Roots Pumping Units RP 35C VARIO,... - Manual
Contents
1. Use open ended wrench w f 17 to loosen the union nut of the hose which runs directly to the cover plate of the outlet manifold at the pump head Use open ended wrench w f 15 to turn elbow fitting 1 4 of a turn remove hose Do not remove the elbow fitting from the pump head Unscrew the countersunk head screws atthe manifold cover and remove cover plate and manifold cover Note position of valve and remove Check valve for damage and replace if necessary Make sure that the valve is correctly seated Reassemble cover plate and manifold cover Use open ended wrench w f 15 to reconnect hose to elbow fitting Tighten union nut first by hand and then tighten one full turn using open ended wrench w f 17 Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 26 of 29 Notes on return to the factory Repair return DKD calibration Safety and health of our staff laws and regulations regarding the handling of danger ous goods occupational health and safety regulations and regulations regarding safe disposal of waste require that for all pumps and other products the Health and safety clearance form must be send to our office duly completed and signed before any equipment is dis patched to our premises Fax or post a completed copy of the health and s2. vacuubrand Technology for Vacuum Systems Instructions for use RP 12C RP 15C VARIO RP 22C VARIO RP 35C VARIO Roots pumping units Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 2 of 29 Dear customer Your VACUUBRAND diaphragm pumps should support you for a long time without trouble and with maximal power Thanks to our long practical experience we have much information how you could ensure powerful application and personal safety Please read these instructions for use before the initial operation of your pump VACUUBRAND diaphragm pumps are the result of many years of experience in construction and practical operation of these pumps combined with the latest developments in material and manufacturing technology Our quality maxim is the zero fault principle Every diaphragm pump leaving our company is tested intensively including an endurance run of 18 hours Therefore also faults which occur rarely are identified and can be eliminated immediately The achievement of the specifications after the endurance run is tested for every pump Every VACUUBRAND pump achieves the specifications We feel obliged to this high quality standard We know that the vacuum pump can not take a part of your real work and hope that our products contribute to an
3. 60 mins We reserve the right for modifications without prior notice Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 Diaphragm pump Housing cover insert page 10 of 29 Wetted parts PTFE carbon reinforced Head cover ETFE carbon fibre reinforced Diaphragm clamping disc ETFE carbon fibre reinforced Valves FFKM Diaphragm PTFE Inlet ETFE ECTFE stainless steel Outlet ETFE EGCTFE Hoses PTFE stainless steel Screw in fittings Roots pump Inlet outlet ETFE ECTFE Aluminium alloy anodized PFA coated Rotors pump chamber PTFE coated Seperator PE PMP O rings NBR Shaft seal motor PTFE Shaft seals gear FPM We reserve the right for modifications without prior notice Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 11 of 29 RP 12C 15C VARIO fig RP 15C VARIO inlet small flange NW 25 motor rating plate roots pump oil filler plug sight glass for oil level with marks min max frequency converte oil drain plug RP 12C with MBS 030 RP 15C V
4. MD4C from pumping unit Cleaning and inspecting the pump heads m Use open ended wrench w f 17 to remove union nuts Use open ended wrench w f 15 to turn elbow fitting 1 4 of a turn remove hose x Do not remove the elbow fitting from the pump head Through reassembly a leak may result o check valves use hex key to remove four socket head screws from pump head and remove upper housing hous ing cover with housing cover insert head cover and valves c Never remove parts by using a spiky 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 head cover from housing cover insert and check valves Note position of valves and remove Replace valves if necessary Use petroleum ether or industrial solvent to remove depos its Do not inhale a R Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 19 of 29 View of the disassembled pump head parts diaphragm clamping disc with square head screw diaphragm support disc head cover diaphragm connecting rod housing cover with housing cover insert t Check diaphragm for damage and replace if necessary odo so use Phillips screw driver to remove four counter sunk head screws and lift off
5. Pumped gases or collected condensate may leak in case the valve is open c Ensure that the inlet pipeline does not become contaminated when using inert gas t Avoid high heat supply e g due to hot process gases cs Pay attention to the max permitted ambient temperature and make sure ventilation is adequate especially if the equipment is installed in a housing In case of excess temperature the motor of the diaphragm pump respectively the motor of the Roots pump is shut down by a self hold thermal cutout in the winding Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 7 of 29 t f the diaphragm pump is shut down the Roots pump is not shut down automati cally However the variable speed drive of the Roots pumps of the pumping units HP 15C 22C 35C VARIO reduces the speed of the Roots pump following a limiting current regulation if necessary to standstill of the Roots pump In case of excess temperature the motor of the Roots pump is shut down by a separate self hold thermal cutout in the winding t f the Roots pump is shut down or if the speed of the pumping units RP 15C 22C 35C VAHIO is reduced the diaphragm pump continues to run Attention In each case manual reset is necessary Switch off the pumping unit or isolate the equipment from mains Iden
6. Roots pump but return it to the factory for repair or maintenance isolate equipment from mains before starting maintenance and wait two min une utes to allow the capacitors to discharge o 5 ts Before starting maintenance vent the system isolate the pump and other compo nents from the vacuum system and the electrical supply Drain condensate if appli cable avoid the release of pollutants Allow sufficient cooling of the pump Ensure that the pump cannot be operated accidentally Never operate the pump if covers or other parts of the pump are disassembled Never operate a defective or damaged pump t Attention The pump might be contaminated with the process chemicals that have been pumped during operation Ensure that the pump is decontaminated before maintenance and take adequate precautions to protect people from the effects of dangerous substances if contamination has occurred ts Wear appropriate safety clothing when you come in contact with contaminated com ponents In order to comply with law occupational health and safety regulations safety at work law and regulations for environmental protection vacuum pumps components and measuring instruments returned to the manufacturer can be repaired only when certain procedures see section Notes on return to the factory are followed Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully
7. and valves for MD 12C 00 ccccceeeeeceeeeeeeeeeteeeeeeeeeeaeeeeas 69 68 21 ve Please read the whole chapter Replacing diaphragms and valves before starting maintenance Partially the pictures show pumps in other versions This doesn t influence replacing diaphragms and valves of the pump t If necessary disassemble diaphragm pump MD 12C from pumping unit Cleaning and inspecting the pump heads Use open ended wrench w f 17 to remove union nuts Use open ended wrench w f 15 to turn elbow fitting 1 4 of a turn remove hose x Do not remove the elbow fitting from the pump head Through reassembly a leak may result o check valves use hex key to remove four socket head screws from pump head and remove upper housing hous ing cover with housing cover insert head cover valves and O rings if applicable c Never remove parts by using a spiky 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 head cover from housing cover insert and check valves Note position of valves and remove Replace valves if necessary Use petroleum ether or industrial solvent to remove depos its Do not inhale S R Check diaphragm for damage and replace if necessary Use Phillips screw driver to remove four countersunk head screws and lift off housing plate together with fittings and manifold yg Documents are only
8. are beyond our control and that you will assist us in expediting the repair procedure c Make sure that you know all about the substances which have been in contact with the equipment and that all questions have been answered correctly and in detail 1 Product Model 5 Way of transport carrier 3 List of substances in contact with the equipment or reaction products 3 1 Chemical substance name chemical symbol If the paint is damaged we wish a repaint or a replacement of parts due to optical aspects at our expense see Notes on return to the factory Q yes LI no We declare that the following measures 3 2 Important information and precautions where applicable have been taken e g danger classification The oil has been drained from the product Important Dispose of according to national regulations The interior of the product has been cleaned All inlet and outlet ports of the product have been sealed The product has been properly packed if necessary please order an original packaging costs will be charged and marked as appropriate The carrier has been informed about the hazardous 4 Declaration please mark as applicable nature or Me goods apPicabie L 4 1 for non dangerous goods We assure VACUUBRAND that Ne accept liability for any damage caused by providing incomplete or incorrect We assure for the returned product that information an
9. distributor A service manual with exploded view drawings spare part lists and directions for repair of the diaphragm pump only is available on request ts The service manual is for trained service people carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 16 of 29 Oil change Before starting maintenance isolate the pump from the vacuum system and the elec trical supply so that the pump cannot be operated accidentally Has the pump been exposed to dangerous or corrosive gases Take appropriate safety measures e g safety clothing and protective goggles to avoid inhalation and skin contact The pump and the oil may be contaminated with pumped chemicals which have been pumped adopt suitable decontamination measures if necessary Aging of the oil necessitates oil change in case of darker colour see new oil strange odour of the oil or foreign particles Depending on individual cases especially if corrosive gases or vapours have been pumped it may be efficient to check the oil at appropriate intervals Under normal operating conditions t Check oil level every time before starting the pump t Change oil on a yearly basis at the latest x Dispose of the used oil which may be contaminated by chemicals according to all applicable regulations Oil change t Heat pump to operating temperature before changing oil t solate the pump from the electrical sup
10. not incinerate fluoroelastomer seals and O rings t You may authorize us to dispose of the equipment at your expense Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 27 of 29 Health and safety clearance form Declaration concerning safety potential hazards and safe disposal of waste e g used oil Safety and health of our staff laws and regulations regarding the handling of dangerous goods occupational health and safety regulations safety at work laws and regulations regarding safe disposal of waste e g waste oil require that for all pumps and other products this form must be sent to our office duly completed and signed before any equipment is dispatched to our premises Products will not be accepted for any procedure and handling and repair DKD calibration will not start before we have received this declaration a Fax or post a completed copy of this form to us in advance The declaration must arrive before the equipment Enclose a second completed copy with the product If the product is contaminated you must notify the carrier GVE GGVS RID ADR b Inevitably the repair process will be delayed considerably if this information is missing or this procedure is not complied with We hope for your understanding for these measures which
11. pressure at the inlet port of the individual head Use a suitable vacuum gauge e g DVR 2 cat no 68 29 02 make sure that it is correctly calibrated and measure the pres sure at the inlet port A vacuum of less than 120 mbar should be indicated c f the reading is higher recheck the pump chamber and make sure that the valves and the diaphragms are correctly seated diaphragms concentric with bore Use open ended wrench w f 15 to reconnect hose to elbow fitting Tighten union nuts first by hand and then tighten one full turn using open ended wrench w f 17 rx Reassemble the pumping unit If the pump does not achieve the ultimate pressure t n case the diaphragms and valves have been replaced a run in period of several hours is required before the pump achieves its ultimate vacuum If all pump heads achieve a vacuum below 120 mbar but pump does not achieve the ultimate total pressure Check hose connectors between pump heads and manifolds for leaks If necessary recheck pump chamber If necessary disassemble fittings again and screw in the el bow fittings another turn use PTFE sealing bond as necessary Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 22 of 29 RP 22C 35C VARIO with MD 12C Set of seals diaphragms
