Jurop PVT Series Manual

PVT Series Manual
INDEX
1. General information
1.1.
General description and use
1.2.
Construction characteristics
2. Pump identification
3. Technical data
3.1.
Arrangements
3.2.
Dimensions
3.2.1. Mufflers dimensions
3.3.
Performances
3.3.1. Gas conveyed
3.3.2. Operating limits
3.3.3. Operation in vacuum mode
3.3.4. Operation in pressure mode
3.3.5. Noise
4. Safety and accidents prevention
5. Installation
5.1.
Compulsory accessory
5.2.
Checking upon goods recival
5.3.
Storing in the warehouse
5.4.
Installing the vacuum pump
6. Vacuum - Pressure line
7. Air injection cooling system
8. Alarm devices
8.1
Overheating alarm
8.2
Oil level alarm (optional)
9. Drive systems
9.1.
Belt drive
9.2.
Hydraulic drive
10. System start up
11. Operating suggestions
12. Maintenance
12.1 Routine maintenance
12.2 Extraordinary maintenance
13. Troubleshooting
14. Scrapping
15. Request for spare parts
1.
GENERAL INFORMATION
All the information needed for installing, starting, using and servicing the vacuum pump is included
in this manual.
x It is essential that the contents of this manual are known to ensure the correct use of the pump.
The manufacturer cannot be considered liable for damages deriving from an improper,
erroneous or unreasonable use.
x The guarantee for faulty parts can be approved only if the pump is installed/used/serviced
according to the information included in this manual.
x Comply with the safety instructions given. Do not use the machine in different ways from those
explained in the manual.
It is therefore necessary that:
x the users and installer are aware of the instructions given in the manual.
x the manual has to be available to all the pump users.
1.1.
GENERAL DESCRIPTION AND USE
PVT vacuum pumps are 3 lobe blowers specifically designed for vacuum plants that must convey
gas free from polluting substances, oil or water: this is made possible due to the lack of sliding
parts, and therefore oil lubrication within the compression chambers.
Moreover, PVT blowers don't need any auxiliary cooling system, as they're provided with a built in
air injection cooling system.The specific and accurate lobes profiles grant high volumetric efficiency
and high flow rates combined with minimized dimensions and vacuum rates that can reach 92%
1.2.
x
x
x
x
x
x
x
x
x
x
x
x
4
CONSTRUCTION CHARACTERISTICS
Tri-lobe rotary volumetric pump with synchronised phase helical gears.
No oil emission into the atmosphere.
Wear-proof operation, reduced maintenance.
Clockwise or counter clockwise rotation on request.
Dynamically balanced rotors to reduce vibrations (A).
Splash lubricated bearings (B) and gears (C) in the front and rear boxes.
Internal combined seals: Y-seals and labyrinth seals (D) with PTFE/cast iron rings with
discharge into the atmosphere.
Seals and gaskets for high temperatures.
Side Air injection cooling system with clapet valve (E). This valve opens only in the vacuum
functioning mode.
Injection muffler (compulsory accessory) and vacuum pump exhaust.
Overheating thermostat on the exhaust port (F).
Removable lifting points (G)(H).
2.
PUMP IDENTIFICATION
Each PVT shows a manufacturer plate
that specifies:
1.
2.
3.
4.
5.
PVT Model
Serial number
Year of manufacture
Max Pressure
Maximum speed at maximum
vacuum rate
6. Maximum speed at vacuum rate
equal of 80%
7. Maximum required power.
It is compulsory to provide the PVT
Model and Serial Number when
asking spare parts.
3.
TECHNICAL DATA
3.1. ARRANGEMENTS
PVT200M
(with gearbox 3:1)
is available only in the
following arrangements:
- PVT DX-O-B
- PVT SX-O-B
SX= Counter Clockwise
rotation
DX= Clockwise rotation
O= Horizontal ports
A= Upper shaft
B= Lower shaft
V= Vertical ports
D= Right hand shaft
S= Left hand shaft
HDR= Hydraulic motor
3.2. DIMENSIONS
CODE G170851102
CODE G230851102
CODE G160851102
CODE G270851102
PVT200 DX-O-B
PVT400 DX-O-B
PVT700 DX-O-B
PVT1000 DX-O-B
CODE G170951102
