Edition: 1.12.2011 · BA 200-EN
Original Operating Instructions
R-VWP
RR-VWP 500 | 1000 | 1500 | 2500
R-Serie
R-Series
Wälzkolben
Rotary Lobe
Table of contents
Table of contents
1 |
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1.1 |
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1.2 |
Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1.3 |
Supplier documentation and accompanying documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
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1.4 |
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1.5 |
Directives, standards, laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
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1.6 |
Symbols and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
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1.7 |
Technical terms and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
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1.8 |
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Safety . |
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6 |
2.1 |
Warning instruction markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
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2.2 |
General. . |
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2.3 |
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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2.4 |
Unacceptable operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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2.5 |
Personal qualifications and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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2.6 |
Safety-conscious work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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2.7 |
Safety notes for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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2.8 |
Safety instructions for installing, commissioning and maintenance . . . . . . . . . . . . . . . . . . . . . . |
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2.9 |
Guarantee conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3 |
Transport, storage and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3.1 |
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3.1.1 |
Unpack and check the delivery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3.1.2 |
Lifting and transporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3.2 |
Storage. . |
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3.2.1 |
Ambient conditions for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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3.3 |
Disposal . |
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4 |
Set up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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4.1 |
Setup . . . |
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4.1.1 |
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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4.2 |
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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4.3 |
Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5 |
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.1 |
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
16 |
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5.2 |
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.2.1 |
Connection positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.3 |
Connecting pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.4 |
Sealing gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.5 |
Gauge connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.6 |
Filling with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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5.7 |
Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Table of contents
6 |
Commissioning and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
20 |
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6.1 |
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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6.1.1 |
Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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6.2 |
Decommissioning/ storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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6.3 |
Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
21 |
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7 |
Maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
22 |
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7.1 |
Ensuring operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
22 |
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7.2 |
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
22 |
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7.2.1 |
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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7.2.2 |
Air filtering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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7.2.3 |
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
26 |
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7.2.4 |
Changing of the shaft sealing rings and the shaft wearing sleeve . . . . . . . . . . . . . . . . |
28 |
7.3 |
Repair/ Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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7.4 |
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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8 |
Malfunctions: Causes and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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9 |
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Foreword
1Foreword
1.1Principles
These operating instructions:
• are a part of the following contact free running rotary lobe vacuum pumps, models R-VWP 500, R-VWP 1000, R-VWP 1500 and R-VWP 2500.
• describe how to use them safely and properly in all life phases.
• must be available where the equipment is used.
1.2Target group
The target group for these instructions is technically trained specialists.
1.3Supplier documentation and accompanying documents
Document |
Contents |
No. |
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Operating Instructions |
BA 200-EN |
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Supplier documentation |
Declaration of Conformity |
C 0050-EN |
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Declaration of harmlessness |
7.7025.003.17 |
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Spare parts‘ list |
Spare parts document |
E 199 / E 200 |
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E 201 |
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Data sheet |
Technical data and graphs |
D 200 / D 201 |
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Info sheet |
Storage guidelines for machines |
I 150 |
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Manufacturer’s declaration |
EU Directive 2002/95/EG (RoHS) |
— |
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1.4Abbreviations
Fig. |
Figure |
R-VWP |
vacuum pump |
m3/h |
pumping capacity |
1.5Directives, standards, laws
See Conformity Declaration
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Foreword
1.6Symbols and meaning
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Explanation |
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Condition, pre-requisite |
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Instructions, action |
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a), b),... |
Instructions in several steps |
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Results |
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[-> 14] |
Cross reference with page number |
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Information, note |
Safety symbol
Warns of potential risk of injury
Obey all the safety instructions with this symbol in order to avoid injury and death.
