LEYBOLD OF-1000, Operating Manual

Page 1: ...LEYBOLD Vacuum Solutions Application Support Service VACUUM PRODUCTS INC Part Number 772 78 009 Edition N OF 1000 OIL FILTERING SYSTEM MANUAL Operating Manual ...

Page 2: ...explanation o psig 30 to 55 psig 5 to 30 psig 50 psig 3 75 quarts of hydrocarbon oil or 15 pounds of perfluoropolyether 7 5 quarts of hydrocarbon oil or 30 pou nd s of perfluoropolyether 4 feet long x 3 8 10 Teflon with stainless steel braid 14 Wx 14 L x 10 1 2 H 14 Wx 23 L x 10 1 2 H 44 5 pounds OF IOOO can operate 10 to 15 feet away from the vacuum pump horizontally Vertically it can operate up ...

Page 3: ... Monitoring the Oil Pressure and Color 19 6 2 Gas Bubbles in the Oil During Operation 20 6 3 Using One OF 1000 to Service Several Pumps 21 SECTION 7 ROUTINE MAINTENANCE 7 1 Checking for Contamination 7 2 Changing the Filtering Element 7 3 Changing the Oil 7 4 Checking the Oil Level 23 24 26 32 33 SECTION 8 TROUBLESHOOTING 34 SECTION 9 PARTS LIST 41 APPENDIX A CONVERSION INSTRUCTIONS FOR E AND DK P...

Page 4: ...5 7 2 Filter Housing Assembly 898555 29 9 1 Side View of OF 1000 9 2 Top View of OF lOOO 9 3 Sectional View of Filter Housing A I Drilling Modification to E and OK Pump for Oil 42 44 46 Filtering System 50 B 1 Cross Section of the Gear Pump 52 LIST OF TABLES Table Title Page 3 1 OF 1000 Specifications 5 6 1 Part Numbers for the Quick Connect Stem Elbow and Adapters 21 8 1 Troubleshooting Chart 35 ...

Page 5: ...h of these two models 1 a standard version 2 a version prepared for perfluoropolyether oil and 3 a coated corrosive series version prepared for perfluoropolyether oil The coated version is referred to as the OF IOOOC Unless otherwise noted all references to the OF 1000 in this manual apply to all three versions of the oil filtering system Check the nameplate on the OF 1000 pan to determine which v...

Page 6: ... 3 for information on selecting the correct filtering element for your process Proceed as follows to unpack the OF IOOO and check for shipping damage 1 Inspect the outside of the shipping container for shipping damage If you will be making a damage claim keep the shipping container and packing materials 2 Carefully unpack the OF lOOO 3 Inspect the OF lOOO for damages 4 If you find any evidence of ...

Page 7: ...activated alumina element See Section 3 3 for more information on filtering elements A standard version and two degreased versions are available for both the single canister and the dual canister models The degreased versions are for use with perfluoropolyether oil see Section 3 4 One degreased version is uncoated The other the OF1000C is chemically treated with a fluorocarbon material to resist c...

Page 8: ...000 If you keep a spare filter housing with a clean filtering element on hand the filter housing filtering element assembly can be changed in a few minutes thus minimizing down time for filter changes This feature also allows you to replace the filter housing filtering element assembly in a clean room The used assembly can then be removed from the clean room and be recharged with a new filtering e...

Page 9: ... of hydrocarbon oil or 15 pounds of perf1uoropo1yether 7 5 qts of hydrocarbon oil or 30 pounds of perf1uoropo1yether See Section 3 2 o psig 30 to 55 psig 5 to 30 psig 50 psig 4 feet long x 3 8 1 0 Teflon with stainless steel braid 14 Wx 14 L x 10 1 2 H 14 Wx 23 L x 10 1 2 H Element or the Oil 44 5 pounds Maximum Run OF 1000 can operate 10 to 15 ft away from the vacuum pump horizontally Vertically ...

Page 10: ...low are for the single canister models the corresponding pressures for the dual canister models are higher o psig The gauge will read 0 psi until the oil displaces any air that may be in the OF lOOO 30 to 55 The pressure will rise to 30 to 55 psi while the psig OF lOOO is filtering room temperature oil This pressure will gradually decrease as the vacuum pump approaches its operating temperature 5 ...

