LEYBOLD ScrewLine SP250 User manual

P/N

115 001

115 003 ATEX 3i

115 006

SCREWLINE SP 250

Dry Compressing Screw Vacuum Pump

Operating Instructions GA02412_002_C0

Contents

GA02412_002_C0 - 10/2016 - © Leybold

Page

0 Important Safety Information 5

Explanation of Warning Symbols 5

0.1 Mechanical Hazards 7

0.2 Electrical Hazards 8

0.3 Thermal Hazards 9

0.4 Hazards Caused by Materials and Substances 9

0.5 Ignition Risk 11

0.6 Noise Hazard 11

0.7 Risk of Pump Damage 12

SP 250 ATEX Category 3i (inside) Vacuum Pump 14

Classification and Marking of the Pump 14

Areas of Application 15

Safety Measures 18

1 Description 20

1.1 Design and Function 20

1.2 Technical Data 23

1.2.1 Technical Data of the SP-Guard Monitoring System 24

1.2.2 Technical Data of the Solenoid Gas Ballast Valve 24

1.2.3 Technical Data of the Purge Gas Facility 25

1.3 Supplied Equipment 27

1.4 Built-in Accessories 28

1.5 Accessories 30

1.6 Wearing Parts and Original Spare Parts 30

2 Transport and Storing 31

2.1 Pumps with Castors 32

2.2 Storing the Pump 32

3 Installation 33

3.1 Placement 33

3.1.1 Floor 33

3.1.2 Air Cooling and Pump Covers 33

3.1.3 Ambient Conditions 34

3.2 Conforming Utilisation 34

3.3 Connection to the System 35

3.3.1 Connections at the Intake Side 36

3.3.2 Connections at the Delivery Side (Exhaust 36

3.4 Electrical Connection 37

3.4.1 Motor Protection 37

3.4.2 Star/Delta Start-up Circuit 38

3.4.3 Soft Start 38

3.4.4 Mains Connection 38

3.4.5 Power Failure 42

3.4.6 Operation with a Frequency Converter (FC Operation) 42

Contents

GA02412_002_C0 - 10/2016 - © Leybold

These Operating Instructions are the original instructions.

3.5 Oil Temperature Sensor Pt 100 43

3.6 Connecting the SP-Guard 45

3.7 Retrofitting the Manual Gas Ballast with a 24 V DC Valve 48

3.7.1 Connecting the Electro-pneumatic Gas Ballast Valve 49

3.8 Connecting the Purge Gas Valve 50

4 Operation 51

4.1 Start-up 51

4.1.1 Oil Filling for the Gear 51

4.1.2 Switching the Pump On 53

4.2 Operation 54

4.2.1 Operation with SP-Guard 54

4.2.2 Gas Ballast Operation 55

4.2.3 Purge Gas Operation 56

4.2.4 Regular Checks 57

4.3 Switching Off/Shutting Down 58

5 Maintenance 59

5.1 Checking the Oil Level 60

5.1.1 Oil Change and Oil Filter Change 60

5.2 Cleaning the Oil Cooler 62

5.3 Draining Out Condensate 63

5.4 Cleaning the Dust Filter in the Intake Line 63

5.5 Checking and Cleaning the Gas Ballast Filter 64

5.6 Replacing the Throttle in the Purge Gas Device 64

5.7 Service at Leybold 66

5.8 Maintenance Schedule 67

6 Troubleshooting 68

7 Waste Disposal 71

EC Declaration of Conformity 72

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

Obligation to Provide Information

Before installing and commissioning the pump, carefully read these

Operating Instructions and follow the information so as to ensure optimum

and safe working right from the start.

The Leybold SCREWLINE SP 250 have been designed for safe and efficient

operation when used properly and in accordance with these Operating

Instructions. It is the responsibility of the user to carefully read and strictly

observe all safety precautions described in this Section and throughout the

Operating Instructions. The pump must only be operated in the proper

condition and under the conditions described in the Operating

Instructions. It must be operated and maintained by trained personnel only.

Also consult local, state, and national agencies regarding specific require-

ments and regulations. Address any further safety, operation and/or mainte-

nance questions to our nearest office.

DANGER indicates an imminently hazardous situation which, if not avoid-

ed, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury.

NOTICE is used to notify users of installation, operation, programming or

maintenance information that is important, but not hazard related.

We reserve the right to alter the design or any data given in these Operating

Instructions. The illustrations are not binding.

Retain the Operating Instructions for further use.

In order to avoid the destruction of systems and injury to operating personnel

we urgently recommend to observe the information and installation informa-

tion provided in these Operating Instructions.

NOTICE

DANGER

WARNING

CAUTION

NOTICE

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

0 Important Safety Information

Explanation of Warning Symbols

Hazardous voltage

Disconnect power before opening.

