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1. tion of vacuum in vessels designed for that purpose Any other use will automatically invalidate all warranty and li ability claims Remain aware of safety and risks page 9 of 59 Setting up and installing the equipment A DANGER eg US Equipment must be connected only to a suitable elec trical supply and a suitable ground point As such the plug must be plugged into an outlet that is properly grounded Failure to connect the motor to ground may result in deadly electrical shock The supply cable may be fitted with a molded Europe an IEC plug or a plug suitable for your local electrical supply The cable contains wires color coded as fol lows green or green and yellow ground blue or white neutral brown or black hot Due to the high compression ratio the pump may gen erate overpressure at the outlet Check pressure com patibility with system components e g exhaust pipe line or exhaust valve at the outlet Do not permit any uncontrolled pressurizing Make sure that the exhaust tubing cannot become blocked If there is an exhaust isolation valve make sure that you cannot operate the equipment with the valve closed to avoid a risk of bursting Keep the electrical power cord away from heated sur faces Provide a firm level platform for the equipment Check that the system which you are going to evacuate is mechanically stable Check that all fittings are secure Ensure a stable position of the pump without a2. DIN EN 61326 1 2006 DIN EN 50581 2013 Bevollm chtigter f r die Zusammenstellung der technischen Unterlagen Person authorized to compile the technical file Personne autoris e constituer le dossier technique Dr J Dirscherl VACUUBRAND GMBH CO KG Alfred Zippe Str 4 97877 Wertheim Ger many Wertheim 28 11 2013 Dr F Gitmans Dr J Dirscherl Managing director G rant Technischer Leiter Technical Director Directeur technique VACUUBRAND GMBH CO KG Alfred Zippe Str 4 97877 Wertheim Tel 49 9342 808 0 Fax 49 9342 808 5555 E Mail info vacuubrand de Web www vacuubrand com page 59 of 59 Disclaimer Our technical literature is only intended to inform our cus tomer The applicability of general empirical values and results obtained under lab conditions to your specific operations depends on a number of factors beyond our control It is therefore strictly the users responsibil ity to very carefully check the application of these data to their specific requirements No claims arising from the information provided in this lit erature will consequently be be entertained Alfred Zippe Str 4 97877 Wertheim Germany T 49 9342 808 0 F 49 9342 808 5555 info vacuubrand com www vacuubrand com VACUUBRAND GMBH CO KG Technology for Vacuum Systems 2013 VACUUBRAND GMBH CO KG Printed in Germany Manual no 997829 11 28 2013
3. With the gas ballast valve closed the rotary vane pump shuts off vacuum tight This in turn prolongs the intervals between oil changes and im proves corrosion resistance The oil system incorporates an oil pump this forced lubrication system ensures an adequate supply of oil to the pump unit even at high inlet pressures A mechanical retaining valve in the oil system prevents oil suck back into the vacuum system The oil mist filter of the rotary vane pump removes 99 of the oil mist If an exhaust waste vapor condenser is fitted available on request the va pors handled by the pump can be condensed to a large extent and either be recycled or disposed of in accordance with regulations page 24 of 59 Initial operation Pouring in the pump oil ACAUTION e The pump is supplied dry e without oil filling This is in order to ensure that oil cannot make its way from the rotary vane pump into the housing of the oil mist filter during transport A can containing 0 5 liter 0 53 quarts of rotary pump oil is supplied with the pump Before starting the pump for the first time pour in the oil as described below Pouring in the oil Remove the oil inlet plug A 6 mm jo wide Allen key M Note Because new oil contains S gas a considerable degree of foam ing can occur during operation with new oil and oil could penetrate the oil separator Pour only approx 350 ml 0 37 quarts of oil into the pump bringing oil
4. and it is necessary to change the oil at appropriate intervals When the pump will stand still for prolonged periods i e for several days the oil must be drained and the pump must be filled with mineral oil Synthetic oil perfluoropolyether oil e g Fomblin Synthetic oils have an excellent chemical resistance and are certified for pumping pure oxygen Therefore these oils are excellent for handling strong oxidants e g halogens nitrogen oxides etc Attention As perfluoropolyether oils mixed with mineral oils result in an emulsion pumps used with these oils must be absolutely free of any residues of mineral oils To accomplish this you must completely disas semble and diligently clean the pump unit reg trade mark Montedison Attention if using special oils Due to a different viscosity density com pared to the standard oil pumps filled with special oil may not achieve the specified ultimate pressure or the pumps may not start reliably at temperatures below 54 F 12 C VACUUBRAND Bou eege 687010 Sliter 5 3 Q eee eae EES eee ene oe men EEE PRIS Ue Eee Serr en PREETI eS prey 687011 ve OE te gk e EE 687012 POO liter 52 8 KE 687013 Rotary vane pump oil K8 Miter TOSO E 687100 Sliter 5 3 EE 687101 RE 687102 Perfluoropolyether oil 500 MI 9 53 Q EE 687600 page 39 of 59 Accessories Glass cold trap GKF 7000 667056 at the inlet Protection of the pump against aggressive substanc es
5. cleaning agent ultrasonic treatment and mechanical stress from pressurized water may re sult in damage to the paint Please mark in the health and safety clearance form if you wish a repaint at your ex pense just in case such a damage should occur We will also replace parts for cosmetic reasons at your request and at your expense Before returning the equipment ensure that if applicable Oil sealed pumps Oil has been drained and an ad equate quantity of fresh oil has been filled in to protect against corrosion Dispose according to regulations Equipment has been cleaned and or decontaminated inside and outside All inlet and outlet ports have been capped Equipment has been properly packed if necessary please order original packaging materials at your cost marked appropriately and the carrier has been notified of any possible contamination The completed health and safety clearance form is en closed We thank you in advance for your understanding of the necessity for these measures that protect our employees and ensure that your pump is protected in shipment page 55 of 59 Scrapping and waste disposal Dispose of the equipment and any components removed from it safely in accordance with all local and national safety and environmental requirements Particular care must be taken with components and waste oil which have been contaminated with dangerous substances from your processes Do not incinerate
6. the pump might generate overpressure at the outlet Check pressure compatibility with system components e g exhaust tubing or exhaust valve at the outlet Ensure that the pump outlet is neither blocked nor restricted t Maximum ambient temperature 104 F 40 C Check the maximum temperatures if installing the pump in a cabinet or a housing Make sure ventilation is adequate especially if the ambient temperature is elevated ACAUTION e Ifthe pump is installed at an altitude of more than 6500 ft 2000 m above mean sea level check compatibility with applicable safety requirements and adopt suit able measures There is a risk of the motor overheat ing due to insufficient cooling e Check compatibility with the maximally permitted pressures at inlet and outlet and the maximum pres sure difference between inlet and outlet ports e Check the oil level of the rotary vane pump every time before starting the pump however atleast once a week page 28 of 59 Check the oil level more frequently if high amounts of gas or vapor are pumped e If pumping aggressive corrosive or otherwise danger ous gases and vapors take appropriate measures to protect personnel pump and environment Use ap propriate equipment such as cold trap separator oil separator full flow oil filter shut off valve or exhaust waste vapor condenser see Accessories pg 39 as well as special oil Nokio he ambient temperature should b
7. 40 Permissible relative atmospheric moisture during operation no condensation 30 to 85 Maximum permissible installation alti tude above mean sea level ft m 6500 2000 Rated motor power hp 0 5 0 37 No load speed 50 60 Hz 1500 1800 Maximum permissible range of supply voltage Attention Observe specifications of rating plate 100 120 V 5 10 50 60 Hz 230 V 10 50 60 Hz page 20 of 59 Type RC 6 self hold thermal cutout manual reset Motor protection Rated current during operation at 100 120 V 50 60 Hz 230 V 50 60 Hz Degree of protection IEC 529 A weighted emission sound pressure level 9 50 uncertainty Ka 3 dB A Inlet small flange KF DN 16 hose nozzle for tubing D 3 8 hose nozzle DN 10 mm Dimensions L x W x H approx 10 308 230 Outlet Weight with oil filling approx 242 a Partial pressure of permanent gases measured at pump inlet b The total pressure is higher than the partial pressure because the former includes the vapor pressure of the pump oil and other condensable vapors e g water the condition of the oil cleanliness content of hydrocarbons with higher partial pressures is crucial for this value c The maximum inlet pressure for water vapor or rather the maximum inlet pressure for vapor cannot be specified in accordance with ISO 21360 2 because it cannot be determin
