This document provides an instruction manual for the BAOSI hydraulic coupling series Roots vacuum pump, specifically models BSJ600LC and BSJ1200LC. It covers installation, operation, and maintenance, emphasizing safety precautions throughout.
Function Description
The BAOSI hydraulic coupling series Roots vacuum pump is a positive displacement pump designed for high pumping speed. It operates in conjunction with a suitable backing pump and can continuously function at inlet pressures up to 1000 mbar, although prolonged operation at this pressure may lead to abnormally high pump body temperatures. For achieving lower system pressures, two or more pumps can be used in series. The BSJ600LC and BSJ1200LC models are equipped with a cooling pipeline at the pump outlet to reduce the temperature of the rotor and exhaust gas. The pump is designed to safely pump non-combustible gases and vapors when operated within the specified parameters.
The pump's motor shaft drives one of the rotors through a hydraulic drive located inside the motor side cover. Synchronizing gears then drive the second rotor in the opposite direction within the rotor housing. A small clearance is maintained between the rotors and between the rotors and the inner wall of the rotor housing, enabling high-speed operation without mechanical wear or the need for lubrication within the swept volume.
The hydraulic drive incorporates a fluid coupling that connects the motor shaft to the rotor. This system configuration ensures that the rotor's rotational speed is reduced when the gas load is excessively high. As the gas load decreases, the rotors accelerate to full speed. This mechanism allows the pump to operate continuously across the vacuum range without the risk of motor overload and eliminates the need for bypass valves and associated pipelines. The fluid coupling's performance is highly sensitive to the viscosity of the pump oil, and the packaged pump comes with special oil specifically for BAOSI vacuum pumps.
The motor side cover and the gear side cover are connected to the pump outlet via a pressure equalization passageway, forming part of the vacuum system. This passageway includes felt to remove debris, preventing contamination of the lubricating oil and bearings.
Important Technical Specifications
Models: BSJ600LC, BSJ1200LC
Dimensions:
- BSJ600LC: 1253 mm (length) x 596 mm (width) x 515 mm (height)
- BSJ1200LC: 1431 mm (length) x 596 mm (width) x 481 mm (height)
Weight:
- BSJ600LC: 350 kg
- BSJ1200LC: 425 kg
Operation and Storage Conditions:
- Ambient operating temperature and humidity: 5 to 40°C, below 90% RH
- Ambient storage temperature and humidity: -10 to 50°C, below 90% RH
- Altitude: Below 1000m
Performance (Rotational Speed):
- 50Hz power supply: 0 to 2950 r/min
- 60Hz power supply: 0 to 3560 r/min
- Maximum outlet pressure: 1000 mbar absolute (1x10^5 Pa)
Pressure Differential (determined by hydraulic drive):
- BSJ600LC (50Hz power supply): 0 to 80 mbar (0 to 8x10^3 Pa)
- BSJ600LC (60Hz power supply): 0 to 67 mbar (0 to 6.7x10^3 Pa)
- BSJ1200LC (50Hz power supply): 0 to 70 mbar (0 to 7x10^3 Pa)
- BSJ1200LC (60Hz power supply): 0 to 50 mbar (0 to 5x10^3 Pa)
Electrical Data:
- Electrical supply: 380/400/415V-50Hz, 440/460V-60Hz, 3 Phases
- Voltage tolerance: ±10% (50Hz), -2.5%, +5% (60Hz)
- Full load rated current (BSJ600LC): 21.2A (380V-50Hz), 20.3A (400V-50Hz), 20A (415V-50Hz), 18.3A (440V-60Hz), 17.8A (460V-60Hz)
- Rated power (BSJ1200LC): 11 kW across all listed voltages/frequencies
Lubrication Data:
- Recommended oil: BSO-46
- Oil capacity:
- Shaft seal oil reservoir: 1.5L
- Hydraulic drive: 7.5L
- Gear cover: 4L
Cooling Water Data (with inlet temperature of 20°C):
- Recommended cooling water flow:
- BSJ300LC: 3L/min
- BSJ600LC: 6L/min
- BSJ1200LC: 6L/min
- Recommended cooling water supply pressure: 2 to 6 bar gauge (2x10^5 to 6x10^5 Pa) or 3 to 7 bar absolute (3x10^5 to 7x10^5 Pa)
- Permissible temperature range: 5 to 35 °C
Vibration and Noise Data:
- Vibration level: <1.8mm/s r.m.s. in the range 10 to 1000 Hz
- Continuous A-weighted sound pressure level (measured at 1 meter): 83 dB(A)
Connections:
- Cooling water connection: Inlet 3/8inch, Outlet 3/8inch
- Vacuum connection:
- BSJ600LC: Inlet ISO160, Outlet ISO100
- BSJ1200LC: Inlet ISO250, Outlet ISO100
- Inlet and outlet flanges are standard ISO flanges.