Page 11: ...s filtered a second time before returning to the vacuum pump The sight glass flow indicator on the filter housing gives a visual indication of flow and allows you to monitor the color and appearance of the filtered oil The actual flow depends on the oil viscosity at pump operating temperature and the specific gravity of the particular oil that you are using When the oil is cold the float should be...

Page 12: ...ng the alumina element from becoming clogged with particulates The Aluminum Oxide filte effectively degasses the oil and is an outstanding particulate filter It also removes Lewis acids polar compounds solvents and mineral acids such as Hel and HF The Particulate filter is a pleated paper element that traps particulates as small as 10 microns The Hydrophilic element is best for removing particulat...

Page 13: ...minimizes your investment in PFPE When using PFPE oils the vacuum pump and OF IOOO must be kept completely free of all hydrocarbon oils solvents greases and other hydrocarbon substances for the following reasons o Hydrocarbons could react with the process gas to create a fire or explosion hazard and o PFPE and hydrocarbon oils emulsify when they come in contact with each other As mentioned previou...

Page 14: ...cially prepared for perfluoropolyether See Section 3 4 and contact our factory for more information Use care when working near the sight glass If you break this glass oil will squirt out You can special order longer hoses if you need to operate the OF lOOO farther than 4 feet away from the vacuum pump With the longer hoses the OF lOOO can operate as far as 10 to 15 feet horizontally away from the ...

Page 15: ... A new cover O ring comes with each filtering element Coat the O ring with the proper oil and install the new O ring H5 onto the rim of the cover the cover will be difficult to remove if the O ring hasn t been coated with oil 2 IMPORTANT Failure to seat the cover onto the filtering element could result in oil bypassing the filtering element An improperly installed cover could also result in an oil...

Page 16: ...1000 hoses 18 by pulling back on the spring loaded quick connect coupler 15 and pulling the stem 20 away from the coupler see Figure 4 1 b Place the gasket Part No 239 55 165 from the vacuum pump s oil drain fill plugscrews onto the elbow 22 on the quick connect stem 20 see Figure 4 1 c Screw the stem elbow gasket assembly into the oil drain port of the vacuum pump 5 Pour the correct vacuum oil th...

Page 17: ...CAUTION Failure to connect the OF lOOO hoses to the correct oil ports on the vacuum pump could result in overfilling of the vacuum pump with oil Connect the OF IOOO hoses as follows TO OF l000 GEAR PUMP 2 FROM OF l000 a Connect the hose from the bottom of the OF IOOO gear pump to the quick connect stem 20 on the vacuum pump s oil drain port b Connect the hose from the OF lOOO filter housing to the...

Page 18: ...the gear pump being damaged from pumping air Make the electrical connection and check the direction of motor rotation as follows see Figure 7 1 a Connect the OF 1000 to a power outlet that matches the voltage requirements of the gear pump motor 2 see motor nameplate b Switch ON the OF lOaD momentarily to check the direction of rotation looking from the fan end of the gear pump motor 2 the motor fa...

Page 19: ...fore it will start To prime the gear pump remove the pressure gauge fill thp gear pump with the correct vacuum oil and reinstall the pressure gauge see Figure 3 1 The oil pressures change as follows during start up The pressures listed below are for the single canister models the corresponding pressures for the dual canister models are higher o psig On cold start up the OF IOOO oil pressure gauge ...

Page 20: ...ce the pressure on the OF lOOO gauge reaches 30 to 50 psig refill the vacuum pump as follows a Remove the extra oil fill plug from the top of the vacuum pump b Pour the correct vacuum oil see vacuum pump identification plate or manual into the vacuum pump s oil fill port until the oil level reaches the middle of the vacuum pump s oil sight glass c Reinstall the oil fill plug and switch ON the vacu...

Page 21: ...ng from the vacuum pump or oil filtering system Ensure that your process gas is compatible with the OF IOOO materials If the process gas isn t compatible it could result in contaminated oil lea ing out of the OF IOOO or air leaking into the OF IOOO and vacuum pump See Sections 9 2 and 9 3 for a list of materials used in the OF IOOO Contact our factory for more information Removing the cover from t...

Page 22: ...tly adjusted bypass valve can also cause the oil pressure to stay low even though the oil is contaminated See Symptom 6c of the troubleshooting chart for instructions on adjusting the bypass valve 6 2 GAS BUBBLES IN THE OIL DURING OPERATION 20 During normal operation gas bubbles may appear in the OF lOOO sight glass An occasional spurt of bubbles several seconds apart may come from exhaust gases o...

