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Instr Manual: iQ Dry Pumping System - en A532-40-880
Issue K
Manor Royal, Crawley, West Sussex, RH10 9LW, UK
Telephone: +44 (0) 1293 528844 Fax: +44 (0) 1293 533453
http://www.bocedwards.com
iQ Dry Pumping System
Instruction Manual
A532-40-880
Setup Password
iQ Dry Pumping System - Setup Password
The setup password for this equipment is preset as follows:
SETUP PASSWORD:
202
You can remove this sheet from the instruction manual and retain it in a safe place to prevent
unauthorised access to the setup menus in the iQ system. (This page deliberately left blank) CONTENTS
Section
Title
Page
1
INTRODUCTION
1-1
1.1
Scope and definitions
1-1
1.2
ATEX directive implications
1-2
1.3
The iQ system
1-3
1.4
The iQDP pump
1-3
1.5
The iQDP pump gas system
1-5
1.6
Gas Modules
1-5
1.6.1
Introduction
1-5
1.6.2
iQDP Shaft-Seals Purge Module
1-5
1.6.3
iQDP Gas-Ballast Module
1-7
1.6.4
iQDP Gas System Module Series 2
1-9
1.7
The iQMB mechanical booster pump
1-9
1.8
Temperature control system
1-12
1.8.1
iQDP pump temperature control system
1-12
1.8.2
iQMB pump temperature control system
1-14
1.9
Exhaust system
1-14
1.10
Electrical system
1-15
1.10.1
Introduction
1-15
1.10.2
Electrics Module
1-15
1.10.3
Sensor Monitoring Module
1-20
1.11
Control functions
1-22
1.11.1
Priority of control
1-22
1.11.2
Setpoints, warning and alarm conditions
1-22
1.11.3
Safety sensors
1-23
1.12
Pump Display Module accessory
1-23
1.13
iQ Interface Module accessories
1-28
1.14
iQ PC Interface Kit accessory
1-28
1.15
iQ Central Monitoring System
1-28
1.16
Labels
1-28
2
TECHNICAL DATA
2-1
2.1
General
2-1
2.2
Performance
2-1
2.3
Cooling-water supply
2-1
2.4
Temperature control system
2-13
2.5
Lubrication
2-13
2.5.1
iQDP pump
2-13
2.5.2
iQMB pump
2-14
2.6
Exhaust-silencer
2-14
2.7
Exhaust check-valve
2-14
2.8
Electrical data
2-14
2.9
Gas system
2-15
2.10
Materials in contact with process gases
2-17
2.11
Default setpoints
2-17
2.12
Connections
2-19
iQ Dry Pumping System
i
Ipsitech
8097-03 Section
Title
Page
3
INSTALLATION
3-1
3.1
Safety
3-1
3.2
Installation checklist
3-1
3.3
Unpack and inspect
3-3
3.4
Locate the iQ system
3-4
3.5
Install the iQMB mechanical booster pump (if necessary)
3-6
3.6
Configure the Sensor Monitoring Module for your iQ system
3-6
3.7
Fit Oil-Level Monitors (optional)
3-7
3.8
Fill the iQMB pump with oil (if fitted)
3-7
3.8.1
Coupling-cover
3-7
3.8.2
Shaft-seal reservoir
3-7
3.8.3
Rear-bearing end-cover (iQMB1200F only)
3-9
3.9
Install or replace optional accessories (if necessary)
3-10
3.9.1
Replace the Gas Module
3-10
3.9.2
Install the Pump Display Module
3-10
3.9.3
Install the Interface Module(s)
3-10
3.9.4
Install the iQ PC Interface Kit
3-10
3.9.5
Install the iQ Water Flow-Switch
3-10
3.10
Check the iQDP pump oil level
3-10
3.11
Check the iQDP pump coolant level
3-10
3.12
Connect to your process system
3-12
3.12.1
Adjust the height of the system
3-12
3.12.2
Connect the inlet of the iQ system to your process system
3-12
3.13
Connect to your exhaust-extraction system
3-13
3.13.1
Install the iQ Exhaust Temperature Sensor (optional)
3-13
3.13.2
Configure the iQ system to use the alternative outlet position
3-13
3.13.3
Connect the iQ outlet to your exhaust-extraction system
3-14
3.14
Connect the nitrogen supply
3-14
3.15
Leak test the system
3-15
3.16
Install additional safety equipment (optional)
3-15
3.17
Connect to your emergency stop circuit (optional)
3-16
3.18
Connect the GRC bypass output to your GRC (optional)
3-16
3.19
Electrical supply and RF earth (ground) connections
3-17
3.19.1
Configure the Electrics Module for your electrical supply
3-17
3.19.2
Configure the pump(s) for your electrical supply
3-17
3.19.3
Connect the electrical supply
3-21
3.19.4
Connect an additional RF earth (ground): optional
3-22
3.20
Connect the cooling-water pipelines
3-24
3.21
Adjust the interstage purge flow rates if necessary
3-25
3.22
Commission the iQ system
3-25
3.22.1
Switch on the iQ system pumps
3-25
3.22.2
Check the nitrogen pressure and adjust if necessary
(Shaft-Seals Purge Module)
3-26
3.22.3
Check the nitrogen pressure and adjust if necessary
(Gas-Ballast Module and Gas System Module Series 2)
3-26
3.22.4
Adjust the iQDP pump operating temperature (optional)
3-27