CODE G230951102
CODE G160951102
CODE G270951102
PVT200 SX-O-B
PVT400 SX-O-B
PVT700 SX-O-B
PVT1000 SX-O-B
PVT
200
400
700
1000
PVT
200
400
700
1000
CODE F178151102
CODE F238151102
CODE F168151102
CODE F278151102
CODE F170951102
CODE F230951102
CODE F168051102
CODE F278051102
PVT200 DX-O-B-HDR
PVT400 DX-O-B-HDR
PVT700 DX-O-B-HDR
PVT1000 DX-O-B-HDR
PVT200 SX-O-B-HDR
PVT400 SX-O-B-HDR
PVT700 SX-O-B-HDR
PVT1000 SX-O-B-HDR
A
B
C
D
E
F
H
I
K
L
M
276
312
386
386
168
200
239
239
176
236
532
532
270
392
438
462
458
508
607
607
155
203
234
234
373
470
658
658
207
270
339
339
M 14
M 14
M 20
M 20
69
106
150
150
266
231
344
344
N
O
P
Q
328
460
422
630
154
261
385
385
428
536
828
828
215
315
364
364
R
38 g6
50 g6
70 g6
70 g6
-0.009
-0.025
-0.009
-0.025
-0.010
-0.029
-0.010
-0.029
S
T
10
14
20
20
41
53.5
74.5
74.5
U
110
155
200
220
DN100 PN10
UNI2276-67
DN150 PN10
UNI2276-67
DN175 PN10
UNI2276-67
DN200 PN10
UNI2276-67
Peso
160 Kg
240 Kg
610 Kg
780 Kg
CODE G170951101
CODE G230951101
CODE G160951101
CODE G270951101
CODE G170851101
CODE G230851101
CODE G160851101
CODE G270851101
PVT200 SX-O-B
PVT400 SX-O-B
PVT700 SX-O-B
PVT1000 SX-O-B
PVT200 DX-O-A
PVT400 DX-O-A
PVT700 DX-O-A
PVT1000 DX-O-A
PVT
200
400
700
1000
A
B
C
D
E
F
H
I
K
L
M
276
312
386
386
168
200
239
239
176
236
532
532
270
392
438
462
458
508
607
607
259
337
444
444
373
470
658
658
207
270
339
339
M 14
M 14
M 20
M 20
69
106
150
150
266
231
344
344
PVT
200
400
700
1000
N
O
S
T
328
460
422
630
154
261
385
385
-0.009
-0.025
-0.009
-0.025
-0.010
-0.029
-0.010
-0.029
10
14
20
20
41
53.5
74.5
74.5
R
38 g6
50 g6
70 g6
70 g6
U
110
155
200
220
DN100 PN10
UNI2276-67
DN150 PN10
UNI2276-67
DN175 PN10
UNI2276-67
DN200 PN10
UNI2276-67
Peso
160 Kg
240 Kg
610 Kg
780 Kg
CODE G170850103
CODE G230850103
CODE G160850103
CODE G270850103
PVT200 DX-V-S
PVT400 DX-V-S
PVT700 DX-V-S
PVT1000 DX-V-S
CODE F178150103
CODE F238150103
CODE F168150103
CODE F278150103
PVT200 DX-V-S-HDR
PVT400 DX-V-S-HDR
PVT700 DX-V-S-HDR
PVT1000 DX-V-S-HDR
CODE G170950104
CODE G230950104
CODE G160950104
CODE G270950104
PVT200 SX-V-D
PVT400 SX-V-D
PVT700 SX-V-D
PVT1000 SX-V-D
CODE F178050104
CODE F238050104
CODE F168050104
CODE F278050104
PVT200 SX-V-D-HDR
PVT400 SX-V-D-HDR
PVT700 SX-V-D-HDR
PVT1000 SX-V-D-HDR
PVT
200
400
700
1000
PVT
200
400
700
1000
A
B
C
C1
C2
D
E
F
H
I
K
K1
K2
52
67
105
105
-15
-15
264
318.6
745
745
316
372
-
212
236
-
270
392
438
462
381
448
642
642
80
92
234
234
430
508
339
339
168
200
623
623
M20
M20
M10
M10
-
35
35
-
L
M
N
O
P
Q
69
106
150
150
266
231
344
344
328
460
422
630
154
261
385
385
428
536
828
828
215
315
364
364
R
38 g6
50 g6
70 g6
70 g6
-0.009
-0.025
-0.009
-0.025
-0.010
-0.029
-0.010
-0.029
S
T
10
14
20
20
41
53.5
74.5
74.5
U
110
155
200
220
DN100 PN10
UNI2276-67
DN150 PN10
UNI2276-67
DN175 PN10
UNI2276-67
DN200 PN10
UNI2276-67
Peso
160 Kg
240 Kg
610 Kg
780 Kg
CODE G170950103
CODE G230950103
CODE G160950103
CODE G270950103
CODE G170850104
CODE G230850104
CODE G160850104
CODE G270850104
PVT200 SX-V-S
PVT400 SX-V-S
PVT700 SX-V-S
PVT1000 SX-V-S
PVT200 DX-V-D
PVT400 DX-V-D
PVT700 DX-V-D
PVT1000 DX-V-D
PVT
200
400
700
1000
A
B
C
D
E
F
H
I
K
L
M
52
67
105
105
20
7
15
15
280
372
745
745
270
392
438
462
381
448
641
641
155
203
234
234
432
515
432
432
168
200
239
239
M14
M14
M20
M20
69
106
150
150
266
231
344
344
PVT
200
400
700
1000
N
O
P
Q
328
460
422
630
154
261
385
385
428
536
828
828
215
315
364
364
R
38 g6
50 g6
70 g6
70 g6
-0.009
-0.025
-0.009
-0.025
-0.010
-0.029
-0.010
-0.029
S
T
10
14
20
20
41
53.5
74.5
74.5
U
110
155
200
220
DN100 PN10
UNI2276-67
DN150 PN10
UNI2276-67
DN175 PN10
UNI2276-67
DN200 PN10
UNI2276-67
Peso
160 Kg
240 Kg
610 Kg
780 Kg
CODE G177751100
PVT200 DX-O-MOLTIPLICATORE
CODE G177851100
PVT200 SX-O-MOLTIPLICATORE
PVT200 M: With gear box
PVT
200M
A
B
C
D
E
F
H
I
K
L
M
N
276
168
176
270
482
119
373
207
M14
74
266
328
PVT
200M
O
P
269
17
R
45 g6
-0.009
-0.025
S
T
14
48.5
U
110
DN100 PN10
UNI2276-67
Peso
210 Kg
3.2.1.
