Presentation of the product range A wide range Specific solutions adapted to various applications Alcatel oil seal rotary vane pumps are used in all vacuum technology applications. They can be used on their own to achieve a maximum vacuum of 10-3 Torr (10-3 mbar), or in pumping assemblies, e.g. at the exhaust of a diffusion pump or turbomolecular pump. SD series Standard pumps for several purposes (non-corrosive applications).
Four 5 to 21 m3/h pump models with the following main characteristics: Presentation 5 to 21 m3/h rotary vane pumps. I, SD, C1, C2 Pascal series 10 8 - A direct drive motor, making them very compact. 9 11 5 12 - An electrically insulated fold-away handle is used for easy carrying. 4 - An anti-suckback system ensures the tightness of the pump during accidental or voluntary shutdowns. 6 - A gas ballast enables the pumping of condensable vapours (except for C2 series).
Operating principle of the rotary vane pump Single-stage rotary vane pump This is a volumetric pump, with a functional part composed of: - A hollow cylindrical stator with inlet and exhaust valves. - A rotor mounted eccentrically inside the stator for pumping. - Two vanes sliding in the rotor, forced against the stator by centrifugal force and springs. The pumping cycle is given below: In. Exh. In. Exh.
Two-stage rotary vane pump To improve the backing pressure and flowrate at low pressure, two stages are connected in series. The second is similar to the first both structurally and operationally. The gases pulled in by the first (low pressure) stage are transferred to the second (high pressure) stage and discharged through the high pressure (HP) valve. Exh. Presentation In.
Oil Its function Choosing the right oil Lubrication and anti-noise device Gas ballast Oil has several important functions in the pump: - It lubricates mechanical components (bearings, seals, rotor, vanes, etc.). - It makes moving parts relatively tight by limiting internal leakage. - It carries away the heat produced by the compressed gases. Not all oils produce the same ultimate pressure in a given pump.
For analycal instrumentation: I Series Two-stage pumps Characteristics Unit Frequency Number of stages Rotation speed Nominal flow rate Hz 2005 I 50 60 2010 I 50 2 Flow rate Pneurop method Partial ultimate pressure* (with Alcatel 120 oil) Ultimate pressure with gas ballast closed Ultimate pressure with gas ballast open Oil capacity Maximum water vapour pumping capacity (Ballast flowrate 1.
Corrosive applications: C1 Series Two-stage pumps Characteristics Unit Frequency Number of stages Rotation speed Nominal flow rate Hz 2005 C1 50 60 2010 C1 50 2 Flow rate Pneurop method Partial ultimate pressure* with Alcatel 120 oil Ultimate pressure with gas ballast closed Ultimate pressure with gas ballast open Oil capacity Weight (pump + motor)** Maximum water vapour pumping capacity (Ballast flowrate 1.
For industry: SD Series Characteristics Unit Frequency Number of stages Rotation speed Nominal flow rate Flow rate Pneurop method Ultimate pressure* with gas ballast closed Ultimate pressure* with gas ballast open Oil capacity Weight (pump + motor)** Maximum water vapour pumping capacity (Ballast flowrate 1.1 m3/h) Water vapour pumping capacity Inlet and exhaust end fittings Hz 1005 SD 50 60 1010 SD 50 1 60 1015 SD 50 1 60 1021 SD 50 1 60 1 rpm 1500 1800 1500 1800 1500 1800 1500 1800 m3/h 5.
Pump dimensions Filling Bubbler C2 Series 3/8 G Inlet Exhaust DN25 ISO KF DN25 ISO KF 4.5 (113.5) 7.6 (192) A 3.8 (96.5) 2.4 (63) 3.6 (91.5) 1.5 (37) 1.77 (45) 1.41 (36) 3.9 (98) 10.2 (259) B 5.5 (141) 9.3 (237) Pump type Dim. 62 6.5 (164) 4 x 8 mm diam. holes Drain 3/8 G A B C 8.5 (216) 0.86 (22) 1.76 (4.5) 8.9 (226) 3.9 (100) 4.8 (122) 6.5 (165) 2.18 (55.5) 0.8 (19.5) 8.7 (221) 9.5 (240) C 3.8 (95.5) inch/(mm) 1.