8. Reg No 3 833 788 VARIO SP VACUUBRAND US Reg No 3 733 388 and also the shown company logos are trademarks of VACUUBRAND GMBH CO KG in Germany and or other countries page 3 of 59 Contents Safety information cccseceeesssseeeeeeeeeeeeeeeeseeneesseeneessnees H Important information 00 0 0 eeccccceecececeeeeeeeeeeeceeeeeeeeeeseeeeeeseeeeeeteaes 4 General information ccccccccccccsescececeeceeceeeeceeceeeeeeseegeeeeseaeeeseegees 6 Intended Bh 6 Setting up and installing the equipment ce ceeeceeeeeeeeeeeaeeeeees 8 Ambient eer ele 10 Operating feierte 11 Safety during operation sccsccccacccdsvencicadiastassawecardaweneecddieaiseweceornseenenctetes 12 Maintenance and repair 15 vlait dalde EE EEEa 18 Gas inlet temperatures ccccccccccceceeseececeeeeeeseeeeeeeseeeeesseeeeeeeeaes 20 Wetted parts s aesct terencncnmnssreneetesndexmnasncsreeancmmetnaennosdenceessneobecenenereatect 20 Abbreviations EE 20 Purp PaSa anainn eE EEE AROARI EEN 21 Use and operation ccccscccsseecseeeceseeeeeeceneeeeeeeeneseneesenes 22 Initial operation Pouring in the pump ol 23 Installing a pump in a vacuum System 24 Durning Operassa E 26 Important notes regarding the use of gas ballaet 29 Operating the pump with condensate in the catchpots 31 Pumping chemically aggressive or toxic gases and vapors 32 UON EE EE 39 EE ne resni 34 Eer Le Ee 35 Notes on choosing the appr
9. a delay in processing the equipment if informa tion is missing or if this procedure is not followed A CAUTION If the product has come in contact with chemicals radioac tive substances or other substances dangerous to health or environment the product must be decontaminated pri or to sending it back to the service center Return the product to us disassembled and cleaned and accompanied by a certificate verifying decontami nation or Contact an industrial cleaning and decontamination service directly or Authorize us to send the product to an industrial clean ing facility at your expense To expedite repair and to reduce costs please enclose a detailed description of the problem and the product s op erating conditions with every product returned for repair NOTICE page 54 of 59 We submit repair quotations only on request and always at the customer s expense If an order is placed the costs incurred for problem diagnosis are offset from the costs for repair or from the purchase price if the customer pre fers to buy a new product instead of repairing the defec tive one If you do not wish a repair on the basis of our quo tation the equipment may be returned to you dis assembled and at your expense In many cases the components must be cleaned in the factory prior to repair For cleaning we use an environmentally friendly water based process Unfortunately the combined attack of el evated temperature
10. and that possible toxic effects of certain vapors are avoided Maintain adequate levels of hygiene and cleanliness e Comply with all relevant statutory requirements and regulations concerning the handling storage and dis posal of oil Note Do not allow oils to enter the drainage system or other bodies of water Spillage can cause accidents slip hazard NOTICE Make sure ventilation is adequate to maintain recommend ed operating temperature Keep a minimum distance of 2 in 5 cm between the cooling fan and surrounding items A DANGER page 11 of 59 e g housing walls etc or else install an external au tomatic ventilation system Check fan regularly for dust dirt Clean fan guard if necessary to avoid a reduction of ventilation The On Off switch is located at the side of the terminal box Use only hoses at the inlet and outlet of the pump with an inner diameter at least as large as the diameter of the pump s connections to avoid overpressure at the outlet and reduction of pumping speed at the inlet Allow the equipment to equilibrate to ambient temperature if you bring it from cold environment into a room prior to operation Notice if there is water condensation on cold surfaces Comply with all applicable and relevant safety require ments regulations and guidelines Implement the re quired actions and adopt suitable safety measures Ambient conditions Do not reach for this product if it has fa
11. is measured with inlet port and gas bal last valve closed check the diaphragm pump and replace the diaphragms if necessary Any drop in the diaphragm pump s pumping speed pro duces a pressure increase in the oil reservoir Although page 30 of 59 this does not have a direct effect on the pumping speed and on the ultimate vacuum attainable by the HYBRID pump it does have a considerable effect on the aging of the oil and the HYBRID pump s chemical resistance All bearings are encapsulated and are filled with long life lubricant Under normal operating conditions the drive system is maintenance free The valves and diaphragms are wear parts Aging of the oil of the rotary vane pump necessitates oil changes Important notes regarding the use of gas bal last Gas ballast is a continuous purge to keep the pump s in terior as clean as possible and to reduce the possibility of condensation inside the pump A DANGER Air and pumped media might react inside the pump or at the outlet of the pump and form hazardous or explo sive mixtures when you use air rather than inert gas for the gas ballast This constitutes a risk of significant damage to equipment and or facilities a risk of per sonal injury or even loss of life AWARNING t Make sure that air gas intake through the gas ballast valve can never lead to hazardous explosive or other wise dangerous mixtures If in doubt use inert gas Ufekriel 9 To reduce conde
12. protection of the recipient against oil molecules Separator AK R at hemlet ee 698006 Protection of the pump against damaging liquid and solid substances protection of the vacuum chamber against back flow of pump oil Retrofit kit Chemistry pumping unit PC8 699949 Pump base with pre mounted exhaust waste vapor condenser and collecting flask Shut off valve Ball valve VKE 16 KF DN 16 675504 Butterfly valve VE 665007 page 40 of 59 Hose nipple aluminum for hoses DN 19 662531 Vacuum hose rubber DN 201 686005 PTFE vacuum hose antistatic with stainless steel small flanges The inner side of the PTFE hose is smooth for increased chemical resistance reduced deposits and high conductance PE DIN 16500 mm 19 7 cccitecsssnarsnenenteccsernsetisi vetapenceesnendsthecneceace EEEE EES 686030 KF DN 16 1000 MM I Ae Yer gee ch cece reset eee cete ere en on tee eeeecee 686031 KEDN 25 500 mm 19 7 Jersin raeed raa e Ene RE 686032 KF DN 25 1000 mm 39 4 EE 686033 Vacuum gauge DCP 3000 with gauge head VSP 3000 Pirani 7 5 10 Torr 1 10 Torr 1 10 mbar 1 10 mbar eececc2s 2 eiedcseweedetsncectiececeds 683190 100 230V 50 60 Hz Maintenance kit RC 6 eebe eege hee EEGENEN egent 649990 rotary vane pump and diaphragm pump A service manual with exploded view drawings spare parts list and directions for repair is available on request t The service manual is intended for trained s
13. the method of replacing diaphragms and valves A DANGER Never operate the pump if covers or other parts of the pump are disassembled Before starting maintenance disconnect the electri SA cal power cord Wait five seconds after isolating the equipment from AC power to allow the capacitors to discharge Ensure that the pump cannot be operated accidentally Note The pump might be contaminated with the pro cess chemicals that have been pumped during opera tion Ensure that the pump is decontaminated before maintenance Avoid the release of pollutants O AWARNING t Never operate a defective or damaged pump t Take adequate precautions to protect people from the effects e g in case of inhalation or skin contact of dangerous substances that may have contaminated the pump and may be released upon disassembly En sure that the maintenance technician is familiar with the safety procedures which relate to the products pro cessed by the pumping system Use appropriate protective clothing safety goggles and protective gloves t Check every motor capacitor regularly by measuring its capacity and estimating its service life Replace old capacitors early enough to prevent a failure The ca pacitors must be replaced by a trained electrician t Allow sufficient cooling of the pump before starting maintenance Drain condensate if applicable t Vent the pump and isolate it from the vacuum sys tem before
14. without air self inflammable substances substances which are inflammable without air explosive substances The pumps are not approved for operation below ground Do not operate the pump below ground Do not pump substances which may form depos its inside the pump The pumps are not suitable for pumping substances which may form deposits inside the pump Deposits and condensate in the pump may lead to increased temperatures even to the point of exceeding the maximum permitted temperatures De posits may cause seizing of the pump unit page 13 of 59 Check the inlet and outlet of the pump and its oil condi tion if there is a danger of forming deposits inside the pump e g in the pump unit of the rotary vane pump or in the pump chamber of the diaphragm pump Inspect the pump regularly and clean if necessary Install a cold trap in front of the pump if pumping ag gressive or corrosive gases or vapors Consider interactions and chemical reactions of the pumped media Ensure that the materials of the pump s wetted parts are compatible with the pumped substances see section Technical data pg 19 When changing the substances pumped we recom mend purging the pump with air or inert gas prior to changing the pumped media Purging the pump will pump out residues and it will reduce the possibility of reactions of the pumped substances with each other and with the pump s materials Safety during operation A DA
