5.8.1The pump has failed to start or has stopped26
5.8.2The pump has failed to achieve the specified performance27
5.8.3The pump is noisy27
5.8.4The pump surface temperature is high27
5.8.5The pumping speed is poor or if pump down time is too long27
6STORAGE AND DISPOSAL29
6.1Storage29
6.2Disposal29
7SERVICE, SPARES AND ACCESSORIES31
7.1Introduction31
7.2Service31
7.3Accessories31
7.3.1Electrical cables31
7.3.2Silencer31
7.3.3Gas ballast adaptor31
7.3.4Solenoid operated pipeline valves31
7.3.5Tip seal service kit31
INDEX 33
RETURN OF BOC EDWARDS EQUIPMENT
ILLUSTRATIONS
FigureTitlePage
1XDS35i scroll pump2
2Performance characteristics6
3Installation drawing10
4Logic interface schematic17
5Inlet strainer assembly20
6Gas ballast control assembly21
7Fan connector / fixed scroll retaining screws22
8Fixed scroll lever slot23
9Fitting tip seals24
10Tip seal length adjustment25
Issue ANov 02
ii
XDS Dry Pump
TABLES
TableTitlePage
1 Operating and storage conditions5
2 General characteristics5
3 Performance characteristics5
4 General mechanical data6
5 Vibration data7
6 Electrical data7
7 Recommended fuses12
8 Pin status on the logic interface connector17
9 Maintenance plan20
10 Electrical cables31
11 Solenoid operated pipeline valves32
ASSOCIATED PUBLICATIONS
Publication TitlePublication Number
PAGE
iii
Vacuum pump and vacuum system safetyP300-20-000
Nov 02Issue A
iii
PAGE
iv
XDS Dry Pump
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Issue ANov 02
iv
XDS Dry Pump
1INTRODUCTION
1.1Scope of this manual
This manual provides installation, operation and
maintenance instructions for the BOC Edwards
XDS35i Scroll pump. You must use your pump as
specified in this manual. Read this manual before you
attempt to install and operate your pump.
Important safety information is highlighted as
WARNING and CAUTION instructions; you must
obey these instructions. The use of WARNINGS
and CAUTIONS is defined below.
WARNING
Warnings are given where failure to
observe the instruction could result
in injury or death to people.
CAUTION
Cautions are given where failure to observe the
instruction could result in damage to the
equipment, associated equipment and process.
The units used throughout this manual conform to
the SI international system of units of measurement.
Pressures are stated as absolute pressures
throughout this manual.
Warning - hot surfaces.
1.2Description
The XDS35i pump is shown in Figure 1. Refer to
Figure 1 for item numbers in brackets in the
following descriptions.
The XDS pump is a compact, reliable vacuum pump
which is suitable for use on vapour handling
processes. The XDS pump may be used for some
pumping applications involving corrosive substances
and particulates; for information on pumping
flammable gases, please refer to Section 4.5 and
contact BOC Edwards for any further assistance.
The body of the pump includes a fixed scroll and an
orbiting scroll. The orbiting scroll is controlled by
the electric motor through an eccentric cam on the
motor drive shaft. The movement of the orbiting
scroll, meshed with the fixed scroll, forms
successive crescent shaped volumes in the pump.
Gas that enters the pump through the inlet is
compressed by the movement of the orbiting scroll
and swept towards the centre of the fixed scroll.
The compressed gas enters the exhaust port near
the centre of the stationary scroll and is exhausted
from the pump through the outlet.
PAGE
1
INTRODUCTION
The following IEC warning labels appear on the
pump:
Warning - refer to accompanying
documentation.
Warning - risk of electric shock.
Nov 02Issue A
The XDS is a truly dry vacuum pump, as all the
bearings, with their hydrocarbon lubricant, are
isolated from the vacuum space.
The inlet of the pump has a NW40 (1) inlet and inlet
strainer.
1
PAGE
2
INTRODUCTION
XDS Dry Pump
1. NW40 inlet port
2. Gas ballast control
3. Cooling fan
4. NW25 exhaust port
5. Fan connector
6. Rubber feet
Figure 1 - XDS35i scroll pump
The pump mechanism is driven directly by a three
phase electric motor. The motor is controlled by an
inverter, which manages the supply of current to the
motor in accordance with operating conditions, and
allows the pump to be connected to a single phase
supply. The voltage changeover switch (beneath the
voltage changeover switch cover, refer to Figure 1,
item 8) must be set to the correct position in
accordance with the power supply being used, refer
to Section 3.5.2.
The XDS35i is designed to run from atmospheric
pressure however, if the inlet pressure exceeds
100 mbar for an extended period, the inverter may
reduce the motor speed. The pump will speed up
again after the pressure is reduced.
7. Electrical connector
8. Voltage changeover switch cover
9. On/Off switch
10. 15 way connector
11. Hour counter
The pump is air-cooled by a fan (3) mounted at the
opposite end to the motor. The fan will run on for
one minute after the pump is switched off. The
XDS35i incorporates a thermal protection device
that will stop the motor in the event of thermal
overload e.g. high ambient temperature. The pump
will restart after it has cooled down.
The pump is mounted on rubber feet (6).
The pump is fitted with an hours counter (11), which
indicates the total time that the pump has run.
Issue ANov 02
2
1.3Gas ballast control
XDS Dry Pump
To pump high vapour loads, gas ballast can be
delivered into the pump to prevent condensation of
the vapour carried by the pumped gases.
Air can be introduced to the low vacuum stages
through the gas ballast control (2). Alternatively, an
inert gas such as nitrogen can be supplied through a
suitable external valve and by using the appropriate
adaptor, available as an accessory, refer to
Section 7.3.3.
