Maintenance Manual - Precision Plus

A313-24-855Issue A Original

Maintenance Manual

Vacuum Booster PumpsHV30000 and HV40000

This page has been intentionally left blank.For D of C to be inserted

© Edwards Limited 2010. All rights reserved. Page iEdwards and the Edwards logo are trademarks of Edwards Limited.

ContentsA313-24-855 Issue A

Contents

Section Page

1 Introduction ....................................................................................... 1

1.1 Scope and definitions ................................................................................................... 11.2 Safety ...................................................................................................................... 2

2 Internal clearances ............................................................................... 3

2.1 General information ..................................................................................................... 32.2 Identification of clearances ............................................................................................ 32.2.1 Tip clearance ............................................................................................................. 32.2.2 End clearance ............................................................................................................ 32.2.3 Locating end clearance ................................................................................................. 32.2.4 Back and front clearance ............................................................................................... 32.3 Setting clearances ....................................................................................................... 52.3.1 End clearance ............................................................................................................ 52.3.2 Tip clearance ............................................................................................................. 52.3.3 Back and front clearances .............................................................................................. 52.4 Routine clearance checks .............................................................................................. 6

3 Dismantling ........................................................................................ 7

3.1 Gearwheels ............................................................................................................... 73.2 Drive shaft seal housing ................................................................................................. 83.3 Outer seal sleeve ........................................................................................................ 83.4 Drive end oil slinger ..................................................................................................... 93.5 Drive end bearings ....................................................................................................... 93.6 Drive end headplate removal .........................................................................................113.7 Rotor removal ...........................................................................................................113.8 Gear end bearings ......................................................................................................123.9 Gear end headplate removal ..........................................................................................133.10 Removal of headplate seals ...........................................................................................143.11 Removal of inner seal sleeves ........................................................................................14

4 Re-assembly ..................................................................................... 15

4.1 General ...................................................................................................................154.2 Headplates ...............................................................................................................154.3 Impellers .................................................................................................................164.4 Gear end bearings ......................................................................................................164.5 Drive end bearing carriers .............................................................................................184.6 Setting tip and end clearances .......................................................................................194.6.1 Tip clearances ...........................................................................................................194.6.2 End clearances ..........................................................................................................19

5 Gearwheels ...................................................................................... 21

5.1 Mounting gear wheels ..................................................................................................21

6 Drive shaft seals ................................................................................ 23

6.1 General ...................................................................................................................23

7 Parts list .......................................................................................... 25

7.1 HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only) ................................................25

dcs/

8541

/02/

10

A313-24-855 Issue A

Page ii © Edwards Limited 2010. All rights reserved.Edwards and the Edwards logo are trademarks of Edwards Limited.

Contents

8 Maintenance equipment ....................................................................... 29

9 External screw fixing torques ................................................................. 31

10 Service, spares and accessories .............................................................. 33

10.1 Introduction .............................................................................................................3310.2 Service ....................................................................................................................3310.3 Spares and maintenance kits ..........................................................................................33

For return of equipment, complete the HS Forms at the end of this manual.

Illustrations

Figure Page1 Tip clearances ............................................................................................................ 42 Back and front clearances (Identification) .......................................................................... 43 Back and front clearances (setting) ................................................................................... 64 Gearwheels ............................................................................................................... 75 Drive shaft seal housing ................................................................................................. 86 Drive end oil slinger ..................................................................................................... 97 Drive end bearings ......................................................................................................108 Drive end headplate removal .........................................................................................119 Rotor removal ...........................................................................................................1210 Gear end headplate removal ..........................................................................................1311 Gear end bearings ......................................................................................................1612 Bearing mounting equipment .........................................................................................1713 Drive end bearing carriers .............................................................................................1814 Mounting gear wheels ..................................................................................................2115 Drive shaft seals ........................................................................................................2316 HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only) ................................................25

Tables

Table Page1 HV 30000 booster clearances .......................................................................................... 62 HV 40000 booster clearances .......................................................................................... 63 HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only) ................................................264 Maintenance equipment ...............................................................................................295 External screw fixing torques .........................................................................................316 Spares and maintenance kits ..........................................................................................33

Trademark credits

Loctite®648 is a registered trademark of Loctite Corporation.

© Edwards Limited 2010. All rights reserved. Page 1Edwards and the Edwards logo are trademarks of Edwards Limited.

IntroductionA313-24-855 Issue A

1 Introduction1.1 Scope and definitions

This manual provides installation, operation and maintenance instructions for the HV30000 and 40000 MK2/3 and MK4 Series Booster pumps. You must use the Booster pumps as specified in this manual.

Read this manual before you install and operate the pump. Important safety information is highlighted as WARNING and CAUTION instructions; you must obey these instructions. The use of WARNINGS and CAUTIONS is defined below.

CAUTIONCautions are given where failure to observe the instruction could result in damage to the equipment, associated equipment and process.

The following IEC warning labels appear on the pump:

The units used throughout this manual conform to the SI international system of units of measurement.

WARNING

Warnings are given where failure to observe the instruction could result in injury or death to people.

Warning - refer to accompanying documentation.

Warning - risk of electric shock.

Warning - hot surfaces.

A313-24-855 Issue A

Page 2 © Edwards Limited 2010. All rights reserved.Edwards and the Edwards logo are trademarks of Edwards Limited.

Introduction

1.2 Safety

Maintenance work on site can be dangerous. Removing the booster from its foundations and transfer into a suitably equipped workshop is strongly recommended.

