quarta-feira, 6 de junho de 2018

Bomba de vácuo : Manutenção Corretiva, Preventiva e Assessoria Técnica em Manutenção

Part Numbers 960 700 to 960 703 960 706 to 960 708 960 711 to 960 713 960 716 to 960 718
1 Description 1.1 Design and function The SOGEVAC SV300 B are single- stage, oil-sealed rotary vane pumps. The antisuckback valve, gas ballast valve (optional), exhaust filter, oil return circuit and oil cooling oil are integrated functional elements. The pumps are driven by a directly flanged motor. The rotor mounted eccentrically in the pump cylinder has three vanes which divide the pump chamber into several compartments. The volume of each changes periodically with the rotation of the rotor. As the rotor rotates, the intake portion of the pumping chamber expands and sucks gas thru the intake port. The gas passes through the dirt trap and the open anti-suckback valve and enters the pump chamber. As the rotor rotates further, the vane separates part of the pump chamber from the intake port. This part of the pump chamber is reduced, and the gas is compressed. At slightly above atmospheric pressure the gas is expelled from the chamber via the exhaust valve. Oil injected into the pump chamber serves to seal, lubricate and cool the pump. The oil entrained with the compressed gas is coarsely trapped in the oil case by deflection. Then fine filtering occurs in the exhaust filter elements. The proportion of oil in the exhaust gas is thus reduced below the visibility threshold (over 99 % entrapment rate). Oil trapped in the exhaust filters is returned to the inlet chamber via an oil return transfer. To prevent gas flowing at atmospheric pressure from the oil reservoir into the intake port, the oil return line is controlled by a float valve. The oil cycle is maintained by the pressure difference existing between the oil case (pressure above or equal to atmospheric pressure) and the intake port (pressure below atmospheric pressure).The ball bearings are greased for 30 000 hours. A fan running on the pump shaft generates the necessary cooling air. The oil cools down through a radiator. By opening the gas ballast valve, a controlled amount of air so called «gas ballast» - is admitted into the pump chamber. This gas ballast prevents condensation (up to the limit of water vapor tolerance specified in the Technical Data) when pumping condensable gases or vapors. There are different types of gas ballast : - small gas ballast ( 4 m3/h) - standard gas ballast ( 7.5 m3/h) - large gas ballast ( 18 m3/h) - gas ballast with electromagnetical valve ( 7.5 m3/h) - See § 2.5.2 On pumps supplied without gas ballast valve, the valve can be retrofitted. The gas ballast flows are indicative and valid at ultimate pressure. Description 4 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum Descrip 1) according to DIN28400 and following numbers, with standard gas ballast 2) operated at ultimate pressure without gas ballast, free-field measurements at a distance of 1m 3) please contact Oerlikon Leybold Vacuum 4) CEI : 460V / NEMA : 200-230/460 V Ordering data Ref. No. SV300 B Pump with three-phase motor CEI w/o gas ballast 230 V/400 V, 50Hz 460 V, 60Hz 960 700 Pump with three-phase motor CEI and integrated gas ballast valve 230 V/400 V, 50Hz 460 V, 60Hz 960 702 Pump with three-phase motor NEMA 208V +/-10% and 230/460 +/-10%, 60Hz 400V +/-10% 50Hz 960 707 Pump with three-phase motor JIS and integrated gas ballast valve 200V +10% -15%, 50/60Hz 960 712 Description 6 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 50Hz 60Hz Nominal speed 1) m3.h-1 280 340 Pumping speed 1) m3.h-1 240 290 Ultimate partial pressure without gas ballast mbar ≤ 8.10-2 ≤ 8.10-2 Ultimate total pressure with gas ballast mbar ≤ 0,7 ≤ 0,7 Water vapour tolerance with standard gas ballast 1) mbar 30 40 Water vapour tolerable load with gas ballast kg.h-1 5,4 7,4 Water vapour tolerance with big gas ballast 1) mbar 60 70 Water vapour tolerable load with big gas ballast 1) kg.h-1 10 12,5 Noise level 2) dB(A) 70 74 Leak rate mbar.l.s-1 ≤ 1.10-3 ≤ 1.10-3 Mains voltage (std) - for other voltages please contact Oerlikon Leybod Vacuum V 230/400 460 4) Motor power kW 5,5 6,3 Type of protection IP55 IP55 3) Rated rotational speed min.