12. pumping speed ultimate total vacuum and vapour pumping rate only at operating temperature after approx 60 minutes In case of oil in the separator t The shaft seal of the roots pump may leak Note Also if the shaft seal is not damaged a small amount of oil may enter the pump chamber of the roots pump Not degassed lubrication oil may foam May this be caused by an oblique position of the roots pumping unit ER ER t Oil consumption increases at inlet pressures above 100 mbar Check oil level at shorter intervals t Operate the pump without gas ballast only with clean systems and without conden sable vapours t Let the pump run with gas ballast to reduce condensation of pumped substances water vapour solvents in the pump or to decontaminate the pump oil from volatile substances The manual gas ballast valve is open if the arrow on the gas ballast cap points upwards RP 12C and 15C VARIO or away from the diaphragm pump RP 22C 35C VARIO t In case of pumping aggressive corrosive or otherwise dangerous gases and va pours take appropriate measures to protect pump and environment by using ap propriate equipment such as cold trap separator oil separator full flow oil filter shut off valve as well as special oil Shut down Has the pump been exposed to condensate ts Allow the pump to continue to run at atmospheric pressure for a few minutes then with the inlet closed t Stop pumping unit and admit ai
13. torque indicator recommended face wrench with torque indicator from VACUUBRAND Cat No 63 75 80 to assemble diaphragm clamping disc dia phragm and diaphragm support disc and eventually wash ers to the connecting rod 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 Optimum torque for the diaphragm support disc 6 Nm t he optimum torque is achieved if the pointer in the handle of the VACUUBRAND face wrench shows to the longer mark ing line By turning eccentric bushing front of connecting rod bring connecting rod into a position in which diaphragm is in con tact with housing and centred with respect to bore Reassemble in reverse order Install head cover with O ring if applicable valves and hous ing cover with housing cover insert c Make sure that the valves are correctly seated Valves at the outlet with round centred opening under valve valves at the inlet with kidney shaped opening beside valve By turning eccentric bushing bring connecting rod into up per turning point position Max stroke of the rod x Pay attention that the diaphragm stays positioned centrally so that it will become clamped uniformly between housing and head cover Screw in four socket head screws fixing housing cover cross wise e g in the sequence first slightly then tighten t Do not tighten until head
14. warm up pay attention to water condensation on cold surfaces x Ensure that installation is in compliance with limitations from the degree of protec tion see section Technical Data t RP 15C 22 35 VARIO only After switching off the pump wait at least 3 minutes before next switching on GG RP 15C 22 35 VARIO only Due to the high leakage current up to 3 5 mA a too low rated Fl safety switch may be activated Comply with all other relevant safety requirements e g safety at work regulations for laboratories and explosion protection guidelines GG Ensure that the equipment is suitable for the intended operation t Provide a firm level platform for the equipment and check that the system to be evacuated is mechanically stable and that all fittings are secure Attention Flexible elements tend to shrink when evacuated Due to the high compression ratio of the pumps pressure at the outlet port might be generated being higher than the max permitted pressure compatible with the mechani cal stability of the system t Comply with maximum permitted pressures and pressure differences see sec tion Technical data Do not operate the pump with overpressure at the inlet Do not permit any uncontrolled pressurizing e g make sure that the exhaust pipe line cannot get blocked If you have an exhaust isolation valve make sure that you cannot operate the equipment with the valve closed Risk of bursting c Ensure that the syst
15. ARIO with MBS 030 and frequency converter rating plate pumping unit condensate drain plug mains switch RP 22C 35C VARIO inlet small flange NW 25 fig RP 22C VARIO oil filler plug rating plate ii a E t ii TT pumping unit mj 2 a i AD A D a 4 7 motor ra Ing p ate N n T eB i ly ww roots pump gas ballast valve sight glass for DAT T TS LOL Zo BN P frequency converter oil level with s marks min max mains switch oil drain plug RP 22C VARIO with MBS 030 RP 35C VARIO with MBS 050 condensate drain plug and frequency converter both Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 12 of 29 Use and operation Installation in a vacuum system cs Avoid throttling losses by using connecting pipes with large diameter and keep them as short as possible t Reduce the transmission of vibration and prevent loading due to rigid pipelines Insert elastic hoses or flexible elements as couplings between the pump and rigid pipes Attention Flexible elements tend to shrink when evacuated t Use a suitable valve to isolate the pump from the vacuum system to allow the pump to warm up before condensable vapours are pumped or to clean the pump before it is switched off t Connect the exhaust to a suitable treatment plant
16. It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 28 of 29 Konformitatserklarung Declaration of conformity Declaration de conformite Pumpstand Pumping unit Groupe de pompage RP 12C 230V 691035 691036 691037 RP 15C VARIO 230V 691040 691041 691042 RP 22C VARIO 230 691050 691051 691052 RP 35C VARIO 230V 691060 691061 691062 Hiermit erklaren wir dass das oben bezeichnete Gerat in Konzeption und Bauart sowie in der von uns in Verkehr gebrachten Ausf hrung den grundlegenden Anforderungen der zutreffenden aufgef hrten EU Richtlinien entspricht Bei einer mit uns nicht abgestimmten Anderung an dem Ger t verliert diese Erkla rung ihre G ltigkeit We herewith declare that the product designated above is in compliance with the basic requirements of the applicable EC directives stated below with regard to design type and model sold by us This certificate ceases to be valid if the product is modified without the agreement of the manufacturer Par la pr sente nous d clarons que le dispositif d sign ci dessus est conforme aux prescriptions de base des directives EU applicables et indiqu s en ci que concerne conception dessin et mod le vendu par nous m mes Cette d claration cesse d tre valable si des modifications sont apport es au dispositif sans notre autorisation pr alable Maschinenrich