NAME PART NUMBER Oil mist OME 25 S 104200 eliminator OME 25 CH 066849 OME 25 S/OME 25 CH LOCATION FUNCTIONS Exhaust • Separates oil droplets and particles contained in exhaust gases emitted by the pump. High pressure oil mist eliminator OME 25 HP 104199 Exhaust • Separates oil droplets and particles contained in exhaust gases emitted by the pump. For high pressure pumping and/or frequent cycles. Can be fitted to the ODK 1 and ODK 2 kits.
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Safety instructions concerning the installation and operation of pumping systems Before switching on the equipment, the user must read all of the start-up and operation sections of this manual and observe the safety instructions listed in the booklet of declarations of compliance supplied with the unit. Unpacking When you receive the equipment, unpack it carefully. Do not discard the packaging until you have ensured that the pump has not been damaged during transport.
Installation and start-up • The machines must be connected to an electrical installation in compliance with decree 88-1056 dated 14th November 1988, as well as any local electrical codes that apply. • lt is important to isolate the machine from the power source before any intervention on the equipment (for maintenance purposes).
Table of recommended oils OIL In the vane pumps, we recommend to use only the ALCATEL oils in the table below: APPLICATION I SD C1 C2 Total ultimate pressure* (mbar) Viscosity mm2/s (cst) Vapour tension 25°C (mbar) Anti-emulsion mineral oil ALCATEL - Drying 102 - Pumping water vapour - Freeze-drying ≤ 3.10-2 Hydro-carbon based synthetic oil with good heat ALCATEL resistance: 111 - Pumping at high pressures - Operating at high ambient temperatures ≤ 1.10-2 Highly stable synthetic oil.
Filling with oil Alcatel 5 to 21 m3/h I, SD, C1 series pumps are tested in the factory with ALCATEL 120 oil (or Alcatel 119 for USA). Alcatel 5 to 21 m3/h C2 series pumps are tested in the factory with Alcatel 113 oil. At delivery, there is some oil remaining in the functional block. Our pumps are tested in the factory with Alcatel oil: it is recommended to use the same oil during operation. To change the type of oil, refer to the Maintenance Chapter, "replacement of type of oil" section.
Mechanical connections For a given application, pump performance, vacuum characteristics, temperature and reliability depend on the following: - assembly conditions, accessory filters. - the oil used. - mechanical connections: pipes, etc. - maintenance frequency and quality. For the assembly of the vacuum circuit, provide the accessories required for maintenance: valves, purges, etc.
Changing position of inlet and exhaust fittings Depending on the types of accessories used and the pumping conditions, these orifices can be fitted vertically on the pump or horizontally as shown on the diagram below. Note: The pump is supplied in configuration A. In. Exh. In. Exh. B A In. Exh. C Disassembling the fittings In. Exh. D Unfasten the attachment screw from the end fitting to be removed. Unfasten the end fitting and remove it from its housing along with the O-ring.
The pumps must be connected to an electrical installation in compliance with the decree 88-1056 dated 14 November 1988, as well as any local electrical codes that apply. • Our products are designed to meet current EEC regulations. Any modification on the part of the user is liable to cause non-compliance with regulations or even affect the EMC (Electromagnetic compatibility) performance and safety of the product. Alcatel cannot be held responsible for consequences resulting from such an intervention.
External motor protection, electrical protection Motor characteristics, connection, protection The information below is given as a recommendation. The user must comply with the electrical standards or recommendations (IEC, VDE, UL, CSA, etc.) applicable in the country in which the pump is used.
Three-phase motors The pumps are equipped with 9 wire terminal box motors, the wiring diagram of the terminals is given as a rough guide only. In the event of doubt, only the plate in the terminal box should be used as a reference.
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Operation Preliminary precautions • The performance and operating safety of this product can only be guaranteed if it is operated according to normal conditions of use. • The vacuum pump is also a compressor: incorrect operation may be dangerous. Study the user manual before starting up the pump. • The pumps are designed to prevent any thermal risk for user safety. However, specific operating conditions may generate temperatures which may justify particular attention on the part of the user > 70°C).
Start-up • When using a three phase motor, check the direction of rotation of the motor (see electrical connections start-up chap. page 71). • Check the oil level (See page 68). • Start-up the pump. • Allow the pump to run for one hour with the inlet blocked at ultimate vacuum: During this operation, make sure that the oil circuit is operating. Remove one of the oil fill plugs to listen to the pump. At start-up, the oil enters the lubrication circuit of the vacuum pump.
