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1. Pump has been exposed to condensate Deposits have been formed inside the pump Diaphragms or valves dam aged Outgassing substances or vapour generated in the proc ess Check pump directly con nect vacuum gauge directly at pump inlet then check con nection pipeline and vacuum system if necessary Use lines with larger di ameter length as short as possible Allow pump to run for some minutes with atmospheric pressure at the inlet Clean and inspect the pump heads Replace diaphragms and or valves Check process parameters Q Pump too noisy Atmospheric or high pressure at the pump inlet Diaphragm crack or dia phragm clamping disc loose Other than above mentioned causes Connect hose or silencer to pump outlet Perform maintenance Contact local distributor Q Pump seized NOTICE Contact local distributor A service manual with exploded view drawings spare parts list and directions for repair is available on request ts The service manual is intended for trained service people only 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 997832 03 02 2009 page 17 of 26 Replacing diaphragms and valves All bearings are encapsulated and are filled with long life lubricant Under normal NOTICE operatin2. 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 ad vance The declaration must arrive before the equipment Enclose a second com pleted 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 to health or environment the product must be decontami nated 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
3. 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 Technol for Svef Tel 49 9342 808 0 Fax 49 9342 808 450 b d lecnnology tor Vacuum oystems E Mail info vacuubrand de vacuuoran 2009 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 997832 03 02 2009
4. off manual flow control module VCL 02 ooo eececcecceceeeeseeeeseeeeseeeneneeees 677107 VACUUseLAN automatic control module VCL B 10 W 677208 VACUU LAN manual flow control automatic control module VCL B 11 0 a 677209 On this page we offer only a small selection of VACUU LAN options Please refer for further informa tion Vacuum hose caoutchouc 10 mm ID 686002 Metal hose stainless steel KF DN 25 1000mm 673337 For additional accessories such as vacuum valves small flange components vacuum gauges or vacuum controllers refer to 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 9997832 03 02 2009 page 16 of 26 Troubleshooting Fault Q Pump does not start or stops immediately Possible cause Mains not plugged in electri cal supply failure WW Pressure in outlet pipeline too high Motor overloaded Remedy Plug in mains Check fuse Remove blockade in line Allow motor to cool down identify and eliminate cause of failure Manual reset is necessary Switch off pump or unplug mains Q Pump does not achieve its ultimate vacuum or usual pumping speed Centring ring at small flange connection not correctly posi tioned or leak in the pipeline or vacuum system Long narrow line
5. 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 Intended use ts The pump and all system parts are not to be used on humans or animals Prevent any part of the human body from coming in contact with the vacuum Make sure 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 sev eral parameters like inlet pressure or ambient temperature see Technical data is not exceeded e Particles and dust must not be aspirated S R Use the equipment for the intended use only i e for generation of vacuum in ves sels designed for that purpose Setting up and installing the equipment Equipment must be connected only to a suitable fused and prot
6. 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 measures to prevent any danger arising from the formation of hot surfaces or electric sparks Provide a suitable protection against contact if necessary t Ensure that the exhaust pipeline is always free and pressureless 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 997832 03 02 2009 NOTICE NOTICE page 7 of 26 e Attention Due to soiling of the silencer an internal overpressure may build up which can damage bearings diaphragms and valves Preferably use the hose noz Zle as outlet and make sure that the exhaust pipeline cannot become blocked e Comply with applicable regulations when disposing of chemicals Take into con sideration that chemicals may be polluted Take adequate precautions to protect people from the effects of dangerous sub stances chemic
7. 222 x 294 Weight approx kg 23 During the start up period of the pump first 6 minutes after switching on the current draw might be elevated up to twice the given nominal current draw MD 8 silencer without overpressure safety relief device We reserve the right for technical 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 9997832 03 02 2009 page 10 of 26 Gas inlet temperatures Operating condition Inlet pressure Permitted range of gas temperatures at inlet Continuous operation gt 100 mbar high gas load 10 C to 40 C 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 Components Wetted materials Housing cover Head cover Diaphragm clamping disc Diaphragm Small flange Hose nozzle Silencer Overpressure safety relief device Fittings Seal rings ME 16 MD 8 Seal rings MD 12 MV 10 aluminium alloy AlSi12 aluminium alloy AlSi12 aluminium alloy AlSi12 stainless steel PA PE aluminium alloy PM PM PM BT E VC M 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 respon
