Instruction manual & spare parts lists for models TRP-6 to TRP-90

Transcription

1 Instruction manual & spare parts lists for models TRP-6 to TRP-90 1

2 Table of Contents TRP High Vacuum Pump Instruction Manual... 1 Table of Contents... 2 Critical Dimensions... 3 Critical Performance... 4 Installation... 7 Pipe Connection... 8 Electrical Wiring... 9 Operation Non-condensable gases (e.g.: dry air, Nitrogen) Condensable gases (e.g.: water vapour) Operating Temperature Shutting Down the Pump Maintenance Checking the oil Replacing oil Cleaning inlet port dirt trap Checking / replacing the pump coupling element Major Maintenance or Pump Remanufacture Supplemental Freeze Drying Application Notes Exploded Parts Drawing Spare Parts List

3 Critical Dimensions MODEL A B C D E F G H I J K L M N O TRP TRP TRP TRP TRP TRP

4 Critical Performance UNIT TRP 6 TRP 12 Displacement 50Hz m 3 /hr Without G/B mbar 7 x x 10-4 Ultimate Gas ballast I mbar 7 x x 10-3 pressure Gas ballast II mbar 1.3 x x 10-2 Water vapour tolerance mbar Inlet port DN NW25 NW25 Outlet port DN NW25 NW25 Motor rating kw Motor speed rpm Average noise level db (A) Maximum weight kg

5 UNIT TRP 24 TRP 36 Displacement 50Hz m 3 /hr Without G/B mbar 7 x x 10-4 Ultimate pressure Gas ballast I mbar 7 x x 10-3 Gas ballast II mbar 1.3 x x 10-2 Water vapour tolerance mbar Inlet port DN NW25 NW25 Outlet port DN NW25 NW25 Motor rating kw Motor speed rpm Average noise level db (A) Maximum weight kg

6 UNIT TRP 60 TRP 90 Displacement 50Hz m 3 /hr Without G/B mbar 7 x x 10-4 Ultimate pressure Gas ballast I mbar 7 x x 10-3 Gas ballast II mbar 1.3 x x 10-2 Water vapour tolerance mbar Inlet port DN NW40 NW40 Outlet port DN NW40 NW40 Motor rating kw Motor speed rpm Average noise level db (A) Maximum weight kg

7 Installation The pump should be installed on a flat and horizontal surface, using the standard anti-vibration mounts to minimise unusual noise and vibration. The installation space should be carefully considered, especially in regard to convenience for piping/electrically connecting, operating and maintaining the vacuum pump. It should also be well ventilated for correct air cooling. The ambient temperature should lie in the range of C to C. 7

8 Pipe Connection The inlet and outlet ports can be connected using the international standard KF/NW/QF type quick clamp fittings. Ensure that the special inlet centering ring complete with stainless steel dirt trap is used to prevent debris from entering the pump. Check the cleanliness of the connecting pipe work before operating the pump. Any contaminant present in the system could be ingested into the pump, causing major damage. The length of any interconnecting pipe-work to the pump flanges should be as short as possible and of the same diameter as the ports on the pump to ensure correct operation. o o If the inlet pipe is smaller than the inlet port, the evacuation speed will be decreased. If the exhaust pipe is smaller than the outlet port, the internal pressure will rise due to system backpressure, which will cause damage. Check all inlet pipe/flange joints for leakage, as any leaks will adversely affect pump performance. If the exhaust is piped away, run the exhaust line downhill from the pump or install a catch pot at the pump. Condensate must not be allowed to drain back into the pump, as it will lead to corrosion. 8

9 Electrical Wiring All wiring connections must be performed be an authorised electrician. For single phase motored pumps, simply connect the 3-pin plug to a standard outlet, firstly ensuring that the exhaust port is not covered or partially obstructed. For three phase motor connection, ensure that the electrical supply is isolated before connecting the power supply to the motor terminal box. Check the direction of motor rotation with a quick flick /short duration of running (less than 5 seconds). Rotation should be anti-clockwise when looking from the motor end. If incorrect, change any two phase wires to reverse the rotation. PRE-OPERATION CHECKS Check the oil level ensuring that it is above the minimum level line. Add more oil if required. When a three phase motor is fitted, always check for correct rotation whenever the wiring is changed. After changing the oil or starting the pump after a long period of disuse, operate the pump against a closed inlet and open gas ballast valve (position I or II preferably) to remove gas from the oil and reach maximum vacuum. 9

