PVR PVL 401 - PVL 401/B Manual

PVL 401 - PVL 401/B
PVL 541 - PVL 541/B
Lubricated vane
vacuum pump
Operating and maintenance
instructions
EN
TRANSLATION
Publication Number:
LI 3019.03 January 2020

Operating and maintenance instructions
EN
2
LI 3019.03
Index
1. General information ..............................................................................................page 3
2. Product specifications ....................................................................................... page 4
2.1 Pump description ............................................................................................. page 4
2.2 Expected use.....................................................................................................page 5
2.3 Forbidden use....................................................................................................page 5
2.4 Protections ........................................................................................................page 5
2.5 Accessories .......................................................................................................page 5
3. Safety rules ........................................................................................................... page 6
4. Transport/handling ............................................................................................ page 8
4.1 Lifting ................................................................................................................ page 8
4.2 Unpacking and components control.............................................................. page 8
4.3 Storage ............................................................................................................. page 8
5. Commissioning and operation........................................................................... page 9
5.1 Assembly........................................................................................................... page 9
5.2 Location ...........................................................................................................page 10
5.3 Connection to the machine............................................................................ page 11
5.4 Discharge air pipe line installation................................................................. page 11
5.5 Electric connection......................................................................................... page 12
5.6 Commissioning ...............................................................................................page 13
5.7 Tips for use ......................................................................................................page 13
5.8 Water vapour suction .....................................................................................page 14
6. Servicing...............................................................................................................page 14
6.1 General information ........................................................................................page 14
6.2 Oil change........................................................................................................page 16
6.3 Coupling rubber insert replacement.............................................................page 16
6.4 Exhaust filters replacement...........................................................................page 16
6.5 Spares necessary for the normal servicing .................................................. page 17
6.6 Pump overhaul ................................................................................................ page 17
6.7 How to order spare parts................................................................................ page 17
7. Lubricants............................................................................................................. page 17
8. De-commissioning ..............................................................................................page 18
9. Return for repair..................................................................................................page 18
10. Disposal...............................................................................................................page 18
11. Troubleshooting .................................................................................................page 19
Attachments
Technical data sheet, exploded view and parts list (RDT)
EC declaration of conformity (DC)
Electric motor operating instructions
Instructions for the accessories

Operating and maintenance instructions
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1. General information
This manual contains information necessary for the proper operation of the pump in
order to prevent unsuitable use and for the safety of the operators. Do not attempt any
other type of operation without having first contacted our Service Department. The
information provided herewith does not intend to replace,integrate or change any rules,
regulations, law by decree, directive or law of specific character in force in the Country
where the installation takes place.
The suggestions given to the sta engaged in the installation and servicing assumes
that the personnel is expert and prepared in facing any problem of servicing, both
mechanical and electrical. For any questions or information not included in this manual,
please contact our Service Department, always providing: model (Model), serial number
(Serial), year of manufacture, stated on the pump name plate.
Symbols used:
WARNING:
Instructions that, if not followed, ELECTRIC SAFETY
could result in serious
personal injuries.
FIRE HAZARD
NOTE:
Instructions that, if not followed,
could result in pump damages. READ THE OPERATING
INSTRUCTIONS
HOT SURFACES
INLET PORT
HARMFUL SUBSTANCES
EMISSIONS EXHAUST PORT
DO NOT DISPOSE INTO
THE ENVIRONMENT DISPOSAL

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2. Product specifications
2.1 Pump description
The pumps series PVL 401 - PVL 541 have a nominal capacity (50 Hz) of 403 and 536
m3/h respectively.
They are lubricated, with oil recirculation system, rotary vane vacuum pumps.
The flanged electric motor is coupled by means of an elastic coupling.
The cooling is made by means an air/oil cooler, cooled with a centrifugal fan.
At the inlet there is a mesh filter in order to protect the pump from solid parts having
diameter bigger than 1,5 mm.
Furthermore, an integrated no-return valve prevents the oil from coming back and the
return of air in the chamber to be pumped down during the stop phase.
In the tank there is a system of separation of oil smokes from discharge air (maximum
residual 2PPM/weight corresponding to 2.4 mg/m3 ).
The separated oil is recovered automatically by the pump.
A gas ballast valve, always on, prevents condensation inside the pump when pumping
down small quantity of vapour.