15. you start maintenance page 45 of 59 Meie Ensure that maintenance is done only by suitably trained and supervised technicians The valves and diaphragms as well as the motor capaci tors are wear parts At the latest if the pressure inside the oil reservoir should rise significantly manometer needle clearly in the red zone or in case of increased noise level the pump interior the diaphragms and the valves must be cleaned and the diaphragms and valves must be checked for cracks or other damage All bearings are encapsulated and are filled with long life lubricant Under normal operating conditions the drive system is maintenance free The operability of the diaphragm pump can be checked as well by measuring the pressure in the oil reservoir Unscrew the manometer with its adapter open end wrench width 17 mm Remove the hose nozzle from the distributor plate outlet and install at the oil inlet Make sure the O ring is seated correctly sw Using a suitable vacuum gauge e g DVR 2 and making sure that it is correctly calibrated measure the pressure in the oil reservoir When the pump operates with the inlet line closed the measured pressure in the oil reservoir should be less than 25 mbar 19 Torr with gas ballast valve of rotary vane pump closed sw Remove the hose nozzle from oil inlet Reinstall it in the distributor plate and reassemble the manometer with O ring In demanding circumstances it may be efficient
16. E busters Release for repair grant by VACUUBRAND date signature VACUUBRAND GMBH CO KG Tel 49 9342 808 5660 Alfred Zippe Stra e 4 Fax 49 9342 808 5666 97877 Wertheim Germany E Mail service vacuubrand com www vacuubrand com page 58 of 59 LE EG Konformitatserklarung f r Maschinen EC Declaration of Conformity of the Machinery D claration CE de conformit des machines Hersteller Manufacturer Fabricant VACUUBRAND GMBH CO KG Alfred Zippe Str 4 97877 Wertheim Germany Hiermit erkl rt der Hersteller dass die Maschine konform ist mit den Bestimmungen der Richtli nie 2006 42 EG Hereby the manufacturer declares that the machinery is in conformity with the directive 2006 42 EC Par la pr sente le fabricant d clare que la machine est conforme directive 2006 42 CE Drehschieberpumpe Rotary vane pump Pompe palettes Typ Type Type RC 6 Artikelnummer Order number Num ro d article 698560 698561 698562 Seriennummer Serial number Num ro de s rie Siehe Typenschild See rating plate Voir plaque signal tique Die Maschine ist konform mit weiteren Richtlinien The machinery is in conformity with other di rectives La machine est conforme d autres directives 2006 95 EG 2004 108 EG 2011 65 EU Angewandte harmonisierte Normen Harmonized standards applied Normes harmonis es utilis es DIN EN ISO 12100 2011 DIN EN IEC 61010 1 2010 Ed 3 DIN EN 1012 2 2011
17. Keep a minimum distance of 2 in 5 cm between the cool ing fan and surrounding items e g housing walls etc or else install an external automatic ventilation system Use connecting hoses with large diameter and keep them as short as possible to avoid flow losses Locate the pump as closely as possible to the application Use only hoses at the inlet and outlet of the pump with an inner diameter at least as large as the diameter of the pump s connec tions Always install outlet tubing descending from the pump or provide other measures to avoid backflow of condensate towards the pump Use a suitable valve see Accessories pg 39 to iso late the pump from the vacuum application This is to allow the pump to warm up before pumping condensable vapors and to clean the pump after use before it is switched off When assembling ensure vacuum tightness After as sembly check the whole system for leaks page 27 of 59 Secure hose connections at the pump appropriately e g with hose clamps to protect against accidental detach ment Note The pump must only be operated in a horizontal position When transporting a pump containing oil take great care not to tilt the pump to an angle that would allow oil to make its way into the filter element During operation A DANGER Vent and dispose of potentially dangerous gases or vapors at the outlet of the pump appropriately AWARNING t Due to the high compression ratio
18. NGER Adopt suitable measures to prevent the release of dan gt m gerous toxic explosive corrosive noxious or pollut ing fluids vapors and gases To prevent any emission of such substances from the pump outlet install an appropriate collecting and disposal system and take protective action for pump and environment You must take suitable precautions to prevent any for mation of explosive mixtures in the expansion cham ber in the oil reservoir in the pump chamber of the diaphragm pump or at the outlet of the pump In case e g of a diaphragm failure mechanically generated sparks hot surfaces or static electricity may ignite these mixtures Use inert gas for gas ballast or vent ing if necessary Drain appropriately or otherwise remove any poten page 14 of 59 tially explosive mixtures at the outlet of the pump or dilute them to non explosive concentrations Never operate this pump if it has a damaged cord or plug t f the pump is not working properly has been dropped or has fallen into water contact your pump service pro vider t Prevent any part of the human body from coming into contact with vacuum t Always provide a free and pressureless exhaust out let Make sure that the exhaust tubing cannot become blocked Do not exceed an pressure of 16 psi 1 1 bar in the exhaust tubing t Comply with applicable regulations when disposing of chemicals Take into consideration that chemicals ma
19. Technology for Vacuum Systems Instructions for use Chemistry HYBRID pump page 2 of 59 Dear customer Your VACUUBRAND pumps are designed to provide you with many years of trouble free service with optimal performance Through our long expe rience in design construction and operation of vacuum pumps combined with the latest developments in material and manufacturing technology we have accumulated a wealth of application and safety insights that we want to share with you Please read these instructions for use before the initial operation of your pump Our quality maxim is the zero fault principle Every pump before leaving our factory is tested intensively including an endurance run of 60 hours Any faults even those which occur rarely are identified and can be eliminated immediately After completion of the endurance run every pump is tested and must achieve specifications before shipment We are committed to providing our customers only pumps that meet this high quality standard While our pumps cannot eliminate all of your work we design manufac ture and test them to ensure that they will be an effective and trouble free tool to assist you in that work Yours VACUUBRAND GMBH CO KG After sales service Contact your local dealer or call 49 9342 808 5500 Trademark index VACUUsLAN US Reg No 3 704 401 VACUUsBUS VACUUsCONTROL chemistry HYBRID Peltronic TURBO MODE VARIO US
20. asma nitrated nickel plated zinc plated Plastic materials epoxy resin FFKM FPM NBR PBT PEEK PFA PPS glass fiber reinforced PTFE PVC The pump RC 6 doesn t contain any nonferrous heavy metal Abbreviations FFKM Perfluoro elastomer FPM Fluoroelastomer NBR Nitrile butadiene rubber PBT Polybutylene terephthalate PEEK Polyether ether ketone PFA Perfluoroalkoxy PPS Polyphenylene sulfide PTFE Polytetrafluoroethylene PVC Polyvinyl chloride We reserve the right for technical modification without prior notice page 22 of 59 Pump parts Position Component ech Inlet Outlet Manual gas ballast valve ON OFF switch Power connection Handle Rating plate with min max mark for oil level Oil inlet O CO N QO or BRB Ww PD Oil outlet Sight glass for oil level Manometer for oil reservoir pressure control Oil mist filter page 23 of 59 Use and operation Method of operation The RC 6 is a four stage vacuum pump consisting of an oil sealed two stage rotary vane pump with a series connected two stage diaphragm pump The two units are mounted on a common shaft and are connected directly to the drive motor The dry running compressor type diaphragm pump evacuates the headspace of the oil reservoir of the rotary vane pump thus considerably increasing the latter s maximum vapor inlet pressure and chemical resistance