-1 1450 1750 Weight (with oil filling) kg 200 200 Oil capacity (min./max.) l 8,5/11,5 8,5/11,5 Intake connection G2 G2 NPT2 3) 1.3 Technical Data Description GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 7 Fig. 1 60Hz Nominal speed 1) cfm 200 Pumping speed 1) cfm 171 Ultimate partial pressure without gas ballast Torr 6.10-2 Ultimate total pressure with gas ballast Torrr 0.5 Water vapour tolerance with standard gas ballast standard1) Torr ≤ 30 Motor power hp 10.5 Rated rotational speed rpm 1750 Weight (with oil filling) lb 430 Oil capacity (min./max.) qt 9/12.2 Intake connection NPT (F) inches NPT2 Exhaust connection NPT (F) inches NPT2 Description 8 GA02330_002_02 - 09/2007- © Oerlikon Leybold Vacuum without gas ballast with gas ballast at 60Hz mbar (millibar) torr inches Hg vacuum 1lb = 0.453 kg 1013 760 0 1 qt = 0.946 l 400 300 18.12 1 hp = 0.735 kW 133 100 25.98 1 inch = 25.4 mm 4 3 29.80 1 r.p.m. = 1 min - 1 0,75 29.89 0,1 0,75 29.92 1 atm (atmosphere) = 1013 mbar 1 Pa (pascal) = 0.01 mbar =10-2 mbar 1 bar = 1000 mbar 1 torr = 1.33 mbar Different pressure units Different pumping speed units m3.h-1 l.s-1 cfm m3. h-1 = m3/h 1 1 0.278 0.589 I.s-1 = I/s 3.60 1 2.12 cfm (cubic feet per minute) 1.699 0.472 1 Example : 1m3.h-1 = 0.589 cfm Note : the nominal pumping speed of a pump at 60Hz is 20% higher than at 50Hz Conversion factors at 50Hz 1 10 100 1000 0,01 0,1 1 10 100 1000 Pressure (mbar) Pumping speed (m3/h) 50 Hz GB 7,5 m3/h 1 10 100 1000 0,01 0,1 1 10 100 1000 Pressure (mbar) Pumping speed (m3/h) 50 Hz GB 7,5 m3/h Fig. 2 Installation Item Description Size Cat. Nr. 1 Union coupling + seal G2 F/M 711 18 025 2 Nipple G2 M/M - 150 mm long 711 18 035 3 Threaded flange adapter G2 M - DN 63 ISO-K 711 18 126 4 Centering ring 63 ISO-K AL/NBR 268 07 5 Set of 4 clamps for M10 x 24 267 01 ISO-K flanges 6 Adapter for tubing G2 DN 50 711 18 015 7 PVC tubing 50 mm, 1 m long 711 18 325 8 Adapter for tubing G2 DN 60 711 18 016 9 PVC tubing 60 mm, 1 m long 711 18 326 10 Right-angle bend 90° 63 ISO K 887 25 11 Dust filter, paper Dust filter, charcoal Dust filter metal Dust filter polyester 63 ISO K 951 68 711 27 125 711 27 126 711 27 127 12 Ball valve G2 F/F 711 30 107 13 Tee reducer bush G2-G2-G1/2 F/F/F 711 18 265 14 Elbow 90° G2 F/F 711 18 215 15 Dust filter, paper Dust filter, charcoal Dust filter, metal Dust filter polyester G2 M/F 951 65 711 27 122 711 27 123 711 27 124 16 Vacuum gauge G1/2 M 951 92 17 Ball valve G1/2 M/F 711 30 113 18 Threaded flange adapter G1/2 M - DN 16 KF 711 18 120 19 Regulation valve with isolation valve G1/2 M 951 87 20 Regulation valve G1/2 M 951 86 21 Condensate Trap G2 F -G2 F 951 44 Fig. 3 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 9 1.5 Accessories Description Size Cat. Nr. Oil filter by-pass 712 30 573 Oil drain tap G" ¾ 711 30 114 Gas ballast kit manual ("small", "standard", "big") 9 714 64 130 Gas ballast standard with EM valve 24 V DC (retrofit kit) Upon request Exhaust filter gauge 951 94 Exhaust filter overpressure switch Upon request Oil level monitor Upon request Thermal switch (105°C) 9 714 63 930 PT100 9 714 64 020 Adapter Roots 500 9 714 63 880 Adapter Roots 1000 9 714 63 890 Base frame for pump only 711 19 208 Base frame for Roots direct mounting 9 714 56 590 Water cooling with thermostatic valve upon request Separator SEP 63 953 56 Separator SEP 63 stainless steel 953 57 Separator - Condenser SEPC 63 953 66 Separator - Condenser SEPC 63 stainless steel 953 67 * Please consult us for retrofit Stability of pump is insured with accessories of Oerlikon Leybold Valence; mounting of any other accessory will engage the responsability of user concerning stability of pump. Description 10 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum Description 1.6 Spare parts Description Size 9 714 64 970Cat.Nr. Oil filter standard 710 18 850 Exhaust filter 9 714 31 120 Set of seals FKM 9 714 64 950 Repair set 9 714 64 960 Module kit G2" 9 714 47 390 Module kit NPT2" 9 714 58 970 1.7 Lubricants Unless otherwise specified on the pump, we recommend to run the Sogevac pumps with GS77 from Oerlikon Leybold Vacuum or an equivalent oil which meets following requirements and is approved by OLV: - low vapor pressure, even at high temperatures ; - flat viscosity curve ; - minimum water content and absorption ; - good lubricating properties ; - resistant to aging under mechanical strain. If you use a non-approved oil, we cannot guarantee that our pumps will meet their operating specifications (ultimate pressure, pumping speed, operating temperature, etc). However, the warranty is voided only if the nonapproved oil adversely affects the operation or reliability of the pump. When using other oil brands, employ nondetergent mineral oils of viscosity class ISO VG68 to ISO VG 100. Use of other special-grade lubricants for specific applications is possible. Please consult us. Only use lubricants which have been fully qualified by Oerlikon Leybold Vacuum. Pump oil GS77 Ref. No. 5 liters 711 17 774 25 liters 711 17 776 200 liters 711 17 779 1.8 Manipulation and stock Pumps which have been filled with operating agent must only be moved in the upright position (horizontally). The angle of slope may not be over 