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Microvac 149-HS
Instruction Manual
46 pgs1.86 Mb0

Edwards Microvac 149-HS, Microvac 212-J, Microvac 412-J, Microvac 149-H Instruction Manual

S149-01-880
Issue F Original
Instruction Manual
149-H/149-HS/212-J/412-J Microvac® Pumps
Description Item Number
This product has been manufactured under a quality system registered to ISO9001
Declaration of Conformity
We, Edwards, Manor Royal, Crawley, West Sussex, RH10 9LW, UK
declare under our sole responsibility, as manufacturer and person within the EU authorised to assemble the technical file, that the product(s)
900 YYYYYY 50 Z Pump Model Voltage/TCV Option
YYYYYY Z 149011 = 149-H Pump 1 = 400 V, 3 Ph, 50 Hz/380 V, 3 Ph, 50 Hz 212014 = 212-J Pump 2 = 400 V, 3 Ph, 50 Hz/415 V, 3 Ph, 50 Hz 412014 = 412-J Pump 3 = 400 V, 3 Ph, 50 Hz/380 V, 3 Ph, 50 Hz with TCV 4 = 400 V, 3 Ph, 50 Hz/415 V, 3 Ph, 50 Hz with TCV
930 14901150 Z Pump Model Voltage/TCV Option
Z 149-HR Pump 1 = 400 V, 3 Ph, 50 Hz/380 V, 3 Ph, 50 Hz 2 = 400 V, 3 Ph, 50 Hz/415 V, 3 Ph, 50 Hz 3 = 400 V, 3 Ph, 50 Hz/380 V, 3 Ph, 50 Hz with TCV 4 = 400 V, 3 Ph, 50 Hz/415 V, 3 Ph, 50 Hz with TCV
to which this declaration relates is in conformity with the following standard(s) or other normative document(s)
EN1012-2:1996, A1: 2009 Compressors and Vacuum Pumps. Safety Requirements. Vacuum Pumps EN60034-1: 2004 Rotating electrical machines. Rating and performance
and fulfils all the relevant provisions of 2006/42/EC Machinery Directive
2006/95/EC Low Voltage Directive 2004/108/EC Electromagnetic Compatibility (EMC) Directive
Note: This declaration covers all product serial numbers from the date this Declaration was
signed onwards.
Peter Meares, Technical Support Manager – Industrial & Chemical
Date and Place
P200-04-280 Issue A
9 December 2009
© Edwards Limited 2011. All rights reserved. Page i Edwards and the Edwards logo are trademarks of Edwards Limited.
Contents
S149-01-880 Issue F
Contents
Section Page
1 Introduction .......................................................................................1
1.1 Scope ...................................................................................................................... 1
1.2 ATEX directive implications ............................................................................................ 2
1.3 Description ................................................................................................................ 2
1.3.1 Gas ballast ................................................................................................................ 2
1.3.2 Water system ............................................................................................................. 2
1.3.3 Electrical system .........................................................................................................6
1.3.4 Lubricants ................................................................................................................. 6
1.3.5 Guards ..................................................................................................................... 6
1.3.6 Vacuum access ports .................................................................................................... 6
1.3.7 Oil temperature sensor/heater access ports (412-J pump only) ................................................. 6
1.3.8 Oil drain port (412-J pump only) ...................................................................................... 6
2 Technical data ....................................................................................7
2.1 Operating and storage conditions ..................................................................................... 7
2.2 Pump specifications ..................................................................................................... 7
2.3 Materials in contact with process gases .............................................................................. 8
2.4 Electrical data ............................................................................................................ 8
3 Installation .................................................... ................................... 13
3.1 Safety ..................................................................................................................... 13
3.2 System design considerations .........................................................................................14
3.3 Unpack and inspect .....................................................................................................14
3.4 Locate the pump ........................................................................................................14
3.5 Inlet piping ...............................................................................................................15
3.5.1 Vacuum access port locations ........................................................................................16
3.6 Exhaust piping ...........................................................................................................17
3.7 Electrical connections ..................................................................................................18
3.8 Cooling ...................................................................................................................20
3.9 Pump lubrication ........................................................................................................20
3.9.1 Initial oil fill .............................................................................................................21
4 Operation ........................................................................................ 23
4.1 Pre-start check ..........................................................................................................23
4.2 Pump start ...............................................................................................................23
4.3 Gas ballast operation ...................................................................................................24
4.4 Pump stop ................................................................................................................25
4.5 Operating notes .........................................................................................................25
5 Maintenance ..................................................................................... 27
5.1 Safety information ......................................................................................................27
5.2 Leak detection ..........................................................................................................27
5.3 Maintenance plan .......................................................................................................28
5.4 Oil change ................................................................................................................29
5.5 Oil level check ..........................................................................................................29