10 Operation Non-condensable gases (e.g.: dry air, Nitrogen) When pumping systems which release a continuous gas load, you can operate the pump without using the gas ballast valve, i.e. at maximum vacuum. Condensable gases (e.g.: water vapour) Ensure that the pump reaches operating temperature before the inlet is exposed to the condensable gas. Operation for minutes should be sufficient. Pumping condensable gases when cold is likely to result in condensation inside pump. This is likely to lead to corrosion of the pump internals. Operate the pump with the gas ballast valve open to maximise oil life and reduce corrosion. At the completion of the operation, avoid turning the pump off immediately. Instead, operate the pump against a closed inlet valve for a minimum of 30 minutes, with the gas ballast valve open (position I or II preferably). Run the pump in this mode until the oil appearance returns to normal. In cyclic uses, don t turn the pump off between cycles. Instead isolate the pump whilst using full gas ballast airflow until the next requirement. Energy usage will be minimal when operating against a closed valve and continued operation will help remove condensed vapour from the oil. 10

11 Operating Temperature The ambient temperature should lie in the range C to C. Under normal operation, the oil casing temperature range should lie within C to C. 11

12 Shutting Down the Pump When pumping clean gases, you can switch the pump off immediately. When pumping condensable vapours, operate the pump against a closed inlet valve for a minimum of 30 minutes with the gas ballast valve open (position I or II preferably). Confined operation will help to remove condensed vapour from the oil. For longer term storage, replace the oil and seal the inlet port and outlet ports. 12

13 Maintenance Always disconnect the power supply before performing any maintenance operation. If the pump has been used with harmful gases, follow recommended safety precautions for the gas concerned! When pumping dirty/wet gases, change the oil frequently and clean the inlet screen. The pump oil level should be maintained between the upper and lower limits at all times. In case of insufficient oil, turn off the pump and add top-up oil as required (see figure 1). Checking the oil Visually check to verify that the colour is clear and transparent. If the oil has become dark or milky, change immediately. MAX MIN Replacing oil For best vacuum performance and maximum pump life, the oil must be maintained in good condition. The oil charge should be replaced, according to the following criteria; After the first 100 hours of operation with a new pump. Whenever the oil discolours (either becoming milky or dark). In dirty/wet applications, the oil may need to be changed daily. When the vacuum performance degrades noticeably. Figure 1. After a maximum of hours of clean operation (usually 3-4 months of 24 hour operation). To change the oil, operate the pump for a few minutes to get it to operating temperature. Then open the drain valve and empty the contaminated oil into a collection tank and dispose of appropriately. For optimum oil removal, run the pump for a short period (5 seconds maximum) with the inlet port open and with the oil drain valve closed. This will discharge any oil still remaining inside the pumping chamber. After stopping the pump again, open the oil drain and remove the last of the old oil. Cleaning inlet port dirt trap 13

14 The dirt trap fitted to the inlet port helps to filter out larger particles entering the pump. Clean the trap regularly (depending on contamination rate) to prevent a reduction in pumping speed. The trap should be removed from the pump, cleaned and then completely dried with compressed air prior to re-fitting into the pump. Replace the dirt trap if becomes distorted or broken. Checking / replacing the pump coupling element Disconnect the power supply before removing the motor. With reference to fig 2. below, remove the two cap s located at the bottom of the motor housing flange. Then remove the two upper cap s, making sure to support the weight of the motor. Remove the motor complete with housing by gently pulling the assembly away from the pump body. Examine the old coupling element for unusual wear and replace with a new one as required. Complete the process in the reverse order, tightening all bolts equally, in order to return the pump to operation. Figure 2. Major Maintenance or Pump Remanufacture Please contact your nearest authorised service agent. 14

15 In New Zealand: North Island VABS Limited Silverdale, Auckland Free call: Fax: (09) Authorised NZ service agents: Hivac Ltd Silverdale, Auckland Phone: (09) Fax: (09) Absolute Vacuum Services 12 Stewart Avenue Panmure, Auckland Phone: (09) Fax: (09)