The gas ballast control has three positions:
• Closed (position '0')
• Low flow (position 'I')
• High flow (position 'II')
1.4Construction
The pump scrolls are made of anodised aluminium.
The motor housing is aluminium. All surfaces of the
pump which are exposed to the pumped gases are
free from copper, zinc and cadmium.
PAGE
3
INTRODUCTION
Other materials of construction include
fluorocarbon elastomer, nitrile, chemically resistant
polymers, nickel and stainless steel.
The tip seal is a PTFE composite material.
Nov 02Issue A
3
PAGE
4
XDS Dry Pump
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Issue ANov 02
4
2TECHNICAL DATA
2.1Operating and storage conditions
XDS Dry Pump
PAGE
5
Operating and storage conditionsXDS35i
Ambient temperature range (operation)+10 °C to +40 °C
Maximum surface temperature of pump body at ultimate vacuum.
+40 °C to +70 °C
(Depending on ambient temperature)
Maximum humidity (operation)90% RH
Ambient temperature range (storage)-30 °C to +70 °C
Table 1 - Operating and storage conditions
2.2Performance
2.2.1General
GeneralXDS35i
Suckback protection (no solenoid valve on inlet)By exhaust valve
Maximum initial pressure rise with no gas ballast flow (mbar l)5
3
Maximum displacement (m
Maximum pumping speed (m
/hr)44
3
/hr)35
Maximum permitted inlet pressure and gas ballast inlet pressure (barg)0.5
Maximum permitted outlet pressure (barg)1
Leak tightness (mbar l s
-1
)<1 x 10-6
TECHNICAL DATA
Table 2 - General characteristics
2.2.2Performance characteristics
The position of the gas ballast control defines the
performance characteristics of the pump. These
performance characteristics are listed in Table 3.
Pump
Gas ballast
control position
Ultimate total
pressure (mbar)
Gas ballast
flow (l min
XDS35i0<0.01-
1<0.023
2<0.0312
Table 3 - Performance characteristics
-1
)
Nov 02Issue A
5
PAGE
6
TECHNICAL DATA
XDS Dry Pump
1. Speed2. Power
Figure 2 - Performance characteristics
2.3Mechanical data
2.3.1General
ParameterUnitsXDS35i
Overall dimensions (L x W x H)mm476 x 333 x 396
Maximum tilt angledegree10
Nominal rotational speedrpm1750
Masskg48
Inlet connectionNW40
Outlet connectionNW25
Degree of protection (IEC60529)IP44
Table 4 - General mechanical data
Issue ANov 02
6
XDS Dry Pump
2.3.2Vibration data
ParameterXDS35i
Sound pressure, measured at ultimate vacuum 1 metre from the end of the pump
61.5 dB (A)
to ISO 11201
Vibration: measured at the inlet port (ISO3744)Class 1C…< 4.5 mms
(rms)
Table 5 - Vibration data
2.4Electrical data
PumpSupply (V)Phase
Frequency
(Hz)
Power (W)Current (A)
PAGE
7
TECHNICAL DATA
-1
XDS35i
200/230Single50/605205
100/120Single50/605208.5
Table 6 - Electrical data
Nov 02Issue A
7
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8
XDS Dry Pump
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XDS Dry Pump
3INSTALLATION
3.1Safety
WARNING
Obey the safety instructions given
below and take note of appropriate
precautions. If you do not, you can
cause injury to people and damage to
equipment.
WARNING
The BOC Edwards XDS35i pump is
not recommended for pumping
explosive gases or hazardous
substances.
You must ensure that the XDS35i pump is suitable
for your application. If you have any doubt about the
suitability of the XDS35i pump for your application,
refer to the BOC Edwards guidelines on vacuum
pump and vacuum system safety (see associated
publications at the end of the contents list at the
front of this manual).
• Loose slings should not be used to lift the
XDS35i.
WARNING
Take care when moving the pump
into position. The pump's weight
makes it difficult to slide and
movement should be attempted
using two people.
• Wear the appropriate safety clothing when
you come into contact with contaminated
components. Dismantle and clean
contaminated components inside a fume
cupboard.
• Vent and purge your vacuum system before
you start installation work.
• Ensure that the installation technician is
familiar with the safety procedures that relate
to the products handled by the pumping
system.
• Disconnect the other components in the
pumping system from the electrical supply so
that they cannot be operated accidentally.
PAGE
9
INSTALLATION
WARNING
Prevent any part of the human body
coming into contact with the vacuum.
A suitably trained and supervised technician must
perform the installation of the XDS35i pump. Obey
the safety instructions listed below when you install
the XDS pump, especially when you connect the
pump into an existing system. Details of the specific
safety precautions are given at the appropriate point
in the instructions.
WARNING
Use suitable lifting equipment
to move the XDS35i pump.
The mass of the pump is
approximately 48 kg.
• Mechanical lifting equipment should be
attached to the lifting eye on the pump.
3.2System design considerations
Consider the following points when you design your
pumping system:
Use a suitable valve to isolate the pump from your
vacuum system if you need to allow the pump to
warm up before pumping condensable vapours or if
you need to maintain vacuum when the pump is
switched off.
Avoid high levels of heat input into the pump from
the process gases, otherwise the pump may
overheat, and cause the thermal overload device to
open.
If you use the pump in a high ambient temperature
and have a high gas throughput, the temperature of
the pump body may approach 70 ºC and you must
fit suitable guards to prevent contact with hot
surfaces.