1.7Technical terms and meaning
Term |
Explanation |
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Machine |
Pump and motor combination ready to be connected |
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Motor |
Pump drive motor |
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Vacuum pump |
Machine to create a vacuum |
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Rotary lobe |
Machine‘s design or active principle |
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Pumping capacity |
Vacuum pump volume flow related to the condition in the suction con- |
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Compression ratio |
The compression ratio specifies the proportion between the intake pres- |
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sure and the pre-vacuum. |
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Noise emission |
The noise emitted at a specific loading given as a figure, sound pressure |
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level dB(A) as per EN ISO 3744. |
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1.8 Copyright |
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Passing on or copying this document, using and |
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providing information on its contents are prohibited |
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unless expressly permitted. Contraventions will lead |
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to claims for damages. |
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Safety
2Safety
The manufacturer is not responsible for damage if you do not follow all of this documentation.
2.1Warning instruction markings
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Warning |
Danger level |
Consequences if not obeyed |
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DANGER |
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immediately imminent danger |
Death, severe bodily injury |
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WARNING |
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possible imminent danger |
Death, severe bodily injury |
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CAUTION |
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possible hazardous situation |
Slight bodily injury |
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NOTICE |
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possible hazardous situation |
Material damage |
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2.2 General
These operating instructions contain basic instructions for installation, commissioning, maintenance and inspection work which must be obeyed to ensure the safe operation of the machine and prevent physical and material damage.
The safety instructions in all sections must be taken into consideration.
The operating instructions must be read by the responsible technical personnel/ operator before installing and commissioning and must be fully understood. The contents of the operating instructions must always be available on site for the technical personnel / operator. Instructions fixed directly onto the machine must be obeyed and must always remain legible. This applies for example to:
• Symbols for connections
• Data and motor data plate
• Instruction and warning plates
The operator is responsible for observing local regulations.
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Safety
2.3Designated use
The machine must only be operated in such areas as are described in the operating instructions:
• only operate the machine in a technically perfect condition
• do not operate the machine when it is only partially assembled
• the machine must only be operated at an ambient temperature and suction temperature of between 5 and 40°C. Please contact us for temperatures outside this range.
• Rotary lobe pumps are used, normally, in combination with backing pumps.
• the machine may convey, compress or extract the following media:
• all non-explosive, non-inflammable, non-ag- gressive and non-poisonous dry gases and gas air mixtures
• also to feed in extremely damp gases. The water vapour compatibility is very high.
2.4Unacceptable operating modes
• extracting, conveying and compressing explosive, inflammable, aggressive or poisonous media, e.g. dust as per ATEX zone 20-22, solvents as well as gaseous oxygen and other oxidants, water vapour, liquids or solid materials
• using the machine in non-commercial plants if the necessary precautions and protective measures have not been taken in the plant
• installing in environments that are at risk of explosions
• using the machine in areas with ionising radiation
• modifications to the machine and accessories
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Safety
2.5Personal qualifications and training
• Ensure that people entrusted with working on the machine have read and understood these operating instructions before starting work, particularly the safety instructions for installation, commissioning, maintenance and inspection work.
• Manage the responsibilities, competence and monitoring of staff
• all work must only be carried out be technical specialists:
• Installation, commissioning, maintenance and inspection work
• Working with electricity
• personnel being trained to work on the machine must be supervised by technical specialists only
2.6Safety-conscious work
The following safety regulations apply in addition to the safety instructions and intended use listed in these instructions:
• Accident prevention regulations, safety and operating regulations
• the standards and laws in force
2.7Safety notes for the operator
• hot parts of the machine must not be accessible during operation or must be fitted with a guard
• People must not be endangered by the free extraction or discharge of pumped media
• Risks arising from electrical energy must be eliminated.
• The machine must not be in touch with inflammable substances.
Danger of fire by hot surfaces, discharge of pumped media or cooling air
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Safety
2.8Safety instructions for installing, commissioning and maintenance
•The operator will ensure that any installation, commissioning and maintenance work is carried out by authorised, qualified specialists who have gained sufficient information by an in-depth study of the operating instructions.
•Only work on the machine when it is idle and cannot be switched on again
•Ensure that you follow the procedure for decommissioning the machine described in the operating instructions.
•Fit or start up safety and protective devices again immediately after finishing work.
