SOGEVAC Rotary Disc Pump Maintenance Guide

Leybold SOGEVAC DI/BI series rotary vane pumps: a complete guide to selection, replacement, maintenance, and troubleshooting

Introduction: When your analytical instrument requires a reliable front-end vacuum

In high-end analytical instruments such as liquid chromatography-mass spectrometry (LC-MS), gas chromatography-mass spectrometry (GC-MS), inductively coupled plasma mass spectrometry (ICP-MS), electron microscopy, and leak detection, the performance of the front-end vacuum pump directly affects the sensitivity and stability of the instrument. Oil sealed rotary vane pumps have become the mainstream choice for these applications due to their simple structure, easy maintenance, and moderate cost. However, as the equipment ages, when the pumping speed of the pump decreases, noise increases, the maximum pressure rises, or oil mist appears, engineers often face the choice of repair or replacement.

Leybold's SOGEVAC DI and BI series oil sealed rotary vane pumps are the preferred products designed specifically for analytical instruments and medium vacuum applications. They are known for their ultra long maintenance free cycles (up to 24000 hours on liquid/gas mass spectrometers), extremely low noise levels (≤ 61 dB (A)), efficient exhaust filtration (oil mist loss<1 ppm), and flexible power compatibility. The FC model integrates variable frequency drive and RS 485 interface, which can achieve preventive maintenance and pump speed control.

This article is based on the SOGEVAC DI/BI series product manual, providing a detailed technical guide from model comparison, selection and replacement, installation and wiring, maintenance cycle, common troubleshooting to accessory upgrades, to help engineers quickly solve on-site problems.

Overview and Selection of SOGEVAC DI/BI Series Models

The SOGEVAC series covers a pumping speed range from 16 m ³/h to 147 m ³/h, divided into two sub series: DI and BI. The DI series (such as SV 16 DI) adopts a compact design, with the pump and motor coaxial; The BI series (such as SV 28 BI, SV 40 BI) also uses integrated motors, and some high pumping speed models (SV 40 BI FC, SV 65 BI FC, SV 120 BI FC) are equipped with variable frequency drives.

1.1 Key technical parameters of each model

Model nominal pumping speed (50/60 Hz) m ³/h ultimate pressure (without gas ballast) mbar ultimate pressure (with gas ballast) mbar noise dB (A) oil volume L power supply

SV 16 DI 16.0/18.7 ≤ 0.1 ≤ 1.0 59 2.0 single-phase/three-phase optional

SV 28 BI 25/29 ≤ 0.05 ≤ 0.5 57 (single-phase) 1.5 wide range single-phase/three-phase

SV 40 BI 42/50 ≤ 0.20 ≤ 0.5 60 1.0 single-phase

SV 40 BI FC 53 (50/60) ≤ 0.20 ≤ 1.0 ≤ 59 1.0 single-phase+frequency converter

SV 65 BI FC 71 (50/60) ≤ 0.20 ≤ 1.0 ≤ 60 2.0 single-phase+frequency converter

SV 120 BI FC ≥ 147 (50/60) ≤ 0.20 ≤ 1.0 ≤ 61 2.0 single-phase+frequency converter

Key selection points:

LC/GC-MS: Recommended SV 16 DI or SV 28 BI, combined with synthetic oil LVO 700, can achieve 24000 hours of maintenance free operation.

ICP-MS: SV 40 BI FC, SV 65 BI FC, or SV 120 BI FC are recommended, and PFPE oil (LVO 420) is used to resist corrosive gases.

General industrial applications (vacuum drying, metallurgy, refrigeration): Select the corresponding model according to the required pumping speed, and pay attention to single-phase/three-phase power supply limitations.

Core technological advantages and design features

2.1 Ultra long maintenance free cycle

SOGEVAC pumps can operate maintenance free for up to 3 years (approximately 24000 hours) in LC/GC-MS applications. This is due to:

Optimized oil circuit design and larger oil capacity (up to 4 times more oil volume than similar pumps)

Efficient oil separation system, oil mist loss<1 ppm, slow oil aging

Integrated oil recovery system, no need for external oil pipes

2.2 Extremely low noise and vibration

The noise level of all SOGEVAC pumps is below 61 dB (A), with some models as low as 54 dB (A) (three-phase motors). Low speed design (1500-1800 rpm) and precise dynamic balancing ensure minimal vibration, typically without the need for expensive soundproof enclosures.

2.3 Anti Buckle Valve

The inlet of the pump is equipped with an anti backflow oil valve. When the pump is shut down (normal shutdown or power outage), the valve automatically closes the air inlet and the pump body releases air. This prevents the pump oil from being sucked into the vacuum system and also prevents the chamber pressure from rapidly rising. The valve is effective under all operating conditions (pressure below 800 mbar) and is not affected even when the gas damper is open.

2.4 Efficient exhaust filtration

The integrated exhaust filter can effectively remove oil mist within the entire working pressure range (from atmospheric pressure to maximum pressure). The oil content of the discharged gas is less than 1 ppm, which meets the environmental requirements of the laboratory and clean room.