5.6 Valve deck maintenance ...............................................................................................29
5.7 Belt maintenance .......................................................................................................30
5.8 Drive belt tension .......................................................................................................30
5.9 Gas ballast check valve replacement ................................................................................30
5.10 Fitment or replacement of the motor (412J models only) .......................................................31
dcs/8822/11/11
S149-01-880 Issue F
Page ii © Edwards Limited 2011. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
Contents
5.11 Fault finding .............................................................................................................32
6 Storage and disposal ...... .... ..... ............................................................ 35
6.1 Storage ...................................................................................................................35
6.2 Disposal ...................................................................................................................35
7 Spares and accessories ......................................................................... 37
7.1 Introduction .............................................................................................................37
7.2 Service ....................................................................................................................37
7.3 Spares .....................................................................................................................37
7.4 Accessories ...............................................................................................................37
8 PFPE-prepared Microvac pumps .............................................................. 39
8.1 Summary .................................................................................................................39
8.2 Installation ............................................................................................................... 39
8.3 Operation ................................................................................................................39
8.4 Maintenance ............................................................................................................. 39
For return of equipment, complete the HS Forms at the end of this manual.
Illustrations
Figure Page
1 Theory of operation ..................................................................................................... 2
2 149-H/149-HS pump general arrangement ........................................................................... 3
3 212-J pump general arrangement ..................................................................................... 4
4 412-J pump general arrangement ..................................................................................... 5
5 149-H/149-HS pump dimensions ....................................................................................... 8
6 212-J pump dimensions .................................................................................................9
7 412-J pump dimensions ................................................................................................10
8 Pump speed curves .....................................................................................................11
9 Inlet piping configurations ............................................................................................16
10 Exhaust piping ...........................................................................................................18
11 Electrical schematic .................................................................................................... 19
12 Gas ballast setting ......................................................................................................24
13 Typical vacuum system piping ........................................................................................28
14 Collar bolt positions and motor frame sizes ........................................................................31
© Edwards Limited 2011. All rights reserved. Page iii Edwards and the Edwards logo are trademarks of Edwards Limited.
Contents
S149-01-880 Issue F
Tables
Table Page
1 General data .............................................................................................................. 7
2 Pump technical specifications ......................................................................................... 7
3 Motor specifications, IEC motors (CE pumps) ....................................................................... 9
4 Motor specifications, NEMA motors ..................................................................................10
5 Maintenance plan .......................................................................................................28
6 Belt tension ..............................................................................................................30
7 Motors the can be fitted to 412J pump models ....................................................................31
8 Fault finding guide ......................................................................................................32
Associated publications
Publication title Publication number
Vacuum pump and vacuum system safety P300-20-000
Trademark credits
Fomblin® is a registered trademark of Ausimont SpA.
This page has been intentionally left blank.
S149-01-880 Issue F
Page iv © Edwards Limited 2011. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
© Edwards Limited 2011. All rights reserved. Page 1 Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
S149-01-880 Issue F
1Introduction
1.1 Scope
This manual provides installation, operation and maintenance instructions for Model 149-H, 149-HS, 212-J and 412-J Microvac pumps (referenced as ‘Microvac pump’ throughout the remainder of the manual). The Microvac pump must be used as specified in this manual. Read this manual before installing and operating the pump.
Important safety information is highlighted as WARNING and/or CAUTION instructions which must be followed. The use of WARNINGS and/or CAUTIONS is defined below.
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 SI international system of measurement followed by imperial units in parenthesis; SI (imperial).
The following warning symbols are on the pump:
WARNING
Warnings are given where failure to observe the instruction could result in injury or death to people.
Warning - refer to accompanying documentation.
Warning - risk of electric shock.
Warning - hot surfaces. Warning - risk of explosion
Warning - use protective equipment Warning - moving parts
S149-01-880 Issue F
Page 2 © Edwards Limited 2 0 11. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
1.2 ATEX directive implications
The Microvac pump is not designed to meet European ATEX requirements.