MUFFLERS DIMENSIONS
MODEL
PVT200
PVT200
EXHAUST
INJECTION
TYPE
DN100 PN6 DN100 PN6
FLANGE*
MILD
14140BW7B0 14140BVNB0
STEEL
STAINLESS
14140BUQB0 14140BTDB0
STEEL
PVT400
PVT400
EXHAUST
DN125 PN6
INJECTION
DN125 PN6
PVT700
PVT700
PVT1000
PVT1000
1547003600
1445005600
1414012500
1414012600
154705PCB0
141405Q5B0
1547003400
1445005800
1414012900
1414013000
-
-
EXHAUST
INJECTION
EXHAUST
INJECTION
DN175 PN10 DN175 PN10 DN200 PN10 DN200 PN10
*UNI 2277-67
3.3 PERFORMANCES
3.3.1.
GAS CONVEYED
The PVT400 pump is suitable for conveying filtered air. Before conveying other kind of gases,
verify compatibility with vacuum pump’s characteristics. Please contact Jurop’s Technical dept. if
necessary.
The vacuum pump can be seriously damaged by the accidental suction inside of solid
bodies or liquids.
3.3.2.
OPERATING LIMITS
Model
PVT200
PVT200M
PVT400
PVT700-1000
RPM
P2
(mbar)
Min
Max
2500
833
1700
1000
4200
1400
3300
2500
Max
continuos
800
800
800
800
Max
intermittent
1000
1000
1000
1000
P2-P1
(mbar)
Max
T2
(°C)
Max
T2- T1
(°C)
Max
1000
1000
1000
1000
160
160
160
160
130
130
130
130
P1 : inlet absolute pressure
T1 : inlet air temperature
T2 : oulet air temperature
P2 : oulet absolute pressure
P2 max continuos: pressure limit for continuos duty
P2 max intermittent: pressure limit for intermittent duty
3.3.3.
OPERATION IN VACUUM MODE
Room conditions: 1013 mbar abs, 20°C.
Counterpressure at the exhaust port: 1013 mbar abs.
Tolerances on the air flow and power: ±5%
Broken line speed: MAX vacuum rate 80%.
PVT200M performances are identical to PVT200 performances. The rotation speed of
the PVT200M is 1/3 of the rotation speed showed on the graphs.
FLOW [m3/h]
PVT 200
POWER [kW]
VACUUM RATE [%]
VACUUM RATE [%]
FLOW [m3/h]
PVT 400
POWER
POWER [kW]
[kW]
VACUUM RATE [%]
VACUUM RATE [%]
FLOW [m3/h]
PVT 700
POWER [kW]
VACUUM RATE [%]
VACUUM RATE [%]
FLOW [m3/h]
PVT 1000
POWER [kW]
VACUUM RATE [%]
VACUUM RATE [%]
3.3.4
OPERATION IN PRESSURE MODE
Room conditions: 1013 mbar abs, 20°C.
Pressure at the inlet port: 1013 mbar abs.
Tolerances on the air flow and power: ±5%
PVT operations with exhaust pressure higher than 800 mbar rel are allowed only in
intermittent duty.
PVT200M performances are identical to PVT200 performances. The rotation speed
of the PVT200M is 1/3 of the rotation speed showed on the graphs.
FLOW [m3/h]
PVT 200
POWER [kW]
PRESSURE [mbar]
PRESSURE [mbar]
………………………………………………………………….……………………….
FLOW [m3/h]
PVT 400
POWER [kW]
PRESSURE [mbar]
PRESSURE [mbar]
FLOW [m3/h]
PVT 700
POWER [kW]
PRESSURE [mbar]
PRESSURE [mbar]
FLOW [m3/h]
PVT 1000
POWER [kW]
PRESSURE [mbar]
PRESSURE [mbar]
3.3.5.
NOISE
Noise power LwA of the pump only and relative noise pressure LpA in free field, at 7m from the
pump.
Measure tolerance: ±2%
Measures according to: UNI EN ISO 9614-2
PVT200
Rotation
Speed
Vacuum/Pressure
Lw (A)
Lp (A)
Noise power of the only pump. (without
drive trasmission suction group,
mufflers).
Noise pressure of the only pump at 7m in
free field. (without drive trasmission
suction group, mufflers)
[dB(A)]
[dB(A)]
vacuum 50%
91
63
vacuum 80%
92
64
ǻ press. 600 mbar
97
69
vacuum 50%
92
64
vacuum 80%
93
65
ǻ press. 600 mbar
98
70
vacuum 50%
95
67
vacuum 80%
96
68
ǻ press. 600 mbar
100
72
vacuum 50%
96
68
vacuum 80%
97
69
ǻ press. 600 mbar
103
75
[rpm]
3300
3600
3900
4200
PVT200M
Rotation
Speed
Lw (A)
Lp (A)
Noise power of the only pump. (without
drive trasmission suction group,
mufflers).
Noise pressure of the only pump at 7m in
free field. (without drive trasmission
suction group, mufflers)
[dB(A)]
[dB(A)]
vacuum 50%
92
64
vacuum 80%
93
65
ǻ press 600 mbar
97
69
vacuum 50%
93
65
vacuum 80%
94
66
ǻ press 600 mbar
98
70
vacuum 50%
96
68
vacuum 80%
97
69
ǻ press 600 mbar
101
73
vacuum 50%
97
69
vacuum 80%
98
70
ǻ press 600 mbar
104
76
Vacuum/Pressure
[rpm]
1100
1200
1300
1400
PVT400
Rotation
Speed
Lw (A)
Lp (A)
Noise power of the only pump. (without
drive trasmission suction group,
mufflers).