Before any work is started, the drive motor should be isolated and a section of the pipework removed from both the inlet and outlet of the booster. This ensures that any difference between the pressure in the pipework and normal atmospheric pressure cannot cause the impellers to rotate. An alternative to removing the pipework is to break a flanged joint in the pipe and insert a blanking off plate.

All work on the machine, including oil changes, must be done during shutdown with the power supply to the drive motor switched off and isolated.

The discharge piping and booster casing may reach temperatures between 100°C and 150°C and must not be touched.

Many of the larger booster components are heavy, and it will often be necessary to employ safe, adequate lifting tackle.

WARNING

It is essential that anyone involved in the installation and operation of Positive Displacement Vacuum Boosters, must have read and understood these instructions. There is a risk of damage and injury resulting from improper handling and operation.


Internal clearancesA313-24-855 Issue A

2 Internal clearances2.1 General information

Correct internal clearances are vital to the safe continuous operation of the booster pumps. If any metal to metal contact were to occur between the impellers and any part of the casing, then total seizure would quickly follow.

Under working conditions, internal clearances are reduced by the effect of differential thermal expansion because the impellers get hotter than the casing. For this reason, clearances less than the specified minimums must not be used.

On the other hand, larger clearances will allow a greater amount of internal slip. That is, more gas will be able to leak back through the clearances from the high pressure outlet side, to the lower pressure inlet side, and this will result in a lower volumetric efficiency. For this reason, the specified maximum clearances must not be exceeded.

2.2 Identification of clearances

2.2.1 Tip clearance

The clearance between the tips of the impellers and the inside surfaces of the cylinder bore. This clearance is normally measured in three places. The following clearances are shown in Figure 1.

2.2.2 End clearance

This is the clearance between the ends of the impellers and the headplates. These clearances are given as either:

2.2.3 Locating end clearance

A. Locating end clearance:

This is the clearance at the end of the impeller at which the locating shims are fitted.

B. Free end clearance:

This is the clearance at the opposite end of the impeller to the locating shims.

2.2.4 Back and front clearance

This is the clearance between the mating flanks of the impellers. Refer to Figure 2 and the following notes.

a) Inlet clearance - (Adjacent to inlet port)

b) Outlet clearance - (Adjacent to outlet port)

c) Centre clearance - (Midway between a) and b))

A313-24-855 Issue A


Internal clearances

Figure 1 - Tip clearances

Figure 2 - Back and front clearances (Identification)

The leading flanks of the driving rotor (for example the two flanks which face in the direction of rotation and which are marked 'F' on Figure 2) form 'FRONT' clearances when in engagement with the driven rotor.

The trailing or rearward facing flanks of the driving rotor (marked 'B' on Figure 2) form 'BACK' clearances when in engagement with the driven rotor.

Each complete revolution of the drive shaft presents two 'FRONT' clearances and two 'BACK' clearances.

Figure 2, detail A shows a position in which a 'BACK' clearance has just ended and a 'FRONT' clearance is about to start.

Figure 2, detail B shows the impellers advanced through 45° to a position in Figure 2, detail A and clearly indicate the 'FRONT' clearance formed between the mating flanks of the two impellers.

Figure 2, detail C shows the impellers advanced a further 45° to a position where the 'FRONT' clearance has just ended and a 'BACK' clearance is about to start.


Internal clearancesA313-24-855 Issue A

Figure 2, detail D shows the impellers advanced a further 45° and clearly show the 'BACK' clearance formed between the mating flanks of the two impellers.

An advancement of the impellers through a further 45° from the position shown in Figure 2, detail D would bring about a return to the position in Figure 2, detail A with the cycle ready to start again.

A 'BACK' or 'FRONT' clearance is presented through a full 90° of rotation of the impellers, for example from the position shown in Figure 2, detail A to the position shown in Figure 2, detail C or between any other two similar positions.

2.3 Setting clearances

When setting clearances it is not sufficient to measure them with the impellers in one position only. All clearances – ends, tips, backs and fronts – must be checked over their full area whilst the impellers are turned through 360°. Only in this way is it possible to locate the area of least clearance, and even in this area the clearance must not be less than the specified minimum.

2.3.1 End clearance

End clearances on the HV vacuum booster pump are controlled by bearing carrier adjustment. This is a method in which the locating bearing is axially fixed on its shaft and within its carrier, and the position of the carrier relative to the headplates is adjusted by shims behind the carrier flanges (refer to Figure 3 and Section 4.5). The thickness of shims is adjusted until the clearance between the rotor end and the headplates is of the desired value.

If the impellers are of such a length compared with the cylinder that the minimum total end clearance cannot be achieved then the impellers must be machined until the correct clearance can be obtained between the rotor ends and the headplate.

2.3.2 Tip clearance

The clearances between the tips of the impellers and the bores of the cylinder are adjusted by moving the headplates relative to the cylinder in the radial plane.

Once the desired clearances are obtained, all the headplate retaining screws must be tightened, and the headplate solidly fixed by doweling through into the cylinder end flange.

2.3.3 Back and front clearances

The impellers are held in the correct position relative to each other by means of the gear wheels. This means that to alter the clearance between the two impellers, it is necessary to move one of the gears rotationally relative to its shaft seating as follows.

Mount one gearwheel (refer to Section 3.6) then set the impellers in the correct relationship to each other by inserting feeler gauges to the thickness of the desired clearance between the impellers when their major axis is at 45° to vertical (refer to Figure 2).