8. 42 808 0 Fax 49 9342 808 450 2008 VACUUBRAND GMBH CO KG Printed in Germany E Mail info vacuubrand de Web www vacuubrand com 5 Way of transport carrier If the paint is damaged we wish a repaint or a replacement of parts due to optical as pects 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 packaging 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 infor mation 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 dam ages suffered by third parties particularly VACUUBRAND employees occupied with handling repairing the product SNA aea a E Name le leg GE JOD TING e EE Company S Seal Ae gE eebe eege Documents are only to be used and distributed completely and unchanged It
9. ain 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 997832 03 02 2009 page 9 of 26 Technical data Maximum pumping speed 50 60 Hz 3 ISO 21360 mb 12 0 12 9 6 5 7 5 9 6 10 4 8 1 8 8 Ultimate vacuum absolute mbar lt 80 2 Maximum permissible outlet pres sure absolute zech bar Maximum pressure difference be tween inlet and outlet bar Permissible ambient temperature de 10 to 60 10 to 40 storage operation o_o ech gt Es Permissible relative atmospheric moisture during operation 30 to 85 no condensation Rated motor power kW No load speed 50 60 Hz min 1500 1800 Maximum permissible range of sup 100 V 10 50 60 Hz ply voltage 120 V 5 10 60 Hz Attention Observe specifications 230 V 10 50 60 Hz of rating plate 400 V 3 10 50 Hz Maximum rated current at 100 V 50 60 Hz 120 V 60 Hz 230 V 50 60 Hz 400 V 3 50 Hz Motor protection single phase thermal cutout manual reset three phase in case of an overload all poles are isolated Degree of protection IEC 529 IP 20 hose nozzle DN 10mm or Outlet l KEE silencer with overpressure safety relief device 486 x 222 x 294 Dimensions L x W XH approx mm 470 x
10. ainst unintentional detach ing During operation e Maximum ambient temperature 40 C e Make sure ventilation is adequate especially if the pump is installed in a housing or if the ambient temperature is elevated Keep a distance of minimum 20 cm between fan underside the pump and ambient parts e g housing walls e Potentially dangerous gases or vapours at the outlet of the pump have to be drained and disposed appropriately 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 9997832 03 02 2009 NOTICE NOTICE page 14 of 26 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 me chanical stability of the system Ensure that the pump outlet is not blocked or restricted 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 be
11. als thermal decomposition products of fluoroelastomers wear appropriate safety clothing and safety glasses e Use only OEM spare parts and accessories Otherwise safety and perform ance of the equipment as well as the electromagnetic compatibility of the equip ment might be reduced Possibly the CE mark or the cTUVus mark become void if not using OEM spare parts Do not start the pump if the pressure difference between inlet and outlet port ex ceeds 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 failure and malfunction 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 situa tion 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 hous ing or motor Comply especially with notes on operation and use and maintenance 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 In case of overload the motor is shut down by a
12. are attained Shutdown Short term 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 997832 03 02 2009 page 15 of 26 Accessories Base plate with exhaust waste vapour condenser and collecting Task 699949 Set of castere ennnen nenen nnrnrrnrererrrnn 699981 for base plate Separator inlet ce cceeeeeeeseeeeeeaeeeeeaeeees 699980 small flange KF DN 25 Centring ing 660196 with FPM seal Clamping ring DN 20 25 aluminium aaannnaannaann 660001 Digital vacuum gauge DVR J N 682902 Vacuum controller CVC 3000 ee 683160 100 230 V 50 60 Hz The VACUU LAN modules allow process oriented flexible NCEE and cost effective connections according to the requirements One vacuum pump for multiple work stations VACUUseLAN manual flow control module Ve EE 677106 VACUUsLAN shut