Page 23: ...mbers 2 Attach the OF lOOO hoses 18 to the stem elbow gasket assemblies on one of the vacuum pumps see Section 4 Step 9 3 Start the OF lOOO see Section 5 and allow it to operate until the oil in the first pump s free of contamination 4 CAUTION Failure to turn off the OF lOOO before disconnecting it from the vacuum pump could result in damage to the OF lOOO gear pump Switch off the OF lOOO and disc...

Page 24: ...ription Material Part Number No Addit i ona1 Pump 20 All Models 2 3lB l nch FNPT quic k Steel 72 1 52 001 connect stem Sta inl ess Stl 715 54 024 22 TRIVAC 2 3 B i nch NPT 0 M16 Sta inl ess 725 54 304 1 5 mm sw ivel el bow Stee l adapter N A E OK 2 3 8 lnch NPT close Stainless 725 57 001 see Appendh A nipple Steel 22 ...

Page 25: ...kin contact with toxic or highly corrosive substances specially ventilated work areas fume hoods safety masks breathing apparatus etc Removing the cover from the filter housing while the OF IOOO is running could result in contaminated oil squirting out of the filter housing Use care when working near the sight glass If you break this glass oil will squirt out If the vacuum pump is exposed to hazar...

Page 26: ...at the filtering element may need to be changed The OF lOOO filtering element needs to be changed if the oil in the OF lOOO sight glass flow indicator has an unusual color or odor is dark contains particles or appears dirty or turbid Use the color chart on the filter housing as a general guide for determining if the filtering element needs to be changed see Section 7 2 OF lOOO versions that are pr...

Page 27: ... r LEYBOLD Figure 7 1 Top View of the OF 1000 25 ...

Page 28: ... Before pumping pyrophoric gas seal the pump s inlet switch ON the OF IOOO and run the pump with nitrogen purging for 1 2 hour to allow all of the trapped air to be exhausted from the oil filter and vacuum pump See Section 7 1 to determine if the filtering element needs to be changed The dual canister models have two filtering elements to change It takes only a few minutes to change the filtering ...

Page 29: ...ding the filter housing away from the gear pump see Figure 7 1 5 If you don t have a spare filter housing skip Step 5 and proceed to Steps to change the filtering element If you have a spare filter housing containing a new filtering element and oil proceed as follows to install the spare housing onto the pan a Start but don t tighten the thumbscrew into its threaded hole in the pan see Figure 7 1 ...

Page 30: ...umbscrew should be in the slot in the back foot d Tighten the thumbscrew that secures the filter housing to the pan see Figure 7 1 e Reconnect the hose to the filter housing s quick connect stem H24 see Figures 7 1 and 7 2 f Mark the installation date on the label that came with the filtering element and attach the label to the filter housing cover g Do the steps in Section 5 to start the OF 1000 ...

Page 31: ...ousing to sit for more than three days with contaminated oil or it may begin to corrode Proceed as follows to install a new filtering element into the used filter housing which you removed in Step 4 see Fi gure 7 2 a If your OF lOOO is in a clean room take the used filter housing out of the clean room to change the filtering el ement b Unsc rew the top nut H4 and carefull y rem ove t he cover H2 f...

Page 32: ...Insert a new filtering element see Section 3 3 into the filter housing If the element has a wire handle the handle should face up g Pour the correct vacuum oil into the center and outside of the filtering element until the oil level is just below the machined step in the filter housing see Figure 9 3 h Replace the used cover O ring with the new O ring H5 that came with the filtering element Be sur...

Page 33: ...ore it is seated on the gasket on top of the filtering element Tighten the cover hand tight see Figure 9 3 don t use a wrench or channel lock pliers to tighten the top nut A properly installed cover will be approximately 1 16 to 3 16 inch below the top rim of the filter housing If the cover is less than 1 16 inch below the rim of the housing it means that the filtering element isn t installed prop...

Page 34: ...zardous media you can also try draining the PFPE allowing it to sit for at least 24 hours while the heavy contaminants settle out and then decanting the light contaminants However some contaminants won t separate and must be removed by a reclamation vendor Contact Leybo1d for recommended reclamation vendors NOTE For E DK pump models only drain the oil from the pump using the procedure outlined in ...