A313-24-855 Issue A


Internal clearances

Figure 3 - Back and front clearances (setting)

With the impellers held in this position, mount the second gearwheel then rotate the impellers and check that all back and front clearances are within the specified limits. If any adjustment is necessary dismount one of the gearwheels using the SKF oil injection equipment and repeat the exercise.

2.4 Routine clearance checks

It is recommended that clearances should be checked periodically during the working life of the booster.

At the time of commissioning, when it has been determined that all internal clearances are satisfactory, then a set of datum measurements should be taken, against which all future checks can be compared.

The clearances for the HV boosters can be found in the table below.

Table 1 - HV 30000 booster clearances

HV30000 Booster Clearances

Inlet tips Centre tips Outlet tips Drive end Gear end Fronts Backs

1.07/1.17 mm 0.94/1.02 mm 0.84/0.89 mm 0.36/0.41 mm 2.16/2.31 mm 0.76/0.84 mm 0.76/0.84 mm

(0.042 inch/0.046 inch)

(0.037 inch/0.040 inch)

(0.033 inch/0.035 inch)

(0.014 inch/0.016 inch)

(0.085 inch/0.091 inch)

(0.030 inch/0.033 inch)

(0.030 inch/0.033 inch)

Table 2 - HV 40000 booster clearances

HV40000 Booster Clearances

Inlet tips Centre tips Outlet tips Drive end Gear end Fronts Backs

1.12/1.22 mm 0.99/1.07 mm 0.89/0.94 mm 0.41/0.46 mm 2.39/2.49 mm 0.82/0.89 mm 0.82/0.89 mm

0.044 inch/0.048 inch

0.039 inch/0.042 inch

0.035 inch/0.037 inch

0.016 inch/0.018 inch

0.094 inch/0.098 inch

0.032 inch/0.035 inch

0.032 inch/0.035 inch

1. Impeller2. Headplate

3. Bearing carrier4. Shims


Dism

antlingA313-24-855 Issue A

3 Dismantling3.1 Gearwheels

On removal of the gearbox you will see the gearwheels which are mounted with a heavy interference fit onto a tapered shaft; no keys are used. Removal is affected by injecting oil at a high pressure into the interface between the gearwheel bore and the shaft, thus expanding the gearwheel off its tapered seating. The procedure for gearwheel removal is as follows:

Note: On boosters designed for 60 Hz speed you will find an oil pump, this pump should be examined at every major maintenance period, but should definitely be checked at least once every two years. This will necessitate gear box removal and pump removal. The drive dog and pump should be checked for wear, lateral or radial movement on the shaft, if this exists both the dog and oil pump must be replaced, on re-assembly care must be taken to align the oil pump with the shaft centre.

After draining out the oil, remove the gear case. A crane or some other suitable lifting equipment must support the weight of the gearcase before its retaining screws are removed.

Assemble the gearwheel removal equipment as shown in Figure 4 making sure that there is a gap of about 8 mm between the HOLORAM and the speed nut. Assembling the equipment in this way is essential, as it acts as an arrestor for the gearwheel, which is released from its seating with considerable velocity.

The SKF oil injection pump is filled by submerging the connection end of the reservoir cylinder in a light mineral oil (Mobile Velocite No 6 or equivalent) and then slowly pulling out the plunger. After assembly the pump is primed by slackening off the pipe coupling at the gearwheel end whilst slowly pumping. When all the air has been expelled, tighten the pipe coupling and raise the full oil pressure by continuous pumping. The gearwheel will then be released from its seating.

When the gearwheels have been removed, they must be protected against damage.

Figure 4 - Gearwheels

1. Gear2. Oil injection pump3. Adaptor4. Speed nut

5. Centre screw6. Holoram7. Gear pusher8. Boster shaft

A313-24-855 Issue A


Dism

antling

3.2 Drive shaft seal housing

The drive shaft seal housing should be removed before the drive end gear case in order to prevent any damage to the drive shaft seals. The procedure for removing the drive shaft seal housing is as follows:

The four retaining screws must be removed. Following this, the seal housing can be removed by using suitable screws in the two jacking holes provided for this purpose (refer to Figure 5).

It is recommended that the sealing O-rings be replaced upon re-build.

Figure 5 - Drive shaft seal housing

3.3 Outer seal sleeve

Before the bearings can be removed it is necessary to remove the outer seal sleeve. This is accomplished by the use of the extractor ring fitted behind the seal sleeve. The withdrawal equipment should be set up as shown in Figure 6 and the seal sleeve withdrawn.

Once the sleeve has been removed it should be protected against damage, unless it is being replaced.

It is recommended that the O-ring should be replaced upon re-build.

1. M8 jacking screw2. Drive end cover3. M8 jacking screw

4. Front seal housing5. Booster shaft


Dism


3.4 Drive end oil slinger

The drive end oil slinger must also be removed to allow removal of the bearings.

Figure 6 - Drive end oil slinger

3.5 Drive end bearings

The bearings have parallel bores, and are mounted with an interference fit on the shafts. They are pulled off their shaft seatings by means of the carriers in which they are housed. The procedure for removal is as follows:

Remove the bearing carrier retaining screws.

Assemble the bearing withdrawal equipment as shown in Figure 7, operation of the HOLORAM will withdraw the bearing carrier. NB: If a cylinder roller bearing is fitted (as shown), the 'Loose Rib' should slide easily off the shaft, either with the rest of the bearing, or after the bearing has been removed. If a deep groove ball bearing is fitted, the whole bearing will be removed using this procedure. The 'Loose Rib' from the cylindrical roller bearings may be left on the shaft, but should have sufficient clearance to be slid off).

