MD 1 Vario-SP/MD 1 Diaphragm Pumps
Contents
1. ified Me PEEEEHEY o HHHHHHHHH DIP switch trimming potentiometer 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 999085 30 09 2008 page 14 of 29 Settings at the slide switch PWM factory set or v2. Safety during operation Adopt suitable measures to prevent the release of dangerous toxic explosive corrosive noxious or polluting fluids vapours and gases In case install an ap propriate collecting and disposal system and take protective action for pump and environment Prevent any part of the human body from coming into contact with vacuum The user must take suitable precautions to prevent any formation of explosive mixtures in the expansion chamber or at the outlet In case of e g a diaphragm crack mechanically generated sparks hot surfaces or static electricity may ignite these mixtures Use inert gas for venting if necessary Potentially explosive mixtures at the outlet of the pump have to be drained ap propriately sucked off or diluted with inert gas to non explosive mixtures t Pay attention to the symbol hot surfaces on the equipment Adopt suitable meas ures to prevent any danger arising from the formation of hot surfaces or electric sparks Provide a suitable protection against contact if 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 999085 30 09 2008 NOTICE page 7 of 29 e Comply with applicable regulations when disposing of chemicals Take into con sideration that chemicals may be polluted Take adequate precautions to p
3. biologically active explosive radio active nor contamination dangerous in any way has occurred the product is free of dangerous substances the oil or residues of pumped media have been drained E 4 2 for dangerous goods We assure for the returned product that all substances toxic corrosive biologically active explo sive radioactive or dangerous in any way which have been pumped or been in contact with the product are listed in 3 1 that the information is complete and that we have not withheld any information the product in accordance with regulations has been Q cleaned U decontaminated U sterilized VACUUBRAND GMBH CO KG Technology for Vacuum Systems 2008 VACUUBRAND GMBH CO KG Printed in Germany Alfred Zippe Str 4 97877 Wertheim Tel 49 9342 808 0 Fax 49 9342 808 450 E Mail info vacuubrand de Web www vacuubrand de 5 Way of transport carrier 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 Q no We declare that the following measures where applicable have been taken The oil has been drained from the product Important Dispose of according to national regula tions 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 neces sary please order an original packagin
4. data is not exceeded e Particles and dust must not be aspirated Use the equipment for the intended use only i e for generation of vacuum in ves NOTICE sels designed for that purpose Setting up and installing the equipment Equipment pumps with AC motor must be connected only to a suitable fused and protected electrical supply and a suitable earth point provide slow blow fuse according to voltage supply see Technical data Failure to connect the motor to ground may result in deadly electrical shock The supply cable may be fitted with a moulded European IEC plug or a plug suit able 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 Due to the high compression ratio of the pumps pressure at the outlet port might be generated being higher than the maximum permissible pressure compatible with the mechanical stability of the system t Do not permit any uncontrolled pressurizing e g make sure that the exhaust pipeline cannot become blocked If there is an exhaust isolation valve make sure that you cannot operate the equipment with the valve closed Risk of bursting gt O gt Z G LL Er Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of
5. failure and malfunction Pumps with 115 V motor 230 V motor and dual voltage motor In case of overload the motor is shut down by a self hold thermal cutout in the winding Attention Reset possible only manually Switch off the pump or isolate the equip ment from mains Identify and eliminate the cause of failure Wait approx five minutes before restarting the pump Attention In case of supply voltage below 100V the lock of the cutout might be restricted and the pump might restart on its own after sufficient cooling down Take suitable precautions if an automatic restart of the pump may lead to a critical dan gerous situation Pumps with 24 V DC voltage The motor is protected by a temperature sensor at the circuit board Current limitation if the temperature at the circuit board is higher than 70 C switching off the pump if the temperature is higher than 85 C In case of blockade of the motor after 10 attempts to start up the pump is switched off If the pump is switched off due to safety measures manual reset is necessary Isolate the pump from mains Eliminate the cause of failure before restarting 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 999085 30 09 2008 page 8 of 29 Maintenance and repair Wear parts have to be replaced regularly In case of norma