Noise pressure of the only pump at 7m in
free field. (without drive trasmission suction
group, mufflers)
[dB(A)]
[dB(A)]
vacuum 50%
93
65
vacuum 80%
95
67
ǻ press 600 mbar
115
87
vacuum 50%
95
67
vacuum 80%
96
68
ǻ press 600 mbar
118
90
vacuum 50%
96
68
vacuum 80%
97
69
ǻ press 600 mbar
121
93
vacuum 50%
98
70
vacuum 80%
99
71
ǻ press 600 mbar
124
96
vacuum 50%
99
71
vacuum 80%
100
72
ǻ press 600 mbar
126
98
vacuum 50%
100
72
vacuum 80%
101
73
ǻ press 600 mbar
129
101
Vacuum/Pressure
[rpm]
2300
2500
2700
2900
3100
3300
PVT700-1000
Regime
rotazione
Vuoto/Pressione
Lw (A)
Lp (A)
Noise power of the only pump. (without
drive trasmission suction group,
mufflers).
Noise pressure of the only pump at 7m in
free field. (without drive trasmission suction
group, mufflers)
[dB(A)]
[dB(A)]
[rpm]
1200
1600
2000
2400
PVT700
PVT1000
PVT700
PVT1000
vac 50%
98
99
70
72
vac 80%
99
100
71
73
ǻ press 600 mbar
104
105
76
78
vac 50%
101
102
73
75
vac 80%
102
103
74
76
ǻ press 600 mbar
106
107
78
80
vac 50%
104
105
76
78
vac 80%
106
107
78
80
ǻ press 600 mbar
109
110
81
83
vac 50%
107
108
79
81
vac 80%
109
110
81
83
ǻ press 600 mbar
113
112
85
87
4.
SAFETY AND ACCIDENTS PREVENTION
THE FOLLOWING INSTRUCTIONS MUST BE IN COMPILANCE WITH
x
When the pump is being transported it must be placed on a stable point and fixed with safety
straps.
x
Installation and maintenance must be carried out by qualified personnel only, wearing suitable
clothing as well as the necessary individual protective gear and tools.
x
Before doing any maintenance work:
x stop the pump and discharge pressure so the system is at atmospheric pressure.
x disengage power transmission
x work on the pump only when it is still and cold.
x
During operation the pump components can reach very high temperatures (over 100°C). Take
all the necessary precautions to avoid contact.
x
Operators working near the pump must avoid prolonged exposure to the noise source, unless
they are wearing adequate ear protectors.
x
Do not put hands or objects inside the vacuum pump ports when it is running. The rotors can
cause serious injury.
x
Do not start the machine if the safety devices have been removed from the drive line.
Replace damaged guards.
x
Safety valves: direct the air flow away from the operators reach.
Do not use the vacuum pump beyond the set limits of use: risk of breakage and possible harm to
the operators.
5.
INSTALLATION
5.1. COMPULSORY ACCESSORIES
x
x
x
x
x
Exhaust silencer.
Suction silencer for the injection system: use the specific PVT400 silencer.
Overheating alarm to connect to the thermostat on the exhaust port.
Adequate overpressure safety valves.
Undersigned suction filter on the vacuum line to avoid suction of foreign bodies or liquids.
PVT200
Standard air filter
Spark arrester ATEX
PVT400
1445002900
1445003200
14450MNZB0 14450GU6B0
PVT700
1445006300
14450HYJB0
PVT1000
1445006300
14450HYJB0
5.2. CHECKING UPON GOODS RECIVAL
x
x
Remove the packaging and check that all the parts are in perfect condition. Remove the parts
of the packaging that can be dangerous if sucked by the pump
Make sure that the identification plate is fixed to the vacuum pump. Pumps without this
identification plate are to be considered NOT safe, therefore the manufacturer will not take
any liability whatsoever. Contact the supplier.
5.3. STORING IN THE WAREHOUSE
If the vacuum pump will not be installed inside a short time after delivery:
Remove the guards from the ports and spray a film of protective oil over the inner surfaces of
the body, rotors and sides. Then attach again the guards.
x
Store in a closed and dry place. Renew the preserving oil periodically.
x
5.4. INSTALLING THE VACUUM PUMP
x
x
x
When the vacuum pump is installed it must be accessible for maintenance and fitted, with
vibration adsorbing pads, to a bearing frame or level base (Max. admitted angle 3° in all the
directions). The size of the frame must be suitable to support the pump weight and avoid
bending. It is recommended to install the pump on vibration adsorbing pads to reduce the
noise and vibrations produced during its operation.
Leave enough space around the vacuum pump to allow the free circulation of air for cooling;
avoid exposure to dirt and debris.
Leave enough room to access the oil drainage, filling and checking ports.
The oil vent, level control and drainage plugs are mounted correctly during the final inspection in
the factory. Do not change their position
Oil levels, oil vents, filler caps and oil drainages are individual for the front and rear gearboxes.
CAUTION
Any changes made to rotation direction or to the assembly position must be agreed with our
Technical Assistance.
NOTE
The vacuum pump’s rotation direction determines the room taken up by the injection system and
flow direction (see the paragraph 3.2 “Dimensions” page 5).
Legend:
L: oil level (front and rear gearboxes)
CO: filler cap (front and rear gearboxes)
SO: oil drainage (front and rear gearboxes)
PVT200–400–700 with horizontal ports:
SS: gearbox vent (front and rear gearboxes)
ST: seals vent (front and rear gearboxes)
PVT200–400–700 with vertical ports:
PVT200M (with garbox):
6.
