IN-ECO ORV 8 Bedienungsanleitung

Installation and

Operating Instructions

Rotary Vane Vacuum Pumps ORV

ORV 8, ORV 10, ORV 16, ORV 20, ORV 40, ORV 63, ORV 100,

ORV 160, ORV 200, ORV 250, ORV 300, ORV 630

IN-ECO, spol. s r.o.

Radlinského 13, 034 01 Ružomberok, Slovak Republic

Telefón: +421/44/4304662, Fax: +421/44/4304663

www.in-eco.eu, e-mail: [email protected]

www.in-eco.eu

Air and Vacuum

Components

TABLE OF CONTENTS

We reserve the right to change the product at any time without any form of notication. The information in this publication

is accurate to the best of our ability at the time of printing. Company IN-ECO will not be responsible for errors

encountered when attempting to perform tasks outlined in this publication which is copyright protected.

GENERAL

Identication 2

Operating Principles 2

1.0 INSTALLATION 2

1.1 Unpacking 2

1.2 Location 2

1.3 Power Requirements 2

1.4 Vacuum Connections and Drip Legs 3

1.5 Oil Filling 3

2.0 OPERATION 4

2.1 Start-up 4

2.2 Gas Ballast 4

2.3 Process Gas 4

2.4 Stopping Pump 5

3.0 ROUTINE MAINTENANCE 6

3.1 Pump Oil 6

3.1.1 Oil Filter 6

3.1.2 Oil Type and Quantity 6

3.1.3 Oil and Filter Change 6

3.1.4 Oil Flushing procedure 7

3.2 Automotive-Type Oil Filter 8

3.3 Exhaust Filter 8

3.4 Inlet Flange 8

3.5 Vacuum Inlet Filter (optional) 9

3.6 Routine Maintenance Schedule 9

3.7 Overhaul Kit/Filter 9

4.0 TROUBLESHOOTING 9

5.0 LIMITED STANDARD WARRANTY 14

Technical Data 14

Part list 15

Illustration of ORV 25 - ORV 40 16

Illustration of ORV 63-100 17

Illustration of ORV 160, 1200, 250, 300 18

Page

GENERAL

Identication

For model identication, see the nameplate mounted on the side of the exhaust box..

This manual is written to cover ORV versions of models ORV 20, ORV 40, ORV 63, ORV 100, ORV 160, ORV 200, ORV 250, ORV 300,

ORV 630. For example, it would appear as follows: ORV 20

When ordering parts, it is helpful to include the serial number from the nameplate.

Operating Principles

All reference (Ref. XXX) numbers listed in the text and on illustrations throughout this manual are related to the drawings and parts list

shown later in this publication.

All ORV Series, Single Stage, Rotary Vacuum Pumps are direct-driven, air-cooled, oil-sealed, rotary vane pumps that operate as positive

displacement pumps. They consist of a rotor positioned eccentrically in a cylindrical stator (see Fig. 1). The rotor has three radially sliding

vanes which divide the pump chamber into three segments. When the rotor spins, centrifugal force pushes the vanes, which glide in the

slots, towards the wall of the cylinder. The rotor has three vanes which divide the pump chamber into three segments. The gas to be

pumped enters at the inlet port, passes through the inlet screen and the open anti-suck-back valve into the pump chamber. As the rotor

rotates, the inlet aperture is closed, the gas is compressed and forced out through one-way valves between the pump cylinder and the

exhaust box. This operation is repeated three times each revolution.

1.0 INSTALLATION

1.1 Unpacking

Inspect the box and pump carefully for any signs of damage incurred in transit. Since all pumps are ordinarily shipped FOB our factory,

such damage is the normal responsibility of the carrier and should be reported to them.

Remove the nuts from the bottom of the box/crate and pull the pump out of the container, then unscrew the studs from the bottom of the

rubber feet.

The inlet port of the pump is covered with a plastic cap prior to shipment to prevent dirt and other foreign material

from entering the pump. Do not remove this cover until the pump is actually ready for connection to your system.