6. request Before returning the equipment ensure that if applicable Equipment has been cleaned and or decontaminated Allinlet and outlet ports have been sealed 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 notified 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 dangerous substances from the process Do not incinerate fluoroelastomer seals and O rings 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 999085 30 09 2008 page 26 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 regulation
7. with our products to an effective and troublefree realisation of your work Yours VACUUBRAND GMBH CO KG After sales service Contact your local dealer or call 49 9342 808 193 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 999085 30 09 2008 page 3 of 29 Contents Safety information egene 4 General information EH 4 Jade Ee E E 4 Setting up and installing the equipment cece ceeccceececeeeeceeeeceeeeeseeeecaueeceeeeceueeseeessueessueesseeesseeeess 4 PATI ICI COMGINOING aocesccscas eciec ce ates eigenen seancee cose ences eanewensdeastecuntaceasteenareanneancceaeveaseeeina access asceeesedetees 5 Operating conditions cccceeeecccceeeceecceeeeeeeceeeeecccaaueeeecsaueeeeseeaseeesaeaeeeessaeeeessaaueeesseaeeeeeseeeeeessseeeseaas 6 Satety CUMING OO CL ANON eiciia ea eaa aara A ATEEN Ea ana E sss dddraiuareudionts 6 Maintenance and repnair nennen 8 ee algele CC A E A E E E E 9 Gas inlet temperatures EE 10 Wetted parts 10 POND DG a a E etre E E dees eden cares eciere 10 Controlling the MD 1 VARIO SP asccccscsssskededasseswassanes send eavecdouanseonapeiqea den nadwanteuedasnncsauoasenbeiaaadawiassieeswenss 13 MS SANG ODE RAMON Era E E E E E E ES 15 Modling ina vacuum Syste EE 15 D ring operati AE 16 SIE 17 MRO UBISS NO OUI BE 18 Replacing diaphragms and VAaIVES cccsscce
8. Leiter Technical Director Directeur technique VACUUBRAND GMBH CO KG Alfred 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 999085 30 09 2008 page 28 of 29 Certificate TUV Certificate no CU 72070564 01 License Holder Manufacturing Plant VACUUBRAND GMBH Co KG VACUUBRAND GMBH Co KG Alfred Zippe Str 4 Alfred Zippe Str 4 97877 Wertheim 97877 Wertheim Germany Germany Test report no USA RC 02271487 003 Client Reference Jurgen Dirscherl Tested to VG GLlULGAHST E2002 R12 02 CAN CSA C22 2 No 1010 1 92 A2 97 Certified Product Diaphragm Vacuum Pump for Laboratory Use License Fee Units Model Designation Mvwx yy z 7 Web w n vd NS W 0 5 1 1 5 x C S blank y A Z blank Z AK EK 2AK AK EK AK EK TE AK EK Peltronik IK EK AK SY EK blank Rated Voltage AC 100 120 200 230V 50 60Hz Rated Current 1 7 0 85A Protection Class I Special Remarks Replaces Certificate CU72032013 7 Appendix 1 1 2 Licensed Test mark Signatures Date of Issue day mo yr 4 01 03 2007 Stephan Schmitt Dipl Ing M Raa President QA Cert
9. Short term NOTICE Has the pump been exposed to condensate Allow the pump to continue to run at atmospheric pressure for a few minutes Has the pump been exposed to media which may damage the pump materials or form deposits Check and clean pump heads if necessary Long term Take measures as described in section short term shutdown Separate pump from the apparatus Close inlet and outlet port e g with transport caps Store the pump in dry conditions 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 999085 30 09 2008 page 18 of 29 Troubleshooting Fault Q Pump does not start or stops immediately Possible cause Supply voltage too low or power supply failure Remedy L Check supply voltage Check fuse gt Only VARIO SP version Check control signal Control signal for motor speed is missing Pressure in outlet pipeline too zs Remove blockade in line high open valve Motor overloaded Allow motor to cool down identify and eliminate cause of failure Manual reset is necessary Switch off pump or unplug mains gt Only C US version Check and replace motor Motor fuse blown fuse Identify and eliminate cause of failure Q Pump does not achieve Centring ring at small flange oe Check pump directly con its ultimat
10. bly 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 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 the validity of this document with respect to his product manual no 999085 30 09 2008 page 9 of 29 Technical data MD 1 VARIO SP Maximum pumping speed ISO 21360 m3 h 1 2 1 4 1 7 2200 rpm Ultimate vacuum absolute mbar 1 5 lt 1 0 700 rpm Maximum permissible outlet pressure bar absolute Maximum pressure difference between bar inlet and outlet Permissible ambient temperature C 10 to 60 10 to 40 storage operation Permissible relative atmospheric moisture o l A 30 to 85 during operation no condensation 0 Rated motor power kW 0 08 0 064 No load speed min 1500 1800 350 2200 Maximum permissible range of supply 400 115 V 50 60 Hz voltage 10 ete 200 230 V 50 60 Hz 24 VDC Attention Observe specifications of 115 V 60 Hz rating plate Maximum rated curr