This in turn will release the sets of shims which are fitted into the gap between the back of the bearing carrier flange and the headplate. These shims must be kept in their sets until they are needed for re-assembly.

1. Sykes-Packavant ram2. Body

3. Capscrew4. Setscrew (modified)

A313-24-855 Issue A


Dism

antling

Figure 7 - Drive end bearings

It is recommended that the O-ring should be replaced upon re-build.

At this stage when the bearing has been removed, it is possible to remove the drive end oil thrower. This item should be protected from damage.

Once the bearing carriers have been removed they can be dismantled, this is done as follows:

1. Remove the bearing ring retaining screws.

2. Remove the bearing ring, bearing spacer ring and bearing.

The seal at the back of the bearing carrier can now be removed by means of a suitable drift. In most cases it is not possible to remove the seals without damaging them, therefore it is recommended that they be replaced upon rebuild.

1. Centre screw2. Crossblock3. Drawbar4. Speed nut

5. Headplate6. Bearing carrier7. Booster shaft8. Holoram


Dism


3.6 Drive end headplate removal

Before removing the drive end headplate it will be necessary to remove the gearwheels and D/E bearings as already described.

Drive out the dowel pins which locate the headplates to the cylinder, and remove all but four of the headplate retaining screws. These four screws should be evenly spaced about the periphery of the headplate.

Support the weight of the headplate with suitable lifting gear, and remove the remaining retaining screws. The headplate is now free to be lifted clear, but during this operation great care must be taken to ensure that the headplate bores do not scrape along the rotor shafts thus damaging the seal sleeves or the bearing seatings.

It is recommended that the headplate sealing O-rings be replaced upon re-build.

Figure 8 - Drive end headplate removal

3.7 Rotor removal

The impellers cannot be removed until the gearwheels, D/E bearings and the headplate have been removed.

Due to the construction of this type of booster it is advisable to leave the gear end bearings in place and to remove the impellers by setting up the bearing withdrawal equipment as shown in Figure 9, but leaving the bearing carrier retaining screws in position. Thus when the HOLORAM is operated, the rotor will be pushed through the bearing. This is necessary because the oil throwers at the gear end of this booster are an interference fit on the rotor shaft, and pushing the rotor through allows both the bearings and oil throwers to be easily removed.

A313-24-855 Issue A


Dism

antling

Figure 9 - Rotor removal

Using a rope sling round the rotor shaft, lift the driving rotor off the driven rotor and slide it out of the cylinder until half of the rotor body is withdrawn. Then transfer the rope from the shaft to the middle of the rotor body and then complete the withdrawal.

3.8 Gear end bearings

Before removing the bearings it will be necessary to remove the gearwheels as described in Section 3.1. If the gear end bearings are to be removed without dismantling the entire booster than the same procedure as for the drive end bearings can be used (Section 3.5).

If however the gear end bearing removal is as part of a complete dismantling of the booster, then following removal of the impellers, the bearings should be removed as follows:

1. Remove the bearing carrier retaining screws.

2. Using the bearing carrier jacking screws (IAT 5047) in the appropriate holes, jack the bearing carriers out of the headplate.

At this stage when the bearing has been removed it is possible to remove the gear end oil thrower. This item should be protected from damage.

Once the bearing carriers have been removed they can be dismantled, this is done as follows:

1. Remove the bearing ring retaining screws.

2. Remove the bearing ring and bearing.

The seal at the back of the bearing carrier can now be removed by means of a suitable drift. In most cases it is not possible to remove the seals without damaging them therefore it is recommended that they be replaced upon re-build.

1. Gear end bearing carrier2. Drawbar3. Speed nut4. Crossblock

5. Centre screw6. Holoram7. Booster shaft8. Gear end headplate


Dism


3.9 Gear end headplate removal

Gear end headplate removal procedure is the same as for the drive end headplate, in the event of a complete strip down. However, when the gear end headplate only is to be removed, then the following procedure must be followed.

The impellers should be positioned as in Figure 8 and the bearing carriers removed using the procedure as for the drive end bearing carriers laid down in Section 3.5. Once the bearing carriers have been removed then the following procedure should be followed.

Drive out the dowel pins which locate the headplates to the cylinder, and remove all but four of the headplate retaining screws. These four screws should be evenly spaced about the periphery of the headplate. Set up the withdrawal equipment as shown in Figure 9. Remove the remaining headplate retaining screws.

By operating both HOLORAMS together, the headplate, along with the gear end oil throwers, will be pulled away from the cylinder.

Figure 10 - Gear end headplate removal

1. Headplate2. Drawbar3. Speed nut4. Holoram

5. Crossblock6. Centre screw7. Booster shaft

A313-24-855 Issue A


Dism

antling

3.10 Removal of headplate seals

Following the removal of the headplates and inspection of the seals, it may be that the seals need replacing. The old seals can be removed using a pin punch to drive the seal from its housing through the holes provided in the headplate for this purpose.

If there are no holes present in the headplate then the seal must be driven out by using a pin punch against the inner sidewall of the seal itself. This will invariably damage the seal so it is only to be done when the seals need replacing.

Care must be taken during the above operations not to damage the seal bores or the surfaces of the headplates.

3.11 Removal of inner seal sleeves

The inner seals run on hardened and ground sleeves, which are a shrink fit on the rotor shafts. These should be carefully inspected for signs of wear and if necessary replaced.

If replacement is necessary then the old seal sleeves must be ground off using a small hand grinder.