21. at low pressures This is a welcome condition which helps to protect the pump against corrosion and to prolong the working life of the oil The quantity condition and quality of the pump oil have a decisive effect on the pump s performance and depend ability Important It may not be possible to reach the specified ultimate vacuum if an oil other than VACUUBRAND B oil is used Similarly failure to use the recommended oil may impair cold start performance and pump lubrication Notes on choosing the appropriate oil for the application The standard oil for VACUUBRAND rotary vane pumps is the B oil This is a mineral oil which is used for the first filling of the pump The advantages of the B oil are Flat viscosity curve low vapor pressure good chemical resistance extended stability when pumping oxidants acid or basic vapors compared to conventional mineral oils and good skin compatibility Certain pumped media may attack the conventional oil in the pump Spe cial oils can be used preventively It is at the users responsibility to check if the materials of the wetted parts are resistant against the pumped sub stances This is also mandatory if special oils are used page 38 of 59 Special oils Rotary vane pump oil K8 The rotary vane pump oil K8 is a special oil designed for pumping acid vapors The oil is very hygroscopic and has a limited capacity for acids With decreasing pH the anticorrosive effect decreases as well
22. c pressure Discon nect the electrical power cord To vent the oil reservoir remove the manometer with its adapter carefully open end wrench width 17 mm Pay attention to the O ring Do not turn the manometer itself as leaks might be caused t Choose a suitable pad oil may drip Use a suitable container to catch the oil sw Place a suitable container below the oil out e let 9 N Remove the oil drain plug 9 below the rat M ing plate paying attention to the O ring Tilt the pump slightly and catch the oil in a suitable container ts Dispose of the used oil according to regula tions Screw in oil drain plug 9 with O ring m Screw in manometer with O ring To flush the pump pour in fresh oil approx 0 05 quarts 50 ml through the pump inlet 1 remove separator if necessary page 37 of 59 Operate the pump briefly Drain flushing oil and repeat flushing procedure if necessary until all contamina tions are flushed out Remove the manometer see above Add fresh oil at first approx 0 37 quarts 350 ml only through the oil inlet port for the oil level to reach the mm mark 10 Close the oil inlet port 8 Operate the pump with closed inlet for approx 5 10 minutes Top off the oil add approx 0 11 quarts 100 ml As a rule it is not necessary to use the maximum quantity of oil Do not overfill m Screw in manometer with O ring Note The oil degasses and foams
23. ctrician t Vent the pump before starting maintenance Isolate the pump and other components from the vacuum system Allow sufficient cooling of the pump Drain condensate if applicable NOTICE Ensure that maintenance is done only by suitably trained and supervised technicians Ensure that the maintenance technician is familiar with the safety procedures which re late to the products processed by the pumping system page 19 of 59 Maximum pumping speed 50 60 Hz ISO 21360 Technical data Ultimate partial pressure without gas ballast Ultimate total pressure without gas ballast gt Torr mbar 2 10 Ultimate total pressure with gas ballast Torr mbar 0 75 102 1 10 2 Water vapor tolerance Torr mbar gt gt 30 gt gt 40 Oil capacity min max uarts mi 0 36 0 56 340 530 Total pressure in oil reservoir Torr mbar 13 5 18 Oil temperature under typical operating conditions F C 140 60 Recommended oil VACUUBRAND B oil Maximum permissible inlet outlet pressure absolute psi bar 16 1 1 Maximum permissible pressure difference between inlet and outlet psi bar 16 1 1 Maximum permissible pressure absolute at gas ballast valve psi bar 17 5 1 2 Permissible ambient temperature storage operation F C 14 to 140 54 to 104 10 to 60 12 to
24. dividual components are only con nected combined and operated according to their de sign and as indicated in the instructions for use Use only original manufacturer s spare parts and page 8 of 59 accessories Otherwise the safety and performance of the equipment as well as the electromagnetic com patibility of the equipment might be reduced The CE mark mark may be voided if not using original manufacturer s spare parts t Comply with all notes on correct vacuum and electri cal connections see section Use and operation pg 23 t Do not use the pump to generate pressure t The pumps are designed for ambient temperatures during operation between 54 F and 104 F 12 C and 40 C Periodically check maximum tempera tures if installing the pump in a cabinet or a housing Make sure ventilation is adequate to maintain recom mended operating temperature Install an external au tomatic ventilation system if necessary If pumping hot process gases make sure that the maximum permitted gas inlet temperature is not exceeded The maximum permitted gas inlet temperature depends on several parameters like inlet pressure and ambient tempera ture see Technical data pg 19 t Particles and dust must not enter the pump t Do not pump liquids ACAUTION e Ensure that the pump is chemically resistant to the pumped substances prior to operation Neki Use the equipment only as intended that is for genera
25. does not be come blocked Check small flange con nections Use lines with larger di ameter length as short as possible Fault page 42 of 59 Possible cause Remedy Pump does not achieve its ultimate vacuum or usual pumping speed Leak in the pipeline or vacuum system Long narrow vacuum line Not enough oil Wrong type of oil Oil contaminated also with solvents Outgassing substances or vapor generated in the process Pump has not yet reached its operating temperature None of the above mentioned causes d Check pump directly connect vacuum gauge directly at pump inlet then check connection pipeline and vacuum system if necessary Use lines with larger di ameter length as short as possible Top up oil to correct level Change oil and flush with oil see Oil change Change oil and flush with oil see Ou change Check process parame ters Allow the pump to reach its operating temperature Contact local distributor Pump too noisy or strange noise Too much oil Motor thermally over loaded Diaphragm damaged Pump seized Overpressure in outlet line None of the above mentioned causes Lower oil level to mark Allow motor to cool down lt 50 C 122 F identify and eliminate cause of failure Provide sufficient ventilation Replace diaphragm See below Remove blockage in line open valve Contac
26. e at least 54 F 12 C Otherwise the pump may not start because of the high oil viscosity at low temperature Pumping down can be started at any pressure at the inlet below atmospheric pressure Do not start the pump if the pressure at the outlet port exceeds 16 0 psi 1 1 bar absolute Continuous operation is possible at any pressure below atmospheric pressure Oil consumption will increase at inlet pressures above 75 Torr 100 mbar Check oil level more frequently Prevent internal condensation transfer of liquids or dust The pump unit as well as the diaphragms and valves will be damaged if liquids are pumped in significant amounts Check the pump regularly for external soiling and depos its Clean the pump if necessary to avoid an increase of the pump s operating temperature The motor is protected by a self hold thermal cutout in the winding Note Only a manual reset is possible Switch off the pump and disconnect the electrical power cord Identify and eliminate the cause of failure Wait approximately five minutes before restarting the pump page 29 of 59 Avoid high heat supply e g due to hot process gases See Technical data pg 19 for maximum permitted gas and ambient temperatures A warm up period approximately 30 min is required to ensure that the rated ultimate vacuum and pumping speed as well as the full vapor pumping rate and chemical resis tance of the pump are attained To warm up the
27. e the housing cover with housing cover insert onto the head cover By turning the eccentric bushing bring the connecting rod into the up per turning point position max stroke of the rod Loosely screw in the Allen head screws at the head cover diagonally at first slightly with a 5 mm wide Allen key then tighten ts Recommended torque 8 9 ftlb 12 Nm page 51 of 59 Assembling the connecting hose Slip the hoses onto the hose connectors by turning the fittings with an open ended 14 mm wrench Tighten the union nuts of the hose connec tions at the pump heads with an open end ed 17 mm wrench t Tighten union nuts first by hand and then tighten one full turn using the open ended wrench Replace diaphragm and valves of the opposite side of the pump in the same way Assemble the cover plate Pay attention to lock washers Put the pump in normal operating position t Attention Make sure that the pump is filled with oil before switching it on refill oil if necessary see OU change pg 35 Checking the operability of the diaphragm pump Check the operability of the diaphragm pump by measuring the pressure in the oil reservoir Unscrew the manometer with its adapter open end wrench width 17 mm Remove the hose nozzle from the distributor plate outlet and install at the oil inlet Make sure the O ring is seated correctly Using a suitable vacuum gauge e g DVR 2 and making su
