance of 1 m
3) with room temperature 20 to 25 °C
Description

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Description
SV25FP
INLET PORT
MOUNTING 3 M6X4
SPACE FOR THE MOTOR’S VENTILATIONSPACE FOR EXHAUST FILTER EXCHANGE AND COOLING
EXHAUST PORT
FAN OPTION٭
Ref. No SV25 FP Capacitors L max. HWeight
960251 FP 3 -0231 26kg
960256 FP 1- 230V C1 275 193 26kg
960261 FP 1- 115V C1 + C2 275 235 27kg
OIL FILLING
LIFTING LUG
OIL SIGHT GLASS
CAPACITOR C1
CAPACITOR C2
INLET PORT
OIL DRAIN
EXHAUST PORT

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Description

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Description
1.4 Connection fittings
1.5 Lubricants
The SOGEVAC SV25 FP should be run with LVO140, or an equivalent
oil approved by Leybold that meets these requirements:
■low vapor pressure, when at high temperatures;
■flat viscosity curve;
■minimum water content and absorption;
■good lubricating properties; and
■resistant to aging under mechanical strain.
When using other oil brands, employ low doped, non detergent mineral
oils of viscosity class ISO VG 32.
Using the other special-grade lubricants for specific applications is pos-
sible.
Please consult Leybold.
Only use lubricants which have been fully qualified by Leybold.
Item Specification Size Part No.
1* Reduction + O-ring G 3/4 M - G 1/2 F 951 24
2Connecting piece (three piece) G 1/2 M/F 711 18 020
3Screw in nipple G 1/2 M - 16KF 711 18 120
4Centering ring DN 16KF 183 26
5Clamping ring DN 16KF 183 41
6Hose connection DN 16KF– 25mm 711 18 300
7Hose connection G 1/2 M - 25mm 711 18 011
8PVC tubing 25mm 711 18 323
9T - piece G 1/2 M-F-F711 18 250
10 Vacuum control valve G 1/2 M 951 86
11 Vacuum control valve with shut-off valve G 1/2 M 951 87
12 Ball valve G 1/2 M/F 711 30 113
13 Spring vacuum meter G 1/2 M 951 92
14 Elbow 90° G 1/2 M/F 711 18 210
15 Dust filter paper G 1/2 M/F 951 50
15 Dust filter charcoal G 1/2 M/F 711 27 092
15 Dust filter metal G 1/2 M/F 711 27 093
15 Dust filter polyester G 1/2 M/F 711 27 094
Inlet filter element for filter pos. (15):
Filter element metal
Filter element polyester
E710 65 813
712 61 280
*Delivered with the pump depending on pump part no.

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Description
Oil LVO140 Ref.No.
1L L14001
LVO140 is a food grade oil, H1 certificated by the NSF for incidental contact with food products.

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Transport and Storing
2Transport and Storing
2.1 Transport and packing
SOGEVAC vacuum pumps pass a rigorous operating test in our factory and are
packed to avoid transport damage. Please check packing on delivery for transport
damage.
Packing materials should be disposed off according to environmental laws or re-
used.
These operating instructions are part of the consignment.
The connection ports are blanked off by plastic protective caps or self-adhesives.
Take these caps or self-adhesives away before turning on the pump.
The necessary LVO140 oil is shipped in a separate can.
Pumps which have been filled with oil must only be moved in the upright position
(horizon-tally). Otherwise oil may escape. The angle of slope may not be over 10°
max. Avoid any other orientations while moving the pump.
Use only lifting devices appropriated to the pump weight. Check name plate. Do
not use other pump elements than the lifting lugs as handles.
Check the pump for the presence of any oil leaks, because there is the danger
that someone may slip on the oil which has leaked from the pump.
2.2 Storing
Until the pump is put back in to service again, the pump should be stored in a
dry place, preferably at room temperature (20 °C - 168 °F). Before taking the
pump out of service, it should be properly disconnected from the vacuum sys-
tem, purged with dry nitrogen and the oil should be exchanged too. The gas bal-
last must be closed and if the pump is to be shelved for a longer period of time is
should be sealed in a plastic bag together with a desiccant (Silicagel).
If the pump has been shelved for over one year, standard maintenance must be
done and the oil must be exchanged too before the pump is put in to service once
more. We recommend that you contact the service from Oerlikon Leybold.
CAUTION
NOTICE