CAUTIONExtreme care must be taken when grinding off the old seal sleeves so that no damage is inflicted upon the rotor shafts or the rotor bodies.


Re-assembly

A313-24-855 Issue A

4 Re-assembly4.1 General

The item numbers referred to in this section correspond to the item numbers shown on the assembly drawing.

Make sure that all the parts of the booster are clean and in good condition. In particular, the timing gears, bearings and seals should be examined and replaced if wear is evident. (It is always recommended that new seals, bearings and O-rings are fitted).

If new inner seals are required then they should be fitted into the headplates before the headplates are fitted to the cylinder.

Likewise new bearing carrier seals, and new drive shaft seals should be fitted into their housings before assembly.

Great care must be taken when fitting the seals so as not to cause any damage to them.

The use of anaerobic adhesives for such things as thread locking and bearing retention is now standard practice in many fields of engineering, and for some years Edwards have been using these adhesives in vacuum pump assembly with very satisfactory results.

On the HV series vacuum pumps anaerobic adhesives are used for the following applications:

Recommended adhesive Loctite 241 (A product of the Loctite Corporation) or equivalent.

Recommended adhesive Loctite®648 or equivalent.

It is important that the surfaces to be treated should be clean and dry. The use of a solvent for cleaning screw threads and inner races is recommended. A safety solvent in the form of an aerosol spray is usually obtained from the adhesive manufacturer.

4.2 Headplates

The first step in re-assembly is to fit the gear end headplate to the cylinder. The sealing O-ring should be placed in its groove on the inner side of the headplate and held in place with four O-ring retainers (IAT 5059).

Using suitable lifting tackle, offer the headplate up to its facing on the cylinder, and loosely fit four retaining screws approximately equally spaced around the periphery of the headplate. At this point the O-ring retainers can be removed by carefully sliding them out of the narrow gap between the cylinder and the headplate. If it is an original headplate it will now be possible to refit the location dowels and to re-fit the remaining retaining screws and tighten them up.

If a new headplate is being fitted it will not be possible at this stage to fit the dowel pins and the rest of the retaining screws, as the exact position of the headplate cannot be determined until the rotor tip clearances have been set. This in turn cannot be done until the bearings have been fitted (see Section 4.6).

The impellers must be fitted into the cylinder (see Section 4.3) before the second headplate can be fitted. When fitting the second headplate take care not to let the bores damage the rotor shaft as it is guided over them. Care must also be taken so that no damage occurs to the headplate seals.

Thread Locking: Bearing carrier retaining screws

Bearing clamp ring retaining screws

Oil slinger retaining screws

Drive end bearing locknuts

Seal Sleeves: Inner and Outer seal sleeves

A313-24-855 Issue A


Re-assembly

4.3 Impellers

If new impellers are being fitted, carefully measure the length of the cylinder and the length of the rotor bodies. The amount by which the impellers are shorter than the cylinder should be at least equal to the sum of the locating end and free end clearances given in Table 2. If this is not the case then the rotor bodies will need to be shortened by the required amount. This operation requires the use of a suitably equipped machine shop and should only be undertaken by skilled personnel.

The procedure for fitting the impellers is as follows:

Using the same lifting arrangement as for removal, the driven rotor must be inserted first and must be aligned vertically. Once the driven rotor is in position the driving rotor can be inserted, this is done using the same lifting arrangement as for removal and the rotor should be aligned horizontally so as to be supported by the driven impeller.

Care must be taken so as not to cause damage to the rotor shafts or the headplate seals when fitting the impellers.

4.4 Gear end bearings

The gear end bearing components are shown in Figure 11.

Figure 11 - Gear end bearings

When fitting new bearing carriers, it will first be necessary to check that they fit correctly into the headplate bores. This is a clearance fit of not less than 0.01 mm and not more than 0.05 mm. If in order to achieve this fit, it is necessary to machine the outside diameter of the carrier, great care must be exercised to ensure that it is kept concentric with the bore into which the bearing fits.

1. Gear end bearing carrier2. Retaining ring screw3. Bearing retaining ring4. Bearing

5. Booster shaft6. Gear end bearing carrier seal7. Gear end headplate8. Gear end oil thrower


Re-assembly

A313-24-855 Issue A

Heat the gear end oil throwers on a suitable heat source (an SKF bearing heater is ideal), to about 200°C. Once the oil thrower temperature has stabilised it can be fitted to the gear end shaft of the rotor. This operation should be repeated for both impellers.

Fit the sealing O-ring into its groove in the bearing carrier and lubricate it with a little oil.

Fit the oil seal into the bearing carrier using the appropriate mounting tool (AT 4349). Lubricate the seal lip with a little oil before assembling the bearing carrier into the headplate.

Screw the bearing carrier guide pins into two diametrically opposed holes in the headplate and fit the bearing carrier over them with the oil groove at the bottom. It will be necessary to use a soft hammer to drive the carrier into its bore in the headplate taking care not to damage the O-ring. Remove the guide pins and fit the four retaining screws.

Clean the bore and outside diameter of the bearing and position it on the shaft. Assembly the bearing mounting equipment as shown in Figure 12 and press the bearing home until it is solidly up against its abutment on the shaft.

Fit the bearing retaining ring and tighten up the retaining screws to the specified torque (refer to Section 9).

Repeat for the other bearing carrier.