Contact causes electrical shock.

Hot surface

Do not touch.

Allow this area to cool before servicing

Burn hazard

Hot surface inside. Do not touch.

Wear protective equipment.

Reactive or corrosive media

Reactive or corrosive gases may cause health problems .

When the pump has been used to pump reactive or corrosive gases

before, introduce corresponding safety precautions before opening it,

e.g. wear gloves, breathing protection or protection clothing

Toxic gases

must not be pumped with this pump.

Danger of explosion

Explosive gases and vapours

must not be pumped with this pump.

Fire danger

Combustible gases and vapours,

gas mixtures with an oxygen share exceeding 21% and

pyrophorous (self-igniting) substances

must not be pumped with this pump.

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

Purge gas

Check compatibility with applications.

Overpressure in the discharge line

Components can be thrown in all directions.

The pressure in the discharge line must not exceed atmospheric

pressure by 200 mbar max.

The discharge line must not be blocked or restricted

Pumps with wheels

must only be placed and moved on levelled horizontal surfaces!

Rotating parts

When operating the pump with open intake port, there is the risk of

suffering injury by rotating parts.

Never operate the pump with open intake port or fan cover, except

from checking the direction of rotation.

Vacuum

Avoid exposing any part of the human body to the vacuum.

Machinery starts automatically

Connect the pump so that it not will restart automatically after a mains

power failure, once the power returns.

Overhead load

Transport the pump only at the two crane eyes or with a forklift

secured on a suitable palette.

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

0.1 Mechanical Hazards

1 When operated with an open intake flange, there exists a risk of suffer-

ing injury by rotating parts. Do not operate the pump with an open

intake flange or fan cover except when checking the direction of rota-

tion.

2 Avoid exposing any part of the human body to the vacuum.

3 The pump is intended for generating a vacuum only. If an overpressure

can occur in the system then the pump must be protected against

such an overpressure by an overpressure safety valve, for example.

4 We recommend to always operate the pump with a silencer or a con-

nected discharge line. The pressure in the discharge line must not

exceed atmospheric pressure by 200 mbar max.

Make sure that the gas flow at the discharge is not blocked or restrict-

ed in any way, even when the pumped out gases need to be collected

or contained.

The discharge line must not be blocked or restricted. Before commis-

sioning the pump, open all shutoff devices or valves in the discharge

line.

In the case of processes involving much condensate, we recommend

the installation of a condensate separator in the discharge line.

5 Select the location where the pump is installed so that all controls can

be easily accessed. Deposit the pump only on a floor which is level. It

can topple when it is tilted by more than 10° with respect to the verti-

cal axis. When the pump is filled with oil an angle exceeding 2° is not

permissible.

For pumps on castors only

Because of the fitted castors, the pump must only be placed on a level

floor capable of supporting the pump’s weight, as otherwise there

exists the risk of the pump rolling away. Moreover, the pump may only

be moved on a level floor! Moving the pump along sloping paths or

ramps is prohibited! The pump must only be transported with a forklift

or a crane! At the installation location, secure against rolling away.

6 For transporting the pump use only approved transport means. When

selecting the lifting and transport means take note of the total weight

before transporting the pump. As standard, the pump has been

equipped with two crane eyes. When transporting the pump with a

forklift or alike, ensure that the pump has been secured on the

supplied or a suitable palette.

The crane eyes of the screw pump must never be used to lift any

pump combinations (Roots pump + backing pump).

CAUTION

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

7 Before beginning with any maintenance and servicing work always

ensure that no gas can flow backwards through the pump since then

the rotors might turn against the normal direction of rotation. For this

reason vent the vacuum chamber to the exhaust pressure level or

ensure through suitable valves that the vacuum chamber and the lines

are reliably separated from the pump. When connecting several pump

systems, pressure differences between inlet and discharge can give

rise to uncontrolled turning of the pump’s shafts.

8 Lay the electric feed lines so that there is no risk of tripping over these.

9 The warning information on the pump must not be covered.

10 When changing the oil remove any escaped oil as otherwise there is

the risk of slipping.

0.2 Electrical Hazards

1 The electrical connection must only be provided by a trained person.

Please observe the national regulations in the country of use like

EN50110-1 for Europe, for example.

2 Lay the connecting lines so that they cannot be damaged. Protect the

lines against humidity and contact with water. Avoid thermally stressing

the lines due to unfavourable laying.

3 Note the information on the type of protection.

4 The pump must only be operated at the frequency specified for the

motor even when operated off a frequency converter.

When using frequency converters you must ensure an effective protec-

tion against overspeeding.

5 Always operate the pump with a properly connected protective earth

conductor.

6 The pump must be integrated within the system controller such that

the pump can not run up automatically when the pump has been shut

down before due to an overloaded motor.