Usage Features
- Installation: The pump must be installed by suitably trained technicians on a firm, level surface. The vacuum pipeline should be adequately supported to prevent stress on joints. Hoses can be used to reduce vibration transmission, ensuring their pressure rating exceeds the system's maximum pressure. Inlet filters are recommended for dusty applications to minimize abrasion.
- Oil Filling: Correct oil grade and levels are crucial for pump performance and safety. The manual provides detailed instructions for filling oil in the hydraulic drive, shaft seal oil reservoir, and gear cover, including visual indicators like sight glasses and reflector plates.
- Electrical Connection: The motor is configured for "high pressure" operation (380V and above) and lacks internal protective devices, necessitating external overload and leakage circuit breakers. Proper wiring and earthing are essential, adhering to local and national safety requirements. A contactor with manual reset control is required to prevent automatic restarts after power failures or overloads.
- Direction of Rotation Check: Before operation, the motor's fan rotation direction must be checked against the marked arrow. Incorrect phasing can cause the rotor to reverse or not rotate.
- Outlet Configuration: Both BSJ600LC and BSJ1200LC models offer two alternative outlet positions (underside and side). The pump is supplied with the side outlet active and the bottom outlet blocked, but users can reconfigure this as needed.
- Start-up Procedure: Involves checking oil levels, verifying correct installation, turning on cooling water, closing all atmospheric valves, switching on the backing pump, then the Roots pump, allowing it to reach operating temperature, and finally slowly opening the pump inlet isolation valve.
- Stop Procedure: Requires closing the pump inlet isolation valve, allowing sufficient time for dangerous substances to drain, switching off the pump, closing the backing air pump admittance valve, switching off the backing pump, and turning off the cooling water supply.
- Safety: Emphasizes obeying safety instructions, wearing protective clothing when handling contaminated parts, degassing and purging the system before installation, ensuring no debris enters the pump, disconnecting electrical components during maintenance, ensuring unobstructed cooling air flow, and maintaining accessible servicing points and sight glasses.
Maintenance Features
- Maintenance Plan: The manual outlines a maintenance schedule:
- Oil level check: Weekly
- Pump connection check: Monthly
- Oil change: Every 12 months
- Overhaul the pump: Every 6 years
- Oil Level Check: Regular checks of oil levels in the shaft seal reservoir, motor side cover, and gear side cover are critical. During operation, oil in the motor side cover circulates, so a visible oil level or foam may indicate normal circulation. If the shaft seal reservoir oil is depleted, it may indicate a failed oil seal, requiring contact with BAOSI Service Department.
- Oil Change: Detailed steps are provided for draining contaminated oil and refilling with new BAOSI vacuum pump oil BSO-46. This involves stopping the pump, venting to atmospheric pressure, cooling down, unscrewing drain plugs, and refilling to the recommended levels. Waste oil must be disposed of according to environmental regulations.
- Pump Connection Check: Regular inspection of cooling water connections, pipelines (for corrosion, leakage, damage), electrical connections, and vacuum pipelines (for corrosion, damage, security) is required.
- Troubleshooting: A comprehensive trouble checklist is provided, detailing common issues (e.g., pump not running, abnormal surface temperature, pressure not dropping, abnormal sound, motor current abnormal, oil leakage) and their corresponding causes and processing methods.
- Storage: For long-term storage, the pump should be stopped, disconnected from power and vacuum systems, cleaned, and protective covers installed on flanges. It must be stored in cool, dry conditions within specified temperature limits (5 to 50°C, not below -30°C to prevent seal and lubricant damage).
- Disposal: The pump and its parts must be disposed of safely, adhering to local and national safety and environmental regulations, with special attention to parts and waste oil contaminated with dangerous process substances.
- Warranty: The product comes with a one-year warranty from the date of Bill of Lading (BL) for manufacturing defects or non-human damage. The warranty does not cover products exceeding the warranty period, man-made damage, failures due to not following instructions, unauthorized modifications, non-compliant use, bad condition due to noise, adverse environmental conditions, or consumables.
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