17. afety clearance form to us in advance The declaration must arrive before the equipment Enclose a second completed copy with the product If the equipment is contaminated you must notify the carrier No repair DKD calibration is possible unless the correctly completed form is returned Inevitably there will be a delay in processing the equipment if informa tion is missing or if this procedure is not complied with If the product has come in contact with chemicals radioactive substances or other substances dangerous to health or environment the product must be decontaminated prior to sending it back to the factory t Return the product to us disassembled and cleaned and accompanied by a cer tificate verifying decontamination or t Contact an industrial cleaning and decontamination service directly or t Authorize us to send the product to an industrial cleaning facility at your expense To expedite repair and to reduce costs please enclose a detailed description of the problem and the product s operating conditions with every product returned for repair We submit quotations only on request and always at the customer s expense If an order is given the costs incurred are offset from the costs for repair or from the pur chase price if the customer prefers to buy a new product instead of repairing the defective one t If you do not wish a repair on the basis of our quotation the equipment might be returned to you disassembled an
18. ated with the process chemicals that have been pumped during operation Ensure that the pump is decontaminated before maintenance and take adequate 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 proc essed by the pumping system ts Wear appropriate safety clothing when you come into contact with contaminated components Drain condensate Avoid the release of pollutants Before starting maintenance vent the pump and isolate it from the vacuum system Tools required metric Phillips screw driver size 2 Open ended wrench w f 15 17 Hex key size 5 Face wrench with torque indicator meee 63 75 80 Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 18 of 29 RP 12C and RP 15C VARIO with MD 4C Set of seals diaphragms and valves for MD AC 0 cceccccseeeeseeeeeeeeeeeeeeeneeeeneneesaaeeens 69 68 15 ve Please read the whole chapter Replacing diaphragms and valves before starting maintenance Partially the pictures show pumps in other versions This doesn t influence replacing diaphragms and valves of the pump t If necessary disassemble diaphragm pump
19. ation of explosive mixtures in the expansion chamber In case of a diaphragm crack mechanically generated sparks hot surfaces or static electricity may ignite these mixtures t Take adequate precautions to protect people from the effects of dangerous sub stances chemicals thermal decomposition products of fluoroelastomers wear appropriate safety clothing and safety glasses t Comply with applicable regulations when disposing of chemicals Take into consid eration that chemicals may be polluted Always allow the pump to continue to run for a few minutes with the inlet closed or with little gas ballast Adopt suitable measures to prevent any danger arising from potentially explosive or flammable mixtures x Use inert gas for venting the equipment c As regards root pumps the rotors rotate with a minimum clearance and at high speed relatively to each other as well as along the housing The clearance can become smaller because of the thermal expansion due to compression heat There fore the pumping unit RP 12C must not be operated continuously at inlet pressures gt 50 mbar Due to the residual leak rate of the equipment there may be an exchange of gas albeit very small between the environment and the vacuum system ts Adopt suitable measures to prevent contamination of the pumped substances or the environment Avoid overpressure at the gas ballast valve in case of high inlet pressure due to the high compression ratio GG
20. cover is in contact with housing torque 12 Nm By measuring the pressure at the inlet port of the individual head sw Use a suitable vacuum gauge e g DVR 2 cat no 68 29 02 make sure that it is correctly calibrated and measure the pressure at the inlet port A vacuum of less than 120 mbar should be indicated x f the reading is higher recheck the pump chamber and make sure that the valves and the diaphragms are correctly seated diaphragms concentric with bore Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 Montage of the connecting hose gt page 25 of 29 Use open ended wrench w f 15 to reconnect hose to elbow fitting Tighten union nuts first by hand and then tighten one full turn using open ended wrench w f 17 rx Reassemble the pumping unit If the pump does not achieve the ultimate pressure x n case the diaphragms and valves have been replaced a run in period of several hours is required before the pump achieves its ultimate vacuum If all pump heads achieve a vacuum below 120 mbar but pump does not achieve the ultimate total pressure Check hose connectors between pump heads and manifolds for leaks If necessary recheck pump chamber Changing the valve at the outlet manifold B gt qj X
21. ctions and chemical reactions of the pumped media Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 6 of 29 The pumps are not suitable for pumping substances which may form deposits inside the pump t f there is a danger of the formation of deposits in the pump chamber check inlet and outlet of the pump inspect the pump chamber regularly and clean if necessary The pumps are not suitable to pump unstable substances and substances which react explosively under impact mechanical stress and or when being exposed to elevated temperatures without air The pumps are not suitable to pump self inflammable substances substances which are inflammable without air and explosive substances The pumps are not suitable for pumping dust and have no approval for operation below ground Ensure that the materials of the wetted parts are compatible with the pumped substances see section Technical data x f residues can occur or if aggressive or condensable substances may enter the product install suitable protection e g gas washing bottle t Adopt suitable measures to prevent the release of dangerous explosive corrosive or polluting fluids t Use inert gas for gas ballast or venting if necessary t The user must take suitable precautions to prevent any form