Page 35: ...il 8 Reconnect the hose 18 to the vacuum pump and do the steps in Section 5to restart the system and adjust the ofl level 7 4 CHECKING THE OIL LEVEL WARNING See the warning at the beginning of Section 7 before proceeding Occasionally check the oil level by looking through the vacuum pump s oil sight glass If the level is in the lower portion of the vacuum pump s oil sight glass while the pump is r...

Page 36: ...as fume hoods safety masks breathing apparatus etc Process gas is often entrained in the vacuum oil If the process gas is hazardous you must take special safety precautions when handling the oil see Section 7 If an oil leak develops repair it immediately to prevent the contaminated oil from leaking from the vacuum pump or oil filtering system Use care when working near the sight glass If you break...

Page 37: ...ning noise 3 The OF lOOO starts but the pressure gauge reads 0 Page 36 36 even though the oi 1 i s col d 37 4 The oil pressure on the gauge doesn t drop after the oil is warm 38 5 The quick connects won t snap together 39 6 Oil in the OF lOOO sight glass flow indicator is dirty or dark even though the gauge reading is less than 50 psi 39 7 Oil level in the vacuum pump drops after startup 39 8 OF l...

Page 38: ...htening does sea led properly not solve the problem replace the fitting that is leaking d Hoses 18 Puncture or other Install new hoses Sec 4 damage 2 A bnormal running a Gear pump 2 Dirt buildup in the Disassemble and clean the gear Appendix B noise gea r pump 2 pump 2 Use new gasket set and Table 9 1 mechanical seal b Filter Housing 16 Vibration Tighten thumbscrews 17 securing the housing 16 to t...

Page 39: ...e fan end of the Sec 4 Step 8 running backwards OF IOOO motor the fan should rotate counterclockwise If it is rotating clockwise disconnect t he pow er and reverse two of the input leads in the m otor iunction box d Hose Co nnecti ons The OF IOOO connect Ensure that the OF IOOO FILL hose 1s Sec 4 Step 7 ing hoses are connected to the vacUum pump s oi1 switched fill port and tha t the OF 1 000 DRAI...

Page 40: ...the in Section 9 2 flow and fncrease the pres sure Ensure that the OF IOOO hose 1s connect ed to the vacuum pump s oil drain port Then remove the filter housing from the pan and switch ON the gear pump Remove the cap nut from the bottom of the gear pump 2 and adjust the setscrew untfl the OF IOOO pressure reads approximately 55 psi The setscrew should extend out about 5 8 inch from the gear pump O...

Page 41: ...nt is install ed Sec 4 is less than properly on filtering properly Step ld SO psi element c Gear pump bypass The bypa 5S va1ve is F nsllre that the OF lOna hose is connect See the sketch valve set too low ed to the vacuum pump s oil drain port on the previ ous Then remove the filter housing from page the pan and switch ON the gear pump RE move the cap nut from the bottom of the gear pump 2 and adj...

Page 42: ... the OF 1000 tighten down the Cover c Gear pump 2 See Symptom 2a See Symptom 2a 9 V ac uum oil isn t See Symptoms 2a 3c See Symptoms 2a 3c See Symptoms 2a 3c 4a 4b and 8a ci rculating 4a 4b and 8a 4a 4b and 8a suff ci ently through the OF 1000 10 The ultimate a OF lOOO filteri ng 011 f s contam Change filtering element in O F IODD pressure of the el ement and oil inated If oil is very dirty change...

Page 43: ...orrespond to the item numbers listed for each part in the first column of the parts list For example the first column on Page 45 lists 1 for the pan On Figure 9 2 the number I is pointing to a drawi ng of the pan Unless noted otherwise the part numbers marked OF 1000 apply to corrosive single and dual canister models and the part numbers marked OF lOOO apply to standard single and dual canister mo...

Page 44: ... N I NOTE The numbers on this figure correspond to the item no listed for each part on page 45 See figure 3 1 for a side view photograph of the OF 1000 Figure 9 1 Side View of the OF 1OOO 5 rs t Iq b ...

Page 45: ...ted Ii t il prepared for f Iuoroca rbon perfluoropolyether J2 Spare Cen ter Ca ni Her for f JZ Standard Dual C anister M odeL Spare Center C aiiTSter for 898557 _ Alum inum Dua l Cani s ter H odel prepared 898558 AllJminum f J2 fo f1uoropo th _ f 898559 t Coa ted OF IOOOC TlumiOuiil Spare Center Canis ter for coa ted I i th Dual Canister Model prepared f1 uorOCd rbon for perfluoropolyether Does no...