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2.2 Expected use
These vacuum pumps have been designed to handle air and small quantity of water
vapour only. They are suitable to evacuate closed systems or to operate at a constant
vacuum within the following vacuum range:
PVL 401 - PVL 541 from 0.5 to 400 mbar (absolute)
PVL 401/B - PVL 541/B from 10 to 850 mbar (absolute)
The ambient temperature and the inlet temperatures must be included between 5° and
40°C.
In case you get temperatures outside this range, please get in touch with us.
Handling of other types of gas or vapours must be declared in advance to P.V.R. that will
give the conformity to the specific use.
2.3 Forbidden use
ATTENTION:
The pump MUST NOT handle:
- liquids or solid substances;
- dangerous, explosive or aggressive gases and vapours;
- pure oxygen or air mixtures enriched with oxygen;
It is forbidden to use the discharge of the pump to create even limited pressures.
ATTENTION:
It is forbidden to install the pump in a potentially explosive environment.
2.4 Protections
The pump must be protected against suction of dust, solids or liquids.
For those applications where such a protection is not ensured, a vacuum gauge must be
installed on the oil tank for a visual check of the exhaust filter clogging.
In order to get an automatic pump stop, a pressure switch set at 0.7 bar can be installed.
Thepumpissupplied withoutelectriccontrol panel.The electricmotormust beprotected
according to the regulations in force.
ATTENTION:
In case of applications where the pump stop or failure can cause damages to people
or things, safety measures for the system must be adopted.
2.5 Accessories
The following accessories useful for the installation and for the control of the operation
parameters of the pump are available:
- external inlet filter
- connection fittings
- vacuum meters/ vacuum switches
- pressure meters/ pressure switches
- temperature switch
- low oil level switch

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3. Safety rules
WARNING:
Despite of all the precautions adopted when designing the equipment, there are
some risk elements that arise during operation and servicing.
HOT SURFACES
The temperature of the pump surfaces may exceed 80°C.
Install the pump in a protected area accessible only by authorized personnel, to prevent
possible personal injures due to contact with hot surfaces.
The pump can be placed inside other machines by adopting the necessary safeguards.
Before carrying out any maintenance on the pump, be sure the pump is cold.
HARMFUL SUBSTANCES EMISSIONS
The discharged air contains part of traces of oil mist.
Check the compatibility with the environment.
Make sure a correct air change is allowed otherwise convey the pump discharge outside.
A failure or the seals wear can cause an oil leakage.
Avoid the dispersion to the ground and the pollution of other materials. In case that any
air containing dangerous substances must be pumped down (for example, biological
or microbiological agents), make sure to adopt filtering systems before introducing air
in the work environment.
Used discharged oil from the pump must be disposed in accordance with the regulations
in force in the Country of use.
Do not dispose into the environment.
HAZARD CAUSED BY VACUUM
Any contact with parts under vacuum can cause injuries.
Avoid any contact with the pump inlet port during the pump operation. Introduce air in
the inlet circuit before every operation cycle.
HAZARD CAUSED BY PRESSURE
The pump tank is pressurized. Do not open the oil filling and discharge plugs during
operation.
FOR A SAFE MAINTENANCE
All maintenance operations must be carried out with the pump idle, disconnected from
the electrical supply, with the pump cold, vented to atmospheric pressure. Prevent
unexpected start-up (e.g. block the power switch with a personal lock).

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ELECTRIC SAFETY
Some components of the electric equipment are electrically charged during operation.
Any contact may cause serious injuries to persons or objects.
Connection and control of the electric system must be carried out by skilled personnel
only.
The electrical equipment must comply with the EN 60204-1 standard and with any other
law in force in the Country of use.
Besides, electrical equipment must comply with EN 61000-6-4 and EN 61000-6-2
standards concerning electromagnetic compatibility and electromagnetic immunity
for industrial environment.
FIRE HAZARD
WARNING! The use of the pump in situations unforeseen or not recommended by this
manual, as well as lack of correct maintenance, may create high risks for overheating
or fire.
In case of a fire do not use water to extinguish but use a powder CO2extinguisher or
other means compatible with the electrical equipment and lubricating oil.