11. e vacuum of the pump and also the lifetime of diaphragms and valves 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 999085 30 09 2008 page 15 of 29 Use and operation Installing in a vacuum system e Connection lines at the pump inlet have to be gas tight Particles and dust must ACAUTION not be aspirated the user has to provide appropriate filters if necessary The user must ensure their suitability concerning gas flow chemical resistance and safeness against clogging prior to use e Connect an exhaust line gas tight at the pump outlet if necessary Always dispose of exhaust gases appropriately e g into a fume hood If there is risk of release of dangerous or polluting fluids install an appropriate system to catch and dispose of those fluids e Reduce the transmission of vibration and prevent mechanical load 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 e The gas outlet must never be blocked The exhaust line has always to be free pressureless to ensure an unimpeded discharge of gas e A power failure may cause accidental ventilation of the pump In case this consti tutes a potential source of danger take appropriate safety measures e Make sure
12. e vacuum or connection not correctly nect vacuum gauge directly usual pumping speed positioned or leak in the at pump inlet then check pipeline or vacuum system connection pipeline and vacuum system if necessary Long narrow line Use lines with larger diameter length as short as possible Pump has been exposed to Allow pump to run for some condensate minutes with atmospheric pressure at the inlet Deposits have been formed e Clean and inspect the pump inside the pump heads Diaphragms or valves ze Replace diaphragms and or damaged valves Outgassing substances or va Check process parameters pour generated in the process Only VARIO SP version Ensure sufficient cooling of the Pump temperature too high pump or reduce inlet pressure motor speed reduced LJ Pump too noisy Atmospheric or high pressure Connect hose or silencer to at the pump inlet pump outlet gt Diaphragm crack or diaphragm Perform maintenance clamping disc loose gt Other than above mentioned Contact local distributor causes e Contact local distributor Q Pump seized A service manual with exploded view drawings spare part lists and directions for repair is available on request only in German or English t The service manual is for trained service people Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of t
13. eep a distance of minimum 20 cm between fan and ambient parts e g housing walls Check fan regularly for dust dirt clean if necessary to avoid a cutback of ventilation If the equipment is brought from cold environment into a room for operation allow the equipment to warm up pay attention to water condensation on cold surfaces The diameter of the inlet and outlet pipeline should be at least as large as the diameter of the pump connection pipelines Comply with all applicable and relevant safety requirements regulations and guide lines implement the required actions and adopt suitable safety measures Ambient conditions 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 con formity with regard to design type and model Directive IEC 1010 gives in detail conditions under which the equipment can be operated safely see also IP degree of protection 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 999085 30 09 2008 A DANGER NOTICE A DANGER page 6 of 29 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 pol lution or bedewing Pay a
14. em for leaks Secure hose connections at the pump appropriately against accidental detaching 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 999085 30 09 2008 page 16 of 29 During operation or if the ambient temperature is elevated e Potentially dangerous gases or vapours at the outlet of the pump have to be drained and disposed of appropriately e Due to the high compression ratio of the pumps the pressure at the outlet port might get higher than the maximally permitted pressure compatible with the mechanical stability of the system Ensure that the pump outlet is not blocked or restricted e Maximum ambient temperature 40 C e Make sure ventilation is adequate especially if the pump is installed in a housing NOTICE If the pump is installed in altitudes of more than 1000 m above mean sea level check compatibility with applicable safety requirements especially IEC 60034 motor might overheat due to insufficient cooling Do not start the pump if the pressure difference between inlet and outlet ports exceeds max 1 1 bar Attempts to start the pump at higher difference may cause blockade and damage of the motor Check compatibility with maximally permitted pressure at outlet and maximum pressure difference between inlet and outlet ports Prevent internal condensation transfer
15. ent at 100 115 V 50 60 Hz 200 230 V 50 60 Hz 115 V 60 Hz 24V DC h ch thermal cutout manual reset MD 1 C US addi tional fuse 2 5 AT Degree of protection IEC 529 IP 44 IP 20 Outlet silencer G 1 8 Dimensions L x W x H approx mm 303 x 143 x 216 MD 1 C US mm 313 x 148 x 216 303 x 143 x 163 temperature sensor on the pcb current limitation Motor protection 223 X 143 x 163 Dimensions L x W x H w o handle approx MD 1 C US 313 x 143 x 163 6 5 6 7 Weight approx MD 1 C US ar 50 60 Hz In case of supply voltage below 100V the lock of the cutout might be restricted We reserve the right for technical modification 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 999085 30 09 2008 page 10 of 29 Gas inlet temperatures Operating condition Inlet pressure Permitted range of gas temperatures at inlet C Continuous operation gt 100 mbar high gas load 10 C to 40 Continuous operation lt 100 mbar low gas load 0 C to 60 C Short time lt 5 minutes lt 100 mbar low gas load 10 C to 80 C Wetted parts Diaphragm clamping disc Pump parts component Poon componen or Les ren i e Recessed grip handle removable Fuse carrier Control line Pump rating plate In