Page 46: ... FROM OIL DRAIN PORT OF VACUUM PUMP I un 1 2 CD 2 1 D 6 NOTE SEE FIGURE 7 1 FOR A TOP VIEW PHOTOGRAPH OF THE OF 1OOO Figure 9 2 Top View of the OF IOOO TO OIL FILL PORT ON VACUUM PUMP rJ ...

Page 47: ...uge 722 14 000 1 1 z 01 4l11l ter Center bac mount 0 100 051 4 f t OOO outside Hn Bush n9 725 58 2 ri NPT to mp Steel ttJd OOOCHex Bus I Q 4 02 B NPT to I HPl itaI ness Steer S 1 1 Of O Male Street Tee Lffi O T Stee 3 HPT 1 of 1OirnCMa iStrl e 2 54 400 sWiiTes s Steel 6 r lllQIl2 t eetillow _ 12 JOO Kf II Stee l Plated l treertTliO I 72 S4 OJ 8t1Pr Stainless Steel 4 Foot 123 07 002 Rubber 8 Round ...

Page 48: ... 0 1 N 8 JII I NOTE SEE FIGURE 7 2 FOR A PHOTOGRAPH OF THE FILTER HOUSING Figure 9 3 Sectional View of the Filter Housing 80 FILL LEVEL FOR PUMP FLUID tJ l1li ...

Page 49: ...x 1 064 10 Steel x 0 032 Thk Snap Rlng 720 19 035 1 1 l6dlameter Steel ower S uDe ous ng 720 19 006 r stain1es5SteeT or S a a u __ r Sfght Tube HOUSlng 720 19 135 OF 1000C mo er S ght Tube Hous ng 9 0 4 Stainless For standard OF 1000 pper Tube Houslng 9 1 For OF 100OC Upper 19 t Tube g 9 13 Sta1n1 ess stee1 For centercanis ter 112 on dual canister models Slght Glass Flow Indicator 722 11 001 High ...

Page 50: ...s follows o Mark the hole locations shown in Figure A I o Drill the pilot holes o Drill and tap the pilot holes for the 3 8 inch NPT nipples o Clean the drill filings from the E or OK pump s exhaust valve housing 4 Install the quick connect stem onto the E or OK pump as follows o Remove the quick connect stem elbow assemblies 20 22 from the OF lOOO hoses see Figure 9 2 o Remove the elbows from the...

Page 51: ...INLET 10 4 7 OK 50 OK lOOt or DK 200 Pump Model 10 4 8 E 75 E 150 or E 250 Pump Model Figure A I Drilling Modification to E or DK Pumps for Installing an Oil Filtering System LEYBOLD 49 ...

Page 52: ...vacuum oil see pump manual 6 The OF IOOO hose leading from the filter housing attaches to the hole labeled INLET in Figure A I The OF lOOn hose leading from the OF 1000 s gear pump attaches to the hole labeled OUTLET Proceed with normal installation and startup procedures see Section 4 and 5 r fi f ...

Page 53: ...use the same type that will be used in the OF lOOO Proceed as follows to remove the old mechanical seal assembly from the gear pump 1 Switch off the OF lOOO gear pump motor 2 Allow the pressure on the OF lOOO pressure gauge to reach 0 psi 3 Remove the filter housing from the pan 4 Remove the gear pump from its motor as follows a Remove the four l 2 inch hex bolts that secure the gear pump to the m...

Page 54: ...hanical seal contains a black seal about l 8 inch thick that fits loosely into the wider end of the metal seal housing One side of this seal has a raised rim ensure that the side of this seal with the raised rim is facing out and that it is free from nicks and scratches f Wet the new mechanical seal with the correct vacuum oil and work it down the shaft the wider end of the mechanical seal faces u...

Page 55: ... Buyer s expensa THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL REPRESENTATIONS AND WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY EXCEPT THE WARRANTY OF TITLE THIS WARRANTY CONSTITUTES THE EXCLUSIVE REMEDY and shail not be deemed to have failed of its essential purpose so long as Seller is willing and able t...

Page 56: ...LEYBOLD VACUUM PRODUCTS rNC 5700 Mellon Road Export PA 15632 8900 Telephone 724327 5700 Telefax 724 733 5960 J i Q oS 5 6 j Ll C I c c ci D ...