1.2 Location

The pump must be installed in a horizontal position on a level surface so that the pump is evenly supported on its rubber feet. Allow suf-

cient air space between the pump and any walls or other obstructions; adequate ventilation must be provided for the fans on the pump

and motor (i.e., do not locate the pump in a stagnant air location).

Whenever the pump is transported, be sure to drain the oil prior to shipping to avoid vane breakage when restarting the pump.

Do not tip the pump over if it is lled with oil.

Locate the pump for easy access to the oil sight glass (Ref. 83) in order to inspect and control the oil level properly. Allow clearance at the

exhaust ange area to provide service access to the exhaust lters.

1.3 Power Requirements

The schematic diagram for the electrical connection is located in the junction box or on the nameplate of the pump motor.

The motor must be connected according to the electrical codes governing the installation. The power supply must be routed through a

fused switch to protect the motor against electrical or mechanical overloads. The motor starter has to be set consistent with the motor

current listed on the motor nameplate.

If the pump is supplied with a manual motor starter, it is preset at the factory in accordance with the customer’s

specication. For other voltage requirements, contact the factory for motor and/or starter information.

Note: See the motor manufacturer’s manual for startup maintenance of the motor.

Correct direction of rotation is marked by an arrow on the motor fan housing and is counterclockwise when looking at the motor from the

motor‘s fan side.

Rotary Vane Vacuum Pump ORV 8

1 - Directional arrow

2 - Suction connection with non-return valve

3 - Gas discharge

4 - Exhaust cover

5 - Exhaust lter

6 - Oil ll plug

7 - Oil drain plug

8 - Oil sight glass

1 - Directional arrow

2 - Suction connection

3 - Gas discharge, Exhaust cover

4 - Exhaust lter

5 - Oil ll plug

6 - Oil drain plug

7 - Oil sight glass

1 - Directional arrow

2 - Suction connection

3 - Gas discharges

4 - Exhaust lter

5 - Oil ll plug

6 - Oil drain plug

7 - Oil sight glass

8 - Oil lter

Rotary Vane Vacuum Pump ORV 10 - ORV 20

Rotary Vane Vacuum Pump ORV 40 - ORV 300

CAUTION: After the electrical connection

has been made, but before the pump is

lled with oil, the rotation of the motor

must be checked. Open the inlet port and

jog the motor briey to make sure rotation

is correct. If it runs backwards and if it is

wired three phase power, reverse any two

leads of the three at the power connection.

CAUTION: The built-in, anti-suck-back valve

is not positive action; do not use it as a system

check valve.

1.4 Vacuum Connections and Drip Legs

Use a line size to the vacuum system that is at least as large as that of the pump inlet. Smaller lines will result in lower pumping speeds

than the rated values.

Install a drip leg and drain on the vertical pipe near the pump inlet. Also, when installing discharge piping, a drip leg should be installed.

Drain the drip legs often to remove any condensation which may have collected.

If more than one vacuum pump or a receiver tank is connected to a common main line, each pump should have its own manual or au-

tomatic operated shut-off valve or positive action check valve. The built-in, antisuck- back valve should not be used as a shut-off valve

for the vacuum system.

Remove the plastic protective cap from the inlet port prior to connection of the pump to the system. Vertical connection of the vacuum

line can be made directly to the pump inlet (Ref. 260).

Type and size of the inlet connections of the ORV Series pumps are shown in the TECHNICAL DATA page 14.

If the gas that is pumped contains dust or other foreign solid particles, a suitable inlet lter (10 micron rating or less) should be con-

nected to the inlet port. Consult the factory for recommendations.

1.5 Oil Filling

The pump is shipped without oil. After level installation, and after correct rotation has been established and with the pump switched

„off“ and secured against accidental start-up, ll the pump with the recommended vacuum oil through the oil lling port (Ref. 88), ob-

serving the „MAX“ and „MIN“ position at the oil sight glass (Ref. 83).

Non-detergent oil should be used. Do not use detergent motor oil as additives in detergent oil will plug exhaust lter elements and

shorten their life.