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3 Installation
The standard pump is not suitable for installation in explosion hazard areas.
Please contact us, when you are planning such an application. Before installing
the pump you must reliably disconnect it from the electrical power supply and
prevent the pump from running up inadvertently.
The pump must only be installed and started by suitably qualified and trained
personnel.
Observe all safety regulations.
3.1 Setting up
The pump can be set up on any flat, horizontal surface on its rubber supports.
Under the pump are threaded bores M6 for securing the pump or screwing in vi-
bration absorbers (extras).
The oil level cannot be read properly if the pump is tilted. The may lead to insuffi-
cient being sucked in even though the oil level glass is still covered.
The pump’s ambient temperature should be between 12°C (55°F) and 40°C (104°
F). By modifying the pump or changing the oil type, the pump can be run at a
higher or lower ambient temperature. Please consult us about this.
To ensure adequate cooling of the pump; leave space at the air intake and ex-
haust points (see Fig. 1). Also ensure that there is enough space for changing the
exhaust filter (see Fig. 1).
Make sure to keep the air intake of the motor clean. The pump must be kept
clean (no dust deposit).
3.2 Conforming Use
SOGEVAC® pumps are designed for pumping of inert gases in the range of medi-
um vacuum, between atmospheric pressure and ultimate pressure of the pump.
When removing condensable vapors, a gas ballast valve must be opened.
SOGEVAC® pumps are not designed for pumping of aggressive, corrosive, flam-
mable or explosive gases. By presence of aggressive, flammable, corrosive or
explosive gases, contact Oerlikon Leybold. These pumps are not designed for
working in flammable or explosive environment. In case of doubt, contact Oer-
likon Leybold for the ATEX pump range.
The pumps are not suitable for pumping liquids or media which contain dust. Cor-
responding protective measures must be introduced. In case of doubt, contact
Leybold.
Installation
WARNING

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3.3 Connection to system
Inlet connection
The inlet flange can be connected with a vacuum-tight flexible hose and/or pipe.
The pipes should cause no stresses on the pump’s flanges. If necessary, com-
pensators must be installed.
Avoid restriction of the pipes in order not to decrease the pumping speed of the
pump. The nominal diameter of the pipes has to be least the same as the diame-
ter of pump’s inlet flange.
Liquid and solid particles 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 at-
mospheric pressure.
Connection to exhaust side
No isolation or restricting devices should be installed in the exhaust line of the
pump.
If an exhaust line is installed, it must at least have the same diameter as the ex-
haust flange. It should be installed in a manner so that no condensate can enter
the pump (siphon, slope).
The maximum exhaust pressure must neither exceed 1.15 bar absolute (0.15
bar relative), nor fall under atmosphere pressure minus 15 mbar corresponding
pressure regulating devices to be installed by the user.
A pump exhaust to be connected if oil mist or process gases are to be avoided
in the pump area.
3.4 Oil filling
The necessary oil is supplied in a can beside the pump. To fill in the oil, unscrew
the oil fill plug and fill in until the oil level reaches the MAX–mark beside the oil
sight glass.
Operating of the pump without oil or operating with incorrect direction of rotation
can destroy the pump.
Installation
WARNING
WARNING
NOTICE

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3.5 Electrical connection
The electrical connection must only be provided by a trained person. Please
observe the national regulations in the country of use like EN 50110-1 for Eu-
rope, for example.
Disconnect the unit from the power supply before starting any work.
Voltage and frequency mentioned on the motor nameplate must agree with the
supply voltage.
The drive motor must be protected against over loads according to IEC 60204-1
and IEC 61010-1.
To check the direction of rotation of pumps with three-phase motor, flick the ON/
OFF switch for a short time at atmospheric pressure. If the direction of rotation is
not identical with the one indicated by the arrow sticking on the motor hood, then
inverse any two of the electrical phases in the terminal box. Looking at the motor
fan cover, the direction of rotation has to be counter-clockwise.
DANGER
Installation