Operation of gas ballast Regeneration of pump oil In a pump stored with the same oil for a long time, condensed vapours may contaminate the oil bath and affect performance. This is also the case after pumping vapours and when the oil appears cloudy or discolored through the sight glass. - Run the pump, shutting it off from the system at the inlet by a valve or a plug. - Open the gas ballast and allow the pump to operate for 1/2 hour to 1 hour, or longer if the oil remains cloudy.
Assembly (continued) - we do not recommend an oil mist eliminator when pumping condensable vapors: if it is essential, do not connect it directly to the pump exhaust but place it outside the condensation zone. - remove the stop valve from the pump exhaust; - if possible, connect the exhaust to a mechanical device creating a negative pressure from 0.1 to 0.2 bar. In. Exh.
Purges for pumping condensable, corrosive, and hazardous gases All pumps models Purges Oil case purges The use of vane pumps may result in pumping gases or vapours which are flammable or that could contaminate the oil. In this case, these products must be diluted using purges supplied with dry gases, such as nitrogen to avoid undesirable reactions.
Settings (continued) Run the pump at ultimate vacuum for one hour and set the nitrogen flow rate as follows (at atmospheric pressure and at 20°C). C2 Series Pumps Nitrogen flow rate in l/h Min Average Maxi 60 200 500 Corresponding absolute pressures (bar) 1.05 to 1.10 Note: these characteristics apply for pumps operating at a constant inlet pressure (1 to 5 mbar): they are adapted for each case of pumping. 80 Start-up Start-up the pump at ultimate vacuum. When it is hot, run the nitrogen purge.
Oxygen pumping In certain applications, mixtures containing oxygen at different concentrations, or even pure oxygen, are used. Oils of mineral origin are combustible. Exposure to pure oxygen at high temperatures may cause them to self-ignite. In addition, they are highly oxidized during pumping and quickly lose their lubricating properties. Mineral oils must not be used for oxygen levels of over 21 % in pumped gases. In this case, perfluorinated synthetic oils must be used, see list on page 67.
Recovery of oil (high pressure and cycling) When the pump operates at high pressure, the oil heats up, becomes more fluid and is flushed out of the functional block by the gas stream. Oil losses at the exhaust are increased. For intermittent pumping If the pump only operates for a very short time at high pressure, the lubricating oil is replaced when the pump returns to low pressure. The use of a oil mist eliminator prevents losses due to intermittent high pressure operation.
Maintenance For normal operation, the maintenance of ALCATEL 5 to 21 m3/h series pumps only require regular oil changes. Before any draining or maintenance operation, check the pumping conditions of the installation: potential toxicity, corrosion or radioacitivity of pumped gases.
Troubleshooting and corrective actions Incidents The pump is not running Causes • Incorrect motor power supply. • Temperature too low. • Gumming of seals after prolonged storage. • Oil contaminated after pumping. • Motor coupling damaged. • Pump seized, due to a stopping after pumping in difficult conditions (no draining or flushing). The pump does not start • Oil cold. • Insufficient oil in the oil case. • Oil contaminated. • Oil pump inlet partially blocked. • Lubrication holes blocked.
Incidents The vacuum pump does not produce a vacuum (continued) DiagnosticCauses et remèdes Corrective actions Ultimate pressure obtained: a few 10-2 Torr (10-2 mbar) • Gas ballast adjustment button open. • O-ring pinched. • One of the seals is damaged. • One of the HP safety valves is damaged. • Lubrication holes blocked. • Incorrect anti-suckback assembly. • Part forgotten in reassembly. Close. Replace. Replace. Replace. Disassemble and clean. Repeat the assembly and setting. Repeat the reassembly.
Incidents Considerable oil losses. DiagnosticCauses et remèdes • Oil level too high. Drain and fill with new oil. • Operation at high pressure. Use an HP type oil mist eliminator with oil recovery. • Gas ballast open: 1 - accidentally, 2 - pumping of condensable vapours. • Leak at oil case seal or at front seal. Poor pump tightness when switched off. • • • • • • Oil in base. • Oil case and frame cleaned poorly during reassembly. • Oil case seal pinched. Gas ballast open. Safety valve damaged.