VACUUM – PRESSURE LINE
x The diameter of the vacuum and pressure line pipes must be suitable for the pump’s flow rate
(approximate average air speed is 15-30 m/s); in any case, it should not be smaller than the
ports diameter.
x The weight or dimensions of the pipes must in no way stress the vacuum pump body. Use high
temperature resistant rubber sleeves.
x Remove the port guards when mounting. The pipes and components of the whole line must be
clean.
x Avoid constrictions and tight curves where they are not essential.
x The exhaust pipes can reach high temperatures. Protect those adequately from the operator
reach.
x A clapet valve on suction pipe avoids rotation in the opposite direction when the vacuum pump
stops.
x Over-pressure safety relief valve on the vacuum line: install it close to the vacuum pump. Valve
relief flow rate must limits the PVT400 from exceeding a pressure of 1800 mbar or, in any case,
the maximum allowed by the system. Do not interpose shutoff valves on the line between the
pump and the safety relief valve.
x If necessary apply:
x A second shutoff valve or suction filter. Liquids and materials must never reach the pump.
x A venting valve on the suction line, controlled by the thermostat: when the vacuum pump is
overheating, this valve will open a direct connection with the atmosphere and consequently
the pump will suck fresh air ,from the outside, for a better cooling (a 2” valve size can be
enough for a good cooling without loosing too much vacuum rate). Install a silencer filter.
x A 4-way change-over valve to obtain alternatively vacuum or pressure in the system (this is
not required if the pump is used only for vacuum or only for pressure).
VACUUM – PRESSURE LINE
(Vacuum operation)
ITEM DESCRIPTION
1
Vacuum pump
2
Clapet valve
3
4-way change-over valve
(opt.)
4
Overheating safety venting
valve (opt.)
5
Over-pressure safety relief
valve
6
Silencer
VACUUM – PRESSURE LINE
(Pressure operation)
Turning of 90 deg. (from the vacuum
position) the 4-way valve changeover,
the pump can suck air from the exhaust
silencer to pressurize the tank. In this
case it is recommended to control the
pump speed in order to avoid
dangerous overpressure in the line.
NOTE
In case of overheating working under
pressure condition, opening of the
safety venting valve mounted on
suction line will not cool down the
pump.
The only possible solution is to Stop
the pump drive and wait for a proper
cooling.
The clapet valve, on the suction line, avoids opposite rotation of the vacuum pump when it
is stopped under vacuum conditions.
It is recommended to vent the vacuum tank to the atmospheric pressure in the following cases:
x Before servicing the vacuum pump or its drive system. The pressure difference between
inlet/outlet ports can start the machine turning automatically.
x Before starting the machine again: otherwise it would require a higher starting torque.
7.
AIR INJECTION COOLING SYSTEM
(Operating only in the vacuum mode).
x
x
Use only the specific air injection muffler for the PVT, standard or compact.
The minimum pipeline inner diameter (Di) of the injection system must be:
PVT200
PVT400
PVT700
PVT1000
x
x
x
x
Di=98mm
Di=127mm
Di=160mm
Di=190mm
The silencer should be mounted as close as possible to the vacuum pump (max. 1-1.5 m)
and in a position protected against debris and water.
Avoid tight curves.
Avoid pumping nearby heat sources.
Prestare attenzione all’orientamento della valvola a clapet.
An inefficient AIR injection could cause the vacuum pump overheating during the vacuum
operation.
Standard injection muffler
Compact injection muffler
Check weekly the cleanliness of the muffler suchtion port.
Remove all the filth that obstruct the air flow.
8. ALARM DEVICES
8.1 OVERHEATIG ALARM
FUSE
The vacuum pump is supplied
with a thermostatic switch on
the exhaust port.
When reaching the maximum
allowed temperature, the switch
must send an electric signal to
the alarm system or open a
valve on the suction line, to let
the fresh air coming in and cool
the pump
Electric characteristics of the SPDT connector:
x DC power supply: max 220V, 12W dc-13 (control coils data)
x AC power supply:
max 440V, 10A ca-1 (resistive load)
max 440V, 6A ca-3 (start-stop for asynchronous motors)
max 440V, 4A ca-15 (power supply with control coils > 72VA)
Protection: IP67 (IEC 529 e DIN 40050).
Ambient temperature: from -40 to +70°C.
Core hitch: Pg 13.5 for cables from 5 to 14 mm.
Use the NC (normally closed) contact of the switch to control the coils of a power relay. In this way
(see above diagram) the alarm advises also in case of accidental wires damage (safety protection
of the circuit).
Sensor installation:
x The sensor of the thermostat is supplied by us already fitted inside its housing. In case of
disassembling, follow the instruction (above drawing) to reassemble.
x Unwind the protected capillary of the sensor avoiding tight curves or buckling. Fix the unit to
a stable support before proceeding (to avoid vibrations or accidental impacts).
x The thermostat operation can be influenced by the ambient temperature. The setting made
by the manufacturer is correct to work in ambient temperatures between 0°C and 40°C. If
the thermostat is frequently used over said temperature range, it could be necessary a new
setting. Please contact the after sale technical service.
Check the following points to grant a correct operation of the thermostat:
x The spacer sheet keeps the sensor fitted on the lowest part of its housing.
x The fitting sheet must fill the clearance between the sensor and its seat in the housing; this is
important to grant an easy and correct heat transmission.