13. arefully sidewise t Never use a spiky or sharp edged tool to lift the dia phragm Use the diaphragm key to grip the diaphragm support disc under the diaphragm Unscrew the diaphragm support disc with diaphragm and diaphragm clamping disc Check for washers between the diaphragm support disc and the connecting rod Do not mix the washers from the different pump heads Make sure that the original number is reassembled at the individual pump head t f the old diaphragm is difficult to separate from the support disc immerse assembly in naphtha or petroleum ether Do not inhale ts Smaller number of washers The pump will not attain ulti mate vacuum More washers Clamping disc will hit head cover noise or even blockade and damage of the pump Position the new diaphragm between the diaphragm clamping disc with square head screw and the diaphragm Support disc ts Attention Double diaphragm Put the two diaphragms to gether with the printed sides outwards t Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide hole of the diaphragm support disc Lift the diaphragm at the side and position it carefully together with the diaphragm clamping disc and the dia phragm support disc in the diaphragm key t Avoid damage of the diaphragm Do not bend the dia phragm too much Screw diaphragm clamping disc diaphragm diaphragm support disc and washers if applicable to con
14. at the inlet port of the individual head Use a suitable vacuum gauge make sure that it is correctly calibrated and measure the pressure at the inlet port A vacuum of less than 110 mbar should be indicated c f the reading is higher recheck the pump chamber and make sure that the valves and the dia phragms are correctly seated diaphragms concentric with bore Replacing the valve at the distributor outlet side of MD 12 MV 10 An additional valve is located underneath the cover plate Use open ended wrench w f 15 to loosen the union nut of the hose which runs directly to the cover plate of the distributor at the pump head Pull the bent connecting hose off the hose connector at the pump head Unscrew the two countersunk screws at the distributor us ing a Phillips screw driver Remove the cover plate Note the position of the valve and remove it t Check valve for damage and replace if necessary Make sure that the valve is correctly seated Assemble the cover plate and fixate with both counter sunk screws 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 9997832 03 02 2009 page 22 of 26 Assembling the connecting hoses sw Use an open ended wrench w f 20 to slip the hoses onto the hose connectors by turning the fittings t Mount t
15. buy a new product instead of repairing the defective one If you do not 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 request Before returning the equipment ensure that if applicable Equipment has been cleaned and or decontaminated All inlet 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 contaminat
16. ce all of your real work and hope that our products con tribute to an 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 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 997832 03 02 2009 page 3 of 26 Contents Seet Eege 4 General MON re EE 4 Ve OC E 4 Setting up and installing the equipment cc eeccceeccceeeeceeeeeseeeeseeeeseeeeseaeeseaeeseaseseeessueeesaeeeseeees 4 Ambient conditions E 5 Operating eil le 6 Safety during operation ccc cece seccceeeceeeeeceeeeceeeeceececeaeeceeeeseaeessaeeeseeeseeeseueesseessegeeseneesenseseneesaees 6 Maintenance and E T Tecnic Al CAC ME 9 Gas inlet temperatures ccccccceccccesecceeecceeeeceeeese cece eesseeessaeeeseeeesaeeesaueeseueeseeeessaeeeseneeseuseseneeseas 10 wened DIE E 10 PUMO DAN einernie NE EERS E N EEE AEOS E 11 Use and ODEIO ME 13 installing in a vac umi Syste E 13 UN EE 14 e 15 TROUDIES MOO d Uu Le E 16 Replacing diaphragms anq VaIVES ccsccceeceeeseceeeeeeeceeeeeeseneeseeeeeseneseneenesenessness 17 Cleaning and inspecting the pump headS nnnnannnannnannnannnnnnsnnnnnnnsnrnrnnnnrnnnrrsrrrnnrrsnrenrrnrrnenrenrrnne 18 Replacing the al Elle EE 19 Assembling pump headS EE 21 Re
17. d 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 temperatures even to the point of excessing the maximum permitted tempera tures e lf there is a danger 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 opera tion 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 ma terials 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 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 in contact with vacuum The user must
18. derungen 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 Vertraglichkeit Electromagnetic Compatibility Directive Directive Com patibilite Electromagnetique 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 Systemes de Management EN ISO 9001 EN ISO 14001 1997 2006 Wertheim 29 01 2009 Dr F Gitmans Dr J Dirscherl Gesch ftsf hrer Managing Director G rant Technischer Leiter Technical Director Directeur technique VACUUBRAND GMBH COKG 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 a 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 9997832 03 02 2009 page 26 of 26 Disclaimer Our technical literature is only intended to inform our customer The validity of general em pirical values and results obtained under test conditions for specific applications depend on a