16. ent with respect to his product manual no 999085 30 09 2008 page 22 of 29 Lift diaphragm at the side and position carefully together with diaphragm clamping disc and diaphragm support disc in the diaphragm key t Avoid damage of the diaphragm Do not crack diaphragm in a way that white lines at the diaphragm s upper side oc Cur Check for washers under clamping disc Do not mix the washers from the different heads Make sure that the original number is reassembled at the individual pump head ts Smaller number of washers The pump will not attain final vacuum More washers Clamping disc will hit head cover noise or even blockage of the pump Replacing the valves and assembling the pump heads ts Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide hole of the diaphragm support disc Assemble diaphragm clamping disc diaphragm and dia phragm support disc to connecting rod t Position washers between diaphragm support disc and rod Bring diaphragm into a position in which diaphragm is in contact with housing and centred with respect to bore Assemble head cover and valves t Check for correct position see fig below 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 999085 30 09 2008 page 23 o
17. es its ultimate vacuum If the pump does not achieve the ultimate vacuum Check hose connection between pump heads and manifolds for leaks If necessary recheck pump chamber 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 999085 30 09 2008 page 25 of 29 Notes on return to the factory Repair return DKD calibration NOTICE NOTICE Safety and health of our staff laws and regulations regarding the handling of dan gerous 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 dispatched to our premises Fax or post a completed copy of the health and safety 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 infor mation is missing or if this procedure is not obeyed If the product has come in contact with chemicals radioactive substances or other substances dangerous t
18. eseeeeseeeeseeeeeeeeaeeeeseeeeseeonseeenseseaeeeeaeeneaes 19 Cleaning and inspecting the pump beade nnnnannnannnannnannnnnnnnnnnnennnnnnnnnnrernnnnnrrnnrenrennrrnnrennrenneennee 20 Replacing the le e e un WEE 20 Replacing the valves and assembling the PUMP beade 22 Assembling the CONNECHON NOSE EE 24 Notes on return to the factory sssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn 25 Health and safety clearance form cc ccessccesceeseeenscenseenseeeseoeeseesssenssonseoeeeneesseaees 26 Danger Immediate danger Death or severe injuries as well as damage to equipment and environment can occur A DANGER t Warning Possible danger Severe injuries as well as damage to equip ment and environment can occur e Caution Possible danger Slight injuries as well as damage to equipment and environment can occur N TICE Note Disregarding of notes may cause damage to the product Caution Hot surface Isolate equipment from mains before removing the cover Ki gt gt HI 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 999085 30 09 2008 page 4 of 29 Safety information General information N OTI C E GG Read and comply with this manual before installing or operating the equip ment ts Transport the pump at the provided hand
19. f 29 It is essential to mind the position and orientation of the head cov ers and the valves Scheme of pump head with head covers and valves valves at the outlet N 5 round centred opening under valve valves at the inlet kidney shaped opening beside valve Position housing cover t Move housing cover slightly to make sure that the head covers are correctly positioned Screw in six socket head screws fixing housing cover cross wise first slightly then tighten t Do not tighten until head cover is in contact with housing max torque 6 Nm Assemble handle with screws and tighten t Check for correct position of the handle over the centre of gravity of the pump The handle is correctly positioned if the end of the handle is flush with the end of the housing cover 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 999085 30 09 2008 page 24 of 29 Assembling the connection hose Use an open ended wrench w f15 to reconnect the fitting with the connection hose to the pump head t Steady with open ended wrench w f 16 when tightening the hollow bolt If the pump does not achieve the ultimate vacuum t n case the diaphragms and valves have been replaced a run in period of several hours is required before the pump achiev
20. g costs will be charged and marked as appropriate The carrier has been informed about the hazardous nature of the goods if applicable We assure VACUUBRAND that we accept liability for any damage caused by providing incomplete 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 Germany we are directly liable for injuries or damages suffered by third parties particularly VACUUBRAND employees occupied with handling repairing the product el Name DINU sii ea EEEa eier Seu KEE COMPANY El Aieeedegedene Seed eegen 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 999085 30 09 2008 page 27 of 29 A Konformitatserklarung Declaration of conformity Declaration de conformite Membranpumpe Diaphragm pump Pompe a membrane MD 1 230V 696080 696081 696082 MD 1 VARIO SP 24V 696101 Hiermit erklaren wir daB 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 nderung an dem Ger t verliert diese Erkl rung ihre G ltigkeit We herewith declare that the