Exhaust lter

Exhaust

Inlet

Inlet screen

Anti-suckback valve

Vane

Rotor

Main oil feed line

Automotive type

spin-on lter

Oil sight glass

Exhaust valve

Oil return valve

Oil return line to inlet*

Gas ballast

Fig. 1 - Principle of ORV Pump

It is recommended that OV500 Series oil be used to receive the best performance from your vacuum equipment. OV500 Series oil is

a high quality vacuum oil that will give longer running time between oil changes, will provide better lubrication at high operating

temperatures, and will prolong the life of exhaust lter elements. This oil can be obtained directly from IN-ECO company.

The strict use of IN-ECO oils and parts from the day of purchase can extend the life of the vacuum pump.

For general applications, use OV530 in all models covered by this manual. Use OV590 or OV570 in pumps that are operated in high

ambient temperatures (above 90°F) or when the oil carbonizes (turns black) before the change interval.

Use OV590 or OV570 on ORV 250 pumps. Contact the factory for recommendations when using other oils.

OIL TECHNICAL DATA

Type oil OV530 OV568 OV570 OV590

Flash Point (COC)°, min.: °C 237 254 271 252

Pour Point, max.: °C -17 -43 -48 -12

Viscosity at 40°C (mm2/s) 106.2 79.27 108.74 120.8

Viscosity at 100°C (mm2/s) 11.3 7.91 16.15 12.5

Viscosity Index 91 63 145 100

The TECHNICAL DATA chart on page 14 gives the approximate quantities of oil required for each pump. The oil capacity chart should

only be used as a guide, since oil capacity may be slightly lower, depending on whether the pump was lled previously, and whether all

components such as oil lter, oil lines, etc., were allowed to completely drain. Use only the sight glass reading for proper level. Never

overll!

WARNING: Keep the oil ll plug tight as pressure in the exhaust box could cause bodily injury if

the plug is blown out. Do not ll/add the pump with oil through the exhaust/inlet ports as there is

danger of breaking the vanes!

For ambient operating temperatures lower than 5 °C, use OV580 synthetic oil. If this does not help (where the pump has difculty

starting due to high oil viscosity), contact the IN-ECO company.

Replace the oil ll plug (Ref. 88), making sure that the gasket (Ref. 89) is in place and properly seated and secured. Some pumps are

equipped with an exhaust pressure gauge as an integral part of the oil ll plug. Switch the power back into the „on“ position..

2.0 OPERATION

2.1 Start-up

Check rotation of the motor as described in Section 1.3.

- Power Requirements

Fill the pump with oil as described in Section 1.5.

- Oil Filling

Start the pump and immediately close the inlet. Run the pump for a few minutes before checking the oil level again. With the pump

shut off, the oil level should be visible in the oil sight glass (Ref. 83), between the „MIN“ and „MAX“ mark.

Add oil, if necessary, but only add it when the pump has been shut off and the circulating oil has had sufcient time to return to the oil

sump.

Note: The oil separated by the exhaust lter element forms droplets on the outside of the exhaust lter that collect at a low point in

the upper half of the exhaust box. From there the collected oil is drained back to the oil sump via an oil check valve (Ref. 275) which

opens on ORV model pumps when the pump is shut off. It is necessary to shut off the ORV model pumps after every 8 hours of opera-

tion to allow the check valve to open. If the pump is not shut off after this time period, it is possible to starve the pump of oil since the

oil is not allowed to drain back into the oil sump and/or oil droplets may be blown out of the exhaust. If the pump is operating at high

pressure it may be necessary to shut it down sooner than 8 hours.

2.2 Gas Ballast

All ORV Series pumps are equipped with a gas ballast valve. The gas ballast valve (Ref. 440) is located between the inlet port and

the exhaust box. ORV series pumps are equipped with a permanent gas ballast which cannot be shut off unless the sintered lter is

removed and the orice plugged. Larger pumps are equipped with an adjustable gas ballast valve.

The adjustable gas ballast valve should normally be left open. Its primary function is to prevent water vapor from condensing in the

pump. Condensation causes emulsication of the oil, loss of lubricity, and possible rotor seizure.