19. e e Direction of rotation of pumps with three phase motor Pumps wired ready for connection with three phase motor are supplied with a mains plug The electrical wiring is laid out for a right handed rotary field Checking the direction of rotation The three phase socket has to be checked and if necessary corrected by an elec trician Otherwise the performance of the pump might be reduced e Avoid overpressure of more than 0 2 bar in case inert gas is connected e Connect pipes gas tight at inlet and outlet of the pump e Attention Flexible elements tend to shrink when evacuated 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 Ensure a stable po sition of the pump without any mechanical contact except of the pump feet Comply with all applicable safety regulations Keep a distance of minimum 20 cm between fan underside the pump and ambient parts e g housing walls Make sure the air supply for the fan is adequate Do not place the pump on soft surfaces e g rubber foam during operation This may cut back or block the fan s air supply Check fan regularly for dust dirt clean if neces sary 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 pipel
20. ected electri cal supply and a suitable earth point 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 pipe line cannot become blocked If you have an exhaust isolation valve make sure that you cannot operate the equipment with the valve closed Risk of bursting t Provide always a free and pressureless exhaust pipeline 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 997832 03 02 2009 NOTICE NOTICE page 5 of 26 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 plat
21. ed 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 9997832 03 02 2009 page 24 of 26 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 b c 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 ho
22. g 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 estimating its operation time Exchange old capacitors early enough to prevent a failure The capacitors have to be replaced by an electrician Depending on in dividual 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 gases or vapour or in case of deposits mainte nance 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 tech nicians c Ensure that the pump cannot be operated accidentally Never operate the pump AAWARNING 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 t
23. he 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 e Attention The pump might be contaminated with the process chemicals that have AACAUTION 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 prod ucts processed by the pumping system e Wear appropriate safety clothing when you come into contact with contaminated components Avoid the release of pollutants NOTICE Before starting maintenance vent the pump and isolate it from the vacuum sys tem gD Set of seals for ME 16 MD 8 diaphragms and valves ccccccecceceeeeeeeeeeeeaeeeeeaeeeeeneeeeeneeeees 696819 Set of seals for MD 12 MV 10 diaphragms valves and O ringS ccccecceesseeeeeeeeeeeseeeeeeeeees 696827 16 x O ring 28 x 1 5 MD 8 MD 12 MV 20 637090 Diaphragm key w f 66 sites psec carseeteacecee cen arene rdonecos ashes gnacpsvauaaeosanaceenensyeatedk taped dueenssuaedaounnateis 636554 ts Please read section Replacing diaphragms and valves completely before starting maintenance Partially the pictures show pumps in other versions This doesn t influence rep
24. he one curved connecting hose at the outlet side of the pump only MD 12 MV 10 directly at the pump head Tighten the fittings at the pump head with an open ended wrench w f 17 Tighten the union nuts of the hose connections at the pump heads with an open ended wrench w f 15 Place the diaphragm pump onto the other side support pump appropriately Perform maintenance of the remaining pump heads according to the instructions above 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 achieves its ultimate vacuum t n case of unusual noise switch off pump immediately and check clamping disc positions If the pump does not achieve the ultimate total vacuum after a run in period of sev eral hours Recheck pump chambers 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 997832 03 02 2009 page 23 of 26 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
25. ine should be at the 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 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 attention to the permissible maximum ambient and gas inlet temperatures see Technical data 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 9997832 03 02 2009 A DANGER NOTICE A DANGER page 6 of 26 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 expose
26. is strictly the users responsibility to check carefully the validity of this document with respect to his product Manual no 997832 03 02 2009 page 25 of 26 LE Konformitatserklarung Declaration of conformity D claration de conformit Membranpumpe Diaphragm pump Pompe membrane ME 16 230V 696427 696434 696435 MD 8 230V 696424 696481 696482 MD 12 230V 710000 710001 710002 MV 10 230V 710050 710051 710052 Hiermit erkl ren wir dass das oben bezeichnete Ger t 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 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 certifi cate 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 dispo sitif sans notre autorisation pr alable Maschinenrichtlinie mit n