21. his document with respect to his product manual no 999085 30 09 2008 page 19 of 29 aolre teilas Ko irtolal e t LLEW Uo D E AYE All bearings are encapsulated and are filled with long life lubricant Under normal operating 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 pump 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 es timating its operation time Exchange old capacitors early enough to prevent a failure The capacitors 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 gt 10000 operating hours 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 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 c Ensure that the pump cann
22. ification Officer UV Rheinland of No America INC ommerce Road Newtown 06470 Tel 203 426 0888 Fax 203 426 4009 This certificate is only valid for pumps with C US mark see pump 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 999085 30 09 2008 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 specific 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 Alfred Zippe Str 4 97877 Wertheim VACUUBRAND GMBH COKG oi A8 9342 808 0 Fax 49 9342 808 450 vacuubrand Technology for vacuum systems E Mail info vacuubrand de 2008 VACUUBRAND GMBH CO KG Printed in Germany 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 999085 30 09 2008
23. l 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 de pending strongly on the operation conditions like ambient temperature humidity or load Check every capacitor regularly by measuring its capacity and estimating its op eration time Exchange old capacitors early enough to prevent a failure If an over aged 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 capacitors have to be replaced by an electrician Isolate equipment from mains and wait two minutes before starting maintenance to allow the capacitors to discharge 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 Attention The pump might be contaminated with process chemicals which 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 Before starting maintenance vent the pump isolate the pump and other components from the vacuum system Allow sufficient cooling of the pump Drain condensate if applicable Ensure that maintenance is done only by suita
24. le or the recessed grips Remove all packing material remove the product from its packing box remove the protective covers from the inlet and outlet ports and keep 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 suppliers 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 Intended use c The pump and all system parts must not be used on humans or animals t Prevent any part of the human body from coming into contact with vacuum c Ensure that the individual components are only connected combined and operated according to their design and as indicated in the instructions for use t Comply with notes on correct vacuum and electrical connections see section Use and operation e The pumps are designed for ambient temperatures during operation between 10 C and 40 C Check the maximum temperatures if installing the pump in a cabinet or a housing and make sure ventilation is adequate Install an external automatic ventilation system if necessary If pumping hot process gases make sure that the maximum permitted gas inlet temperature which depends on several parameters like inlet pressure or ambient temperature see Technical
25. let 8 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 999085 30 09 2008 page 11 of 29 only pump with dual voltage motor MD 1 C US MD 1 VARIO SP AN Ensure sufficient venting 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 999085 30 09 2008 page 12 of 29 Only pumps with dual voltage motor Voltage selection switch Change the selection at the voltage changeover switch only if the pump is separated from mains Use a screw driver to adjust the supply voltage on the voltage changeover switch 115 corresponds to 100 120V and 230 corresponds to 200 230V Pumps with dual voltage motor t Check that the voltage changeover switch is correctly positioned Attention If the voltage is not correctly selected the motor can be damaged if the pump is switched on Change the selection at the voltage changeover switch only if the pump is separated from mains Replacing the motor fuse only MD 1 C US Unscrew the fuse carrier at the side of the pump using a screw driver Replace the defective fuse by a fuse of the same type 2 5 AT and reassemble fuse carrier with fuse to the