28. ed for the HYBRID pump in accordance with this standard Because the diaphragm pump reduces the pressure in the oil sealed part of the RC 6 however the water vapor tolerance is considerably higher than that of a conventional oil sealed rotary vane pump d With inlet sealed and without gas ballast e Oil temperature and pressure in the oil reservoir are the relevant parameters for maximum vapor inlet pressure and chemical resistance f During the start up period of the pump first 6 minutes after switching on the current draw may be elevated to twice the nominal current draw during normal running conditions g Measurement according to EN ISO 2151 2004 and EN ISO 3744 1995 at 230V 50Hz and ultimate vacuum with exhaust tube at outlet h 120V version Additional adapter small flange KF DN 16 hose nozzle DN 10 mm material PP page 21 of 59 Gas inlet temperatures Operating condition Inlet pressure Permitted range of gas temperatures at inlet Continuous operation gt 75 Torr 100 mbar high gas load 50 F to 104 F 10 C to 40 C Continuous operation lt 75 Torr 100 mbar low gas load 32 F to 140 F 0 C to 60 C Short time lt 5 minutes lt 75 Torr 100 mbar low gas load 14 F to 176 F 10 C to 80 C Wetted parts Components Wetted materials Metal parts aluminum alloy stainless steel grey cast iron steel partly pl
29. ervice people only Troubleshooting Fault page 41 of 59 Possible cause Remedy Pump does not start Electrical power cord not plugged in electri cal supply failure Supply voltage does not correspond with the pump see rating plate Start up control defec tive Oil temperature below 54 F 12 C Pump unit of rotary vane pump contami nated Motor thermally over loaded Overpressure in outlet line wk Oil mist filter clogged filter element in con tact with oil or over filled Pump seized d d Plug in power cord Check fuse Connect pump to a suit able supply voltage Contact local distributor Operate the pump in suit able ambient conditions Perform maintenance or clean the pump unit Allow motor to cool down lt 50 C 122 F iden tify and eliminate cause of failure Manual reset is necessary Switch off pump or unplug Provide sufficient ventilation Remove blockage in line open valve Drain oil replace filter element if necessary See below Pump does not achieve its ultimate vacuum or usual pumping speed Measuring procedure or vacuum gauge not suitable for the applica tion Inlet blocked Centring ring at small flange connection not correctly positioned Long narrow vacuum line Choose a suitable mea suring procedure or vacu um gauge Open inlet Ensure that the inlet line
30. evice which have been pumped Prior to return to the factory the device has been decontaminated Description of the decontamination method and the test verification procedure The device is free of hazardous harmful substances Protective measures required for VACUUBRAND employees If the paint is damaged we wish a repaint or a replacement of parts for reason of appearance repaint and replacement at customer s expense yes no 10 Legally binding declaration We assure for the returned device that all substances which have been in contact with the device are listed in section 5 and that the information is complete and that we have not withheld any information We declare that all measures where applicable have been taken listed in section Return to the factory By our signature below we acknowledge that we accept liability for any damage caused by providing in complete or incorrect information and that we shall indemnify VACUUBRAND from any claims as regards damages from third parties We are aware that as expressed in 823 BGB Public Law Code of Ger many we are directly liable for injuries or damages suffered by third parties particularly VACUUBRAND employees occupied with handling repairing the product Shipping of the device must take place according to regulations KI E ele TE JOD HUE arenos onan AEN Company s seal DANCE aseri canyare ex aE GEE AAi A
31. fety information for vacuum equipment and observe the instructions contained therein NOTICE page 7 of 59 General information Remove all packing material from the packing box Re move the product from its packing box and retain all pack aging until the equipment is inspected and tested Re move the protective caps from the inlet and outlet ports and retain for future use Inspect the equipment promptly and carefully If the equipment is damaged notify the supplier and the carrier in writing within three days Retain all packing ma terial for inspection State the item number of the product together with the order number and the supplier s invoice number Failure to check and give notice of damage will void any and all warranty claims for those deficiencies Replace the protective caps if the equipment is not used immediately Store the equipment in dry and non corrosive conditions see also Technical data pg 19 t Do not use any damaged equipment e Check the pumps oil level e The pump is delivered without oil filling Fill with oil before operating the pump see section Use and operation pg 23 e Aging of the oil as indicated by darker color compared to new oil strange odor of the oil particles in the oil or contamination necessitates an oil change e Use the handle when moving the pump Intended use t Do not use the pump or any system parts on humans or animals t Ensure that the in
32. fluoroelastomer seals and O rings You may authorize us to dispose of the equipment at your expense page 56 of 59 VACUUBRAND shall be liable for insuring that this prod uct including any agreed installation has been free of de fects at the time of the transfer of risk VACUUBRAND shall not be liable for the consequences of improper handling use servicing or operation of this product or the consequences of normal wear and tear of wearing parts such as diaphragms seals valves vanes condensers oil and the breakage of glass or ceramic parts for the consequences of chemical electrochemical or electrical influences or the failure to follow the instruc tions in this manual Claims for defects against VACUUBRAND shall be limited to one year from delivery The same shall apply to claims for damages irrespective of legal grounds For further information on general terms and conditions refer to www vacuubrand com page 57 of 59 Health and safety clearance form Devices will not be accepted for any handling before we have received this declaration Please read and comply with Notes on return to the factory Oil filled pumps Drain oil prior to shipping absolutely Device Madel 2 siceseteossenectedindt eerie Eege geg 3 Reason for return malfunction Has the device been used in a copper process step e g semiconductor production Substances gases liquids solids in contact with the d
33. hragm clamping disc and diaphragm support disc in the dia phragm key t Avoid damage of the diaphragm Do not excessively bend or crease the diaphragm t Assemble the original number of washers between diaphragm support disc and con necting rod Screw diaphragm clamping disc dia phragm diaphragm support disc and wash ers to connecting rod Optimum torque for the diaphragm support disc 4 4 ftIb 6 Nm it is recommended to use a torque wrench Attach torque wrench to dia phragm key hexagonal bolt 6 mm wide Note Never use the diaphragm key with any additional tools like tongs or Allen keys without appropriate torque limitation page 50 of 59 Assembling the pump heads Bring the diaphragm into a position in which itis in contact with the housing and centered with respect to the bore Place the head cover over the diaphragm Check for its correct orien tation by aligning it beforehand with the housing cover which has to be put over it later on ts Pay attention that the diaphragm stays positioned centrally so that it will become clamped uniformly between housing and head cover B Place the valves at their respective posi tions on the head cover ts Make sure that the valves are correctly seated See figure for the correct position of the valves Valves at the outlet with round centered opening A under valve valves at the inlet with kidney shaped opening B beside valve Plac
34. id explosive conditions when compressing explo sible and flammable substances mixtures In such in stances use inert gas for gas ballast Attention The gas ballast of the diaphragm pump is permanently connected to the system AWARNING t Implement special protective measures to protect per sonnel pump and environment A CAUTION e Install a cold trap see Accessories pg 39 if the thermodynamic conditions of the application are such that vapors could condense in the rotary vane pump Wait until the pump has reached its operating temper ature before connecting it to the vacuum system NOTICE Before switching off allow the pump to run for a few min utes initially with the rotary vane pump s gas ballast valve open and then with the gas ballast valve closed after the pump has been isolated from the vacuum application Prevent internal condensation transfer of liquids or dust The pump requires regular inspection and maintenance page 34 of 59 Shutdown NOTICE Has the pump been exposed to condensate Allow the pump to continue to run for a few minutes with the rotary vane pump s gas ballast valve open be fore switching off Long term Separate the pump from the application Drain condensates catchpots of the separator at the inlet and of the oil mist filter Flush the pump with dry nitrogen Carry out oil change see Oil change pg 35 Fill the pump completely with new oil to abo