2.5 Wide Range Single Phase Power Supply

All pumps can use single-phase 200~240 V ± 10%, 50/60 Hz power supply without special wiring. Some models also offer 110~115 V versions, suitable for the North American market. The FC model (variable frequency drive) further limits the starting surge current and can use ordinary B-type circuit breakers.

2.6 RS 485 interface and predictive maintenance (FC model)

SV 40 BI FC, SV 65 BI FC, and SV 120 BI FC are equipped with RS 485 interfaces, which can achieve:

Read the operating hours of the pump

Monitor motor power and drive temperature

Remote start/stop

Adjust the pump speed (50%~100%)

These data can be used for predictive maintenance, arranging repairs before faults occur, and avoiding unplanned downtime.

Installation and electrical connection

3.1 Mechanical Installation

Location: The pump should be installed on a horizontal and sturdy surface, ensuring good ventilation at the bottom.

Connection: The intake and exhaust ports are ISO-KF flanges (DN 25, DN 40, or DN 50). Use appropriate centering rings and clamps. For the exhaust port, a 1/2 "hose barbed connector (some models) can be used.

Mobile: The SV 120 BI FC is equipped with wheels and foldable handles, making it easy for a single person to move around.

3.2 Electrical Connections

Power supply: Check the voltage and frequency on the nameplate. Single phase wide range models (200-240 V) can be directly plugged into standard sockets. Attention: The FC model has an internal frequency converter and a starting current limit, so no special circuit breaker is required.

Grounding: It must be reliably grounded (through the power line grounding terminal).

RS 485 wiring (FC model): Use shielded twisted pair to connect to the RS 485 port of the controller. For details of the agreement, please consult Leybold.

3.3 Initial startup

All pumps have been filled with an appropriate amount of oil and tested before leaving the factory. Before the first startup:

Check the oil level (through the oil sight glass), which should be between the maximum and minimum markings.

Ensure that the air intake is connected to the system or blocked.

Start by tapping and confirm the direction of rotation (three-phase motors need to check the phase sequence, single-phase motors do not need to).

After running for 1-2 minutes, check if there is oil mist at the exhaust port (normally it should be very rare).

Maintenance and oil selection

4.1 Oil type

Applicable scenarios for oil product models

LVO 700 synthetic cyclic hydrocarbon oil LC/GC-MS, general vacuum, high antioxidant activity, long life

LVO 420 PFPE (perfluoropolyether) ICP-MS, corrosive gas, strong oxidizing environment

Important notice: PFPE oil (LVO 420) can only be used for pumps specifically designed to use this oil (such as FC models labeled with PFPE). Mixing mineral oil and PFPE can cause seal damage and pump failure.

4.2 Maintenance cycle

Standard application: Replace oil and exhaust filters every 12 months or 8000 hours.

LC/GC-MS: LVO 700 can achieve an oil change cycle of 24000 hours (3 years).

FC model: Read operating hours through RS 485 and schedule maintenance according to actual load.

4.3 Daily Inspection

Check the oil level weekly and replenish it when it falls below the minimum line.

Check the exhaust outlet monthly for obvious oil mist (if so, it indicates that the exhaust filter may be clogged or damaged).

Clean the exterior of the pump body and fan cover every quarter to ensure good heat dissipation.

4.4 Oil Change Procedure

The pump runs until it is warm (which helps the oil flow out), and then stops.

Open the air inlet to release air to atmospheric pressure.

Place an oil pan under the exhaust port.

Remove the drain plug (or use the included drain hose) and drain the old oil into a container.

Replace the exhaust filter (if necessary).

Tighten the oil drain plug and inject new oil from the filling port to the correct level.

Start the pump and run it for a few minutes, then check the oil level again.

Common troubleshooting

The following troubleshooting guide is based on typical failure modes of SOGEVAC pumps.

5.1 Pump does not start or trips immediately

Possible cause inspection and resolution

Check the nameplate voltage if the power supply voltage does not match, and confirm that it is consistent with the power grid

Motor overload relay tripping (FC model external fuse or circuit breaker), resetting circuit breaker or replacing fuse; Check if the pump is stuck

Check the oil level and drain excess oil if there is too much oil accumulation or high oil viscosity in the pump; Using low-temperature oil in cold environments

Measure the resistance of the motor winding when it burns out; If there is a short circuit or open circuit, the motor or the entire pump needs to be replaced

Observe the LED status of the FC model frequency converter for faults; Power off and restart; If the problem persists, contact maintenance

5.2 Insufficient pumping speed or high ultimate pressure

Possible cause inspection and resolution

Check and clean the air inlet filter or pipeline blockage

Fill the oil level to the correct level if it is too low

Oil aging or contamination (black or emulsified oil), replace oil and exhaust filters

Exhaust filter clogged, replace filter

The gas damper is not closed (when low limit pressure is required). Close the gas damper

Check if the valve disc is stuck when the anti backflow valve is not fully opened