26. lift the dia phragm Use diaphragm key to grip under the diaphragm to the diaphragm support disc Apply pressure to the diaphragm clamping disc to bring the diaphragm into lower turning point position Press dia phragm key against diaphragm clamping disc and unscrew diaphragm support disc with diaphragm t f the old diaphragm is difficult to separate from the support disc immerse assembly in naphtha or petroleum ether Do not inhale 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 999085 30 09 2008 page 21 of 29 t Check for washers under clamping disc Do not mix the washers from the different heads Make sure that the original number is reassembled at the individual pump head View of the disassembled pump head parts housing cover valves head cover diaphragm clamping disc with connecting screw diaphragm diaphragm support disc rod and washers housing housing bearing flange E OM Position new diaphragm between diaphragm clamping disc with square head screw and diaphragm support disc ts Note Position diaphragm with light PTFE side to diaphragm clamping disc to pump chamber Documents are only to be used and distributed completely and unchanged It is strictly the users responsibility to check carefully the validity of this docum
27. maintenance Partially the pictures show pumps in other versions This doesn t influence replacing diaphragms and valves 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 999085 30 09 2008 page 20 of 29 Cleaning and inspecting the pump heads Use an open ended wrench w f 15 to loosen the fitting at the pump head and remove fitting together with connecting hose Attention Do not remove the housing bearing flange 1 Loosen the two screws use Phillips screw driver at the handle and remove handle Use a hex key to remove the six socket head screws from the pump head and remove the upper housing housing cover and head cover 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 covers from housing cover and check valves Note position of valves and remove t Replace valves if necessary Use petroleum ether or industrial solvent to remove deposits Do not inhale t Check diaphragm for damage and replace if necessary Lift diaphragm carefully Apply pressure to the clamping disc beside the diaphragm to bring connecting rod into upper turning point position if necessary GG Never use a spiky or sharp edged tool to
28. o health or environment the product must be decontaminated prior to sending it back to the factory Return the product to us disassembled and cleaned and accompanied by a certificate verifying decontamination or Contact an industrial cleaning and decontamination service directly or Authorize us to send the product to an industrial cleaning facility at your ex pense 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 purchase price if the customer prefers to buy a new product instead of repairing the defective one Ifyou donot wish a repair on the basis of our quotation the equipment might be returned to you disassembled and 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 Unfor tunately the combined attack of elevated temperature cleaning agent ultrasonic treatment 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
29. of liquids or dust The diaphragms and valves will be damaged if liquids are pumped in significant amounts Check the pump regularly for external soiling and deposits clean if necessary to avoid an increase of the pump s operating temperature Pumps with 115V motor 230V motor and dual voltage motor In case of excess temperature the motor is shut down by a thermal cutout in the winding Attention Reset possible only manually Switch off the pump or isolate the equipment from mains Determine and eliminate the cause of failure Wait approx five minutes before restarting the pump Attention In case of supply voltage below 100V the lock of the cutout might be restricted and the pump might restart on its own after sufficient cooling down Take Suitable precautions if an automatic restart of the pump might lead to a dangerous situation Pumps with 24 V DC voltage The motor is protected by a temperature sensor at the circuit board current limitation if the temperature at the circuit board is higher than 70 C A warm up period approx 15 min is required to ensure that the rated ultimate vacuum and pumping speed are attained Avoid high heat supply e g due to hot process gases 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 999085 30 09 2008 page 17 of 29 Shutdown
30. oltage input 0 10 V Note Controlling of the motor speed via current input PHIM 8 ex 20n 4 20 mA is available on request H lel Settings at the DIP switch EECH setting the motor speed internally via on on trimming potentiometer programming mode setting the motor speed externally and digitally via PWM factory set analogue and external setting of the off off motor speed voltage 0 External setting of the motor speed via voltage input Voltage input analogue OV 10V max 20V OV to lt 2 5V No operation stand still of the motor 2 5V to 7 5V Linear increase of the motor speed 350 rpm to 2200 rpm 7 5V to 10V Maximum motor speed 2200 rpm Internal setting of the motor speed via trimming potentiometer t Supply the pump with the required supply voltage of 24V DC t For internal setting of the motor speed set the DIP switch to positions on on programming mode Adjusting the motor speed with the trimming potentiometer Turning the trimming potentiometer to the right decreasing motor speed minimum 350 rpm Turning the trimming potentiometer to the left increasing motor speed maximum 2200 rpm Maximum number of motor speed settings 50 t In case separate pump from voltage supply Notes regarding the motor speed Pumping at high motor speed increases the pumping speed of the pump Ensure sufficient cooling of the pump Pumping at low motor speed increases the ultimat