35. ing t Clean or replace the filter element Dispose of oil and filter element in accordance with regulations Assemble again in reverse order Make sure that the O ring and the sealing ring are correctly seated Inspecting the safety pop valve Safety pop valve ccccccccccccceeeeaeeeeeeeeeeeeeeeeeeeeesseaaaeeeseeeeeeeeeeeeeseeeeeaaeees 638836 Remove four countersunk screws and lift off the distributor block t Note the valve s position before re _ distributor moving it Replace the valve if it is damaged Assemble again in reverse order page 53 of 59 Notes on return to the factory Repair return DAkkS calibration Neje Safety and health of our staff laws and regulations re garding the handling of dangerous goods occupational health and safety regulations and regulations regard ing safe disposal of waste require that for all pumps and other products the Health and safety clearance form pg 57 must be sent to our office fully completed and signed before any equipment is shipped to the authorized service center Fax or mail a completed copy of the health and safety clearance form to us in advance The declaration must ar rive before the equipment Enclose a second completed copy with the product If the equipment is contaminated you must notify the carrier No repair DAkkS calibration is possible unless the correctly completed form is returned Inevitably there will be
36. level to mm mark B approx Screw in oil inlet plug and with inlet line closed oper ate the pump for approx 5 10 minutes Remove the oil inlet plug again Add approx 100 ml 0 11 quarts of oil t As a rule it is not necessary to use all of the oil sup plied Do not overfill Screw in the manometer C with its adapter carefully open end wrench width 17 mm z r Pay attention to the O ring Do not turn the manometer itself as leaks might be caused page 25 of 59 Installing a pump in a vacuum system A DANGER eg AWARNING IS IS IS IS If dangerous or polluting fluids oil mist or toxic or nox ious gases could be released at the outlet install an appropriate system to catch and dispose of those flu ids or gases Connect a gas tight exhaust line at the pump outlet if necessary Always vent exhaust gases appropriately e g into a fume hood If needed install an exhaust waste vapor condenser see Accessories pg 39 Never block the gas outlet The exhaust line must al ways be free of obstructions no back pressure to en sure an unimpeded discharge of gas The cross sec tion of the outlet tubing must be at least the size of the pump s exhaust connection Failure to connect the inlet and outlet lines correctly will cause overpressure and risk of bursting The outlet hose nozzle is marked EX Particles and dust must not be aspirated If necessar
37. ling pump flu ids lubricants and solvents Use appropriate protective clothing safety goggles and protective gloves to avoid excessive contact with the skin and possible skin irrita tions including dermatitis Comply with all relevant statutory requirements and regulations concerning the handling storage and dis posal of oil Nroh lA Aging of the oil as indicated by darker color compared to new oil strange odor of the oil particles in the oil or con tamination necessitates an oil change Depending on the application especially if corrosive gas es or vapors have been pumped it may be appropriate to check the oil frequently and to carry out an oil change if necessary page 36 of 59 Under normal operating conditions Check oil level every time before starting the pump Carry out an oil change once aging of the oil is indi cated by darker color compared to new oil Carry out oil changes at least once a year Dispose of the used oil which may be contaminated according to all applicable regulations If the oil contains small quantities of water solvent t The oil can be cleaned to a certain extent by operating the pump for 1 2 hours with the inlet line sealed and the gas ballast valve open Oil change procedure t Carry out the oil change only after the pump has reached its normal operating temperature Switch off the pump and isolate it from its application Ventilate the pump to atmospheri
38. llen into liquid There is a risk of deadly electrical shock Unplug the system immediately t Do not use this product in an area where it can fall or be pulled into water or other liquids e Adopt suitable measures in case of differences from recommended conditions e g using the equipment outdoors installation in higher altitudes conductive pollution or external condensation on the pump e Do not operate this product near flames page 12 of 59 NOTICE To the best of our knowledge the equipment is in com pliance with the requirements of the applicable EC direc tives and harmonized standards see Declaration of Con formity with regard to design type and model Directive EN 61010 1 gives in detail the conditions under which the equipment can be operated safely see also IP degree of protection Technical data pg 19 Operating conditions A DANGER These pumps are not approved for operation in po tentially explosive atmospheres Do not operate the pumps in potentially explosive atmospheres These pumps are not approved for the pumping of po tentially explosive atmospheres Do not pump poten tially explosive atmospheres The pumps are not suitable to pump any of the sub stances listed below Do not pump unstable substances substances which react explosively under impact mechanical stress without air substances which react explosively when being ex posed to elevated temperatures
39. lter to prop up the pump Loosen the union nuts of the hose connec tions at the pump head with an open ended wrench 17 mm Remove the cover plate Use a Phillips screw driver size 2 to loosen both screws A Pay attention to lock washers page 47 of 59 View of the disassembled pump head parts Housing 7 Head cover Connecting rod 8 Valve Washer 9 Housing cover with Diaphragm support disc housing cover insert Diaphragm Diaphragm clamping disc with square head screw Turn the fittings with an open ended wrench 14 mm to detach the hoses from the pump heads 1 4 of a turn at maximum t Do not remove the elbow fittings from the pump heads during reassembly a leak may result page 48 of 59 sw Disassemble the housing cover to check the diaphragm and the valves Unscrew four Allen screws with a 5 mm wide Allen key Remove the housing cover with housing cover insert together with the head cover and the valves head cover with valves will remain within the housing cover ts Never remove parts by using a pointed or sharp edged tool e g screw driver We recommend to use a rubber mallet or compressed air to be blown carefully into port Remove the head cover carefully from the housing cover Note the position and orientation of the valves and remove them t Replace valves if necessary t Check diaphragm for damage and replace if necessary t Use petroleum ethe
40. n working with condensable vapors Allow the pump to attain its operating temperature before pumping condensable vapors Keep the vapor inlet pres sure below the permitted maximum see Technical data pg 19 Open the gas ballast valve in case of pumping significant amounts of vapor Provide appropriate protective measures to allow for the possibility of failure and malfunction The protective mea sures must also allow for the requirements of the respec tive application In case of overload the motor is shut down by a self hold thermal cutout in the winding Note Only manual reset is possible Switch off the pump and disconnect from the power source Identify and elimi nate the cause of failure Wait approx five minutes before restarting the pump Maintenance and repair In order to comply with laws occupational health and safety regulations safety at work law and regulations for environmental protection vacuum pumps components and measuring instruments can only be returned when certain procedures see section Notes on return to the factory pg 53 are followed Take advantage of our service seminars which put special focus on the maintenance and repair of vacuum pumps page 17 of 59 For details and for the online Instructions for repair man ual see www vacuubrand com In normal use the lifetime of the diaphragms and valves is typically 15 000 operating hours Bearings have a typi cal durabilit
41. nsation in the pump do not pump vapor before the pump has reached its operating temperature Open the gas ballast valve when pumping condensable vapors gas ballast page 31 of 59 For condensable vapors water vapor sol vents etc Let the pump run with gas ballast to re duce condensation of pumped substances water vapor solvents in the pump or to decontaminate the pump oil from volatile substances With gas ballast valve open the ultimate vacuum will be reduced Use inert gas for gas ballast to avoid the formation of explosive mixtures To open and to close the gas ballast valve turn the gas ballast valve cap The manual gas ballast valve is open if the arrow on the gas ballast cap is pointing towards the inlet of the pump respectively towards the labelling Gasballast Close the manual gas ballast valve by turning the cap 180 Operate the pump without gas ballast only in case of a clean system or when there are no condensable va pors Do not pump vapors until the pump has reached its oper ating temperature Install an in line valve in the inlet line and open it only approx 30 minutes after the pump has been started Check the maximum vapor inlet pressure The pump can operate continuously at any pressure lower than the maxi mum specified inlet pressure for vapor Avoid sudden va por surges when evacuating commences large inner sur faces large volume vacuum vessel Use a fl