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Operation
4 Operation
Take note of warning labels on the pump.
Use ear protection in case of operation at high inlet pressures.
Clean eventual oil on the floor.
The pumps are equipped with a permanent gas ballast for pumping condensable
vapors.
The vacuum pump must be run for 30 minutes before operating with condensable
vapors with the inlet connection closed, in order to reach the operating tempera-
ture of about 75°C. Only up from this operating temperature, condensable vapors
can be pumped.
Don’t open the pump to condensable vapors until it has warmed to operating
temperature; pumping process gas with a cold pump results in vapors condens-
ing in the oil.
After use, the pump has to be left running for an additional 30 minutes with the
inlet connection closed, to clear the oil of condensates.
4.2 Shutdown
The inlet flange of the SOGEVAC pumps contains an anti-suckback valve. It clos-
es the inlet flange when the pump is voluntarily or accidentally shut down, thus
maintaining the vacuum in the connected system and preventing oil from being
sucked back into the system. Except the indications in chapter 4 there are no par-
ticular precautions for the shutdown of the pump. If the pump must be stopped for
a longer period, see chapter 2.2.
The anti-suckback valve operates reliably only if kept in good and clean condition.
It is not a safety valve.
When the pump has been switched off due to over heating, initiated by the mo-
tor protection, the pump must be cooled down to the ambient temperature, and
must only be switched on again manually after having eliminated the cause.
CAUTION
NOTICE
NOTICE

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Maintenance
DANGER
NOTICE
5 Maintenance
5.1 Safety Information
Depending on the process involved dangerous substances may escape from
the pump and oil. Take the appropriate precautions.
Observe the safety regulations.
The pump is hot and some surfaces could reach a temperature higher than 80°
C (176°F). There is a risk of burn by touching.
Disconnect the power before disassembling the pump.
Make absolutely sure that the pump cannot be accidentally started.
When disposing of used oil please observe the relevant environmental reg-
ulations!
All work must be done by suitably trained personnel. Maintenance or repairs
carried out incorrectly will affect the life and performance of the pump and may
cause problems when filing warranty claims.
Never mount used seals; always mount new seals.
5.2 Maintenance Intervals
The intervals stated in the maintenance schedule are approximate values for nor-
mal pump operation. Unfavorable ambient conditions and/or aggressive media
may significantly reduce the maintenance intervals.
To simplify the maintenance work we recommend to combine several jobs.
Maintenance job Frequency Section
Oil level checking Daily 5.4
1st oil change After 150 h of operation 5.5
Subsequent oil changes Every 500 to 2000 h 5.5
(depending on application) of opera-
tion or 6 months
Exhaust filter replacement If oil mist at ex-haust or annually 5.6
Gas ballast valve Monthly checking 5.7
Inlet flange sifter cleaning 6 months 5.8
Anti-suck back valve checking 6 months 5.9
Fan cover cleaning 6 months 5.10
Electrical connection checking
(only by a specialist) 6 months

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5.3 Leybold Service
Whenever you send us in equipment, indicate whether the equipment is contami-
nated or is free of substances which could pose a health hazard. If it is contami-
nated, specify exactly which substances are involved. You must use the form we
have prepared for this purpose.
A copy of the form has been reproduced at the end of these Operating Instruc-
tions: “Declaration of Contamination for Compressors, Vacuum Pumps and Com-
ponents”. Another suitable form is available from: www.leybold.com → Down-
loads → Download Documents → Declaration of Contamination.
Attach the form to the equipment or enclose it with the equipment.
This statement detailing the type of contamination is required to satisfy legal re-
quirements and for the protection of our employees.
We must return to the sender any equipment which is not accompanied by a con-
tamination statement.
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.
5.4 Oil level
The oil level should be checked at least once a day. If the oil level is below the
“MAX” mark, oil has to be added until the level reaches the mark. If the oil level is
below the “MIN” mark, stop the pump and check it.
5.5 Oil changing
Oil must be changed after the first 150 operating hours. Further oil changes, de-
pending on operating conditions (products, vapors, ambient temperature…) must
be done every 500 to 2000 operating hours or at least every 6 months.
A oil quality label stuck to the pump helps user judge if oil should be changed or
not.
When oil color reaches “CHANGE” shade, it is a signal to change oil.
oil change frequency given by oil label is just informative, the real oil life time de-
pends on chemical characteristics.
-If the viscosity at 25 °C exceeds 0.3 Pa s, the oil should be changed.
-The neutralization value is determined according to DIN51558. If it reaches 2,
the oil should be changed.
User can decide a postponement of oil change based on their experience and
professional management. In case of doubt, don’t risk operation with used oil, it’s
preferable to replace oil.
If there is considerable pollution, it could be necessary to change the oil more
frequently. Oil changing must be done with a switched off and still warm pump.
Open the oil drain plug and let run out the used oil into an appropriate container.
Refasten the oil drain plug when oil runs slower, start up the pump briefly (5 sec.
max) and switch off immediately. Reopen the oil drain plug and drain the rest of
the oil.
Before refastening the oil drain plug, inspect the O-ring and if necessary replace
it. Open the oil fill plug and pour in clean oil ; refasten the oil fill plug. The pump
has to be rinsed out if there is considerable pollution. Therefore pour in clean oil
up to the low edge of the oil level glass, let the pump run briefly (for a few
minutes) then drain the oil again.
CAUTION
Maintenance
Oil quality label