10° max. Otherwise oil may escape. Avoid any other orientations during transportation. Check the pump for the presence of any oil leaks, because there is the danger that someone may slip on the oil which has leaked from the pump. Only use the lifting lugs which are provided on the pump to lift the pump with the specified lifting devices. Caution Warning GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 11 Operation Until the pump is put back in to service again, the pump should be stored in a dry place, preferably at room temperature (20 °C). Before taking the pump out of service, it should be properly disconnected from the vacuum system, purged with dry nitrogen and oil should be exchanged too. The inlet and exhaust ports of the pump must be blanked off using the shipping seals which are included upon delivery of the pump. The gas ballast must be closed and if the pump is to be shelved for a longer period of time it should be sealed in a plastic bag together with a desiccant (Silicagel). If the pump has been shelved for more than one year, standard maintenance must be run and oil must be exchanged too before the pump is put in to service again. We recommend that you contact the service from Oerlikon Leybold Vacuum. 2 Operation 2.1 Installation It is essential to observe the following instructions step by step to ensure a safe start-up. Start-up may only be conducted by trained specialists. The SOGEVACs can be set up on any flat, horizontal surface. Under the four feet, there are metric threaded holes for securing the pump. The oil level cannot be read properly if the pump is tilted. Pump risks to run dry. The ambient temperature should be between 12°C (55°F) and 40°C (104°F) depending on oil type. By modifying the pump or changing the oil type, the pump can be run at a lower ambient temperature. Please consult us about this. To ensure adequate cooling of the pump, leave enough space at the air intake and exhaust points, so as for access and maintenance .Make sure to keep the air intake of motor clear. 2.2 Connection to system The standard pump is not suitable for installation in explosion hazard areas. Please contact us, when you are planning such an application. Before installing the pump you must reliably disconnect it from the electrical power supply and prevent the pump from running up inadvertently. The pump must only be installed by suitably qualified and trained personnel. Observe all safety regulations. Caution Caution 12 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 2.2.1 Intake Side The pump has an internally-threaded intake flange. Using suitable connecting elements (see Fig. 3 and Section 1.4), the pump can be connected to the vacuum system. The cross-section of the intake line should be at least the same as the intake port. If the intake line is too narrow, it reduces the pumping speed. We recommend applying either LOCTITE or TEFLON tape to the screwed unions so that they are vacuum-tight (especially if gases are dangerous). - Pump should be connected to inlet line without any tension. Use flex lines or pipe unions in your inlet and exhaust lines so that they can be easily removed for pump maintenance. - The maximum pressure at the inlet may not exceed atmospheric pressure (about 1013 mbar). Never operate the pump in the presence of over pressures at its intake. - Type of materials used for mounting of canalisations should take care of pumped gases. It is the same for its tightness. If the process gas contains dust or particles, it is absolutely essential to install a dust filter in addition to the dust trap supplied (see Section 1.4). We recommend to install the dust filter horizontally using the T-piece (3/13) or the elbow (3/14). This ensures that when removing the filter, no particle falls into the intake port. You have a choice of four cartridges for the optional inlet filters. The metal cartridge prevents solid particles such as paper or plastics from entering the pump ; the paper and polyester cartridges remove small particles such as dust and powder down to one micron ; the activated carbon cartridge absorbs chemical vapors of acids, solvents, etc. If the carbon cartridge was stored in a damp place, bake it for 2 hours at 212°F (100°C) before use. When pumping vapors, we recommend installing condensate traps or condensers on the intake side (see Section 1.4). By pumping of dangerous gases, inlet line must be tight. No particles or liquids may enter in the pump. 2.2.2 Exhaust Side The SOGEVACs have integrated exhaust filters which, even at a high gas throughput, trap the oil mist and guarantee exhaust gas free of oil mist. If the exhaust filters are clogged, pressure relief valves opens and the filters are bypassed. As