27. lacing diaphragms and valves of the pump Tools required metric Phillips screw driver size 2 Open ended wrench w f 15 17 20 Hex key size 5 Diaphragm key w f 66 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 9997832 03 02 2009 page 18 of 26 Cleaning and inspecting the pump heads Remove the union nuts of the hose connections at the pump head using an open ended wrench w f 15 Use an open ended wrench w f 17 to loosen the fittings at the pump head Turn the hose connections of the fittings with an open end ed wrench w f 20 to detach the hoses t Pull off the one bent connecting hose at the outlet side of the pump only MD 12 MV 10 directly at the pump head To check the valves and the diaphragms use a hex key to remove four socket head screws from the pump head and remove housing cover with head cover valves and O rings only MD 8 MD 12 7 MV 10 t In case place the pump on edge onto the distributor at the inlet or at the outlet Support pump appropriately Maintain only one side of the pump at a time 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 carefully from housing cover Note
28. necting rod Assemble the original number of washers between the support disc and the connecting rod t Optimum torque for the diaphragm support disc 6 Nm it is recommended to use a torque key Attach hex key to diaphragm key hexagonal bolt 6 mm wide Attention Never use the diaphragm key with any addi tional tools like tongs or hex keys without torque limita tion 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 997832 03 02 2009 page 21 of 26 Assembling pump heads Bring the diaphragm into a position in which it is in contact with the housing and centred with respect to the bore Reassemble in reverse order Install head cover with O rings only MD 8 MD 12 MV 10 valves and housing cover ts Make sure that the valves are correctly seated Valves at the outlet 1 with round centred opening under valve valves at the inlet 2 with kidney shaped opening beside valve 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 crosswise first slightly then tighten t Do not tighten until head cover is in contact with housing torque 12 Nm Individual performance check of a pump head By measuring the pressure
29. or 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 Before starting maintenance wait two minutes after isolating the equipment from mains 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 GG 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 compo nents from the vacuum system Allow sufficient cooling of the pump Drain con densate if applicable Ensure that maintenance is done only by suitably trained and supervised techni cians 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 cert
30. pe 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 ques tions have been answered correctly and in detail 1 Product Model ccccccseeeeeeeeeeeees 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 Q 4 1 for non dangerous goods We assure for the returned product that neither toxic corrosive 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 Q 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 with held any information the product in accordance with regulations has been Q cleaned U decontaminated U sterilized VACUUBRAND GMBH CO KG Atfred Zippe Str 4 97877 Wertheim Technology for Vacuum Systems Tel 49 93
31. placing the valve at the distributor outlet side of MD 12 MV 10 21 Assembling the connecting hoses EE 22 Notes on return to Here 23 Health and safety clearance form kee KR KREE EERERR E REEREERREREER ENEE REE RER EEN 24 Declaration of conformity eege 25 A DAN G E R Danger Immediate danger Death or severe injuries as well as damage to equipment and environment can occur 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 equip ment and environment can occur ICE Note Disregarding of notes may cause damage to the product Caution Hot surface Isolate equipment from mains O fg 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 9997832 03 02 2009 page 4 of 26 Safety information NOTICE NOTICE A DANGER General information t Read and comply with this manual before installing or operating the equipment t Transport the pump at the provided handles 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
32. pose of those fluids e Reduce the transmission of vibration and prevent mechanical load due to rig id pipelines Insert elastic hoses or flexible elements as couplings between the pump and rigid pipes Attention Flexible elements tend to shrink when evacu ated 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 unintentional ventilation of the pump In case this con stitutes a potential source of danger take appropriate safety measures e Make sure ventilation is adequate especially if the pump is installed in a housing or if the ambient temperature is elevated Provide external ventilation if neces sary N OTIC E Avoid throttling losses by using connecting pipes with large diameter and by keeping them as short as possible Assemble silencer or hose nozzle at the outlet of the pump Attention Use the silencer only in case of small gas throughput Check the silencer regularly for permeability 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 sys tem for leaks Secure hose connections at the pump appropriately ag