16 Supplemental Freeze Drying Application Notes Make sure the freeze dryer's condenser is down to its correct operating temperature before opening it up to the vacuum pump. This is critical; otherwise the pump oil Warning: Freeze drying can be an aggressive application for vacuum pumps and corrosion of the pump internals is a strong possibility if the freeze dryer is not operated correctly. As corrosion damage is not covered under the pump warranty, pump users are urged to carefully read and implement the following instructions. If there are any queries about the recommended procedures, please contact your nearest authorised service agent for technical advice. will very quickly contaminate, (leading to poor vacuum and, ultimately, corrosion inside the pump). While the condenser is coming down to temperature, warm-up the vacuum pump against a closed inlet (but with the ballast valve open - please refer to following section). Warming up the pump is highly beneficial because vacuum pumps handle water vapour much better when warm. Even with good condenser temperatures, some water vapour inevitably gets to the vacuum pump. Pump warm-up must not be neglected, even if everything else appears ok. Similarly, at the end of the run, don t switch the pump off immediately. Instead, isolate the pump from the condenser and leave the pump run for at least 30 minutes against a closed inlet (again with the ballast valve open). This closedown procedure will do wonders to clean up the pump oil for the next run. For almost all freeze drying applications, the vacuum pump should be run with its ballast valve open all of the time. The ballast valve is controlled by the black plastic knob near the pump s inlet port. There are three functional positions, no gas ballast, position one (low gas ballast) and position two (full gas ballast). Position one should be the correct position go normal freeze drying operation (ensuring good water vapour handling characteristics while note emitting too much oil vapour from the exhaust). When the pump is running with the ballast valve open it will gradually consume oil. Don t forget to check the oil level and top up as necessary! (Stop the pump before adding oil.) When the ballast valve is open, the pump will discharge oil smoke. As this is unpleasant (and, probably, unwise) to breathe, the oil smoke should either be exhausted outside, or trapped in an oil mist filter. If an exhaust pipe is the chosen means of getting rid of the oil smoke, make sure that condensation in the exhaust line cannot run back into the pump. Either run the exhaust line continuously downwards from the pump s exhaust port, or install a catch pot with a drain-cock adjacent to the exhaust port. Stopping condensation from running back into the pump is important, otherwise internal corrosion of the pump will occur. Continued 16

17 Oil changes. If the pump oil looks milky and does not clean-up after an overnight run against a closed inlet (but with the ballast valve open), change the oil. Please refer to the oil changing instructions in the pump instruction manual. For freeze drying, use Shell Tellus 68 as the pump oil. This is relatively inexpensive oil, so frequent oil changes should not be too costly. For good pump performance, do not skimp on oil changes! 17

18 Exploded Parts Drawing 18

19 Spare Parts List (TRP-60/90 information on request) Item No. Description Type & Material Dimensions Number required per model TRP 6 TRP 12 TRP 24 TRP 36 1 Hex socket cap SCM4 M5x Sight glass bezel Aluminium 108x48x Sight glass Glass 91.5x19x Sight glass seal NBR 97x23.5x Oil drain plug SUN24 PF 3/ Oil drain plug washer NBR 15x22x Oil casing Aluminium 165x193x Oil casing Aluminium 165x193x Oil casing Aluminium 205x226x Oil casing Aluminium 205x226x Oil filler plug washer NBR 15x22x Oil filler plug SUM24L PF 3/ O-ring NBR P O-ring NBR G Outlet port SUS304 DN Centering ring Duralumin DN25KF O-ring NBR 28x Outlet port cap KN333G30 DN Clamping ring Aluminium DN Hex socket cap SCM4 M6x Hex socket cap SCM4 M6x Exhaust valve cover Aluminium 90x44x Exhaust valve cover Aluminium 100x50x Screen Stainless 34x15x steel 18 Screen Stainless 48x35x steel 19 O-ring NBR D Gasket V/ x193x Gasket V/ x228.5x Hex socket cap SCM4 M8x Hex socket cap SCM4 M8x Rear cover GC25 D 104x Rear cover GC25 D 124x Intermediate plate GC25 D 104x Intermediate plate GC25 D 124x Spring SUS316J1 D 15.2x Non-return valve Viton D 12x Oil pump 25.8x10x Sleeve SCM4 23x28x