Figure 12 - Bearing mounting equipment

1. Centre screw2. Speed nut3. Bearing pusher4. Booster shaft

5. Headplate6. Bearing carrier7. Holoram

A313-24-855 Issue A


Re-assembly

4.5 Drive end bearing carriers

The drive end driven bearing components are shown in Figure 13.

Fit the O-rings and seals to the drive end bearing carriers the same as for the gear end.

The drive end oil throwers are a push fit on the shaft and therefore will not need heating up.

Fit the bearing carriers into the headplate bores as described in Section 4.4 except that the retaining screws should be loosely fitted.

Mount the driven shaft deep groove ball bearing and drive shaft deep groove ball bearing (if fitted) as described in Section 4.4. Fit the bearing retaining ring and the four retaining screws.

To mount the drive shaft cylindrical roller bearing, (if fitted) slide the bearing 'loose rib' up to the oil thrower face, then continue as described above.

Fit the bearing locknuts and tighten to the correct torque, (refer to Section 9) after coating the threads with Anaerobic adhesive.

Figure 13 - Drive end bearing carriers

1. Headplate2. Lip seal3. Oil thrower sleeve4. O-ring5. Shims6. Bearing carrier

7. Bearing clampring8. Bearing spacer9. Booster shaft10. Locknut11. Bearing12. Bearing clampring screw


Re-assembly

A313-24-855 Issue A

4.6 Setting tip and end clearances

At this stage, with all four bearings fitted, it is possible to rotate the impellers so that the tip and end clearances can be checked and adjusted if necessary (refer to Section 2).

4.6.1 Tip clearances

Position the impellers vertically.

Using feeler gauges, check that the clearances between the tips of the impellers and the bores of the cylinder are within the values given in Table 2, and also that the clearances are uniform along the entire length of the impellers. Rotate the impellers through 180° and repeat the exercise.

After checking inlet and outlet tip clearances in this way, position each rotor in turn in the vertical plane and check the clearance between the rotor tips and the cylinder bore on the vertical centreline.

If these measurements reveal the need for adjustment, this can be achieved by moving one or both of the headplates radially relative to the cylinder. (This should only be necessary if new headplates have been fitted).

Having ensured that all tip clearances are correct, tighten all headplate retaining screws to the required torque value (see Section 8) and fit the four dowel pins in each headplate, re-reaming where necessary.

4.6.2 End clearances

Rotate each impeller at least two full turns in order to centralise the rolling elements of the drive end bearings within their seatings.

Using feeler gauges, measure the clearance between the ends of the impellers and the drive end headplate.

If the clearances differ from those specified in Table 2, they can be corrected by appropriate movement of the drive end bearing carriers relative to the headplate. If the bearing carrier retaining screws are tightened a little, that will push the carrier further into the headplate bore and thus increase the rotor end clearance, at the drive (locating) end. Adjacent to each retaining screw hole in the bearing carrier flange there is a tapped hole, if the carrier retaining screws are removed and screwed into these holes, they can be used to jack the carrier out of the headplate a little way thereby reducing the rotor locating end clearance.

Having ensured that all gear end and drive end clearances are correct, carefully measure (with feeler gauges) the clearance between the back of the drive end carrier flange and the headplate.

Select four sets of shims equal in thickness to this measurement and insert them into the gap straddling the retaining screws. Tighten the carrier retaining screws to the required torque value (see Section 8) after coating the threads with Anaerobic adhesive.

Before proceeding further, re-check all tip and end clearances.

A313-24-855 Issue A


This page has been intentionally left blank.


Gearw

heelsA313-24-855 Issue A

5 Gearwheels5.1 Mounting gear wheels

Mounting the gear wheels also determines the front and back clearances between the impellers (see Section 2).

Clean the gearwheel bore and its taper seating with a chlorinated solvent. Position the gearwheel on the shaft using only hand pressure to hold it onto its taper, then assemble the gearwheel mounting equipment as shown in Figure 4.

Position a dial indicator on the side of the gear as shown in Figure 14 and set it to zero.

Drive the gearwheel further up its taper seating by 4.1/4.3 mm. This is accomplished by simultaneous operation of the HOLORAM and the SKF oil injection pump. (The use of oil injection greatly reduces the axial force required to drive the gearwheel up its taper).

Before mounting the second gearwheel, the impellers must be set in their correct relative positions. This is done by positioning the impellers parallel to each other with their major axes at 45° as shown in Figure 2 and then inserting feeler gauges equal in thickness to clearance specified in Table 2, between them. Whilst holding the impellers in this position mount the second gearwheel (see Section 2).

Rotate the impellers and check that all back and front clearances are as specified. If any adjustment is necessary, dismount one of the gearwheels and repeat the exercise.

Ensure that the gear wheel backlash is 0.08/0.16 mm

After ensuring that all internal clearances are correct, fit the oil slingers, coating the threads of the retaining screws with Anaerobic adhesive and fitting the locating pins.

Figure 14 - Mounting gear wheels

1. Gear2. Oil injection pump3. Adaptor4. Speed nut5. Centre screw

6. Holoram7. Gear pusher8. Dial indicator9. Booster shaft

A313-24-855 Issue A


Gearw

heels

If a Stanhope FL1 oil pump has been fitted (due to the booster running at 60 Hz), make sure the pump shaft and booster shaft are aligned before re-fitting tension pins in the gear trough body.

If the booster duty is at 50 Hz, re-fit the standard fabricated gear trough, ensure the gears have adequate clearance.

Note: HV40000 is 60 Hz only.

The gearcase and drive end covers can now be re-fitted as follows:

The sealing O-ring should be fitted to the headplate and held in place with the O-ring retainers (IAT5059).