a result, the proportion of oil in the exhaust gas as well as the pump’s oil consumption rise. Installing new exhaust filters will correct this problem. (See Section 3.9) This situation must be resolved by changing the exhaust filters. It is under utiliser’s responsability to assure maintenance on materiel to avoid any trespassement of the limits autorised by regulations. Check in the individual case whether an exhaust line is necessary and/or prescribed. Volatile substances can pass through the filter. Depending on the processed gas, we recommend connecting an exhaust line ; this is always necessary when the exhaust gases are dangerous. Operation Warning Warning GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 13 Observe the safety precautions that apply to your application and process gases. The pump’s exhaust port also has an internal thread (ET3/18). A hose can be connected via a suitable screw-in nipple (see Fig. 3 and Section 1.4). The cross-section of the exhaust line should be at least the same as the pump’s exhaust port. If the exhaust line is too narrow, overpressure may occur in the pump. Before installing the exhaust line, remove the exhaust-flange plate and ensure that the exhaust demister(s) are secured tightly in place. They sometimes loosen during shipping and installation. A loose demister results in exhaust smoke during start-up and operation. Install the exhaust line with a downward slope to prevent condensate from flowing back into the pump. If this is not possible, we strongly recommend installing a condensate trap (see Section 1.5). if several pumps are connected to one exhaust line, ensure an adequate cross-section and a non-return valve at the exhaust of each pump. Never operate the pump with a blocked or restricted exhaust line. Before startup ensure, that any blinds or similar shut-off devices in the exhaust line on the pressure side are opened and that the exhaust line is not obstructed. Such restrictions reduce the pumping speed, increase the temperature, and could overload the motor or cause a dangerous overpressure in the pump. Excessive pressure in the pump could damage the seals, blow out the sight glass, or destroy the pump housing. In addition to this explosion hazard, excessive backpressure can result in hazardous process gases leaking out of the pump. If you are purging the oil casing with inert gas, limit the inert-gas flow. Contact Oerlikon Leybold Vacuum for recommendations. When pumping dangerous gases, exhaust line must be tight. The maximum exhaust pressure must not exceed 1,15 bar (absolute). Also reliably prevent the occurrence of any blockage in the exhaust line. Exhaust filter, accessories and the tubing must be rated according to the maximum throughput. The maximum throughput is equivalent to the pumping speed of the pump. 2.3 Electrical Connections (See fig. 4) Ensure that incoming power to the pump is off before wiring the motor or altering the wiring. Electrical connections must be done by a qualified electrician in accordance with the applicable safety regulations. Wire the motor for the correct supply voltage via connections in the junction box. See the wiring diagram on the motor or in the junction box. For proper connection, a suitable motor protection switch must be used. Set the switch in accordance with the rating on the motor nameplate. The switch should be of class 10 at least. Warning Warning Operation 14 GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum Operation After connecting the motor and every time you alter the wiring, check the direction of rotation. Observe the direction arrow on the motor hood. During the check, the intake port should be open. If the direction of rotation is wrong, oil may be ejected out the intake port. The vacuum system may be pressurised. Don’t use the motor fan for checking the rotation direction. The motor fan rotates too fast to clearly check during operation ; when it slows during shutdown, it reserves its direction. Turn off the power supply, and interchange two phases of the connection, if you need to correct the direction of rotation. We recommend checking the direction of rotation with a phase-sequence indicator. Prolonged running of the motor in the wrong direction of rotation will damage the pump ! A thermal overload switch is available as an accessory. It cuts out the pump if a specific temperature is exceeded and/or triggers a warning signal. If any security switch or electrical defect cuts out the pump, re-start-up of the pump is only possible by hand-action. Warning GA02330_002_02 - 09/2007 - © Oerlikon Leybold Vacuum 15 Fig. 4 16 GA02330_002_01 - 12/2006 - © Oerlikon Leybold Vacuum

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