22. d at your charge In many cases the components must be cleaned in the factory prior to repair For cleaning we use an environmentally responsible water based process Unfortu nately the combined attack of elevated temperature cleaning agent ultrasonic treat ment and mechanical stress from pressurised water may result in damage to the paint Please mark in the health and safety clearance form if you wish a repaint at your expense just in case such a damage should occur We also replace parts due to optical aspects upon your request Before returning the equipment ensure that if applicable t Oil has been drained and an adequate quantity of fresh oil has been filled in to protect against corrosion t Equipment has been cleaned and or decontaminated t All inlet and outlet ports have been sealed t Equipment has been properly packed if necessary please order an original pack aging costs will be charged marked as appropriate and the carrier has been noti fied x Ensure that the completed health and safety declaration is enclosed We hope for your understanding for these measures which are beyond our control 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 danger ous substances from the process Do
23. d that we shall indemnity VACUUBRAND from neither toxic corrosive biologically active explosive radio any claims as regards damages from third parties active nor contamination dangerous in any way has occurred We are aware that as expressed in 823 BGB Public the product is free of dangerous substances Law Code of Germany we are directly liable for injuries or the oil or residues of pumped media have been drained damages suffered by third parties particularly VACUUBRAND employees occupied with handling E 4 2 for dangerous goods rapainno the produci We assure for the returned product that all substances toxic corrosive biologically active explo ONAE saries o E EEEE E AERE EES sive radioactive or dangerous in any way which have pumped or been in contact with the product are listed in 3 1 Name print cccccccccssssseseeeeeeeeceeaeeeeeeseeeeeeeeseeseaaeeeees that the information is complete and that we have not withheld any information Job THIS e EE the product in accordance with regulations has been Q cleaned L decontaminated LI sterilized COMPANY SSCA ne EE VACUUBRAND GMBH CO KG Alfred Zippe Str 4 97877 Wertheim Technology for Vacuum Systems Tel 49 9342 808 0 Fax 49 9342 808 450 vacuubrand E Mail info 9 vacuubrand de 2001 VACUUBRAND GMBH CO KG Printed in Germany Web www vacuubrand com Documents are only to be used and distributed completely and unchanged
24. effective and trouble free realisation of your work Yours VACUUBRAND GMBH CO KG After sales service Contact your local dealer or call 49 9342 808 193 A e A Attention Important notes Not permitted Misuse may cause damage Caution Hot surface Isolate equipment from mains Note Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 3 of 29 Contents Safety information Me 4 el UR WE H Use and operallON seroren EEEEEEEEEEER 12 Troubleshooting BE 14 AIR e e E peasan EEE EAEE E E EEOSE EER EEEE 16 Replacing diaphragms and valves cccccceesceeesceeseeeseeeneeenseeeaeeoeseeenseoeaeeeaeeseneees 17 Notes on return to the factory sssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn 26 Health and safety clearance form ccccccessceeeceeseensseeseeneeeesenseenesnseesesenesenseees 27 Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 4 of 29 Safety information Remove all packing material remove the product from its packing box remove protec tive covers from inlet and outlet
25. els of hygiene and cleanliness Ensure that the pump location is well ventilated and that possible toxic effects of certain vapours are avoided t Use suitable collecting and disposing systems if necessary Operate the roots pump only if the oil filling is sufficient see section Oil change Use only oil of the recommended type Other oils or operating fluids may cause dangers or damage of the pump Use only genuine spare parts and accessories t Otherwise safety and performance of the equipment as well as the electromagnetic compatibility of the equipment might be reduced Possibly the CE mark becomes void if not using genuine spare parts Use special oils for the roots pump if t The pump operates in the vicinity of potential ignition sources t Oxygen or other flammable gases account for a large proportion of the evacuated gases Do not allow oils to be poured into or enter the drainage system or other bodies of water opillage can cause accidents Use suitable means for removing spilt oil Observe all relevant statutory requirements and regulations concerning the use stor age and disposal of oil Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 8 of 29 The A weighed emission sound pressure level of the pump does not exceed 70 dB A Measureme
26. em design does not allow the exhaust pipeline to get blocked t Avoid overpressure of more than 0 2 bar in case inert gas is connected t The diameter of the inlet and outlet pipeline should be at the least as large as the diameter of the pump connection pipelines Pay attention to symbol hot surfaces on the equipment t Adopt suitable measures to prevent any danger arising from the formation of hot surfaces or electric sparks t Make sure ventilation is adequate if pump is installed in a housing or if ambient temperature is elevated To the best of our knowledge the equipment is in compliance with the requirements of the applicable EC directives and harmonized standards see Declaration of conform ity with regard to design type and model especially directive IEC 1010 This directive gives in detail conditions under which the equipment can be operated safely see also IP degree of protection t Adopt suitable measures in case of differences e g using the equipment outdoors installation in altitudes of more than 1000 m above mean sea level conductive pollution or moisture The pumps have no approval for operation in or for pumping of potentially ex plosive atmospheres If pumping different substances purge the pump with inert gas prior to changing the pumped media in order to pump out residues and to avoid reactions of the pumped substances with each other with and the pump material Take into consideration intera
27. en plug Replace shaft seal or contact local distributor Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 Oil leakage under the motor flange of the roots pump page 15 of 29 gt Shaft seal at the motor side defective Heplace shaft seal or contact local distributor LI Oil in the separator Too much oil omall leakage in shaft seal Shaft seal is leaking to such a degree that the process cannot be carried out Foaming of not degassed lubrication oil Pumping unit has not been operated in normal position Lower oil level to mark max Top up oil level if necessary Contact local distributor or replace roots pump aggregate Empty the catchpot of the separator Operate pumping unit in normal position LJ Pump too noisy Atmospheric or high pressure at inlet port Diaphragm clamping disc loose Too low oil level None of the above mentioned causes Connect hoose to pump outlet Pay attention to max allowed pressure at operation Perform maintenance Fill in oil to the middle of the sight glass Contact local distributor Q Pump seized Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check Contact local