1.3 Description
The Microvac pumps are self-contained, rotary, oil sealed piston type units. An eccentric mounted on the drive shaft drives the piston. Two free-oscillating floating hinge bars in the pump housing guide the piston slide. The piston assembly rotates clockwise when facing the drive end. Air enters the pump through the intake and passes through the piston slide as the piston performs its in take stroke. As the piston nears the top center position the intake port is closed, separating the system from the pump (see Figure 1). The air is entrapped on the front side of the piston as it begins the next stroke. As the piston continues to rotate, the entrapped air is compressed and discharged through the exhaust valves and out the reservoir exhaust outlet. The exhaust valves are a corrosion-resistant, heavy duty, poppet type.
Figure 1 - Theory of operation
When the pump is in operation, lubrication of the internal parts is completely automatic. Oil is forced by atmospheric pressure from the reservoir thro ugh int er nal oil pa ssa ge s to the shaft bearings. The oil is then fed into the pump to provide the necessary piston-to-cylinder oil seal. The oil in the pumping chamber is forced out throu gh the exha ust valves with the compressed air and returns to the reservoir. A solenoid valve prevents oil from flooding the pump in the event of a power failure or when the pump is shutdown without vacuum being broken.
The pump general arrangements are provided in Figures 2 through 4.
1.3.1 Gas ballast
To pump high vapor loads, gas ballast is delivered into the pump to prevent condensation of the vapor carried by the pump gases.
Air can be introduced to the low vacuum stage. Alternatively, an inert gas such as nitrogen can be supplied through a suitable external valve.
1.3.2 Water system
A cooling water supply rated at 30 °C (85 °F) and 3.8 LPM (1 GPM) for the 149-H/149-HS, 5.7 LPM (1.5 GPM) for the 212-J, and 7.6 LPM (2 GPM) for the 412-J maximum is required for efficient pump performance. Internal pump water pressure should not exceed 35 psig (Refer to Section 3.8 for information).
WARNING
Cooling lines must be installed as to not create a trip hazard which can result in injury to personnel.
© Edwards Limited 2011. All rights reserved. Page 3 Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
S149-01-880 Issue F
Figure 2 - 149-H/149-HS pump general arrangement
1. Check valve
2. Ball valve, gas ballast
3. Oil level sight glass
4. System lift eye-bolt
5. Water outlet conne ction
6. Water inlet connection
7. 1/4 inch vacuum access port
8. Motor lift eye-bolt
9. Motor
10.Oil fill port
11.Vacuum inlet connection
12.1/2 inch vacuum access port
13.Oil drain valve
14.Oil flow indicator
15.Vacuum exhaust connection
16.Belt guard
17.Solenoid valve
S149-01-880 Issue F
Page 4 © Edwards Limited 2 0 11. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
Figure 3 - 212-J pump general arrangement
1. Oil flow indicator
2. Solenoid valve
3. Vacuum exhaust connection
4. Water inlet connection
5. Gas ballast purge connection
6. Gas ballast adjustment
7. 1/4 inch vacuum access port
8. Belt guard
9. Motor lift eye-bolt
10.Vacuum inlet connection
11.1/2 inch vacuum access port
12.Water outlet connection
13.Oil level sight glass
14.Oil fill port
15.Motor
16.System lift eye-bolt
17.Reservoir cover
18.Oil drain valve
© Edwards Limited 2011. All rights reserved. Page 5 Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
S149-01-880 Issue F
Figure 4 - 412-J pump general arrangement
1. Oil level sight glass
2. System lift eye-bolt
3. Motor lift eye-bolt
4. Reservoir cover
5. Oil flow indicator
6. 1/2 inch vacuum access port
7. Oil drain port, dead end
8. Vacuum exhaust connection
9. Motor
10.Oil fill port/pressure relief
11.Water outlet connection
12.Solenoid valve
13.Oil temperature sensor port
14.Oil temperature heater port
15.Oil drain valve
16.Water inlet connection
17.Gas ballast purge connection
18.Gas ballast adjustment
19.1/4 inch vacuum access port
20.Belt guard
21.Vacuum inlet connection
S149-01-880 Issue F
Page 6 © Edwards Limited 2 0 11. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
Introduction
1.3.3 Electrical system
The main power supply is 400 VAC/3 Ph/ 50 Hz and should be wire d through a suitable fused motor starter. Power for the oil solenoid is taken from any two motor leads. Check both motor and solenoid na meplates to insure prop er voltage (Refer to Section 3.7 for information).
1.3.4 Lubricants
Refer to Section 2 for recommended pump fluids.
1.3.5 Guards
The motor pulley, pump pulley, belts and flywheel are enclosed by guards to prevent accidental contact with these parts. The pump should never be operated with guards removed.