Overheating can seize the vacuum pump, causing a damage also in the drive line. Stop the
pump for cooling or drive it at free ports conditions (with the suction valves fully opened) to
let it cool down properly. The pump can be again operated only when the alarm is turned
off after cooling.
FITTING SHEET
PROTECTED CAPILLARY
LOCK THE NUT HOLDING
THE THERMOSTAT
HOUSING WITH A
LOCKING NUT
PLASTIC WASHER
SPECIAL COPPER
WASHER
SPACER SHEET
THERMOSTATIC SENSOR
8.2 OIL LEVEL ALARM (OPTIONAL)
FUSE
The vacuum pump can be
supplied with two optical oil
level switches, one in the
front gearbox and one in
the rear gearbox.
When
reaching
the
oil
level
minimum
necessary for the gears
lubrication in one of the
gearboxes, the switch must
send an electric signal to
the alarm system.
Electric characteristics of the K11 oil level switch:
x DC power supply: 10-28V.
x AC power supply: 24V.
Protection: IP65 (IEC 529 e DIN 40050).
Ambient temperature: from -40 to +125°C.
Use the NC (normally closed) contact of the switch to control the coils of a power relay. In this way
(see above diagram) the alarm advises also in case of accidental wires damage (safety protection
of the circuit).
Working with an oil level lower than the minimum recommended leads to a rapid wear of
internal seals, bearings an gears causing the seize of the vacuum pump. Stop the vacuum
pump and refill both the gearboxes with the recommended oil. (Read paragraphs 5.4
“Installing the vacuum pump” (page 21) and 12.1 “Routine maintenance” (page 31)).
9.
DRIVE SYSTEMS
9.1.
BELT DRIVE
Install a suitable pulley on the smooth shaft as close as possible to the pump in order to avoid
excessive bending stress on the drive shaft.
The smaller pulley must have the below specified characteristics to grant the best possible pump
performances:
PVT200
PVT200 Molt.
PVT400
PVT400
PVT700
PVT1000
Max Speed
T Max
S Max
[rpm]
4200
1400
< 2800
>2800 (max3300)
2500
2500
[N]
3000
3800
5000
5000
6500
11500
[mm]
50
35
55
55
75
87
Min Pitch
diameter
[mm]
180
250
160
180
250
250
Grooves
n°
4 x SPA
4 x SPB
5 x SPB
5 x SPB
4 x SPC
5 x SPC
Belt
type
XPA
XPB
SPBX
SPBX
XPC
XPC
ATTENTION
A higher radial load given by a larger belts number or a pitch diameter smaller than recommended,
will stress the shaft and front bearing excessively.
Align the pulleys correctly and do not tighten the belts too much: follow the belt manufacturer’s
indications. In all cases, do not exceed the maximum load allowed on the pump shaft (see
diagram).
NOTE
A limited speed ratio will extend the belts life and reduce stress on the shafts. When possible
prefer:
x
pulleys with a pitch diameter bigger than the one indicated.
x
engines or power take-offs with a speed similar to the one of the vacuum pump.
9.2.
HYDRAULIC DRIVE
The PVT HDR vacuum pump is completed with a fixed displacement high pressure motor suitable
for open or closed type oil circuits.
x Motor specifications
PVT200 HDR
PVT400 HDR
PVT700 HDR
PVT1000 HDR
Motor
displacement
[cc/rev]
19.6
51.3
110
125
Max. working
pressure
[Bar]
350
420
310
400
Max. drainage
c-pressure
[Bar abs]
1.5
2.5
2.5
2.5
Max. body
temperature
[°C]
90
90
80
80
x Oil flow and pressure: to be defined according to the vacuum pump speed rotation.
x Fluid: mineral oil for hydraulic systems HLP DIN51524.
Temperature
Viscosity
[°C]
-20 / +90
[cSt]
10 - 80
Optimal viscosity
range
[cSt]
15 - 30
Max. viscosity
(at start up)
[cSt]
1000
Find the suitable fluid viscosity according to the working temperature.
Working temperature (°C)
Viscosity (cSt) at 40°C
30°C – 40°C
22
60°C – 80°C
46 o 68
x Filtering: class 18/13 in accordance with ISO 4406.
x Check the oil line connections that must logically following the rotation direction of the
vacuum pump (see the diagram on the right)
PVT200 HDR
PVT400 HDR
PVT700 HDR
PVT1000 HDR
Drain Threaded
G3/8
M22x1.5
M18x1.5
M18x1.5
In-Out Flange
SAE ¾” 6000 psi
SAE ¾” 6000 psi
SAE 1¼” 6000 psi
SAE 1¼” 6000 psi
IN OUT HDR MOTOR
SAE ¾" 6000 psi
IN OUT HDR MOTOR
SAE 1¼” 6000 psi
Drainage: connect this line to the oil tank, to avoid dangerous pressure peaks in the hydraulic
motor.
Max absolute counter-pressure: 2.5 bar
NOTE
x It is recommended to avoid rotation in the opposite direction when the vacuum pump stops; this
because it could damage the hydr. motor whether the circuits are open or closed (see also the
“Vacuum – Pressure Line” paragraph). The hydraulic circuit must be protected against
overpressures.
x Check the rotation speed, using the inductive sensor mounted on the hyd. motor bracket.
Connect it to an electronic rev counter, suitable for 2 kHz max inductive sensors, and set the
teeth number at z:
PVT200 HDR
PVT400 HDR
PVT700 HDR
PVT1000 HDR
10.