2.3 Process Gas

The ORV series pumps are designed to pump air and are not intended for use when water vapor is being pumped. In some applica-

tions, when the quantity of the water vapor is moderate, ORV pumps have been used with good results. On these occasions, the pump

is run until it is up to operating temperature before it is allowed to pump the process gas. The pump is also operated for a period of time

off process and on air (to clear it of process gas) before it is shut down. This operating technique prevents the vapor from condensing

in the pump. Before attempting to pump a gas laden with water vapor, contact IN-ECO company for advice.

2.4 Stopping Pump

To stop the pump, turn off the power. The pump has a built-in, anti-suck-back valve (Ref. 251 thru 255) to prevent the pump from

rotating backwards when it is shut off.

CAUTION: Do not use the anti-suck-back valve as a system check valve for your vacuum system.

Do not depend on the anti-suck-back valve to prevent pump oil from migrating through the inlet

into the system when the pump is shut down.

Install an automatic operated valve (such as a check valve) in front of the pump, if more than one pump is pumping on the same line or

if there is a sufcient volume of vacuum in the system to cause the pump oil to be drawn into the piping when that pump is shut down.

All ORV Series pumps are vented internally to atmospheric pressure through venting holes that are next to the exhaust valve assembly.

3.0 ROUTINE MAINTENANCE

ORV Series pumps require very little maintenance; however, to insure optimum pump performance, the following steps are recom-

mended.

3.1 Pump Oil

3.1.1 Oil Level

CAUTION: Do not add oil while the pump is running since hot oil vapor may escape through the

oil ll port.

CAUTION: Insufcient oil quantity in the pump has the potential, under certain conditions,

to lead to self-ignition of the remaining oil in the pump.

With the pump installed relatively level, make sure that there is sufcient clean oil in the pump. The oil level should be observed on a

daily basis and/or after 8 hours of operation and should be replenished if it drops below the 1/4 mark on the oil sight glass on pumps

with one sight glass.

On ORV Series pumps, you must rst shut the pump off in order to let the oil ow back into the oil sump prior to checking the sight

glass. Allowing insufcient time for the oil to drain back into the sump on ORV Series pumps prior to adding oil could result in overlling.

Oil level readings should be done only when the pump is turned off. Oil can be added to the oil ll port (Ref. 88) if the pump is shut off

and the circulating oil has sufcient time to return to the oil sump. The oil might appear to be foamy, which is a normal phenomenon

with aerated oil.

Under normal circumstances, it should not be necessary to add or drain oil from the pump between recommended oil changes.

A signicant drop in oil level means there is an oil leak or that an exhaust lter is broken, and the pump should be smoking excessively.

It is normal for the oil to be foamy and light in color in an operating pump. However, if the oil is milky colored, it is an indication

that water is present in the oil. Normally, by operating the pump for an extended period, with the inlet suction blanked off and the gas

ballast (Ref. 440) open on ORV pumps, the water will be purged from the oil. If the oil is dark colored, it is contaminated or carbonized

and must be changed. Depending on the severity of the contamination, a thorough ushing may be needed. Contact the IN-ECO

company for ushing oil (OV 568) and refer to Section 3.1.4 for the ushing procedure.

3.1.2 Oil Type and Quantity

See Section 1.5 - Oil Filling for details on oil type and quantity.

3.1.3 Oil and Filter Change

CAUTION: When changing the oil and lters, it may be necessary to ush the pump to remove any

build-up of degraded oil from the sumps, oil lines, radiators, etc., to ensure proper oil ow through

the pump. Reduced oil ow, especially through radiators and cooling coils, can cause mechanical

damage or extreme overheating, which could cause the oil vapors to ignite.

WARNING: Always take the necessary precautions concerning personal protective equipment

when changing oil and make sure the pump is switched to „off“ so that accidental starting will

not occur. Oil temperature can reach 100 °C and may pose a danger of scalding.

See Section 1.5 and the Technical Data on page 14 for details on oil type and quantity.

Check the oil for contamination on a weekly basis by shutting the pump off and draining some of the oil into

a small glass or a similar transparent container through the oil drain port (Ref. 95).