31. ot be operated accidentally Never operate the pump if covers or other parts of the pump are disassembled Never operate a de fective 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 discharge Avoid the release of pollutants Allow sufficient cooling of the pump before starting maintenance e 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 Ensure that the mainte nance technician is familiar with the safety procedures which relate to the products processed by the pumping system e Wear appropriate safety clothing when you come into contact with contaminated components Avoid the release of pollutants Before starting maintenance vent the pump and isolate it from the vacuum system and the electrical supply Avoid the release of pollutants Allow sufficient cooling of the pump Set of seals MD 1 4 diaphragms 8 valves diaphragm key cat no 696824 Tools required metric Diaphragm key SW 46 Open ended wrench w f 15 16 Hex key size 4 Phillips screw driver size 2 GG Please read section Replacing diaphragms and valves completely before starting
32. 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 Maschinenrichtlinie mit nderungen Machine directive with supplements Directive Machines avec des suppl ments 2006 42 EG Niederspannungsrichtlinie Low Voltage Directive Directive Basse Tension nicht anwendbar auf not applicable to pas applicable MD 1 VARIO SP 696101 24V 2006 95 EG Richtlinie Elektromagnetische Vertr glichkeit Electromagnetic Compatibility Directive Directive Com patibilit 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 Managementsysteme Management systems Syst mes de Management EN ISO 9001 EN ISO 14001 1997 2006 Wertheim 23 09 2008 Dr F Gitmans Dr J Dirscherl Gesch ftsf hrer Managing director G rant Technischer
33. 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 999085 30 09 2008 page 13 of 29 Connecting the control line sch 24V 2 GND 24V 3 Signal depending on selection of the signal input OV 10V for voltage input 5V max 24V for PWM 4 GND signal Setting the motor speed externally via PWM factory set PWM 5V max 24V frame frequency gt 100 Hz lt 1 5 kHz Minimum motor speed 350 rpm at 25 PWM Maximum motor speed 2200 rpm at 75 PWM e g at a frame frequency of 100 Hz and 25 PWM pulse width 2 5 ms Factory set the pump is designed for operation with a control signal i e without a control signal the pump does not start To operate the pump without a control signal change the settings on the circuit board see below Selecting the control signal input To select the control signal input use the slide switch the DIP switch and or the trimming potentiometer on the circuit board For that purpose loosen the screw fixing the cover with the cable duct Slide the cover carefully and only as far as necessary aside Layout of circuit board connection of control line voltage and control signal l l see print on the circuit board slide switch
34. rotect people from the effects of dangerous sub stances chemicals thermal decomposition products of fluoroelastomers wear appropriate safety clothing and safety glasses e Use only genuine spare parts and accessories Otherwise safety and perform ance of the equipment as well as the electromagnetic compatibility of the equipment might be reduced Possibly the CE mark or the C US conformity becomes void if not using genuine Spare parts e Failure of the pump e g due to power failure or of connected components parts of the supply or change of parameters must not lead to a critical dangerous situation under any circumstances In case of diaphragm cracks or leaks in the manifold pumped substances might be released into the environment or into the pump housing or motor Comply especially with notes on operation and use and maintenance e Due to the residual leak rate of the equipment there might be an exchange of gas albeit extremely slight between the environment and the vacuum system Adopt suitable measures to prevent contamination of the pumped substances or the environment Do not start the pump if the pressure difference between inlet and outlet port exceeds 1 1 bar at maximum Prevent the backpressure of gases and the backflow of condensates Never suck liquids or dust into the pump Provide appropriate protective measures i e precautions which allow for the require ments of the respective application even for the case of
35. s 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 b 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 GGVE GGVS RID ADR Inevitably the repair process will be delayed considerably if this information is missing or this procedure is not obeyed We hope for your understanding for these measures which are beyond our control and that you will assist us in expediting the repair procedure 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 ccceeeeceeeee neers 2 Serial Ta EE 3 List of substances in contact with the equipment or reaction products 3 1 Chemical substance name chemical symbol 3 2 Important information and precautions e g danger classification 4 Declaration please mark as applicable E 4 1 for non dangerous goods We assure for the returned product that neither toxic corrosive