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4. Transport/handling
4.1 Lifting
The orientation of the packed components must correspond to the instructions given
by the pictograms on the external covering of the packaging.
For the unloading use a lifting equipment suitable for the pump weight.
Use the suitable lifting eyebolt to lift the pump.
4.2 Unpacking and components control
When receiving the machine, check that the packing is intact or if is shows signs of
damages occurred during transportation.
If there is no damage, proceed to the unpacking and check further the machine.
In case damages are found, inform immediately P.V.R. and the carrier. A representative
will contact you or it may be dispatched to the site to inspect and file full damage report.
4.3 Storage
Thepumpsmustbestored ortransportedwithoutoil and protectedfrom the atmospheric
agents at a temperature between -15°C and 70°C (normal humidity rate max. 95% non
condensing).

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5. Commissioning and operation
5.1 Assembly
If the pump is supplied without any electric motor, install a motor whose characteristics
are the same as stated on the technical sheet, constructive form IM B 14.
WARNING:
- Use lifting equipment suitable for the motor weight (about 30 kg)
- To assure the continuity of the equipotential circuit of the pump, clean the contact
surfaces very well, by removing any grease or protective painting.
NOTE:
After the assembly, check that the distance between the two coupling halves
is 4+1 mm (Figure 3)
Remove inlet and exhaust plastic caps.
Fit the external filter in horizontal position to prevent dirt coming inside the pump
during the cleaning of the cartridge. (Figure.4)
Fig.4
Fig.3

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5.3 Location
WARNING:
The pump must be installed in a protected area (see safety rules).
It must be fastened with support feet on horizontal surface.
It must be accessible for correct and easy maintenance, by respecting the minimum
distances from possible obstructions (see figure 6).
It must be accessible to suitable lifting equipment.
NOTE:
Ensure the air exchange in the room or inside the machine where the pump has been
installed.
To assure a sucient cooling, avoid exceeding 40°C of ambient temperature.
The pump must be protected against jets or sprays of water that may penetrate the
tank through the exhaust port.
Whenever the pump is installed outside, it must be protected against atmospheric
agents and it must be used with an oil suitable for low temperature.
Avoid warm air coming from the exhaust or the cooling fans causing discomfort to the
personnel.
Do not install the pump in a dusty area or where other materials may block or cover
the cooling surfaces quickly.
A CB
300 mm 300 mm300 mm
A
B
C
Fig.6

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5.4 Connection to the machine
The connection to the chamber to be pumped down must be carried out by means of
pipes of the same diameter as the inlet port.
Pipe weights and expansions, if any, must not rest on the pump.
It is advisable to make the final connection to the pump inlet port with flexible pipes or
fittings.
It is important that all the pipes and the dierent fittings are tight.
Very long or small diameter pipes decrease the pump performances.
This symbol identifies the inlet port.
For further information, please refer to the RDT attached herewith.
5.5 Discharge air pipe line installation
If the pump has been installed in a room with poor air exchange, it is possible to pipe
the pump discharge air to other rooms or outside.
Use pipes with the same diameter as the tank discharge port with a maximum length
of 15 m.
For longer pipes increase pipe diameter. Pipe weights must not rest on the pump.
In the final length use flexible pipes or pipe fittings.
NOTE:
this pipe must be descending, to avoid the condensate going back to the tank.
WARNING:
do not connect ball valves to this pipeline.
This symbol identifies the exhaust port.
For further information, please refer to the RDT attached herewith.

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5.5 Electric connection
The control panel and electric connections must be carried out by skilled personnel
and conform to the EN 60204-1 rules or to other local regulations in the Country of use.
The electric equipment must comply with EN 61000-6-4 and EN 61000-6-2 standard
concerning electromagneticcompatibility,emissionstandardand immunityforindustrial
environments.
Check the main voltage and frequency in use to correspond to the data stamped on the
motor name plate.
The electric motor must be protected against overload. The full load amperage value on
the motor name plate must be considered when sizing the electrical components and
motor protection against overloading.
Make sure the grounding is correctly done.
Carry outtheelectricconnection following thediagram shownon the motorterminalbox.
Check direction of rotation by starting the pump for a short time (2-3 seconds). The
correct direction is shown by the arrow on the pump (figure 7). In case of wrong rotation,
it is necessary to change the motor rotation by exchanging position of two of the three
connections in the motor terminal box.
Fig.7