Nov 02Issue A
9
PAGE
10
INSTALLATION
XDS Dry Pump
Figure 3 - Installation drawing
Issue ANov 02
10
XDS Dry Pump
Make sure that the exhaust pipeline cannot become
blocked. If you have an exhaust isolation valve, make
sure that you cannot operate the pump with the
valve closed.
Provide for a purge of inert gas when you shut down
the pumping system, to dilute dangerous gases to
safe concentrations.
3.3Unpack and inspect
WARNING
Use suitable lifting equipment
to move the XDS35i pump.
The mass of the pump is
approximately 48 kg.
Remove all packing materials, remove the pump
from its packing box, remove the protective covers
from the inlet and outlet ports and inspect the
pump. If the pump is damaged, notify your supplier
and the carrier in writing; state the item number of
the pump together with your order number and
your supplier's invoice number. Retain all the
packing materials for inspection. Do not use the
pump if it is damaged. If the pump is not to be used
immediately, replace the protective covers. Store
the pump in suitable conditions, as described in
Section 6.1. Refer to Section 6.2 for disposal of
materials.
If your pump will be located inside an enclosure,
make sure that there is adequate ventilation at both
ends of the pump, so that the ambient temperature
around the pump does not exceed 40 ºC. There
must be a minimum space of 25 mm between the
pump and the enclosure walls.
3.5Electrical installation
3.5.1Check and configure the pump
CAUTION
Ensure that the pump is correctly configured for
your electrical supply otherwise you may cause
damage.
Ensure that the voltage shown on the voltage
indicator (refer to Figure 1, item 8) on the motor
cover corresponds with your electrical supply
voltage. If it does not, you must change the
configuration of the pump motor to match your
supply voltage; use the procedure below.
1.Undo the two screws and lift off the voltage
indicator moulding.
2.Rotate the voltage indicator moulding so that
the correct voltage is uppermost.
3.Replace the two screws.
PAGE
11
INSTALLATION
3.4Locate the pump
WARNING
If the pump is to be used on the floor
of a work area, position the power
lead and the exhaust and inlet hoses
with care. Ensure that personnel in
the area are aware of any
obstructions around the pump.
Provide a firm, level platform for the pump. Locate
the pump so that the gas ballast control and the on
/ off switch are accessible.
Nov 02Issue A
11
PAGE
12
XDS Dry Pump
AreaVoltageRating
UK230 V13 A
Europe230 V16 A
INSTALLATION
3.5.2Connect the pump to your electrical
supply
The following fuse ratings should be used (refer to
Table 7).
US110 V20 A
Japan100 V20 A
Table 7 - Recommended fuses
3.6Inlet and outlet connections
WARNING
WARNING
WARNING
If pumping dangerous gases or
Ensure that the electrical
installation of the XDS pump
conforms with your local and
national safety requirements. It
must be connected to a suitably
vapours, connect the exhaust to a
suitable treatment plant to prevent
the discharge of dangerous gases and
vapours to the surrounding
atmosphere.
fused and protected electrical
supply with a suitable earth point.
WARNING
If pumping for a prolonged period
above 100 mbar inlet pressure, use
an exhaust silencer (refer to
CAUTION
Section 7.3.2) or connect to an
appropriate exhaust line.
If using an overload circuit breaker it must be of a
time lag type because of high start up current.
CAUTION
If using an earth leakage device e.g. an RCD, use at
least a 30 mA rated unit to avoid trip during start
up.
The pump will automatically restart after
restoration of the power supply following power
failure.
Make the electrical connections to the pump motor
with an IEC60320 cable socket (C19) that satisfies
your local electrical standards.
Refer to Figure 1. Before you connect the pump to
your vacuum system, remove the plastic cap from
the inlet and the exhaust, and ensure that the inlet
strainer is fitted to the pump inlet port. Use
appropriate NW40 vacuum fittings for connection
to your system.
Take note of the following information when you
connect the pump to your vacuum system.
• To minimise noise and exhaust emissions, it is
recommended that the pump is connected to
an exhaust line or a silencer (refer to
Section 7.3.2).
• For optimum pumping speeds, ensure that the
pipeline connected to the pump inlet is as
short as possible and has a suitable internal
diameter.
• Support the vacuum pipeline to prevent
loading of the coupling joints.
Issue ANov 02
12
XDS Dry Pump
• If necessary, incorporate flexible bellows in
your system pipelines to reduce the
transmission of vibration and to prevent
loading of the coupling joints. If you use
flexible bellows, you must ensure that you use
bellows that have a maximum pressure rating
which is greater than the highest pressure that
can be generated in your system. We
recommend that you use BOC Edwards
bellows.
• Incorporate an inlet isolation valve in the
pipeline from the vacuum system to the pump,
so that you can isolate the vacuum system
from the pump when it is switched off and
prevent the suckback of process gases and
debris into the vacuum system.
• Ensure that the sealing surfaces are clean and
scratch-free.
PAGE
13
INSTALLATION
We recommend that you use an exhaust extraction
system suitable for use with all of the process gases
you will pump. Ensure that the exhaust extraction
system cannot become blocked or obstructed when
the pump is operating.
A small amount of tip seal wear product may collect
in the exhaust duct of the pump. The dust may be
blown out with the initial burst of air after the pump
has been vented. This is quite common and the
amount of dust seen will reduce over time.
3.7Leak test the system
After you have installed the XDS pump, leak test the
system and seal any leaks found.
Nov 02Issue A
13
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14
XDS Dry Pump
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Issue ANov 02
14
XDS Dry Pump
4OPERATION
4.1Use of gas ballast control
You can use the gas ballast control to optimise the
performance of the scroll pump for your application.