28. hole of the diaphragm support disc Optimum torque for the diaphragm support disc 6 Nm t The optimum torque is achieved if the pointer in the handle of the VACUUBRAND face wrench shows to the longer mark ing line By turning eccentric bushing front of connecting rod bring connecting rod into a position in which diaphragm is in con tact with housing and centred with respect to bore Reassemble in reverse order Install head cover valves and housing cover with housing cover insert ts Make sure that the valves are correctly seated Valves at the outlet with round centred opening under valve valves at the inlet with kidney shaped opening beside valve By turning eccentric bushing bring connecting rod into up per turning point position Max stroke of the rod c Pay attention that the diaphragm stays positioned centrally so that it will become clamped uniformly between housing and head cover Screw in four socket head screws fixing housing cover cross wise e g in the sequence first slightly then tighten t Do not tighten until head cover is in contact with housing torque 12 Nm Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 21 of 29 Individual performance check of a pump head By measuring the
29. housing plate with rating plate c Use petroleum ether or industrial solvent to remove depos its if necessary Do not inhale Use face wrench to remove diaphragm support disc Check for washers under clamping disc Do not mix the wash ers from the different heads Make sure that the original number is reassembled at the individual pump head t Smaller number of washers The pump will not attain ulti mate vacuum More washers Clamping disc will hit head cover noise or even blockade of the pump Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 20 of 29 m Position new diaphragm between diaphragm clamping disc with square head screw and diaphragm support disc 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 t Note Position diaphragm with white PTFE side to diaphragm clamping disc to pump chamber Use face wrench with torque indicator recommended face wrench with torque indicator from VACUUBRAND Cat No 63 75 80 to assemble diaphragm clamping disc dia phragm and diaphragm support disc and eventually wash ers to the connecting rod t Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide
30. hragm pump at terminal box of diaphragm pump Keep switched on all times Contact local distributor Q Diaphragm pump operates roots pump does not gt Operating at high pressure gt Roots pump has blocked gt Thermal overload of roots pump motor gt Lubrication oil at low temperature gt Cable of roots pump not plugged in gt RP 15 22 35C VARIO Fre quency control unit defective Check operation condi tions exclude leak at inlet Contact local distributor Allow motor to cool check fan Identify and remove cause of failure Mentilate for a short time restart the unit Plug in roots pump Contact local distributor LI Pump does not achieve ultimate total pressure or normal pumping speed gt Centering ring not correctly positioned or leak in the pipeline or vacuum System gt Long narrow line gt Foreign particles in the oil or too low oil level gt Outgasing substances or vapour generated in the process gt Valves or diaphragms damaged Oil filler or oil drain plug not correctly assembled gt Shaft seal at the motor side defective Check pump directly with a vacuum gauge at pump inlet check connections and line Use line with larger diameter length as short as possible Carry out oil change check oil level Check process parameters Replace valves and or diaphragms Thight
31. nt according to EN ISO 2151 2004 and EN ISO 3744 1995 with standard silencer or exhaust tube at outlet Ensure that maintenance is done only by suitable trained and supervised techni cians Ensure that the maintenance technician is familiar with the safety procedures which relate to the product processed by the vacuum system and that the equipment if necessary is appropriately decontaminated before starting maintenance Comply with local and national safety regulations Wear parts have to be replaced regularly In case of normal wear the lifetime of the diaphragms and valves is gt 10000 operating hours Bearings have a typical durability of 40000 h Motor capacitors have a typical durability in the range of 10000 to 40000 h depending strongly on the operation conditions like ambient temperature humidity or load t Check every capacitor regularly by measuring its capacity and estimating its opera tion time Exchange old capacitors early enough to prevent a failure If an overaged motor capacitor fails it might get hot and even melt and may cause a flame to form which could be dangerous for persons and equipment in the vicinity The ca pacitors have to be replaced by an electrician Ensure that maintenance is done only by suitably trained and supervised technicians Ensure that the maintenance technician is familiar with the safety procedures which relate to the products processed by the pumping system Never disassemble the aggregatof the
32. pecific applications depend on a number of factors beyond our control It is therefore strictly the users responsibility to very carefully check the validity of application to their specific requirements No claims arising from the information provided in this literature will consequently be entertained VACUUBRAND GMBH CO KG Alfred Zippe Str 4 97877 Wertheim Technology for Vacuum Systems D e See Geet bs 49 9342 808 450 EE GE 2009 VACUUBRAND GMBH CO KG Printed in Germany ATEM MO vee Rubee Oe Web www vacuubrand com Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009
33. ply and admit air t Choose suitable pad oil may drop oil filler plug oil drain GG Remove oil filler plug and oil drain plug c Tilt pump and catch oil in a suitable container x Dispose of the used oil according to the regulations GG Reassemble oil drain plug with O ring t To flush the pump pour in fresh oil approx 50 ml through the pump inlet t Operate the pump briefly drain flushing oil and repeat flushing procedure if neces sary x Fill in fresh oil through the oil inlet port until oil level reaches mark Max in the sight glass Note The oil flows from the gearing side of the roots pump through a connecting bore in the housing to the motor side Check oil level after some minutes pour in oil if necessary Do not use too much oil oil may enter the pump chamber Close oil filler plug SS S e Recommended oil B oil 1 68 70 10 Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 17 of 29 Replacing diaphragms and valves All bearings are encapsulated and are filled with long life lubricant Under normal opera ting conditions the pump is maintenance free The valves and diaphragms as well as the motor capacitors are wear parts If the rated ultimate vacuum is no longer achieved or in case of increased noise level the p