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5.6 Commissioning
The pump is supplied without lubricating oil.
NOTE:
the operation without oil causes big damages to the pump.
Carry out the first filling up through the plug (E) up to the half of the sight glass (F) and
close the plug (E) (Figure 8).
Start the pump and take it to the maximum vacuum level for at least 2 minutes.
Stop the pump, check again the oil level and add the lacking oil, if necessary, in order
to get the correct oil level.
NOTE:
a quantity of oil greater than necessary may clog the oil separator and damage
the pump or the electric motor.
5.7 Tips for using
When the room temperature is lower than 10°C, it is a good practice to let the pump
operate at the ultimate pressure (Inlet port closed, without load) for about 15 minutes.
During this period the pump may not reach the stated pressure limits.
NOTE:
Avoid operating the pump for long periods with inlet port vented to atmospheric
pressure.
Avoid frequent stop-starting, as this will lead to premature wear of the coupling
elastic element.
It is recommended not to exceed 5 starting/hour. For more frequent starting, it is
recommended to install a soft starter device.
Fig.8

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5.8 Water vapour intake
In order to pump down any water vapour, the following operations are recommended:
Let the pump run for thirty minutes at the maximum vacuum in order to bring the pump
temperature to its operating value.
At the end of the working cycle, in case of further presence of condensate in the oil, let
the pump run for at least thirty minutes at the maximum vacuum.
It is advisable to carry out this operation before stopping the pump for a long time. The
gas ballast valve will allow the elimination of water condensate from the lubricating oil.
6. Servicing
6.1 General information
In order to keep the pump operating at a high eciency level, it is mandatory to follow
all periodical service points listed in the table below.However, more frequent service
operations may be necessary depending on what the pump is used for (suction of con-
densable vapours, suction of powders or polluting substances).
For such cases,only direct experience canindicate thecorrect servicefrequencyneeded.
The exhausted oil and the replaced spare parts must be considered as special waste
products and handled according to the local regulations in the Country of use.
WARNING:
Before every maintenance operation:
Always ensure that the pump is insulated from the electrical network so that it
can’t start automatically.
Wait until the pump gets cool and make sure it has reached a non-dangerous
temperature.
Introduce air in the inlet circuit.
WARNING:
in the case of maintenance operations involving the removal of the carter, restore
the electrical continuity of the pump by reconnecting the jumper between the
carter and the fan cover.

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Fig.9
SERVICING FREQUENCY DESCRIPTION OF THE OPERATION AUTHORIZED PERSONNEL
24 Hours/every day Check oil level before starting. Operator
100 Hours/every week
Clean the external inlet element with a blast of air Operator
Clean with a blast of air the cooling surfaces of the pump and
of the electric motor. Operator
*500/1000
Hours/every 6
months
Replace the lubricating oil. Skilled Worker
Ifthepressuregaugeisfittedtothepump,checktheoilseparator
(max 0,7 bar), if necessary, replace it. Skilled Worker
Replace the gas-ballast felt disk (pos.115). Skilled Worker
2000 Hours/every year
Replace the oil separator (pos.37) Skilled Worker
Check and if necessary replace the coupling rubber insert
(pos. 23) Skilled Worker
Check the electrical connections. Skilled Worker
30000 Hours/every 5 years Pump overhaul. Customer Service
* The first oil change has to be done after 500 hours of operation. If any polluting substances are found in the oil, next oil
change could take place within 1000 hours.

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6.2 Oil change
For a correct operation, oil change should be done when the pump is still warm.
ATTENTION:
Use protective gloves to avoid injury caused by heat.
If there are big quantities of pollution or if there is some water, clean the pump by letting
it run with fresh oil at maximum vacuum level.
Change again the lubricating oil (see “commissioning” and “recommended oil table”).
6.3 Coupling rubber insert replacement
Remove the motor (pos.24) unscrewing the screws (pos.138/139) and check the
coupling seeve (pos.23) conditions. If necessary, replace it. Assemble by screwing
the screws.
ATTENTION:
please use suitable lifting equipment.
Weight expected for the electric motor between 23 and 27 Kg
NOTE:
the operation with damaged elastic element causes an anomalous pump noise,
especially when starting the pump and may lead to coupling and pump shaft failure.
6.4 Exhaust filters replacement
Very dirty oil separators may cause a considerable pump temperature increase and in
extreme cases oil lubricant spontaneous ignition. Maximum allowed pressure in the
tank is 0.7 bar measured at the maximum capacity (when the pump is working with
the inlet against atmospheric pressure).
If a pressure gauge is fitted on the tank, check the oil separators blockage with the
pump still warmed-up.
For the replacement remove the cover (pos.50) unscrewing the respective screws.
Remove the screws (pos. 40) and replace the oil separators. If necessary replace the
O rings (pos.36) and the gasket (pos. 49).
For the assembly proceed the opposite way.
NOTE:
the oil separator must be fitted so that the external tongue is in the
lowest point, while the holes for the passage of air, which are inside,
stay in the upper point.