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5.6 Exhaust filters replacement
Oil mist escaping form the exhaust during operation indicates that the filter is
probably choked up. Increased motor current could also be the result of a dirty
exhaust filter. Open the exhaust hood, take out the filter and replace it.
Also check the gasket of the exhaust flange and change it if necessary.
5.7 Gas ballast cleaning
If the filter of the gas ballast is dirty, the gas ballast is no longer operative. The
filter has to be replaced (see spare parts list).
5.8 Inlet flange sifter cleaning
To clean the inlet flange sifter, disconnect the inlet flange and clean the sifter with
blast air or an appropriate solvent.
5.9 Anti-suck back valve checking
The anti-suck back valve should be checked at the same time as the inlet flange
screen and if dirty, be cleaned with an appropriate solvent. Also check, if there is
no damage on the sealing part of the valve.
5.10 Fan cover cleaning
Dirt blockage of the fan cover may lead to over heating of the motor and the
pump. Put off the cover and clean it with blast air. Before starting the pump again,
be sure that the cover has been reassembled.
5.11 Checking the oil recovery system
When replacing the exhaust filter, check the cleanliness and the proper operation
of the float valve.
After having disassembled the exhaust flange, unscrew the oil recovery screw and
push the float valve by using its metallic part inside the oil casing, clean the nozzle
and check that the float itself oscillates free around its axle and that the valve is
tight.
Clean the float chamber of the oil casing. Reassemble in the reverse sequence.
Maintenance

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Troubleshooting
6. Troubleshooting
Fault Possible cause Remedy Reference
section*
Pump does not
start.
Pump is connected incorrectly.
Motor protection switch incorrectly set.
Operating voltage does not match motor.
Motor is malfunctioning.
Oil temperature is below 12°C (54°F).
Oil is too viscous.
Exhaust filter / exhaust line is clogged.
Connect the pump correctly.
Set motor protection switch properly.
Replace the motor.
Replace the motor.
Heat the pump and pump oil or use different
oil.
Use appropriate oil grade.
Replace the filter or clean the exhaust line.
3.5
3.5
1.5
5.5
5.6
Pump does not
reach ultimate
pressure.
External leak .
Float valve does not close.
Anti-suckback valve is malfunctioning.
Inadequate lubrication due to :
■unsuitable or contaminated oil,
■clogged oil filter,
■clogged oil lines.
Vacuum lines are dirty.
Pump is too small.
Repair the pump.
Repair the valve.
Repair the valve.
Change the oil (degas it, if necessary).
Replace the oil filter.
Clean the oil casing.
Clean vacuum lines.
Check the process date ; replace the pump,
if necessary.
-
5.11
5.9
5.5
5.5
Pumping speed is
too low.
Dirt trap in the intake port is clogged.
Exhaust filter is clogged.
Connecting lines are too narrow or too
long.
Clean the dirt trap.
Precaution : install a dust filter in intake line.
Install new filter elements.
Use adequately wide and short
connecting lines.
5.8
5.6
3.3
After switching off
pump under vacu-
um, pressure in
system rises too
fast.
System has a leak.
Anti-suckback is malfunctioning.
Check the system.
Repair the valve. 5.9
Pump gets too hot. Cooling air supply is obstructed.
Cooler is dirty.
Ambient temperature is too high.
Process gas is too hot.
Oil level is too low.
Oil is unsuitable.
Oil cycle is obstructed.
Exhaust filter / exhaust line is obstructed.
Set pump up correctly.
Clean the cooler.
Set pump up correctly.
Change the process.
Add oil to reach the correct oil level.
Change the oil.
Clean or repair the oil lines.
Replace the exhaust filter, clean the
exhaust line.
3.1
3.1
-
5.4
5.5
5.6