42. ny me chanical contact other than the pump feet Comply with maximum permissible pressures at in let and outlet and with maximum permissible pres sure differences between inlet and outlet See section Technical data pg 19 Do not operate the pump with overpressure at the inlet Avoid overpressure of more than 17 5 psi absolute 1 2 bar absolute in the event that gas or inert gas is con page 10 of 59 nected to the pump to the gas ballast or to a venting valve e Note Flexible elements will shrink when evacuated e Connect hoses gas tight at inlet and outlet of the pump e Ensure that no foreign objects can be drawn into the pump e Check the power source and the pump s rating plate to be sure that the power source and the equipment match in voltage phase and frequency e Use only oil of the recommended type Other oils or operating fluids may cause damage of the pump or danger Use special oils see Oil change pg 35 for the rotary vane pump if e g acid vapors are pumped extremely high aging stability is required oxygen or other strong oxidizing agents are pumped e Take adequate precautions when handling pump flu ids lubricants and solvents Use appropriate protec tive clothing safety goggles and protective gloves to avoid excessive contact with the skin and possible skin irritations including dermatitis Do not inhale or swallow Ensure that the pump location is well venti lated
43. opriate oil for the application 36 PCOS Eet 38 Troubleshooting isisisi aana 40 Replacing diaphragms and ValVeG c scecseeeeeeeeeeeees 43 Cleaning and inspecting the diaphragm pump heads 6 45 Replacing the diaphragm MEN 47 Assembling the pump headS n0nnnnannnaannnennnnnnnnnnnnennnenennnneennennnne 49 Assembling the connecting NOSGC ccccsscccessseecesseseeeeseseeeessanees 50 Checking the operability of the diaphragm pDump 50 Replacing the filter element in the oil mist filter eeeeeeees 51 Inspecting the safety pop valve cccccceecccceeseceeeseeeceeeseeeeessaeeeeees 51 Notes on return to the factory scccessssseeeeseeeeseenees 52 Warranty page 4 of 59 Health and safety clearance form SEENEN KEREN EC Declaration of Conformity of the Machinery page 5 of 59 Safety information Important information AWARNING t Keep this manual complete and accessible to per sonnel at all times t Read this manual carefully before installing or op erating the equipment Observe the instructions contained in this manual t Do not modify the equipment without authoriza tion Neji This manual is an integral part of the equipment de scribed therein It describes the safe and proper use of the vacuum pump Make operating personnel aware of dangers arising from the pump and the pumped substances VACUUBRAND disclaims an
44. ow control valve in the inlet line and open the valve gradually page 32 of 59 Operating the pump with condensate in the catchpots Observe the condensate levels in the catchpots of the sep arator at the inlet and of the oil mist filter The condensate level in an optional separator at the inlet must always be kept below the bottom of the separator tube The conden sate level in the oil mist filter must always be kept below the bottom edge of the filter Drain condensate in time To drain condensate switch off and vent the pump Then open drain screw of the catch pot Condensate of the inlet catchpot see Accessories pg 39 in particular must not be drained while pump is Operating In case of a clogged filter oil mist might be visible in the oil filter housing or the filter might be discolored or exhibit deposits on the inside If the filter element is clogged dis assemble the oil mist filter and replace the filter element Under certain circumstances clogged filter elements can be cleaned using suitable solvents However it is safer to use a new filter element see section Replacing the filter element in the oil mist filter pg 52 Do not reuse separated oil if it is contaminated or discol ored t Important Comply with regulations when disposing of solvents condensates Recycle if possible purify if contaminated page 33 of 59 Pumping chemically aggressive or toxic gas es and vapors A DANGER Avo
45. pt suitable measures to prevent contamination of the pumped substances or the environment Ensure that no parts of your clothing hair or fingers can be caught or drawn in at the inlet of the pump Never insert fingers or drop any other object into the inlet or outlet Pumping at high inlet pressure may lead to overpres sure at the gas ballast valve Pumped gases or con densate might be expelled if the valve is open If an in ert gas supply is connected to the gas ballast ensure that its inlet pipeline is not contaminated Check oil level of the rotary vane pump through sight glass every time before starting the pump Check the pump s oil level and the condition of the oil on a regular basis Pay attention to the safety symbol hot surfaces on the equipment Hot parts may cause burns if touched Adopt suitable measures to prevent any danger aris ing from hot surfaces or electric sparks Ensure that hot surfaces of the pump do not cause burns Provide a suitable contact guard if necessary A power failure or switching off the pump may cause accidental ventilation of the pump or the vacuum sys tem if the manual gas ballast valve of the rotary vane NOTICE page 16 of 59 pump is open If this constitutes a potential source of danger take appropriate safety measures e g install a solenoid operated gas ballast valve Prevent the backpressure of gases and the backflow of condensates at the outlet Important notes o
46. pump effectively before connecting to the vacuum application install a shut off valve see Accessories pg 39 The attainable ultimate vacuum is limited by the properties of the vacuum vessel leak tightness cleanliness and de gassing of the inner surfaces degassing of substances used and the condition of the pump oil cleanliness con tent of hydrocarbons with higher partial pressures Use the manometer monitoring the pressure in the oil reservoir of the HYBRID pump to check the operability of the diaphragm pump If during the process the pressure inside the oil reservoir should rise significantly manome ter needle clearly in the red zone it is necessary to take appropriate measures to reduce the inlet pressure For the HYBRID principle to work it is necessary to prevent the pumped vapors from condensing inside the oil reservoir Therefore the pressure inside the oil reservoir has to be lower than the vapor pressure of the pumped media at the oil s temperature 140 F 60 C If necessary the volume of pumped vapors has to be reduced or a cold trap has to be installed If no improvement is achieved even with the vacuum chamber being absolutely leak tight this points to a po tential failure of the diaphragm pump e g a diaphragm crack Amore accurate check of the pressure inside the oil reservoir is possible with a more precise manometer e g a DVR 2 digital vacuum gauge If a pressure higher than 19 Torr 25 mbar
47. r or industrial solvent to remove deposits Do not inhale vapors Replacing the diaphragm Lift diaphragm carefully sidewise t Never use a pointed or sharp edged tool to lift the diaphragm Use the diaphragm key to grip the dia phragm support disc below the diaphragm Unscrew diaphragm support disc with dia phragm and diaphragm clamping disc t f the old diaphragm is difficult to separate from the diaphragm support disc immerse assembly in naphtha or petroleum ether Do not inhale vapors Check for washers between the diaphragm support disc and the con necting rod Do not mix the washers from the different pump heads since these are set at the factory to ensure proper pump performance Make sure that the original number is reassembled at the individual pump head page 49 of 59 t Too few washers The pump will not attain vacuum specification Too many washers Diaphragm clamping disc will hit head cover causing noisy operation and possibly causing the pump to seize up Position new diaphragm between dia phragm clamping disc with square head screw and diaphragm support disc t Note Position diaphragm with pale side towards diaphragm clamping disc facing pump chamber t Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide hole of the diaphragm support disc Lift the diaphragm at the side Place the diaphragm carefully together with diap
48. re that it is correctly calibrated measure the pressure in the oil reservoir When the pump operates with the inlet line closed the measured pressure in the oil reservoir should be less than 25 mbar 19 Torr with gas ballast valve of rotary vane pump closed Remove the hose nozzle from oil inlet Reinstall it in the distributor plate and reassemble the manometer with O ring page 52 of 59 If the pump does not achieve the ultimate vacuum Whenever the diaphragms and valves have been replaced a break in period of several hours is required before the pump achieves its ulti mate vacuum Incase of an unusual noise switch off pump immediately and check clamping disc positions If the specified ultimate vacuum is not achieved and if this does not change after the break in period Check hose connectors at pump heads for leaks If necessary recheck valve seats and pump chambers Replacing the filter element in the oil mist filter Filter element FO DN 40 640187 Use a5 mm wide Allen key to remove the drain plug note O ring fitted on drain plug Drain condensate from catchpot Position the pump on the side so that it rests on the side with the power switch Remove the Allen screws 5 mm wide Allen key and remove the catchpot note sealing ring Using a 5 mm wide Allen key remove the Allen screw in the center of the bottom filter thrust plate Remove the filter element both filter thrust plates and the top O r