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6.5 Spares necessary for the normal servicing
The recommended spares are shown in the list of the exploded drawing marked with
the letter “R” (see RDT). They are contained in the minor spare parts kit.
6.6 Pump overhaul
For this operation please request the proper instructions and direct any questions to
our Customer Service department. The overhaul consists of a complete disassembly,
cleaning of all components as well as replacement of parts that are subject to wear
(pump and motor bearings, vanes and gaskets).
6.7 How to order spare parts
When ordering spare parts,always state the pump model,serial number, year of produc-
tion, electric motor characteristics (manufacturer’s name, model, kW, V, Hz), position
reference on the spare parts list, description and quantity needed.
Dierent types of maintenance kits are available (ref. RDT attachment).
7. Lubricants
Mineral oil recommended for generic use
Use the mineral oil for compressors according to DIN 51506 group VC-VCL or VDL
classification ISO L-DAG.
Ambient temperature Grade PVR oil
12 - 40°C ISO 100 Rotant VF 204
5 - 30°C ISO 68 Rotant VF 203
Synthetic oil recommended for generic use
Use the synthetic oil for compressors according to USDA/NSF H2.
Ambient temperature Grade PVR oil
5 - 40°C ISO 100 Rotant VF 304
0 - 30°C ISO 68 Rotant VF 303
Recommended oil for application in the food industry.
Use the synthetic oil compatible for chance contact with food according to USDA H1.
Ambient temperature Grade PVR oil
5 - 40°C ISO 100 Rotant VF 404 H1
0 - 30°C ISO 68 Rotant VF 403 H1
For ambient temperature outside the stated range, please get in touch with our Custo-
mer Service Department.

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8. De-commissioning
Drain the oil from the pump prior to the removal.
If the oil is polluted, flush the pump with fresh oil (see “oil change”).
Drain the oil from the tank, plug the inlet and the discharge ports and store the pump
without oil.
In case of pump disposal, separate the pump parts by materials and trash the parts in
accordance with the local regulations in the Country of use.
9. Return for repair
In case of pump return for repair to P.V.R., provide a list of substances which have come
in contact with the pump and advise the risks involved in handling, if any. Drain the
lubricant from the pump prior to shipping the pump back.
10. Disposal
Meaning of the “WEEE” logo found in labels
The following symbol is applied in accordance with the EC WEEE (Waste Electrical and
Electronic Equipment) Directive.
This symbol (valid only in countries of the European Community) indicates that the
product it applies to must NOT be disposed of together with ordinary domestic or
industrial waste but must be sent to a dierentiated waste collection system.
The end user is therefore invited to contact the supplier of the device, whether the
Parent Company or a retailer, to initiate the collection and disposal process after
checking the
contractual terms and conditions of sale.

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11. Troubleshooting
TROUBLE CAUSE REMEDY
Drop in perfomances
Inlet filter is dirty Clean or replace
Leaks in the inlet pipe or on the using
machine Eliminate leaks
Lack of lubrication Check oil level and conditions. Fill with oil to
the right level or replace the oil
Anomalous noise
No lubrication See previous point
Coupling element worn Replace
Motor or pump bearings damaged Replace
Damaged vanes Replace
Damaged contact surfaces Pump overhaul at our workshop
Oil leak
Shaft oil seal rings worn Replace oil seal ring (pos.14-15)
Inecient oil separator Check and clean oil recovery pipe
Inecient oil recovery system Replace oil separator (pos.37)
Motor protection is tripping
Blocked exhaust filters Replace oil separator (pos.37)
No lubrication Oil level filling up
Pump seizure and jam Pump overhaul
Broken vane Replace vanes
Discharge oil mist
Inecient exhaust filters Replace oil separator (pos.37)
High temperature due to polluted oil Oil change
High operating temperature due to high
ambient temperature
Decrease room temperature by allowing a
better air exchange

PVR Srl
HEADQUARTERS:
Via Santa Vecchia, 107 - 23868 Valmadrera (LC), Italy
T [phone] - F [phone]
[e-mail] - www.pvr.it
LOCAL UNIT:
Via IV Novembre, 104F
23868 Valmadrera (LC), Italy