This equally applies to any emergency shutdowns. After having

removed the fault cause, the pump must be switched on manually

again.

7 Before starting with any maintenance or servicing work reliably discon-

nect the pump from all sources of power (lockout/tagout).

8 High electric voltages! When touching parts at high electric voltages,

there is the risk of suffering severe injuries by an electric shock! Covers

marked with this symbol must only be opened by trained electricians

after having reliably deenergised (lockout/tagout) the equipment.

9 Observe the manufacturer’s information and the Operating Instructions

for the respective frequency converter.

10 After having connected the motor and each time after having made

changes to the wiring, check the direction of rotation. If the direction of

rotation is wrong, the pressure can increase on the intake side.

Moreover, the pump can suffer severe damage.

DANGER

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

0.3 Thermal Hazards

1 With the pump warm from operation, the housing and oil temperature

may exceed 70 °C. Protect hot parts against being touched. Let pump

and oil cool down. Always wear protective gloves and protective gog-

gles, also for protection against aggressive residues in the oil.

2 Handle the pump only while vented and after having let it cool down.

3 Take note of the warning information on the housing surface. If this

warning information was removed, covered or obstructed, then pro-

vide corresponding additional warning information.

4 Never open the oil fill or oil drain plugs while the pump is running.

There is the risk of suffering burns.

0.4 Hazards Caused by Materials and Substances

1 The pump is not suited for pumping of:

■combustible and explosive gases and vapours (except within the

permissible scope for pumps certified in accordance with ATEX

Category 3 inside)

■radioactive and toxic substances

■gas mixtures with an oxygen share exceeding 21%

■pyrophorous (self-igniting) substances.

Moreover, the pumps are not suited for placement and operation

within explosion hazard areas.

Please consult us first when planning such an application.

2 Before commissioning the pump, make sure that the media which are

to be pumped are compatible with each other so as to avoid hazar-

dous situations. All relevant safety standards and regulations must be

observed.

3 Before operating the pump with a gas ballast or a purge gas (option)

check the compatibility of the gas with the pumped media so as to

avoid dangerous conditions during operation.

4 Pump with installed purge gas unit:

When operating the pump with a purge gas valve, secure the purge

gas supply so that in the event of a malfunction no overpressure can

occur in the system.

5 When nitrogen is used as the purge gas or as the gas ballast, small

quantities of nitrogen can escape to the surroundings. Ensure sufficient

ventilation for the room in which to pump has been installed.

6 The vacuum line must be leaktight. Reactive or corrosive process

gases may escape or the pumped gases can react with air or atmos-

pheric humidity. After installation of the pump and after servicing work

on the vacuum, a leak search will always be necessary.

Please note the special information on the pump’s shaft seal given in

the following.

CAUTION

DANGER

Safety Information

GA02412_002_C0 - 10/2016 - © Leybold

7 Shaft seal of the pump

Shaft seals are present only on the discharge side of the pump’s

rotors. The two shaft seals are non-contacting owing to a combination

of piston ring and labyrinth seals, but are not hermetically tight. The

seal in the direction of the atmospheric side and in the direction of the

gear chamber is vented.

In the case of a low pressure in the discharge line there is the risk of

adding small quantities of air via the shaft seal to the process gas.

When the discharge pressure on the process gas side exceeds atmos-

pheric pressure, small quantities of processed gas can escape into the

gear housing and also to the outside.

In order to prevent any process gas from escaping from the pump

chamber, use purge gas for the shaft seal. The purge gas will reliably

prevent any leaks between the gas chamber and the surroundings

provided the correct quantity of purge gas is used within the specified

limits.

Please consult us first when planning such an application.

8 When the pump has been used to pump harmful media before, intro-

duce corresponding safety precautions before opening the intake or

the discharge connections. Before opening the pump, purge it for a

longer period of time with an inert gas. If necessary, wear gloves,

breathing protection or protection clothing and work under a fume

hood. Firmly seal off the pump. When shipping the decontaminated

pump for servicing please also indicate the type of hazard. For this see

Section 5.7 Service at Leybold.

When shipping contaminated pumps which require approval by the

authorities, note the applicable regulations regarding packaging and

shipping.

9 In special cases the composition of these substances may be relevant

to safety. In these cases, the user must carefully review the effect of

these substances and introduce suitable personnel protection meas-

ures.

You must also expect the gas to have a different composition at the

inlet compared to the discharge. This must be included in the assess-

ment of potential hazards.

10 In case of a malfunctioning pump, in particular because of a blocked

discharge line or seized rotors due to hard deposits or foreign objects,

the possibility of leaks in the casing cannot be ruled out. When pump-

ing harmful gases, the operator must ensure that such a malfunction

cannot occur, respectively that leaks at the pump will not be a hazard.

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