Z (teeth number of the inductive sensor gear )
34
34
2
2
SYSTEM STARTUP
Check the oil level, in the front and rear gearboxes.
Be assured that all the guards, protections, safety devices and the overheating alarm are installed
correctly.
Make sure there are no obstructions in the vacuum line, in the pressure line or in the air injection
system.
Verify rotation direction: open all the system’s valves and start slowly.
Rotation in the wrong direction is allowed at slow speed: possible damage to the line and/or
vacuum pump.
Close the valves and increase pressure or vacuum rate.
Check speed under load and operation: absence of anomalous noise or vibrations. Check
effectiveness of the overheating alarm.
11.
OPERATING SUGGESTIONS
The manufacturer declines all responsibility for damages caused if the installation,
operating and maintenance instructions are disregarded.
x
When the overheating alarm advises the operator that the maximum operating temperature
has been reached:
x
Stop the vacuum pump and wait until it has cooled down.
x
If possible drive it with all the valves opened for the time necessary to a proper pump
cooling.
x
x
x
x
Work can be started again only when the temperature has returned to normal values.
If the alarm triggers often during normal use, it is necessary to check the conditions of use
(temperature, pressures, speed) and the conditions of the system.
When ambient temperatures are very low (like in the winter for instance), exhaust
temperatures are lower than usual and the overheating alarm does not advise even if you are
working at high speed and with high vacuum levels. We recommend not to exceed a
temperature difference of 130°C between incoming and outgoing air, to avoid anomalous
deformation of the components and block/seize the vacuum pump. After operation in dusty
environments, after accidental sucking of liquids inside the pump or before a long
inoperativity period it is recommended to wash the pump inside according to the following
procedure.
Before washing the pump, be sure that it has cooled down. To obtain this in a short time, it is
possible to run the pump for a few minutes at zero vacuum conditions, or stop it at all.
It is recommended to avoid doing maintenance on the pump when it is very hot.
x
x
x
x
Use 1-2 liters of water mixed with a non-flammable detergent. We suggest some
product like Henkel P3 Neutrasel 2860 IT: 5% concentration in water. This detergent
grants a good protection against rust and oxidation.
Use one of the openings placed in the vacuum line (closet o the pump) to suck some
water mixed with detergent.
Start the pump at low speed (about 1000 rpm for PVT200-400 and 500 rpm for
PVT200M-700-1000) leaving opened all the suction valves in the tank, in order to keep
low the vacuum rate (max vac. 10-20%). Let the detergent mix entering the pump very
slowly.
The detergent mix stays suspended in the pump inside, before being expelled through
the exhaust silencer.
After keeping the pump speed for a while to make the product reaching the internal
parts, it is necessary to dry the pump preventing oxidation. When the detergent mix is
finished, continue running the pump at the lo west possibile vacuum rate for a few
minutes, then close venting and suction valves up to 50-60% maximum, for a couple of
minutes. With this operation the pump will dry from the heated air and protected from
the chemical attack of the detergent.
After doing the above procedure, we recommend to lubricate again the internal
parts sucking We recommend to avoid doing the above procedure with the pump
hot after long operation. Let the pump cooling down to the ambient temperature
before proceeding with any maintenance operation..
12. MAINTENANCE
12.1.
ROUTINE MAINTENANCE
Observe the safety instructions given in the “Safety and preventing accidents” paragraph
before starting any maintenance work.
PUMP STATUS
OPERATING
STOPPED
CHECK
FREQUENCY
Pressure
Daily
Rotation speed
Daily
Temperature
Daily
Noise (this is also for the hydraulic motor)
Daily
Oil level
Weekly
Oil change in the front and rear boxes
500 h - 5000 h
Filters and second shutoff valves on the
vacuum – injection line
Weekly
NOTE
x Check the oil level in both gearboxes (front/rear) when the pump is still and cold. Oil
sight, refill and drainage are showed in paragraph 5.4. “Installing the vacuum pump”
x The first oil change must be done inside 500 hours operation. Following changes every
5000 hours or 12 months.
x
ATTENTION
OPTIMUM LEVEL
MINIMUM LEVEL
x The level of oil must not drop below minimum otherwise there is the risk of rapid wear of the
internal components.
x Accidental breakage of the internal seals will cause the drop of the oil level in both the boxes. It
is recommended to check frequently the oil level: daily or weekly as maximum, because
frequents oil refills is a clear signal of worn out seals.
x
x
x
Dispose of used oil in accordance with the current standards.
When changing the oil, also replace the washer on the drainage plug.
Check the drive system: follow the manufacturer’s instructions.
Quantity of oil in the front and rear boxes:
PVT200
PVT200
PVT200 M (Overdrive)
PVT400
PVT400
PVT700-1000
PVT700-1000
Ports
Disposition
Horizontal ports
Vertical ports
Horizontal ports
Horizontal ports
Vertical ports
Horizontal ports
Vertical ports
Front box
(shaft side)
0.4
0.6
1.1
0.65
1.2
2
3.5
Rear box
0.55
0.9
0.55
0.5
0.9
1.5
2.5
Recommended lubricant: synthetic gear oil:
TENNEX FACTOR SYNT ISO VG 150
In case this oil is not available, it is possible to refill the level with a gear oil composed of
polyalphaolefine (PAO).