33. self hold thermal cutout in the winding Three phase motors are equipped with a circuit breaker which isolates all poles in the event of an overload Attention Reset possible only manually Switch off the pump or isolate the equip ment from mains Identify and eliminate the cause of failure Allow the pump to cool down sufficiently before restart Wait approx five minutes before restarting the pump Avoid high heat supply e g due to hot process gases The A weighed emission sound pressure level of the pump does not exceed 70 dB A Measurement according to EN ISO 2151 2004 and EN ISO 3744 1995 with standard silencer or exhaust tube at outlet Maintenance and repair 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 du rability 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 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 9997832 03 02 2009 X page 8 of 26 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 overaged motor capacit
34. sibility to check carefully the validity of this document with respect to his product Manual no 997832 03 02 2009 page 11 of 26 Pump parts Distributor at the inlet Distributor at the outlet ME 16 MD 8 MD 12 MV 10 fig ME 16 230V version hose nozzle or silencer 2 with overpressure safety relief device 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 9997832 03 02 2009 page 12 of 26 Fittings at inlet side Fittings at outlet side 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 997832 03 02 2009 page 13 of 26 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 safe ness 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 dis
35. the position of the valves and remove them Replace valves and or O rings if damaged Check diaphragm for damage and replace if necessary Use petroleum ether or industrial solvent to remove de posits Do not inhale SS S 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 997832 03 02 2009 page 19 of 26 View of the disassembled pump head parts Ee d l gf A H UA S p Pump head parts Housing cover O rings only MD 8 MD 12 MV 10 Valves Head cover Diaphragm clamping disc with square head screw Diaphragm Diaphragm support disc Washer Connecting rod Housing Cover plate only at outlet Countersunk screw Union nut Connecting hose Distributor Fitting gt N WO A OA OQO N Replacing the diaphragm Note regarding the replacement of the diaphragm sw Replacing a diaphragm with square hole remove the punched part in the centre of the diaphragm before assembling 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 9997832 03 02 2009 page 20 of 26 t Check the diaphragm for damage and replace if neces Sary Lift the diaphragm c
36. tween inlet and outlet ports Operating the pump at high inlet pressure or pumping dusty gases for a long time may cause clogging of the silencer Use the silencer only in case of low gas through put Check the silencer regularly for permeability and replace or install a hose nozzle instead Prevent internal condensation transfer of liquids or dust The diaphragm 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 In case of excess temperature the motor is shut down by a thermal cutout in the winding Three phase motors are equipped with a circuit breaker which isolates all poles in the event of an overload Attention Reset possible only manually Switch off the pump or isolate the equipment from mains Identify and eliminate the cause of failure Allow the pump to cool down sufficiently before restart Wait approx five minutes before restarting the pump Avoid high heat supply e g due to hot process gases Make sure the air supply for the fan is adequate Do not place the pump on soft surfaces e g rubber foam dur ing operation This may cut back or block the fan s air supply Check fan regularly for dust dirt clean if necessary to avoid a cutback of ventilation A warm up period approx 15 min is required to ensure that the rated ultimate vacuum and pumping speed
37. vacuubrand Technology for Vacuum Systems Instructions for use ME 16 MD 8 MD 12 MV 10 Diaphragm pumps 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 9997832 03 02 2009 page 2 of 26 Dear customer Your VACUUBRAND diaphragm pumps should support you for many years without trouble and with optimal performance Thanks to our long practical experience we have much information and advice how you can achieve powerful application and personal safety through our products 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 design and construction and practical operation of these pumps combined with the latest developments in material and manu facturing 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 faults even those which occur rarely are identified and can be eliminated immedi ately The achievement of the specifications after the endurance run is tested for every pump Every VACUUBRAND pump achieves the specifications We are committed to providing our cus tomers with this high quality standard We know that the vacuum pump can not repla
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