Oil life is dependent upon the conditions to which it is exposed. A clean, dry air stream and an oil operating temperature under 99 °C

are ideal conditions. When using OV530 (hydrocarbon oil), it is recommended that oil changes are made every three (3) to four (4)

months or 500 to 750 hours of operation, or as necessary if high heat is contaminating the oil. The use of OV570 (synthetic) or OV590

(semi-synthetic) oil may signicantly extend the operating hours between oil changes under ideal conditions. However, you may need

to ush out the pump before changing. Contact the factory Service Department for advice. Oil samples should be taken regularly when

exceeding the 500-750 hour recommendation.

Excessive Heat

When the pump is subjected to operating conditions that will cause the oil to be heated above 99 °C, the oil will carbonize and become

contaminated after a relatively low number of operating hours. The higher the temperature, the quicker the oil becomes contaminated.

If the oil temperature is too severe, OV570 (synthetic) or OV590 (semi-synthetic) oil should be used to withstand the elevated tempera-

tures. If synthetic oil is used, the pump should be ushed with OV568 oil. Contact the factory for instructions on the ushing procedure.

Auxiliary oil cooling is the most practical approach to a severe heating problem.

Contaminated Air Stream

When the air stream contains a solid and/or liquid that can contaminate the oil, it must be changed more often. If the air stream con-

tains a small percentage of contaminates and/or they are slightly aggressive* (mild acids, etc.), synthetic oil, such as OV570, will resist

breakdown better than the standard OV530. The solution is to install a lter or knock-out pot to keep the contaminates out of the pump.

*Process air streams with a large percentage of contaminates and/or more than slightly aggressive contaminates must use a chemical duty pump.

Oil change intervals can only be established by experience with the pump operating in the actual conditions (see previous paragraph

for some of the conditions). Develop the oil change interval by periodically checking an oil sample removed from the pump. When the

oil sample has become dark in color (from solids and carbonized particles) or is milky looking (from water), it is time to discard it. As

mentioned before, a thorough ushing may be required.

3.1.4 Oil Flushing Procedure

Flushing is needed under certain conditions. Some pumps will be beyond ushing and will need to be overhauled.

To help determine if ushing is needed, observe the condition of the oil as it is drained from the pump. Is it black and tar like or contami-

nated in any way? Was the pump noisy, overheating, or was the motor overload shutting the pump off? How old is the pump and when

was the last time the oil was changed?

If the above conditions exist or you don‘t know when the last oil change was performed further investigation is needed. Also, when

changing from one oil type such as OV530 to another type such as OV590 or OV570 it will be benecial to ush. Although the oils are

compatible, mixing a lesser grade oil such as OV530 with a synthetic oil like OV570 will reduce the effectiveness of the synthetic oil.

All of the oil will be removed and replaced with the ushing oil (OV568), and eventually that will be replaced by whatever OV oil is

needed for your particular application. Have enough oil and oil lters on hand for a couple of ushes. The following describes the steps

in the ushing procedure:

Shut the pump off and drain all the oil from the pump and remove the access plates (Ref. 205) from the exhaust box (Ref. 075). Remo-

ve the metal bafe (Ref. 078) and take a good look at the internal walls of the oil sump. If the walls are discolored but have no build up

of any kind one can proceed with the ushing. If gelled or burnt oil is clinging to the walls this material must be scraped and removed

prior to ushing. Proceed by scraping and cleaning as much of the exhaust box as possible. The more debris that is removed now the

more effective the ushing will be later. Re-install the metal bafe, cover and proceed with the ushing. At this point one must remem-

ber that the oil lines and oil cooler might also be plugged to a point where no amount of ushing will make a difference and a complete

overhaul will be the only option. Depending on the severity of the oil contamination ushing may be a last ditch effort.

Drain all of the oil from the pump. The more contaminated oil you remove now the more effective the oil ushing will be.

Remove the oil lter (Ref. 100) and install a new one. It is recommended that you do not change the exhaust lter

or lters until after the ushing to prevent contamination of any new lters.

Fill the exhaust box with the proper amount of ushing oil (OV-568).