36. this document with respect to his product manual no 999085 30 09 2008 NOTICE NOTICE page 5 of 29 t Always provide a free and pressureless exhaust pipeline e Comply with maximum permissible pressures at inlet and outlet and pressure differences see section Technical data Do not operate the pump with overpres sure at the inlet e Check that mains voltage and current conform with the equipment see rating plate e Change the setting of the voltage changeover switch pump with dual voltage mo tor 100 120 V 200 230 V 50 60 Hz only if the pump is separated from mains Check that the voltage changeover switch is set correctly Attention If the pump is switched on with wrong voltage selection the motor might be damaged e Avoid overpressure of more than 0 2 bar in case inert gas is connected to the pump or to a venting valve e Connect pipes gas tight at inlet and outlet of the pump e Attention Flexible elements tend to shrink when evacuated e Adopt suitable measures to avoid the flowing of liquids on or into the pump motor when assembling or disassembling vacuum connections at the pump Risk of corrosion and or short circuit Provide a firm level platform for the equipment and check that the system to be evacu ated is mechanically stable and that all fittings are secure Ensure a stable position of the pump without any mechanical contact except of the pump feet Comply with all applicable safety regulations K
37. ttention to the permissible maximum ambient and gas inlet temperatures see Technical data Operating conditions The pumps have no approval for operation in or for pumping of potentially explosive atmospheres 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 self inflammable substances substances which are inflammable without air and explosive substances e 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 tem peratures even to the point of excessing the maximum permitted temperatures e fthere is a danger of formation of deposits in the pump chamber check inlet and outlet of the pump inspect the pump chambers regularly and clean if necessary e The pumps are not suitable for pumping dust and have no approval for operation below ground If pumping different substances it is recommended to purge the pump with air or 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 and with the pump materials Take into consideration interactions and chemical reactions of the pumped media Ensure that the materials of the wetted parts are compatible with the pumped substances see section Technical data
38. vacuubrand Technology for vacuum systems Instructions for use MD 1 VARIO SP MD 1 Diaphragm 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 999085 30 09 2008 page 2 of 29 Dear customer Your VACUUBRAND diaphragm pump shall support you at your work for a long time without any trouble and with full load output Thanks to our large practical experience we attained much information how you could add to an efficient application and to personal safety Please read these instructions for use prior to the initial start up 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 results in material and manufacturing technology Our quality maxim is the zero fault principle Every delivered diaphragm pump is tested extensively including an endurance run of 18 hours Due to this endurance run also faults which occur rarely are reported an can be corrected Every single diaphragm pump is tested on achievement of the specification after the endurance run Every VACUUBRAND pump leaving our factory achieves the specification We feel obliged to this high quality standard We are aware that the vacuum pump should not draw a part of the real work and we hope to contribute
39. ventilation is adequate especially if the pump is installed in a housing or if the ambient temperature is elevated Provide external ventilation if necessary Keep a distance of minimum 20 cm between fan and ambient parts e Check that mains voltage and current conform with the equipment see rating plate Pump with dual voltage motor Check that the voltage changeover switch is positioned correctly Attention If the pump is switched on with wrong voltage selection the motor may be damaged Before starting the pump check that the voltage changeover switch is correctly positioned Change the selection at the voltage changeover switch only if the pump is separated from mains Voltage changeover switch Change the selection at the voltage changeover switch only if the pump is separated from mains Use a screw driver to adjust the supply voltage on the voltage changeover switch 115 corresponds to 90 126 V and 230 corresponds to 180 253 V nat N OTI C E Avoid throttling losses by using connecting pipes with large diameter and by keeping them as short as possible Install outlet pipelines always falling to avoid backflow of condensate towards the pump Use of a suitable valve to isolate the pump from the vacuum system is recommended to allow the pump to warm up before pumping condensable vapours or to clean the pump before it is switched off When assembling ensure vacuum tightness After assembly check the whole syst
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