ii
iQ Dry Pumping System Section
Title
Page
3.23
Fit the Acoustic Enclosure (optional)
3-30
4
PUMP DISPLAY MODULE MENUS AND DISPLAY FORMATS
4-1
4.1
Introduction
4-1
4.2
General operation
4-2
4.3
The CANCEL button
4-2
4.4
Display text and variable text
4-2
4.5
Wrap-around
4-3
4.6
Timeout
4-3
4.7
Menu structure
4-3
4.8
Example
4-3
5
OPERATION
5-1
5.1
ATEX directive implications
5-1
5.1.1
Introduction
5-1
5.1.2
Flammable/pyrophoric materials
5-1
5.1.3
Gas purges
5-2
5.2
Introduction to operation
5-3
5.3
Configure the system
5-3
5.3.1
Change the setpoints
5-3
5.3.2
Use the default setpoints
5-4
5.3.3
Change iQ system configuration information
5-5
5.4
Change the display format
5-5
5.4.1
Change the normal display
5-5
5.4.2
Change the pressure display units
5-6
5.4.3
Change the temperature display units
5-6
5.4.4
Change the language of display messages
5-6
5.5
Take and release control
5-6
5.6
Start-up
5-6
5.7
Check the Gas Module nitrogen pressure and adjust if necessary
5-7
5.8
Monitor the status of the iQ system
5-7
5.9
Warning and alarm indications
5-8
5.10
Manual shut-down
5-10
5.11
Automatic shut-down
5-11
5.12
Emergency stop
5-12
5.13
Restart after emergency stop or automatic shut-down
5-12
5.14
Operation of iQ system components
5-13
5.15
Operation of the load-lock pump
5-14
6
MAINTENANCE
6-1
6.1
Safety
6-1
6.2
Maintenance plan
6-2
6.3
Inspect the connections, pipelines and cables
6-2
6.4
Inspect and clean the exhaust-silencer
6-3
6.5
Check the iQMB pump oil-levels
6-5
6.6
Inspect and clean the exhaust check-valve
6-6
6.7
Check the iQDP pump oil-level
6-8
iQ Dry Pumping System
iii Section
Title
Page
6.8
Check the iQDP pump coolant-level
6-8
6.9
Relubricate the iQDP pump rotor bearings
6-10
6.10
Relubricate the iQMB pump rotor bearings (iQMB250F & iQMB500F only) 6-11
6.11
Change the iQDP pump oil
6-12
6.12
Change the iQMB pump oil
6-12
6.13
Adjust the Pump Display Module display viewing angle
6-13
6.14
Replace an Electrics Module fuse
6-13
6.15
Replace the Gas Module
6-14
6.15.1
Remove the old Gas Module
6-14
6.15.2
Fit the new Gas Module
6-16
6.16
Replace the Pump Display Module
6-17
6.17
Relocate the iQ combination pumping system for maintenance
6-17
6.18
Replace the iQMB pump
6-18
6.19
Replace the iQDP pump with the iQMB pump connected to the process
system (booster frame mounted combination pumping systems only)
6-19
6.20
Zero the Gas Module flow transducers
6-20
6.21
Fault finding
6-20
6.21.1
Warning and alarm message fault finding
6-20
6.21.2
Service LED fault finding
6-21
6.21.3
Other fault finding
6-21
7
STORAGE AND DISPOSAL
7-1
7.1
Storage
7-1
7.2
Disposal
7-1
8
SERVICE, SPARES AND ACCESSORIES
8-1
8.1
Introduction
8-1
8.2
Service
8-1
8.3
Spares
8-1
8.3.1
Pumps
8-1
8.3.2
Other spares
8-2
8.3.3
Greases and oils
8-2
8.4
Accessories
8-2
8.4.1
Gas modules
8-2
8.4.2
iQMB Motor Ancillaries Kits
8-2
8.4.3
iQMB Booster Connection Kits
8-3
8.4.4
iQ Acoustic Enclosures
8-3
8.4.5
iQMB Booster Frames
8-3
8.4.6
QMB Booster Frame Connection Kits
8-4
8.4.7
iQMB Booster Frame Acoustic Enclosures
8-4
8.4.8
OLM500 Oil-Level Monitor
8-4
8.4.9
iQ Exhaust Temperature Sensor
8-4
8.4.10
iQ Pump Display Module and extension cables
8-5
8.4.11
iQ Water Flow-Switch
8-5
iv
iQ Dry Pumping System Section
Title
Page
8.4.12
iQ Interface Modules
8-5
8.4.13
iQ PC Interface Kits
8-6
8.4.14
iQ Central Monitoring System
8-6
RETURN OF BOC EDWARDS EQUIPMENT
Tables
Table
Title
Page
1-1
Safety sensors
1-23
2-1
Technical data
2-2
2-2
Cooling-water consumption
2-2
2-3
Full load current ratings
2-15
2-4
Nitrogen purge flow rates: Shaft-Seals Purge Module
2-16
2-5
Nitrogen purge flow rates: Gas Ballast Module and Gas System Module Series 2
2-16
2-6
Electrics Module default setpoints
2-17
2-7
Gas-Ballast Module default setpoints
2-18
2-8
Gas System Module Series 2 default setpoints
2-18
2-9
Sensor Monitoring Module default setpoints
2-19
3-1
Installation checklist
3-2
3-2
Checklist of components
3-4
3-3
DIP switches 3 and 4 positions
3-6
3-4
DIP switches 1 and 2 positions
3-6
3-5
Pins in the emergency stop connector
3-16
3-6
Pins in the GRC bypass connector
3-16
3-7
Pins in the electrical supply connector
3-22
3-8
Adjust the TCV on the iQDP40
3-30
3-9
Adjust the TCV on the iQDP80
3-30
4-1
Menu structure
4-4
5-1
Setpoints which you