The performance characteristics of the pump with
the different ballast settings are shown in
Section 2.2.2. You can change the position of the gas
ballast control when the pump is off or when the
pump is operating.
4.1.1Gas ballast control
Use the gas ballast control to change the amount of
air introduced into the final stage of the pump. Use
of gas ballast will reduce the condensation of
vapours in the pump; the condensates would
contaminate the pump. You can turn the gas ballast
control to select one of the three positions, as
follows:
4.2Start up procedure
WARNING
Ensure that your system design does
not allow the exhaust pipeline to
become blocked.
CAUTION
A fine black dust may be emitted from the exhaust
of the scroll pump during start up, particularly
when the pump is new or if new tip seals are fitted.
Refer to Section 5.6 for further information when
fitting new tip seals.
Use the procedure below to start up the pump:
1.Ensure that any vacuum system isolation valve is
closed (if fitted).
2.Connect a suitable lead from the power supply
to the electrical socket at the side of the pump.
PAGE
15
OPERATION
To select no gas ballast, turn the control position to
'0'. Use this setting:
• to achieve ultimate vacuum
• to pump dry gases.
To select low flow gas ballast, turn the control to
position 'I'. Use this setting:
• to pump low concentrations of condensable
vapours
• to decontaminate the pump.
To select high flow gas ballast, turn the control to
position 'II'. Use this setting:
• to pump high concentrations of condensable
vapours
• to clear excess vapours after processing.
3.Switch on the electrical supply to the pump,
using the on / off switch on the motor.
4.Always use the on / off switch to start / stop the
pump.
5.Open the vacuum system isolation valve (if
fitted).
4.3To achieve ultimate vacuum
In order to achieve the best possible vacuum, the
pump should be operated with the gas ballast
control on position '0'. However, if the pump, or
elements of the vacuum system it is attached to, are
new or have been newly fitted, some atmospheric
moisture may be present. If atmospheric moisture is
present, run the pump with the gas ballast control in
position 'I' or 'II' for 20 minutes before switching to
position '0'. If moisture is allowed to remain, the
performance of the pump will be impaired.
Nov 02Issue A
15
XDS Dry Pump
4.4To pump condensable vapours
PAGE
16
Select a suitable gas ballast setting (gas ballast control
in position 'I' or 'II') when there is a high proportion
of condensable vapours in the process gases. This
OPERATION
will assist the vapours to pass through the pump
without condensing and keep the pump performance
from degrading.
4.5To pump flammable gases
The XDS35i pump must not be used in an area
where flammable gases, vapours or dust are present
or could be present.
When using the XDS pump for pumping flammable
gases and/or vapours the pump mechanism must be
considered to be a source of ignition.
The following actions must be taken to ensure that
the gas being pumped stays out of the flammable
WARNING
Do not use the XDS pump for
pumping flammable gases, gas
mixtures or vapours that are within
their flammable range.
CAUTION
range.
• Ensure the system is leak tight.
• Dilute any flammable gases or vapours by
using an inert gas purge (e.g. N
) to the pump
2
inlet and/or gas ballast (accessory available) to
reduce their concentration in the pump and
exhaust line to less than one quarter of their
published lower explosive limits (lel).
• Prevent the condensation of flammable
vapours within the pump mechanism and
exhaust line by using an inert gas purge to the
pump gas ballast connection.
• The inert gas purge should be switched on to
remove air from the pump and exhaust before
the process starts. The purge flow can be
switched off at the end of the process only
after any remaining flammable gases or
vapours have been purged from the pump and
exhaust line.
• If liquids that produce flammable vapours
could be present in the pump foreline then the
inert gas purge to the XDS pump should be
left on all the time this liquid is present.
Flammable liquids could be present in the
foreline as a result of condensation or may be
carried over from the process.
• When calculating the flow rate of inert gas
required for dilution, consider the maximum
flow rate for the flammable gases/vapours that
could occur. For example, if a mass flow
controller is being used to supply flammable
gases to the process, you should assume a
flow rate for flammable gases that could arise
if the mass flow controller is fully open. The
inert gas purge flow rate should be continually
measured and if the flow rate falls below that
required, then the flow of flammable gases or
vapours to the pump must be stopped.
We recommend you obtain and read Vacuum
Pump and Vacuum System Safety publication
no P300-20-000 available from BOC Edwards
or your supplier.
4.6Remote operation using 15 way D
connector
It is possible to operate the pump remotely using the
15 way D type connector fitted on the panel at the
side of the pump. (Refer to Figure 1).
The 15 way D connector is insulated to ensure that
it remains protected in the event of a single fault
condition.
Issue ANov 02
16
XDS Dry Pump
PAGE
17
OPERATION
1. Speed control
2. Pump healthy signal, 0 V = OK
Figure 4 - Logic interface schematic
Pumping
speed
3 h-1
(m
)
Pin 1Pin 3Pin 4Pin 5
Mode
Speed
percentage
Normal100%3524 V0 Vopenopen
Boost116%4124 V0 V0 V0 V
Idle67%2324 V0 V0 Vopen
Reserved––24 V0 Vopen0 V
The tolerance of the power supply can be ±10%.
Make sure all the unused pins are not connected.
Table 8 - Pin status on the logic interface connector
The controls available are as follows:
Figure 4 shows which connections to make to
enable these functions.
•On/Off
• Boost (Run pump at 116%)
The power On/Off switch (Figure 1, item 9) should
be in the Off position for remote operation.
• Idle(Run pump at 67%)
• Run(Runs pump at standard speed 100%)
•OK Signal
To completely remove electrical power from the
pump, the plug should be removed from the
electrical connector (Figure 1, item 7).