Internal wear of the pump (blades, cylinder body) requires major repair or replacement

5.3 Abnormal increase in noise or severe vibration

Possible cause inspection and resolution

The pump base is not fixed or loose, and the installation bolts are tightened

Rigid connection of intake or exhaust pipes causes resonance, and flexible connection of corrugated pipes is used

If there are foreign objects or blade fragments inside the pump, stop immediately and disassemble for inspection

Bearing wear, replacement of bearings or entire pump

Loose motor fan cover or damaged fan blades, tighten or replace

5.4 Excessive oil mist at the exhaust port

Possible cause inspection and resolution

Drain excess oil to the normal oil level when the oil level is too high

Exhaust filter saturated or damaged, replace filter

Using the wrong type of oil (such as mineral oil for high loads), drain the old oil, clean the pump, and add the correct oil

Long term operation of the pump under high pressure (>10 mbar) leads to a large amount of oil carryover. Check for leaks in the front stage pipeline and reduce the intake pressure

5.5 Rapid increase in vacuum system pressure after pump shutdown (oil return)

Possible cause inspection and resolution

The anti backflow valve is not tightly sealed or stuck. Remove the inlet flange and check if the valve plate is intact; Clean or replace the valve disc

Stop the pump without releasing air (causing oil to be sucked into the system) and confirm that the automatic release function of the pump is normal (FC model can be set)

Excessive oil volume in the pump discharges excess oil

5.6 RS 485 communication failure (FC model)

Possible cause inspection and resolution

Check if the A/B wires are reversed due to wiring errors or poor contact; Ensure that the shielding layer is grounded at one end

Confirm that the baud rate of the controller and pump is consistent (usually 9600) due to a mismatch in baud rate

Address conflict: If there are multiple devices on the bus, ensure that the addresses are unique

Internal communication board fault of frequency converter, contact for repair

Precautions for replacing old pumps

When you need to replace a discontinued or irreparable rotary vane pump, the SOGEVAC DI/BI series is an ideal alternative. Please verify the following points:

6.1 Speed matching

The pumping speed of the new pump should not be lower than the rated pumping speed of the old pump. Attention: The pumping speed of SOGEVAC is measured under DIN 28 400 standard and may differ from other brands. For example, if an old pump has a nominal capacity of 20 m ³/h, SV 28 BI (25 m ³/h) can be used to obtain a surplus.

6.2 Flange dimensions

Old pump flange SOGEVAC corresponding model

DN 25 ISO-KF SV 16 DI, SV 28 BI, SV 40 BI FC (optional)

DN 40 ISO-KF SV 40 BI, SV 65 BI FC, SV 120 BI FC

DN 50 ISO-KF SV 120 BI FC (optional)

If the flanges do not match, variable diameter flanges or adapters can be used.

6.3 Power Compatibility

The old pump may use a three-phase 380 V or 220 V power supply. SOGEVAC offers a wide range of single-phase (200-240 V) and three-phase versions. If there is only a three-phase power supply on site, a three-phase motor version can be selected. The FC model uses a single-phase power supply, but the internal frequency converter can accept 180-264 V.

6.4 Installation Space

The external dimensions of SOGEVAC pumps (see manual dimension diagram) are usually more compact than similar pumps. Before replacing, measure the installation space of the old pump to ensure that the new pump can fit in. Especially since the SV 120 BI FC has a large size (733 × 470 × 483 mm), sufficient space needs to be reserved.

6.5 Exhaust interface

The exhaust port of the old pump may be a threaded joint or flange. SOGEVAC offers ISO-KF flange or 1/2 "hose barbed connectors. Use adapters or custom tubing.

6.6 Oil Products

If the old pump uses PFPE oil (such as Fomblin), the PFPE version of SOGEVAC (such as the LVO 420 model of SV 40 BI FC) must be selected. Ordinary SOGEVAC cannot be directly filled with PFPE oil because the seals are incompatible.

6.7 Control Integration

If the old pump has remote control function (such as starting and stopping through PLC), the RS 485 interface of SOGEVAC FC model can provide similar or even stronger functions. Non FC models can only control motor start and stop through contactors.

Accessories and upgrade options

7.1 Mobile Base Frame

Suitable for pumps with a pumping speed ≤ 120 m ³/h

Equipped with an oil pan that can hold up to 2 liters of leaked oil

Universal casters (two with brakes)

Easy to move and maintain

7.2 Noise Enclosure

Can further reduce by about 5 dB (A)

Open design on both sides to ensure heat dissipation

Can be used in combination with a mobile base

7.3 Power Cords

Leybold offers a variety of power cords suitable for sockets in different countries:

European standard Schuko (16A)

British Standard (13A)

American standard NEMA 6-15P/5-15P

Switzerland, IEC 309, etc

The length ranges from 1.8 meters to 5 meters

7.4 Oil Product (LEYBONOL)

LVO 700:1 liter bottle (L700 01), suitable for most analytical instruments.

LVO 420:1 liter bottle (L420 01), PFPE version only.