Notes: 1 On early models the O-rings between the headplate, gear case and drive end cover are metric and must be replaced by making to length from the cord supplied in the maintenance kit.

2 On later models there 0-rings are imperial and pre-formed replacements are supplied in the same kit.

Using suitable lifting gear the gear end cover should be lifted into position and the retaining screws should be fitted. The O-ring retainers should then be removed and the retaining screws tightened to the required torque value (see Section 9).

The drive end cover should be fitted in the same way but should be located on the two dowels provided in order to centralise the seal housing bore with the driving rotor shaft.

Once the dowels have been fitted, then the retaining screws can be tightened as for the gear end cover.


Drive shaft seals

A313-24-855 Issue A

6 Drive shaft seals6.1 General

The method sealing the drive shaft on the HV booster pump is both simple and effective. Figure 15 shows a double lip type seal with a third seal a short distance in front of them in the drive end seal housing. The seal housing is fastened into the drive end cover and is sealed by means of O-rings. The space between the seals is filled with oil and a reservoir of oil is kept in the oil bottle screwed into the end cover.

To prolong the life of the seals a hardened steel wear resistant ring is fitted to the shaft.

If this ring should ever need replacing, it is recommended that the new ring should be heated to ease its fit on the shaft. It is recommended that the sealing O-ring should also be replaced at this time.

When fitting new seals, they should be smeared with oil to ease their entry into the seal housing. Seal mounting tools IAT5043 (rear seals) and IAT 5044 (front seals) should be used.

When fitting the seal housing smear the O-rings with a little oil and ensure that care is taken so as not to cause damage to the O-rings.

Once the seal housing has been fitted, the gap between the seals can be filled with oil. When filling the annulus between the seals, the small grub screw should be removed to allow trapped air to escape, otherwise there is a risk of airlocks developing, thus resulting in a lack of oil between the seals leading to air inleakage and/or premature seal wear.

Figure 15 - Drive shaft seals

Note: The wear sleeve and seals are of smaller diameters on the MK4 version than on the MK2 and MK3. Therefore, the correct seal housing must be used for each version.

1. Drive end cover2. O-rings3. Seal housing4. Lip seal

5. Seal sleeve6. Air release screw7. Oil bottle

A313-24-855 Issue A




Parts listA313-24-855 Issue A

7 Parts list7.1 HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only)

Figure 16 - HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only)

A313-24-855 Issue A


Parts list

Table 3 - HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only)

Description Item

Motor 1

Drive key 2

Drive coupling 3

Drive coupling cover 4

Drive shaft 5

Gasket, 1/4 inch RS SS-4-RS-2V 6

Extension, oil bottle 1/4 inch BSP 7

Oil bottle OR7724 ADAMS 8

Set screw M16 x 45 GR8.8 9


Drive end cover 11

Eye-bolt M12 12

Oil seal 120 x 150 x 12 Viton 13

Bearing, INA IR 100 x 110 x 30 14

O-ring 31.95 x 32.50 x 1/4 inch 15

Seal, PDR single 16

Assembly, impeller and shaft drive 17

Cylinder SPC 18

Cap screw hex hd M8 x 1.25P x 25 19

Inspection cover 20

O-ring 9.25 x 9.50 x 1/8 21


HDPL 23


O-ring 27.77 ID Viton 25

Eye-bolt M20 26

Gas bleed adapter 27

Restrictor pin 28

Flanged plug 1/4 inch BSP 29

Gasket 1/4 inch RS SS-4-RS-2V 30

Gasket 1/2 inch RS S-8-RS-2 31

Casing cover with 1/2 inch BSP 32

O-ring 9.25 x 9.50 x 1/8 33




Gear 37

Gearcase 38

Bearing clamp plate 39

Oil pump - FL1 STANHOPE 40


Parts listA313-24-855 Issue A

Set screw M6 x 16 41

NPL rotary lobe HVB 42

Round hd screw #4 x .19 43

TBG-304SS 3/8 inch OD (.035W) 44

Adapter 3/8T X 1/4 inch BSP 45

Pin, spring 1/4 x 1.00 46

Oil pump bush, drv 47

Set screw self locking 10-24 x 3/8 inch 48

Sight glass HSG 49

Glass - 3 inch dia 50

O-ring 65 x 3 51

Cap screw flat socket hd M6 x 20 52

TBG-304SS 3/8 inch OD (.035W) 53

Adapter 3/8T x 1/4 inch BSP 54

Cooling coil GRBX 55

Support clamp 3/4 inch P 56

Socket hd cap screw 10-24 x .38 57

Oil cooling coil, PLT 58

O-ring 50 x 3 59

Cap screw M6 x 25 60

Cooling coil, SPC 61

O-ring 1.046 inch x 0.139 inch 62

Oil pan gear end with pump mounting 63

Cap screw hex hd M12 x 25 64

Elbow union 1/2 inch T SS 65

TBG-304SS 1/2 inch OD (.049W) 66

Bearing carrier 67

Ball bearing 68


Gasket, 3/8 inch RS S-6-RS-2 70

Oil seal 120 x 150 x 12 Viton 71

Oil slinger sleeve, gear end 72


Gasket, 3/4 inch RS SS-12-RS-2V 74

Bearing, INA IR 100 x 110 x 30 75

Locknut, 3/4 inch BSP ENOTS 34022306 76

Cooling coil, SPC 77

O-ring 1.046 inch x 0.139 inch 78

Seal, PDR single 79

Disc cooling coil 80

Table 3 - HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only) (continued)