Nov 02Issue A
17
4.7Shut down
XDS Dry Pump
PAGE
18
Use the procedure below to shut down the pump:
1.If shutting the pump down prior to a period of
OPERATION
2.Close any vacuum system isolation valve to
3.Switch off the pump using the on/off switch.
4.Vent the XDS35i by the gas ballast control or
storage, remove any process gases by running
on high flow gas-ballast for at least one hour.
prevent suckback into the vacuum system
(where fitted).
When the pump is switched off the fan will
continue to run for 1 minute.
valve on the inlet.
Issue ANov 02
18
5MAINTENANCE
XDS Dry Pump
5.1Safety information
WARNING
Obey the safety instructions given
below and take note of appropriate
precautions. If you do not, you can
cause injury to people and damage to
equipment.
WARNING
Wait one minute for capacitor
discharge after disconnecting the
power supply before working on the
pump.
The XDS35i pump is designed to require little user
maintenance. Observe the following guidelines when
carrying out maintenance on your pump:
• Ensure that maintenance is done by a suitably
trained and supervised technician. Obey your
local and national safety requirements.
• Ensure that the maintenance technician is
familiar with the safety procedures which
relate to the products processed by the
pumping system.
• Check that all the required parts are available
and are of the correct type before you start
work. Refer to Section 7.3.5.
• Disconnect the pump and other components
from the electrical supply so that they cannot
be operated accidentally.
WARNING
The pump may be contaminated with
the process chemicals that have been
pumped during operation. If so,
ensure that the pump is
decontaminated before maintenance
and that you take adequate
precautions to protect people from
the effects of dangerous substances if
contamination has occurred.
• Do not touch or inhale the thermal
breakdown products of fluorinated materials
which may be present in the pump if the pump
has been heated to 310 ºC and above.
Fluorinated materials are safe in normal use
but can decompose into very dangerous
substances (which may include hydrofluoric
acid) if they are heated to 310 ºC and above.
The pump may have overheated if it was
misused or if it was in a fire. Health and Safety
Data sheets for fluorinated materials used in
the pump are available on request; contact
your supplier or BOC Edwards.
5.2Maintenance plan
More frequent maintenance may be required if the
pump is used to pump aggressive gases and vapours,
such as solvents, organic substances and acids, or if
the pump is operated continuously at elevated
temperatures. If necessary, adjust the maintenance
plan according to your experience.
PAGE
19
MAINTENANCE
• Allow the pump to cool before you start
maintenance work.
• Do not re-use internal 'O' rings.
Nov 02Issue A
19
XDS Dry Pump
OperationFrequencyRefer to Section
PAGE
20
Inspect and clean inlet strainerYearly5.3
Inspect and clean the gas ballast controlYearly5.4
MAINTENANCE
Clean the external fan coverYearly5.5
Replace the tip seals9000 hours5.6
Test the motor / drive condition15000 hours5.7
Replace the bearings35000 hoursRefer to BOC Edwards
5.3Inspect and clean the inlet strainer
Whenever you disconnect the pump from your
vacuum system, we recommend that you:
• Remove any debris trapped by the inlet
strainer (in the inlet port).
• Inspect the inlet strainer and if necessary,
clean it with a cleaning solution suitable for
the substances pumped. Refit the inlet
strainer before you reconnect the pump to
your vacuum system.
1.Refer to Figure 5. Disconnect your vacuum
system from the pump inlet-port (3) and
remove the centring-ring and strainer assembly
(1) and the 'O' ring (2). Inspect the centring-ring
and the 'O' ring. If they are clean, continue at
Step 5. If they are not clean, continue at Step 2.
Table 9 - Maintenance plan
1. Centring ring and strainer
2. 'O' ring
3. Pump inlet-port
Figure 5 - Inlet strainer assembly
5.4Inspect and clean the gas ballast
control
2.Remove the 'O' ring (2) from the centring-ring
and strainer assembly (1). Do not allow the 'O'
ring to come into contact with the cleaning
Note:The gas ballast filter element (Figure 6, item 7)
is retained in its seating with adhesive; do not
try to remove it.
solution.
3.Wash the centring-ring and strainer assembly in
a suitable cleaning solution and allow it to dry.
4.If necessary, wipe the 'O' ring with a clean, dry,
lint-free cloth.
5.Refit the centring-ring and strainer assembly
and the 'O' ring to the inlet-port. Refit your
vacuum system to the pump inlet-port.
1.Refer to Figure 6. Turn the gas ballast control
to the high flow position (II).
2.Push the control down against the compression
spring (6) as far as it will go, then turn the
control anti-clockwise slightly to release the
bayonet lugs (5) and remove the control (1).
3.If necessary, wipe the control with a clean, dry,
lint-free cloth and check that the air-hole (3) is
not blocked. If necessary, clean the foam with
warm soapy water and allow to air dry.
Issue ANov 02
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XDS Dry Pump
4.Refit the control into the gas ballast inlet and
ensure that the compression spring locates
correctly between the bayonet lugs.
5.Push the control down as far as it will go and
then turn the control clockwise slightly until the
bayonet lugs engage correctly.
6.Reset the gas ballast control to the required
position.
5.5Clean the external fan cover
If the fan cover is not kept clean, the air flow over
the pump can be restricted and the pump may
overheat.
1.Switch off the pump and disconnect it from the
electrical supply.
2.Use a dry cloth and a soft brush to remove dirt
and deposits from the fan cover.