34. ports and keep them Inspect the equipment If the equipment is damaged notify the supplier and the carrier in writing within three days state the item number of the product together with the order number and the supplier s invoice number Retain all packing material for inspection Do not use the equipment if it is damaged If the equipment is not used immediately replace the protective covers Store the equipment in suitable conditions GG Read and comply with this manual before installing or operating the equip ment Note See figures on how to lift up and carry the pumping unit The handles at the diaphragm pump are not suitable to lift up and carry the complete pumping unit HP 12C and 15C VARIO HP 22C 35C VARIO Use the equipment for the intended use only i e for generation of vacuum t Prevent any part of the human body from coming in contact with the vacuum t Comply with notes on correct vacuum and electrical connections t Adopt suitable measures to avoid that liquids flow on or into the pump motor when assembling or disassembling vacuum connections at the pump Risk of corrosion and or short circuit ts Take care when connecting and deconnecting the vacuum tube cs Make sure that the individual components are only connected combined and ope rated according to their design and as indicated in the instructions for use ts Avoid continuous operation of the roots pumping unit RP 12C at inlet pres sures 50 mba
35. r t Drain condensate if necessary Has the pump been exposed to media which may damage the pump materials or form deposits t Let the pump continue to run for a longer time with the gas ballast valve open check and clean pump heads if necessary Short term ts Wait at least 60 s before restarting the pumping unit RP 15C 22C 35C VARIO only Long term ts Separate pump from the apparatus c Flush pump with dry nitrogen t Change oil x Fil the pump with new oil not above upper level line t Close manual gas ballast valve t Close inlet and outlet port e g with transport caps or blind flanges t Store the pump in dry conditions x fnecessary carry out oil change and maintenance prior to use if the pump is stored for a longer time Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 Troubleshooting Fault Q Pump fails to start or stops immediately page 14 of 29 Possible cause gt Mains not plugged in electrical supply failure gt Pressure in outlet pipeline too high gt Motor overloaded gt Diaphragm pump switched off gt Diaphragm pump blocked Remedy Plug in Check fuse Remove blockade in line open valve Allow motor to cool identify and remove cause of failure Switch on diap
36. r in order to prevent overheating caused by the compression heat at high inlet pressure and to prevent blockade of the rotors or activation of the thermal cutout in the winding of the roots pump s motor Comply with national safety regulations and safety requirements concerning the use of vacuum and electrical equipment t Equipment must be connected to a suitable fused and protected electrical sup ply and a suitable earth point Failure to connect the motor to ground may result in deadly electrical shock t The supply cable may be fitted with a moulded European IEC plug or a plug suitable for your local electrical supply If the plug has been removed or has to be removed the cable will contain wires colour coded as follows green or green and yellow earth blue or white neutral brown or black live t Check that mains voltage and current conform with the equipment see rating plate Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 5 of 29 Comply with all relevant safety requirements regulations and guidelines and adopt suitable safety measures The mains on off switch is located sidewise at the terminal box The pumps cannot be hooked up separately t f the equipment is brought from cold environment into a room for operation allow the equipment to
37. the validity of this document with respect to his product manual no 999019 22 12 2009 page 9 of 29 Technical data RP 15C RP 22C RP 35C Type RP 12C VARIO VARIO VARIO Max pumping speed 50 60 Hz ISO 21360 mh 12 14 15 22 40 Bee EES mbar 0 2 0 2 0 2 0 1 Ultimate total pressure with gas ballast mbar 0 4 0 4 0 9 0 9 Max permitted outlet pressure absolute mbar 1 1 1 1 1 1 1 1 Max permitted pressure at inert gas connection bar 1 2 1 2 1 2 1 2 absolute Ambient temperature C 10 to 40 10 to 40 range storage operation Max permitted relative atmospheric moisture 7o 30 to 85 operation Degree of protection IEC 529 IP 20 Type of roots pump MBS 030 MBS 030 MBS 030 MBS 050 Oil capacity roots pump ml 210 210 210 335 Recommended oil VACUUBRAND B oil Hated motor power diaphragm pump W 200 200 390 390 roots pump W 300 300 300 300 Motor protection Rated current draw at 230 V 50 60 Hz A 3 9 4 5 max 4 5 max 5 0 max 5 0 Max permitted range of 230 V 10 50 Hz supply voltage 230 V 5 10 60 Hz Hated speed at 50 60 Hz diaphragm pump min 1500 1800 roots pump min 3000 3600 300 3600 Inlet small flange NUM 25 40 Outlet hose nozzle NW 10 mI MM tons approx mm 460x340x360 495x340x360 570x440x460 585x440x475 Mass kg 34 4 36 8 53 0 55 6 The pump achieves its ultimate pumping speed and ultimate total pressure only at operating termperature after approx
38. tify and eliminate the cause of failure Allow the pump to cool down sufficiently before restart Ensure that in case of failure the pump and the vacuum system always will turn into a safe status x In case of diaphragm cracks or leaks in the manifold pumped substances might be released into the environment or into the pump housing To reduce the risk of leaks ask for a diaphragm pump with additional safety diaphragm t Comply especially with notes on operation and use and maintenance x Failure of the pump e g due to power failure must not lead to a critical dangerous situation under any circumstances Electronic equipment is never 100 fail safe This may lead to an indefinite status of the equipment Provide protective measures against misfunction and failure t Operating the pump stand still of the pump or operating the air admittance valve must not lead to a critical dangerous situation under any circumstances Under normal conditions pump oils and lubrications are not toxic and their use entails no danger Certain hazards are however associated with some of these products The following precautions must be adopted during use and operation in order to meet health and safety requirements Adopt precautionary measures e g wear appropriate safety clothing and protective goggles to avoid excessive contact with the skin and possible skin irritations includ ing dermatitis Do not inhale or swallow Maintain adequate lev