49. t local distributor Q Oil in the inlet line Back diffusion small amount of oil oil film Back streaming large amount of oil Install a sorption trap or a separator if necessary Contact local distributor Fault page 43 of 59 Possible cause Remedy Q Oil leakage gt Oil spilled Other cause d d Absorb the oil and dis pose of according to reg ulations Contact local distributor Q High oil consump tion High inlet pressure Operation with gas bal last Oil level too high Normal Top off oil when ever necessary Install oil mist filter at outlet Top off oil whenever nec essary Install oil mist filter at outlet Lower oil level to mark Fast aging of the oil Pumping aggressive gases Condensation in the pump Oil mist filter defective Diaphragm pump does not reach its pumping speed Use suitable oil Use separator or cold trap Replace filter Check safety pop valve Perform maintenance of diaphragm pump Q Pump seized Ambient temperature too high gt 104 F 40 C None of the above mentioned causes Provide sufficient ventila tion Contact local distributor page 44 of 59 Replacing diaphragms and valves ts Please read section Replacing diaphragms and valves com pletely before starting maintenance The pictures may show other versions of pumps This does not change
50. to check and clean the pump heads on a regular basis In normal use the lifetime of the diaphragms and valves is typically 15 000 operating hours Prevent internal condensation transfer of liquids or dust The diaphragms and valves will be damaged if liquid is pumped in significant amount Carry out maintenance frequently if the pump is ex posed to corrosive media or in case of deposits Regular maintenance will improve the lifetime of the pump and also protect both users and the environment page 46 of 59 Diaphragm reee eee epea e cecommbnberentnedevereeianiwevwensantoceeumsuerehaaaunane 639786 Valve ees a E E A E E 638440 Vacuum gauge DVR eege eege 682902 Diaphragm key width 66 MM scscccecssceceersevscccasssaatevecseesnsivessccissendexesaanereenns 636554 Tools required metric Phillips screw driver size 2 Open ended wrench 14 17 mm 5 mm wide Allen key Diaphragm key width 66 mm Cleaning and inspecting the diaphragm pump heads Drain the catch pot of the oil mist filter before beginning maintenance to prevent leaking of condensate Drain oil see Oil change to prevent oil from making its way into the filter element Refill pump with oil before restarting the pump For maintenance lay the pump on its side with the pump head to be maintained at the top Support the pump appropriately Attention Prevent any damage to the oil mist filter or to the manome ter Do not use the oil mist fi
51. ve the max mark Attention Before restarting the pump drain oil to the maximum oil level max mark Close the manual gas ballast valve Close inlet and outlet ports e g with transport caps or blind flanges Store the pump under dry conditions Carry out oil change and maintenance prior to use if the pump has been stored for longer than one year Note When transporting a pump containing oil take great care not to tilt the pump to an angle that would allow oil to make its way into the filter element Drain oil if necessary page 35 of 59 Oil change AA DANGER eg Never operate the pump if parts of the pump are dis assembled Ensure that the pump cannot be operated accidentally Before starting maintenance isolate the pump from its SA application and disconnect the electrical power cord O Note The pump or the pump oil might be contaminated with dangerous or corrosive process chemicals that have been pumped during operation Adopt suitable decontamination measures if necessary Take ade quate precautions to protect people from the effects of dangerous substances if contamination has occurred Ensure that the maintenance technician is familiar with the safety procedures which relate to the products pro cessed by the pumping system t Use appropriate protective clothing safety goggles and protective gloves Avoid inhalation and skin con tact e Take adequate precautions when hand
52. y you must install appropriate filters You must ensure their suitability concerning gas flow chemical resis tance and resistance to clogging prior to use Make sure ventilation is adequate especially if the pump is installed in an enclosure or if the ambient tempera ture is elevated Provide external ventilation if neces sary Reduce the transmission of vibration Prevent mechan ical load due to rigid pipelines Insert elastic hoses or flexible elements as couplings between the pump and rigid pipes Note Flexible elements will compress or flatten when evacuated if not designed for use under vacuum Hose connections at the pump inlet must always be gas tight NOTICE page 26 of 59 e Install a cold trap in front of the pump if pumping ag gressive or corrosive gases or vapors e A power failure may cause accidental ventilation of the pump or the vacuum system if the manual gas ballast valve is open If this constitutes a potential source of danger take appropriate safety measures e g install a solenoid operated gas ballast valve see Accesso ries pg 39 e The pump is supplied dry e without oil filling Before starting the pump for the first time pour in the oil as described in the above section Initial opera tion Pouring in the pump oil pg 24 e Check the power source and the pump s rating plate to be sure that the power source and the equipment match in voltage phase and frequency
53. y be contaminated Take adequate precautions to pro tect people from the effects of dangerous substances chemicals oil mist thermal decomposition products of fluoroelastomers Use appropriate protective cloth ing and safety goggles t Even if the pumped medium is only air or a pure gas the discharge from rotary vane pumps will contain small quantities of oil vapor and petroleum fractions These substances are particularly contaminating in closed spaces or in case of insufficient ventilation The discharge from the pump invariably contains the pumped gases or vapors Connect a hose to the pump outlet to dispose of the exhaust gases Prevent any dangerous reactions with oil or oil vapors and the formation of impermissible or dangerous emis sions t Failure of the pump teg due to power interruption failure of connected components or of parts of the sup ply or a change of parameters must not be allowed to lead to a dangerous situation under any circumstances IS page 15 of 59 In case of a leak in the manifold or at the shaft seal of the rotary vane pump or in case of a diaphragm crack of the diaphragm pump pumped substances might be released into the environment or into the pump hous ing or motor Especially comply with notes on use and operation and maintenance The residual leak rate of the equipment might render possible an exchange of gas albeit extremely slight between the environment and the vacuum system Ado
54. y liability for inappropri ate use of these pumps and for damage from failure to follow instructions contained in this manual This manual is only to be used and distributed in its com plete and original form It is strictly the users responsibility to check carefully the validity of this manual with respect to his product Manual no 997829 11 28 2013 The following signal word panels and safety symbols are used throughout this manual A This is the safety alert symbol It is used to alert you to po tential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury and death page 6 of 59 AA DANGER e DANGER indicates a hazardous situation which if not avoided will result in death or serious injury AWARNING t WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A CAUTION e CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to personal injury AN Caution Hot surface Disconnect equipment from AC power KE Formatting used in this manual Note The signal word panels in all sections of this manual always refer to all paragraphs of the same format plain text following each signal word panel The document Safety information for vacuum equipment is part of this manual Read the Sa
55. y of 40000 h Motor capacitors have a typi cal durability in the range of 10000 to 40000 h depending strongly on operation conditions including ambient tem perature humidity or load A DANGER Ensure that the pump cannot be operated acciden tally Never operate the pump if covers or other parts of the pump are disassembled Switch off the pump Disconnect the electrical SA power cord and wait five seconds before starting maintenance to allow the capacitors to discharge O Note The pump may be contaminated with process chemicals which have been pumped during operation Ensure that the pump is completely decontaminated before maintenance commences Avoid the release of pollutants AWARNING t Take adequate precautions to protect people from the effects e g in case of inhalation or skin contact of dangerous substances if contamination has occurred Use appropriate protective clothing safety goggles and protective gloves t Wear parts have to be replaced regularly ts Never operate a defective or damaged pump t Check every motor capacitor regularly by measuring its capacity and estimating its time in operation Re place old capacitors early enough to prevent a failure in operation If an old motor capacitor fails the capaci tor may get hot It may even melt or emit a flame which could be dangerous for persons and equipment in the vicinity The capacitors have to be replaced by an page 18 of 59 ele
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