1.3.6 Vacuum access ports
CAUTION
When connecting a gauge to one of the ports, it is necessary to provide a 90° elbow and a minimum of 305 mm (12 inches) of vertical pipe to the gauge sensor to reduce the chance of contaminating the gauge with pump lubricants.
The pump is provided with 1/4 inch and 1/2 inch NPT vacuum access ports. These ports are provided for customer convenience. The ports can be used for gauges to monitor the pump performance or access for introducing purge gases to the pump.
1.3.7 Oil temperature sensor/heater access ports (412-J pump only)
Oil temperature sensor/heater ports have been added to the 412-J pump to provide a means to monitor and heat the pump oil. The sensor monitors the oil temperature in the pump and can be used a s an indicator for service. The heater can be used to heat the oil if it is below minimum starting temperature to reduce the amount of condensables in the oil (Refer to Figure 4 Items 13 and 14).
1.3.8 Oil drain port (412-J pump only)
A 1/4 inch oil drain access port has been added to provide a means of removing oil that pools above the valve decks (Refer to Figure 4 Item 7).
WARNING
Electrical lines must be installed as to not create a trip hazard which can result in injury to personnel.
© Edwards Limited 2011. All rights reserved. Page 7 Edwards and the Edwards logo are trademarks of Edwards Limited.
Technical data
S149-01-880 Issue F
2Technical data
2.1 Operating and storage conditions
2.2 Pump specifications
Technical specifications for Microvac pumps are provided in Table 2. Pump dimensions are shown in Figures 6, 7 and 8.
Table 1 - General data
General items Reference data
Ambient temperature range (operation) 12 to 40 °C (54 to 104 °F) Normal surface temperature of the pump body at ultimate vacuum
(operation), ambient temperature of 20 °C (68 °F)
50 to 70 °C (122 to 158 °F)
Maximum humidity (operation) 90 % RH Ambient temperature range (storage) -30 to 70 °C (-22 to 158 °F)
Table 2 - Pump technical specifications
Specification Unit 149-H 149-HS 212-J 412-J
Ultimate vacuum microns Hg < 25 < 25 < 25 < 25 Displacement cfm 80 100 150 300
m
3h-1
135 170 255 510
Pump speed rpm 490 612 500 490
Vacuum inlet inch 2 ANSI 2 ANSI 3 ANSI 4 ANSI Vacuum exhaust inch 1-1/2 NPT 1-1/2 NPT 2 NPT/FLG 3 NPT/FLG
Pipe connections
Water inlet inch 1/2 NPT 1/2 NPT 1/2 NPT 1/2 NPT
mm 13 13 13 13
Water outlet inch 1/2 NPT 1/2 NPT 1/2 NPT 1/2 NPT
mm 13 13 13 13
Oil capacity gal 2-1/2 2-1/2 4 12
liters 10 10 15 46
Weight
Net lb 686 686 950 1875
kg 311 311 431 850
Shipping lb 800 800 1075 1975
kg 363 363 488 896
Height inch 39-3/4 39-3/4 46 55
mm 1009 1009 1171 1395
Floor space inch 23-1/2 x 20-1/8 23-1/2 x 20-1/8 26-1/4 x 24 40-1/4 x 25-5/8
mm 597 x 511 597 x 511 667 x 610 1022 x 651
Cooling water consumption (maximum)
gpm 1 1 1.5 2
lpm 3.8 3.8 5.7 7.6
S149-01-880 Issue F
Page 8 © Edwards Limited 2 0 11. All rights reserved.
Edwards and the Edwards logo are trademarks of Edwards Limited.
Technical data
2.3 Materials in contact with process gases
The following material will come in contact with process gases. A safety review should be performed considering the effect of process gases on the following materials: Aluminum; Buna N; Brass; Cast Iron; Ductile Iron; Fluoroelastomer; Steel; Stainless Steel; Hydrocarbon Oil, and; Atmosphere.
2.4 Electrical data
The motor specifications are provided in Table 2 and Table 3. Motor speed curves are provided in Figure 6. Items ending with 501 or 503 utilize a 380 VAC, 50 Hz solenoid. Items ending with 502 or 504 utilize a 415 VAC, 5 0 Hz
solenoid.
Figure 5 - 149-H/149-HS pump dimensions
Inlet cooling water temperature (maximum)
°F 85 85 85 85 °C 30 30 30 30
Table 2 - Pump technical specifications (continued)
Specification Unit 149-H 149-HS 212-J 412-J
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