PAGE
21
MAINTENANCE
1. Gas ballast control
2. 'O' ring
3. Air-hole
5. Bayonet-lugs
6. Compression spring
7. Filter element
4. 'O' ring
Figure 6 - Gas ballast control assembly
Nov 02Issue A
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XDS Dry Pump
5.6Replace the tip seals
PAGE
22
MAINTENANCE
This instruction is applicable to the XDS35i
replacement tip seal kit (contained in minor service
kit, refer to Section 7.3.5) that must be fitted.
Take care when removing the fixed scroll assembly
that once all fixings are released the assembly is not
1Refer to Figure 7. Switch off the pump,
disconnect the electrical supply and allow it to
cool to a safe temperature. Vent the pump using
the gas ballast control set to position 2.
2.Undo the fan connector (1).
3.Undo the six fixed scroll retaining screws (2).
CAUTION
dropped.
4.Carefully remove the fixed scroll assembly using
a lever in the slots provided to ease it from the
motor body as shown in Figure 8.
5.Gently move the fixed scroll assembly aside so
that the fan connector can be accessed. This is
fitted at the underside of the fan cowl and must
be undone in order to remove the fixed scroll
completely.
WARNING
Do not place fingers between the
scroll and the pump housing as they
could be injured if the motor is
rotated.
1. Fan connector
2. Scroll retaining screws x6
Figure 7 - Fan connector / fixed scroll retaining screws
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XDS Dry Pump
PAGE
23
MAINTENANCE
1. Fixed scroll lever slot
Figure 8 - Fixed scroll lever slot
WARNING
Do not inhale the tip seal dust.
Do not blow the tip seal dust from
the pump mechanism with
compressed air.
6.Place the fixed scroll assembly on a flat surface
so that the scroll is facing upwards.
7.Remove the tip seals. Dispose of all waste
materials in accordance with the instructions
given in Section 6.2. If the pump has been used
for anything other than clean applications, go to
step 8; if not move straight on to step 10.
8.Loosen the three screws that secure the fixed
scroll into the fan cowl. Remove the gas ballast
control knob and spring. Remove the exhaust
flange. Disconnect the wires going to the
thermal snap switch.
9.Place the scroll downwards taking care not to
damage the tops of the tip seal walls. Remove
the exhaust valve cap and lift out the exhaust
spring and valve, if they have not come out
when removing the valve cap. Replace the
spring and valve pad.
10. Make sure there is no debris visible on the
inside of the scrolls, especially in the tip seal
slot. Wipe with a soft, dry, lint free cloth to
remove any dust etc. Avoid excessive abrasive
cleaning to maintain the PTFE layer that was
deposited by the tip seal on the scrolls during
previous running. This will minimise the dust
generation and running in period on re-starting
the pump.
Nov 02Issue A
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PAGE
24
MAINTENANCE
XDS Dry Pump
2. Tip seal start point
Start at the centre and push the tip seal into the groove, polished side up.
Figure 9 - Fitting tip seals
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XDS Dry Pump
PAGE
25
MAINTENANCE
1. Tip seals trim point
Figure 10 - Tip seal length adjustment
Nov 02Issue A
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XDS Dry Pump
11. The fixed scroll tip seal must be cut into 2
PAGE
26
MAINTENANCE
sections and the orbiting scroll tip seal must be
cut into 3 sections. Each scroll tip seal groove
has indicator marks to show where the tip seal
must be cut (refer to Figure 10).The seals have
a sealing face and the opposite face has minute
grooves. Ensure that the grooved side of the
seal is fitted downwards into the scroll, so that
the sealing face is upwards. Start at the centre
of the orbiting scroll and fit the seal into the
groove (refer to Figure 9). The seal should be as
close to the end of the groove as possible.
When the indicator mark is reached, cut the
seal to the mark. This allows an area into which
the seal can expand. Repeat for all sections in
both scrolls. Ensure that the tip seal is pushed
fully home, particularly at the pinch-points, with
finger pressure before reassembly.
12. Reassemble, making sure that the tip seals do
not fall out. Reconnect the fan connector, then
refit the fixed scroll assembly taking care to
tighten the six fixing screws progressively and
evenly.
13. Some period of running-in may be required
before optimum performance is reached.
Depending on the application, the vacuum
achieved directly following a tip seal
replacement may be sufficient for your
requirements. Typically, this can be up to a
decade more than the final vacuum achievable
with a bedded in tip seal. During run in, deposits
of tip seal dust will be produced. Ensure the
exhaust is connected to a silencer or an exhaust
line to collect tip seal deposit, refer to
Section 7.3.2 for further information. If
possible, occasional venting through the gas
ballast control or valve on the inlet is
recommended.
5.7Test the motor condition
CAUTION
Do not flash test the XDS35i or damage to the
inverter may result.
Test the earth continuity and the insulation
resistance of the pump motor, in accordance with
local regulations for the periodic testing of electrical
equipment.
We recommend that the earth continuity is less
than 0.1
than 2M
If the pump fails these tests, you must contact BOC
Edwards
5.8Fault-finding
5.8.1The pump has failed to start or has
Ω
and the insulation resistance is greater
Ω
. (Reference EN61010-1).
.
stopped
• The electrical supply fuse has blown.
• The electrical supply voltage does not match
that for which the inverter input has been
configured.
• The inverter drive has not reset after an over
temperature event. Disconnect the mains
supply and wait for at least one minute and
attempt to restart.
• The motor is faulty.
• Fan not working or not connected.
• The ambient temperature is too high.
• The cooling air supply is insufficient or is too
hot.
• The process gas is too hot or the throughput
is too high.