39. tlinie mit Anderungen Machine directive with supplements Directive Machines avec des suppl ments 2006 42 EG Niederspannungsrichtlinie Low Voltage Directive Directive Basse Tension 2006 95 EG Richtlinie Elektromagnetische Vertr glichkeit Electromagnetic Compatibility Directive Directive Compatibilit Electromagn tique 2004 108 EG Angewandte Harmonisierte Normen Harmonized Standards applied Normes Harmonis es utilis es DIN EN 12100 2 DIN EN 61010 1 DIN EN 1012 2 DIN EN 61326 1 DIN EN 61800 Managementsysteme Management systems Systemes de Management EN ISO 9001 EN ISO 14001 1997 2006 Wertheim 22 12 2009 Dr F Gitmans Dr J Dirscherl Gesch ftsf hrer Managing Director G rant Technischer Leiter Technical Director Directeur technique VACUUBRAND GMBH CO KG Alfreq Zippe Str 4 97877 Wertheim Vakuumtechnik im System Tel 49 9342 808 0 Fax 49 9342 808 450 Technology for Vacuum Systems E Mail info vacuubrand de Technologie pour syst me vide Web www vacuubrand com Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 29 of 29 Disclaimer Our technical literature is only intended to inform our customer The validity of general empirical values and results obtained under test conditions for s
40. to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 23 of 29 View of the disassembled pump head parts yX cover plate distributor cover countersunk head screw housing connecting rod washer diaphragm support disc diaphragm diaphragm clamping disc head cover valve housing cover with housing cover insert Use a face wrench to remove diaphragm support disc Check for washers Do not mix the washers from the differ ent heads Make sure that the original number is reassem bled at the individual pump head Smaller number of washers The pump will not attain ulti mate vacuum More washers Clamping disc will hit head cover noise or even blockade of the pump Position new diaphragm between diaphragm clamping disc with square head screw and diaphragm support disc Note Position diaphragm with white PTFE side to diaphragm clamping disc to pump chamber Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide hole of the diaphragm support disc Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 24 of 29 Use face wrench with
41. to prevent the discharge of dan gerous gases and vapours to the surrounding atmosphere Use a catchpot to pre vent the drainage of contaminated condensate back into the pump Prior to use t Max ambient temperature 40 C t Check that mains voltage and current conform with the equipment t Make sure ventilation is adequate if pump is installed in a housing or if ambient temperature is elevated Keep a distance of min 20 cm between fans and ambient parts ts Ambient temperature should be at least 12 C because otherwise the pump pos sibly does not start because of the high oil viscosity at low temperature x f the pump is installed in altitudes of more than 1000 m above mean sea level check compatibility with applicable safety requirements e g IEC 60034 motor may overheat due to insufficient cooling Attention Before use pour oil into roots pump See section oil change ts Prevent internal condensation transfer of liquids or dust t The rotors of the pump may block t Pumping of liquids or dust damages the roots pump as well as the diaphragms and valves of the diaphragm pump x f the gas ballast valve is open a power failure may cause unintentional ventilation of the pump In case this constitutes a potential source of danger take appropriate safety measures e g install a electromagnetic operated gas ballast valve t Only operate the pumping unit in a horizontal normal position Avoid turning if pump is
42. transported with oil filling Oil may enter the separator or the pump chamber of the roots pump if the pump is tilted more than 15 t When assembling ensure vacuum tightness After assembly check the complete system for leaks t Check oil level of the roots pump every time before starting the pump however at least once a week Check oil level more frequently if high gas or vapour quantities are pumped During operation xx Pumping down can be started at any pressure max at atmospheric pressure Forthe pumping unit RP 12C continuous operation is possible only at inlet pressures 50 mbar The roots pump in the pumping units RP 15C 22C 35C VARIO are equipped with a frequency control unit which adapts the frequency of the roots pump according to the inlet pressure via a maximum current control t Continuous operation is possible at any pressure below atmospheric pressure Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this document with respect to his product manual no 999019 22 12 2009 page 13 of 29 t The frequency is reduced at high inlet pressures especially at atmospheric pres sure in order to avoid thermal overload of the roots pump c Under normal conditions the maximum pump speed is reached only at inlet pres sures 50 mbar t The noise level can be different when evacuating GG The pump achieves its
43. ump interior the diaphragms and the valves must be cleaned and the diaphragms and valves must be checked for cracks or other damage Check every capacitor regularly by measuring its capacity and estimating its operation time Exchange old capacitors early enough to prevent a failure The capaci tors have to be replaced by an electrician Depending on individual cases it may be efficient to check and clean the pump heads on a regular basis In case of normal wear the lifetime of the diaphragms and valves is 10000 operating hours t Prevent internal condensation transfer of liquids or dust The diaphragm and valves will be damaged if liquids are pumped in significant amount If the pump is exposed to corrosive media or in case of deposits maintenance should be carried out frequently t Regular maintenance will improve the lifetime of the pump and also protect both man and environment Ensure that maintenance is done only by suitable trained and supervised technicians t Ensure that the pump cannot be operated accidentally Never operate the pump if covers or other parts of the pump are disassembled Never operate a defective or damaged pump ts Before starting maintenance isolate the pump from the electrical supply and wait two minutes after isolating the equipment from mains to allow the capacitors to I discharge Avoid the release of pollutants Allow sufficient cooling of the pump c Attention The pump might be contamin
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