Maintenance Maintenance frequency An incorrect ultimate vacuum or a reduction in pumping speed are signs that the oil has deteriorated. The periodic inspection of the state of the oil is performed by comparison with a sample of new oil in order to check the level of contamination or deterioration of the lubricant. The frequency at which oil is renewed is adapted to the type of operation: - if the oil is cloudy, this indicates that condensables have been absorbed during pumping.
Flushing The draining operation can be followed by a flushing operation if the oil is particularly dirty. This operation requires a volume of oil equal to the capacity of the pump. After draining the oil case (see page 87), replace the draining plug. Remove the intake filter, clean it and replace it. Run the pump at atmospheric pressure, pour the flushing oil very slowly through the inlet orifice. Take care with oil mist which may develop at the exhaust.
Replacement of front seal In the event of an external oil leak on the pump, it is necessary to change the shaft seal on the motor side. You will need: - a front seal replacement kit (see page 90), - a screwdriver, - a 3, 4 and 5 mm Allen wrench. Maintenance • Stop the pump and disconnect the power cord motor. • Disconnect the pump from the installation to which it is connected.
Tools and consumable products Special precautions • • • a Read the warning at the beginning of the maintenance chapter. Before disassembling the pump, drain it (see page 87). All the seals and faulty parts should be replaced, provide for a seal kit or maintenance kit. Spare parts Minor kit This contains all the seals on the pump which must be replaced at each complete disassembly. Pump models Part No.
Disassembling the pump Disassembling the motor block 3 Remove the motor cover. 2 5 Remove the motor attachment screws. 1 3 Replacing the front seal Disassembling the gas ballast (1) Disassembling the oil sight glass (2) Removing the oil case (3) Disassembling the bubbler (C2 pump) Remove the fan fastening screw and the support washer. Remove the key. See page 89. 2,5 Remove the gas ballast cover (2 screws), the adjustment button, the spring and the sleeve.
Disassembling the exhaust valve cover (6) Disassembling the SD pump oil system (except 1015 SD, 1021 SD) Disassembling the I, C1, C2 pump oil system also 1015 SD, 1021 SD 5 Remove the cover(s), the exhaust valves and their springs. 6 The oil system is set in the factory, it must be reset in the event of disassembly (see reassembly). However, the rear flange (7) can be disassembled without modifying the setting. Remove the spinner-cam (8) by removing the circlip.
Disassembling the rear flange Disassembling the HP stator and the rotor (two-stage pumps) 10 Remove the 4 nuts (and washers). Release the flange in the axis. Remove the stator by sliding it along the rotor. Release the rotor and the vanes. Disassembling the LP stator and the rotor Insert two screwdrivers in the notches and release the flange in the axis. Remove the LP stator. Remove the rotor and the vanes equipped with the springs.
Cleaning components Cleaning metal components Solvents are required to clean components. Standard precautions should be taken in compliance with the manufacturer's instructions. After use in mineral or synthetic oil, clean the metal components with a mineral products based solvent such as AXAREL(1) , CARECLEAN(2), PREMACLEAN(3), NAPHTEOL(4). Proceed as follows: • Clean when cold or hot (max.
Replacement of shaft seals Specific tools Recommended tools Extracting a shaft seal from its housing Assembling the shaft seal • Specific assembly mandrel. • A support plate (or washer). • A flat screwdriver . With the flange flat, the seal is extracted using a screwdriver, resting on the plate (or washer) so as not to damage the seal housing. The seal housing and the seal lip are lubricated with the lubricant used in the pump. The flange is resting on a flat surface. ø 24.5 ± 0.1 5.5 ± 0.
Reassembling the pump Component preparation • Rest the frame on a flat surface in order to raise the pump. • All surfaces in contact are coated with oil. • Observe a nominal clamping torque of 0.8 mdaN (5.8 ftlbs) for the reassembly of the functional block. The functional block is reassembled in the reverse order of disassembly. Reassembling the median flange On the median flange, check that the lubrication hole is not blocked.
Reassembling the oil case Fit the oil case on the frame. Fasten the attachments after making sure that the seal is positioned in its seal groove (clamping torque 0.8 mdaN (5.8 ft lbs)). Reassembling the gas ballast Position the oil case feed-through equipped with the seal in its housing by centering it on the gas ballast tube. Assemble using the screws. Equip the adjustment knob with the sleeve and the spring. Position the assembly in the cover and secure on the oil case feed-through.
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