If possible run the pump with the inlet closed and off of the process. Run the pump for approximately six hours, shut the pump off and

drain a small sample of oil into a clear container.

Examine it. If it is clear to amber run the pump for another six hours and examine it again. If after the rst six hours it is black drain it

and ll again using another new oil lter.

If after the second ushing the oil still remains black the pump may have too much contaminated oil in it to ush out properly. There

may be residue remaining in the lines and cooler that will not ush out. An overhaul will be necessary.

If after the second six hour period the oil still remains clear to amber in color drain it, change the oil lter and ll with the regular oil. At

this point also change the exhaust lters.

Run the pump with a fresh charge of the oil to be used in your application (not OV-568), and monitor the operating

conditions closely. Check for noise, overheating and oil condition until a regular oil change schedule can be established.

Do not let the oil turn black. Change it before it fails. If the oil is kept in good condition the pump will last for years. If the oil starts to

turn black do not hesitate to ush again. Keeping on top of the oil changes will prevent costly overhauls.

3.2 Automotive-Type Oil Filter

The pump is equipped with an automotive-type oil lter (Ref. 100). When replacing the automotive-type oil lter,use only a IN-ECO

company genuine lter.

Note: Make sure to tighten the IN-ECO oil lter securely against the aluminum sealing surface so that leaks will not occur.

3.3 Exhaust Filter

WARNING: If the gas entering this pump is a health hazard, use rubber gloves and all necessary

personal protection equipment when performing the exhaust lter replacement operation.

Every nine (9) to twelve (12) months, or as necessary, replace the exhaust lter elements. The service life of the exhaust lters varies

widely with pump application. It is only necessary to change the lters when the elements become clogged with foreign material or burned

oil. Indications of clogged lters are smoke and oil mist coming from the pump exhaust, higher than normal motor current or oil leaking

from the gas ballast valve on ORV models.

In order to replace the lter, remove the four socket head cap screws (Ref. 146 on 0025 through 0101 / Ref. 142 0n 0250) and lockwashers

(Ref. 143) retaining the exhaust port housing (see Fig. 3). Pull the housing off the exhaust box and set it aside. Use a slotted head

screw driver to loosen the exhaust lter retaining spring, then rotate and remove the spring (see Fig. 4). Pull the lter cartridge (Ref. 120)

out of the exhaust box.

WARNING: Wear safety glasses when installing or removing the spring retainers. The retainers can, if not

secured correctly, slip off and y out of the exhaust box.

To eld test an exhaust lter element, remove it from the pump, allow it to cool, clean the sealing end (or Oring end), and use compressed

air to blow through the element. Apply approximately 3 to 6 psi (maximum allowable operating pressure across the lter)..

WARNING: Do not inhale through the lter or allow your mouth to come in direct contact with the lter.

Fig. 3 - Removing the Exhaust Housing Fig. 4 - Removing the Filter Spring

Use a shop rag to seal off the connection between the air hose and the lter. If you can blow through it, the element is good. If not, discard

it and install a new one. The lter cannot be cleaned successfully. Visually inspect the lter element for cracks.

Reinstall the lter elements. Make sure the open end of the element is properly seated down in its recess in the exhaust box with the

O-ring (Ref. 121) correctly positioned. Retain the lter with the spring clip, tighten the tension screw until the lter is secure. Place the

exhaust port gasket and cover in position on the exhaust box and retain with the cap screws.

3.4 Inlet Flange

The standard inlet ange assembly contains an inlet screen (Ref. 261) which may require occasional cleanly. The frequency of cleaning

can only be determined by experience and is affected by hours of operation and particle size being trapped. An optional vacuum inlet lter

is offered and can help minimize the need or frequency of cleaning the inlet screen.

To clean the screen, disconnect the ange from the process piping. Remove the four screws and lockwashers (Ref. 265/266). Remove

the inlet ange (Ref. 260). Remove the screen (Ref. 261) and clean with compressed air. After cleaning, install the screen and

inlet securing them with the screws and lockwashers. Make sure the O-ring (Ref. 265) is in place prior to securing the screws. Reattach

the process piping to the inlet.

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