•Conversion work or modifications to the machine are only permissible with the manufacturer’s consent.
•Only use original parts or parts approved by the manufacturer. The use of other parts may invalidate liability for any consequences arising.
•Keep unauthorised people away from the machine
2.9Guarantee conditions
The manufacturer’s guarantee or warranty will no longer apply in the following cases:
• Improper use
• Not complying with these instructions
• Operation by insufficiently qualified staff
• Using spare parts that have not been approved by Gardner Denver Schopfheim GmbH
• Unauthorised modifications to the machine or the accessories supplied by Gardner Denver Schopfheim GmbH
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Transport, storage and disposal
3Transport, storage and disposal
3.1Transportation
3.1.1 Unpack and check the delivery condition
3.1.2 Lifting and transporting
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2 |
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1 |
Fig. 1 Lifting and transporting
1Threaded hole
2Eyebolt
a)Unpack the machine on receipt and check for transport damage.
b)Notify the manufacturer of transport damage immediately
c)Dispose of the packaging in accordance with the local regulations in force.
WARNING
Death or limbs crushed as a result of the items being transported falling or tipping over.
When transporting with the lifting device remember:
a)Select the lifting device suitable for the total weight to be transported.
b)Ensure that the machine cannot tip and fall.
c)Do not stop under a suspended load.
d)Put the goods to be conveyed on a horizontal base.
Lifting device/ Transporting with a crane
WARNING
Bodily injury resulting from improper operation
a)Loads crosswise to the ring level are not permitted.
b)Avoid impact stress.
a)Screw two eyebolts into the threaded holes (Fig. 1/1):
M 10 VWP 500
M 12 VWP 1000 / 1500 M 20 VWP 2500
b)Tighten the eyebolts (Fig. 1/2) firmly.
c)The machine must be suspended on the eyebolts using the lifting device for lifting and transporting.
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Transport, storage and disposal
3.2 |
Storage |
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NOTICE |
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Material damage caused by improper storage. |
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Ensure that the storage area meets the following |
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conditions: |
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a) |
dust free |
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b) |
vibration free |
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3.2.1 |
Ambient conditions for storage |
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Ambient conditions |
Value |
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Relative humidity |
0% to 80% |
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Lagertemperatur |
-10°C to +60°C |
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The machine must be stored in a dry environment with normal air humidity. It should not be stored for more than 6 months.
see Info “Machine storage guidelines”, Page 4
3.3Disposal
WARNING
Danger from inflammable, corrosive or poisonous substances.
Machines that come into contact with hazardous substances must be decontaminated before disposal.
When disposing ensure the following:
a) Collect oils and grease separately and dispose of in accordance with the local regulations in force.
b) Do not mix solvents, limescale removers and paint residues
c) Remove components and dispose of them in accordance with the local regulations in force.
d) Dispose of the machine in accordance with the national and local regulations in force.
e) Parts subject to wear and tear (marked as such in the spare parts list) are special waste and must be disposed of in accordance with the national and local waste laws.
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Set up and operation
4Set up and operation
4.1Setup
O G1 |
Q |
A |
Q H2 |
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B |
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S |
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B |
S |
K2 |
I2 |
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N M |
U |
H1 |
G |
O |
P1 |
P |
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Q |
U |
K1 I1 |
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Fig. 2 |
Rotary lobe vacuum pump R-VWP 500 / R-VWP 1000 / R-VWP 1500 |
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A |
High-vacuum connection |
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M |
Oil recommendation plate |
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B |
Pre-Vacuum connection |
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N |
Data plate |
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E |
Cooling air inlet |
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O |
Rotation direction plate |
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F |
Cooling air outlet |
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P |
Drive motor |
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G |
Sealing oil pot |
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P1 |
Motor data plate |
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G1 |
Ventilation screw |
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Q |
hot surfaces > 70S°C |
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H1, H2 Oil filling point |
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S |
Sealing gas connection |
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I1, I2 |
Oil sight glass |
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U |
Gauge connection |
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K1, K2 Oil discharge point |
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12 |
| www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH |
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