20 Item No. Description Type & Material Dimensions Number required per model TRP 6 TRP 12 TRP 24 TRP nd stage vane EC-4 17x30.5x nd stage vane EC-4 28x40.6x nd stage rotor GC25 D 48x nd stage rotor GC25 D 64x Sleeve SCM4 D 23x28x nd stage cylinder GC25 D104x nd stage cylinder GC25 D 124x Rotor coupling GC30 D 23x19.7x Rotor coupling GC30 D 23x19.7x Sleeve SCM4 D 23x28x Valve plate 7C27MO2 45x30x Valve plate 7C27MO2 57.5x36x Valve catcher Aluminium 47x30x Valve catcher Aluminium 57x36x Hex socket cap SCM4 M6x st stage vane EC-4 24x30.5x st stage vane EC-4 49x30.5x st stage vane EC-4 56x40.6x st stage vane EC-4 85x40.6x st stage rotor GC25 D 48x st stage rotor GC25 D 48x st stage rotor GC25 D 64x st stage rotor GC25 D 64x Plate key S45C 5x5x15x1R Plate key S45C 6x6x20x1R O-ring Viton D 15x O-ring Viton D 20x Oil seal sleeve SCM4 D 20x15x Oil seal sleeve SCM4 D 25x20x Oil seal Viton S20x30x Oil seal Viton S25x35x st stage cylinder GC25 D 104x st stage cylinder GC25 D 104x st stage cylinder GC25 D 124x st stage cylinder GC25 D 124x Dumping valve SUS304 D 14x Pressure control KN333G30 D 9.5x valve 46 Spring SUS316J1 D 9x18x Gasket V/6500 D 105x Gasket V/6500 D 125x O-ring NBR G O-ring NBR P Oil seal Viton D 20x30x Oil seal Viton D 25x35x Stop ring D 30 (hole type)

21 Ite m No. Description Type & Material Dimensions Number required per model TRP 6 TRP 12 TRP 24 TRP Stop ring D 35 (hole type) Coupling ZNDC2 D 55x Coupling ZNDC2 D 55x Coupling disc. SUS304 D 18x Coupling disc. SUS304 D 27x Hex socket cap SCM4 M5x Hex socket cap SCM4 M6x Alignment pin S45C D 4.2x Pump housing Aluminium 165x194x Pump housing Aluminium 205x228.5x Gas ballast valve plate Viton D 19x Gas ballast valve seat KN333G30 D 19x Gas ballast valve SWP D 18.8x spring 59 Gas ballast valve KN333G30 D 20.5x piston 60 Hex socket cap SCM4 M4x Gas ballast valve knob KN333G30 D 35.5x Clamping ring Aluminium DN Inlet cap KN333G30 DN O-ring NBR D 28x Dirt trap SUS304 DN25KF Inlet port SUS304 DN O-ring NBR P O-ring NBR G Hex socket cap SCM4 M6x Hex socket cap SCM4 M8x Top cover Aluminium 146x99x Top cover Aluminium 180x88x Gasket V/ x85x Gasket V/ x80x Valve plate NBR D 32x Valve cover KN333G30 D 60.8x O-ring NBR G O-ring NBR G O-ring Viton P10A Bushing SK-4 D 14.2x9.5x U-seal Viton D 31.7x Piston KN333G30 D 29.8x Spring SUS316J1 D 14.5x Spring SUS316J1 D 15x

22 Item No. Description Type & Material Dimensions Number required per model TRP 6 TRP 12 TRP 24 TRP Hex socket cap SCM4 M6x Hex socket cap SCM4 M8x Hex socket cap SCM4 M6x Hex socket cap SCM4 M8x Coupling element NBR D 55x Cooling fan ZNDC2 D 130x Hex socket cap SCM4 M6x Gasket V/ x178x Gasket V/ x213.5x Hex socket cap SCM4 M6x Hex socket cap SCM4 M6x Motor housing Aluminium 165x178x Motor housing Aluminium 205x213.5x Hex socket cap SCM4 M6x Hex socket cap SCM4 M8x Portable handle KN333G30 146x72x Portable handle KN333G30 180x75x Plate key S45C 5x5x Plate key S45C 6x6x Electric motor 0.4kW Electric motor 0.75kW Nut S45C M Pump base Aluminium 260x146x Pump base Aluminium 330x180x Hex socket cap SCM4 M6x Hex socket cap SCM4 M8x Foot NBR D 26x Spring washer M Spring washer M Spring washer M Spring washer M Insert M Insert M