Mark
CASTROL
FUCHS
KLÜBER
ISO VG150
ALPHASYN
RANGE 150
RENOLIN
CLP 150
KLÜBERSYNT
H EG 4 150
MOBIL (ESSO)
SHELL
TOTAL (ELF)
SHC 629
OMALA OILS
RL 150
CARTER SH 150
It is recommended to refill the oil level always with the same type: avoid mixing of various oil types.
12.2.
EXTRAORDINARY MAINTENANCE
With the exception of the cases described below, extraordinary maintenance on a PVT must be
done by specialized personnel, otherwise the guarantee will be invalidated.
Comply with the safety instructions given in the paragraph 4. ”Safety and accident
prevention” (page 20) before starting any maintenance work.
Replacing the front Y-seal (PVT200 M (with Gear Box), PVT400, PVT700)
x
x
x
x
Remove the transmission.
Clean the front flange (1) and remove.
Replace the sealing ring (3). (Spread the Yseal lip with high temperature grease 220°C
NLGI2).
Change the gasket (2) and fit the flange back
on its seat. Do not damage the sealing lip or
turn it over when remounting.
PVT200 M
PVT400
PVT700-1000
PVT700-1000
HDR
Gasket Code
(2)
1680708700
1680708400
1680710500
Y-seal Code
(3)
4022200412
4022200425
4022200152
1680701400
4022200152
Replacing the front Yseal (PVT200)
x
x
x
x
x
Remove the transmission.
Unscrew the drainage plug (SO) of the front cover and empty it.
Remove the front cover.
Replace the Yseal (3). (Spread the Y-seal lip with high temperature grease 220°C NLGI2).
Change the gasket (2) and fit the flange back on its seat. Do not damage the seal lip or turn it
over when remounting.
x Refill with oil (recommended synthetic gear oil) the front box. Check the oil level sight (L). (read
paragraph 5.4 “Installing the vacuum pump” page 21).
PVT200
Gasket Code
(2)
1680709600
Y-seal Code
(3)
4022200154
Common maintenance (PVT200, PVT200Molt, PVT400, PVT700):
Cleaning the rotors and body
This is necessary to eliminate hard formations.
x Remove the pipes from the suction and exhaust ports.
x Clean the inside surface of the body and rotors with solvents and scrape without scratching.
Checking the clapet valve on the injection
Check it periodically to avoid the accidental suction of solid particles inside the vacuum pump.
x
Once a year: change the O rings.
x
Once every 3 years: change the clapet and related screws and washers.
Replacing the rock wool of the compact air injection muffler
It is possible to replace the internal rock wool of the compact injection muffler if its noise level
increase.
The spare part code of the rock wool is 4022213600 and the quantity is reported on the side table.
x
x
x
x
x
x
Remove the muffler cover.
Extract the exhausted rock wool.
Clean the internal surfaces of the muffler with a solvent.
Insert the new rock wool.
Check the cleanness of the internal air injection duct before
closing the muffler with his cover.
Close the muffler with his cover..
Rock
wool
[Kg]
2.5
.
PVT200
PVT200M
PVT400
PVT700
2.5
2.5
8.5
Cleaning the seals venting plugs
Remove the seals venting plugs (Label ST in pharagraph 5.4
“Installing the vacuum pump” page 21) and clean them with a
solvent.
Do not use compressed air and/or solvents in the seals
venting ducts in the pump benches. Internal seals can
be damaged
In the seals venting ducts: Do not use Solvents !
Do not use Compressed air!
………………………………………………………………………………….……….
13. TROUBLESHOOTING
Reduced performances
Speed not correct
Check and restore
Pipes and/or filters clogged or leaking
Check conditions and restore
Pipes are undersized
Check the maximum pump performance
Safety valves not adjusted
Check and adjust correctly
Overheating
Ambient and/or suction
temperature is too high.
or
injected
air
Reduce pressure or vacuum rate
Inefficient air injection
Check that the suction port of the air injection
muffler is clean, check condition of the injection
line and clapet valve.
Pipes are undersized
Check, close to the pump ports, the effective
suction and delivery pressure. Do not exceed
operating limits.
Oil leakage
Front sealing ring is worn
Replace it
Level indicators broken
Replace it
Oil leakage from internal seals.
Check the pump inclination (max. 3°).
If this is not enough to solve the problem, contact
the after sale Service to check the linternal seals.
Oil in the exhaust port.
Abnormal vibrations or noise (stop the vacuum pump)
The rotors are getting in contact
Temperature is over the max working limits (T2 >
160°C and/or T2 – T1 > 130°C: see par. 11). Stop
the pump and leave it cooling. Start again only
after the alarm has reset.
Rotors with hard formations on the surface
Inner wash of the pump (read page 30).
Remove the in/out pipes and clean rotors and
housing.
Suction of liquids or foreign bodies
If they have caused incrustations, the pipes must
be removed and the rotors must be cleaned.
Not uniform power transmission
Check the operating conditions. Do not install
propellers too much angled.
14. SCRAPPING
The pump can be scrapped according to the current rules.
If the scrapping is made by the end user company itself, all the different materials must be
separated and discharged in special collection areas.
x lubricating oil
x parts in rubber and plastic
x parts in cast iron, steel and aluminium.
Do not leave them in the environment.
Do not use as spare parts the dismantled parts that have to be scrapped.
15. REQUEST FOR SPARE PARTS
When ordering spare parts please provide the following information:
Referring to the spare parts drawing:
x code
x description
x no. of pieces needed
(e.g.: code 1680708400; Front flange seal; 1 pc)
Referring to the vacuum pump data plate:
x model
x serial number
(e.g.: PVT400; H90004)