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XDS Dry Pump
5.8.2The pump has failed to achieve the
specified performance
• Allow 1 hour from cold for the pump to warm
up to full operating temperature. If the pump
does not achieve the performance specified in
Section 2, make sure that this is not because
of your system design before you contact
your supplier or BOC Edwards for advice. In
particular, the vapour pressure of all materials
used in your vacuum system must be lower
than the specified ultimate vacuum of the
pump. Refer to Section 5.8 for a list of
possible causes for failure to achieve the
specified performance.
• If the electrical supply voltage is more than
10% below the lowest voltage specified on the
voltage indicator, the pump may operate
yielding a degraded vacuum performance.
• There is a leak in your vacuum system.
• Your pressure measurement technique or
gauge head is unsuitable or gives an incorrect
indication of pressure.
• Your vacuum fittings are dirty or damaged.
• The inlet strainer is blocked.
• There is a blockage or high pressure in the
exhaust line.
5.8.3The pump is noisy
• The pump is contaminated with solid
particles.
• The bearings are worn.
• Following tip seal replacement, the pump has
not been vented and a build up of eroded tip
seal dust is reducing running clearances. Refer
to Section 5.6 for further information.
5.8.4The pump surface temperature is
high
• The ambient temperature is too high.
• The cooling air supply is insufficient or is too
hot.
• The process gas is too hot or the throughput
is too high.
5.8.5The pumping speed is poor or if
pump down time is too long
• The connecting pipelines are too small in
diameter.
• The connecting pipelines are too long.
• The inlet strainer is blocked.
• There is a leak in the system.
PAGE
27
MAINTENANCE
• The pump contains traces of process vapours.
• The pump is outside the specified range of
• The inverter is current limiting the supply.
• The pump is in idle mode.
operating conditions.
• The gas ballast control is not properly closed.
• The tip seals need replacing.
• The inverter is current limiting the supply.
• The pump is in idle mode.
Nov 02Issue A
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6STORAGE AND
XDS Dry Pump
DISPOSAL
6.1Storage
Use the following procedure to store the pump:
1.Shut down the pump as described in
Section 4.7.
2.Disconnect the pump from the electrical supply.
3.Place and secure protective covers over the
inlet and outlet ports.
4.Store the pump in cool, dry conditions until
required for use. When required, prepare and
install the pump as described in Section 3.
6.2Disposal
Dispose of the pump and any components from it
safely in accordance with all local and national safety
and environmental requirements.
PAGE
29
STORAGE AND DISPOSAL
If this pump is to be returned to BOC Edwards
Vacuum Technology for disposal/ investigation.
Particular care must be taken with components that
have been contaminated with dangerous process
substances.
WARNING
Do not incinerate fluoroelastomer
seals and 'O' rings.
Nov 02Issue A
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30
XDS Dry Pump
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Issue ANov 02
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XDS Dry Pump
7SERVICE, SPARES
AND ACCESSORIES
7.1Introduction
BOC Edwards products, spares and accessories are
available from BOC Edwards companies in Belgium,
Brazil, Canada, France, Germany, Hong Kong, Italy,
Japan, Korea, Switzerland, UK, USA and a worldwide network of distributors. The majority of these
centres employ Service Engineers who have
undergone comprehensive BOC Edwards training
courses. Order spare parts and accessories from
your nearest BOC Edwards company or distributor.
When you order, state for each part required:
• Model and item number of your equipment.
• Serial number (if any).
• Item number and description of part.
7.3Accessories
7.3.1Electrical cables
Refer to Table 10. The following electrical cables are
available as accessories and should be used to
connect the XDS35i to your electrical supply:
7.3.2Silencer
A silencer is available for the pump. The code
number for the silencer is A505-97-001. Refer to
Section 3.6 for guidance on its use. A silencer spares
kit, code number A505-97-801 is also available.
7.3.3Gas ballast adaptor
Fit the gas-ballast adaptor in place of the gas-ballast
control on the pump. The adaptor allows you to
connect a controlled supply of inert gas to the pump.
Gas-ballast adaptor A505-02-000.
PAGE
31
SERVICE, SPARES AND ACCESSORIES
7.2Service
BOC Edwards are supported by a worldwide
network of BOC Edwards Service Centres. Each
Service Centre offers a wide range of options
including: equipment decontamination; service
exchange; repair; rebuild and testing to factory
specifications. Equipment which has been serviced,
repaired or rebuilt is returned with a full warranty.
Your local Service Centre can also provide BOC
Edwards engineers to support on-site maintenance,
service or repair of your equipment.
For more information about service options,
contact your nearest Service Centre or other BOC
Edwards company.
Product descriptionOrdering information
Lead Assembly, 13 A, C19, UKA505-05-003
7.3.4Solenoid operated pipeline valves
Fit the pipeline valve between your vacuum system
and the pump inlet to provide additional system
protection when the pump is switched off. The
following valves are available as accessories and are
recommended. (Refer to Table 11).
7.3.5Tip seal service kit
This kit contains all the necessary components to
replace the tip seals. Tip seals should be replaced as
a pair, and only simple tools are required. The kit
part number is A730-01-805.
Lead Assembly, 16 A, C19, EuropeA505-06-003
Lead Assembly, 15 A, C19, USAA505-07-003
Lead Assembly, 20 A, C19, No PlugA505-08-003
Table 10 - Electrical cables
Nov 02Issue A
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XDS Dry Pump
Product descriptionOrdering information
PAGE
32
SERVICE, SPARES AND ACCESSORIES
PV40EK Valve, 220-240 V 50/60 Hz, AluminiumC414-01-000
PV40EK Valve, 220-240 V 50/60 Hz, SteelC414-02-000
PV40EK Valve, 110-127 V 50/60 Hz, AluminiumC414-03-000
PV40EK Valve, 110-127 V 50/60 Hz, SteelC414-04-000
Remote operation using 15 way D connector . . 16
Replace the tip seals
Nov 02Issue A
. . . . . . . . . . . . . . . . . . . . . . . 22
33
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34
XDS Dry Pump
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Issue ANov 02
34
(Form HS1)
Return of BOC Edwards Equipment - Procedure
Return of BOC Edwards Equipment - Procedure
INTRODUCTION
Before you return your equipment you must warn BOC Edwards if the substances you used (and produced) in the
equipment can be dangerous. This information is fundamental to the safety of our Service Centre employees and will
determine the procedures employed to service your equipment.