Description Item

A313-24-855 Issue A


Parts list Set screw M6 x 16 81

Cable tie SS 18 inch 82

Disc, PLT 83

O-ring 21 x 21 3/8 x 3/16 84

Set screw M20 x 70 85

Hex nut M20 zinc 86

Bright washer 20 mm form A 87


Gasket 3/4 inch RS SS-12-RS-2V 89

Oil slinger sleeve, OGE 90


Gasket 3/8 inch RS S-6-RS-2 92

O-ring 300 x 310 x 5.7 M 93

Bearing carrier 94

Bearing carrier shim set 95

Oil cooling coil, PLT 96

O-ring 50 x 3 97

Cap screw M6 x 25 98

Bearing spacer 99

Cooling coil, CVR 100

Support clamp 3/4 inch P 101

Socket hd cap screw 10-24 x .38 102

Ball bearing 103

Bearing lock nut AN-19 104

O-ring 145 x 3 (1445-30) 105

O-ring 135 x 3 (1345-30) 106

Oil seal 75 x 95 x 7 107

Retaining ring - internal 95 mm 108

Extractor, sleeve - Mk IV 109

O-ring 60 x 66 x 3 110

Sleeve seal - Mk IV 111

Oil seal 75 x 95 x 10 112

Oil seal 75 x 95 x 7 113

Cap screw M4 x 6 lg 114

Gasket, round .156 x .313 x .031 115

Seal housing - Mk IV 116

Table 3 - HV30000 boosters (50 Hz and 60 Hz) and HV40000 (60 Hz only) (continued)

Description Item


Maintenance equipm

entA313-24-855 Issue A

8 Maintenance equipmentTable 4 - Maintenance equipment

Item No Description Code No

1 Pickavant ram PC12475/21

2 Bearing carrier jacking screws IAT5046

3 Drive end cover centralising tool IAT5046

4 Headplate adjusters IAT5045

5 Seal pusher (external seal housing inner seal) IAT5044

6 Seal pusher (external seal housing outer seal) IAT5043

7 Centre screw PC1555104

8 Bearing pusher IAT5050

9 Seal pusher (bearing carrier seals) AT4349

10 Seal pusher (headplate seals)

11 Drive shaft seal sleeve pusher AT4152

12 Bearing carrier locating pin PC1555113

13 Gear pusher PC1555111

14 Speed nut PC1555105

15 Bearing carrier drawing off bolt PC1555102

16 O-ring retainer IAT5059

17 Outer seal sleeve puller IAT5068

18 Crossblock PC1555101

19 Enerpac single speed hand pump PC1234912

20 Enerpac 30 ton hollow ram PC1234913

21 Enerpac pressure gauge PC1234914

22 Enerpac gauge block PC1234915

23 SKF oil injection pump PC1234919

24 SKF adaptor block PC1234920

25 SKF high pressure pipe PC1234921

26 Oil injector adaptor C15920/7

A313-24-855 Issue A




External screw fixing torques

A313-24-855 Issue A

9 External screw fixing torquesTable 5 - External screw fixing torques

Item Torque Setting

Headplates to cylinder 136 Nm (100 lbf.ft)

Gearcase to headplate, drive end cover to headplate 68 Nm (50 lbf.ft)

Inspection cover to gearcase, ext. seal housing to d.e. cover 34 Nm (25 lbf.ft)

Sight glass housing to end boxes, coil adaptor plates to end boxes 14 Nm (10 lbf.ft)

A313-24-855 Issue A




Service, spares and accessoriesA313-24-855 Issue A

10 Service, spares and accessories10.1 Introduction

Edwards products, spares and accessories are available from Edwards companies in Belgium, Brazil, Canada, China, France, Germany, Israel, Italy, Japan, Korea, Singapore, Switzerland, United Kingdom, U.S.A and a world-wide network of distributors. The majority of these centres employ Service Engineers who have undergone comprehensive Edwards training courses.

Order spare parts and accessories from your nearest Edwards company or distributor. When you order, please state for each part required:

Model and Item Number of your equipment

Serial number (if any)

Item Number and description of the part.

10.2 Service

Edwards products are supported by a world-wide network of Edwards Service Centres. Each Service Centre offers a wide range of options including: equipment decontamination; service exchange; repair; rebuild and testing to factory specifications. Equipment which has been serviced, repaired or rebuilt is returned with a full warranty.

Your local Service Centre can also provide Edwards engineers to support on-site maintenance, service or repair of your equipment.

For more information about service options, contact your nearest Service Centre or other Edwards company.

Or email at:

10.3 Spares and maintenance kits

Spares [email protected]

Service [email protected]

Table 6 - Spares and maintenance kits

Spare Item Number

Drive seal kit MK2 and MK3 A31301803

Drive seal kit MK4 A31301804

Service kit (universal) A31301814

Pair of gears A31301820

Cooling coil (discharge) A31301821

Oil sight glass kit A31301822

Pair of rotors (requires MK4 seals) A31301824

Oil pump A31301826

Oil resevoir bottle A31301827

Cooling coil (drive end) A31301828

Cooling coil (gear case end) A31301829

Coupling element (30 kW/40 HP) A31301730

Coupling element (55 kW/75 HP) A31301730

Inlet mesh A31301750

A313-24-855 Issue A



Date post:	17-Jan-2023
Category:	Documents
Upload:	khangminh22
View:	0 times
Download:	0 times

Maintenance Manual - Precision Plus

Documents