Complete the Declaration (HS2) and send it to BOC Edwards before you dispatch the equipment. It is
important to note that this declaration is for BOC Edwards internal use only, and has no relationship to local, national or
international transportation safety or environmental requirements. As the person offering the equipment for shipment, it
is your responsibility to ensure compliance with applicable laws.
GUIDELINES
Your equipment is 'uncontaminated' if it has not been used, or if it has only been used with substances that are not
dangerous/hazardous. Your equipment is 'contaminated' if it has been used with any dangerous/hazardous
substances.
If your equipment has been used with radioactive substances, you must decontaminate it before you return it to BOC
Edwards. You must send independent proof of decontamination (for example a certificate of analysis) to BOC Edwards
with the Declaration (HS2). Phone BOC Edwards for advice.
If your equipment is contaminated, you must either:
Remove all traces of contamination (to the satisfaction of the laws governing the transportation of dangerous/hazardous
substances).
Or, properly classify the hazard, mark, manifest and ship the equipment in accordance with the applicable laws governing
the shipment of contaminated/hazardous materials.
Note: Some contaminated equipment may not be suitable for shipment as airfreight.
PROCEDURE
1. Contact BOC Edwards and obtain a Return Authorisation Number for your equipment.
2. Complete the Return of BOC Edwards Equipment - Declaration (HS2).
3. If the equipment is contaminated, you must contact your transporter to ensure that you properly classify the hazard,
mark, manifest and ship the equipment, in accordance with the applicable laws governing the shipment of contaminated/
hazardous materials. As the person offering the equipment for shipment, it is your responsibility to ensure compliance
with applicable laws. Note: Equipment contaminated with some hazardous materials, such as
semiconductor by-products, may not be suitable for shipment as airfreight - contact your transporter
for advice.
4. Remove all traces of dangerous gases: pass an inert gas through the equipment and any accessories that will be returned
to BOC Edwards. Where possible, drain all fluids and lubricants from the equipment and its accessories.
5. Disconnect all accessories from the equipment.
6. Seal up all of the equipment's inlets and outlets (including those where accessories were attached) with blanking flanges
or, for uncontaminated equipment, with heavy gauge tape.
7. Seal the equipment in a thick polythene bag or sheet.
8. If the equipment is large, strap the equipment and its accessories to a wooden pallet. If the equipment is too small to
be strapped to a pallet, pack it in a suitable strong box.
9. Fax or post a copy of the Declaration (HS2) to BOC Edwards. The Declaration must arrive before the equipment.
10. Give a copy of the Declaration (HS2) to the transporter. You must tell your transporter if the
equipment is contaminated.
11. Seal the original Declaration in a suitable envelope; attach the envelope securely to the outside of the equipment
package, in a clear weatherproof bag.
WRITE YOUR RETURN AUTHORISATION NUMBER CLEARLY ON THE OUTSIDE OF THE
ENVELOPE OR ON THE OUTSIDE OF THE EQUIPMENT PACKAGE.
3,VVXH*
Return of BOC Edwards Equipment - Declaration
You must:
•Know about all
•Read the Return of BOC Edwards Equipment - Procedure (HS1) before you complete this Declaration
•Contact BOC Edwards to obtain a Return Authorisation Number and to obtain advice if you have any questions
•Send this form to BOC Edwards before you return your equipment
Equipment/System Name ___________________________
Part Number ____________________________________
Serial Number ____________________________________
Has the equipment been used, tested or operated ?
YES ❑ Go to Section 2 NO ❑ Go to Section 4
Has the equipment been exposed to substances which are:
•Radioactive (if YES, see Note 1)YES ❑NO
•Biologically activeYES ❏NO
•Dangerous to human
health and safety?YES ❑NO
of the substances which have been used and produced in the equipment before you complete this Declaration
SECTION 1: EQUIPMENT
IF APPLICABLE:
Tool Reference Number _____________________
Process _____________________________________
Failure Date _________________________________
Serial Number of
Replacement Equipment________________________
SECTION 2: SUBSTANCES IN CONTACT WITH THE EQUIPMENT
Note 1
: BOC Edwards will not accept delivery of any equipment that is
❑
❑
❑
contaminated with radioactive substances, unless you:
•Decontaminate the equipment
•Provide proof of decontamination
YOU MUST CONTACT BOC EDWARDS FOR ADVICE
BEFORE YOU RETURN SUCH EQUIPMENT
(Form HS2)
Return Authorisation Number:
SECTION 3: LIST OF SUBSTANCES IN CONTACT WITH THE EQUIPMENT
Substance nameChemical
Symbol
Precautions required (for example,
use protective gloves, etc.)
Action required after a spill,
leak or exposure
SECTION 4: RETURN INFORMATION
Reason for return and symptoms of malfunction _____________________________________________________________________________________
Telephone number: ___________________________Date of equipment delivery: ______________
I have made reasonable enquiry and I have supplied accurate information in this
Declaration. I have not withheld any information, and I have followed the Return of
BOC Edwards Equipment - Procedure (HS1).