page 1 of 61 ROTAVAC vario Pumping unit Instruction manual 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.
page 2 of 61 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.
page 3 of 61 [GB] It is imperative to read this instruction manual prior to initial operation! Comply with safety instructions! Keep for further use! This documentation is not subject to revision service! 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.
page 4 of 61 ➨ Danger! Immediate danger. Death or severe injuries as well as damage to equipment and environment can occur. ☞ Warning! Possible danger. Severe injuries as well as damage to equipment and environment can occur. • NOTICE Caution! Possible danger. Slight injuries as well as damage to equipment and environment can occur. Note. Disregarding of notes may cause damage to the product. Caution! Hot surface! Isolate equipment from mains before removing the cover.
page 5 of 61 Reset / Language selection 1 2 switch off press both V 2.12 3 turn D eutsch E nglish Français Italiano E spañol Türkçe P ortuguê Ρ yccкий P olski N ederl. 日本語 Suomi 한국어 中文 V 2.12 4 press D eutsch E nglish Français Italiano E spañol Türkçe 한국어 中文 P ortuguê Ρ yccкий P olski N ederl. 日本語 Suomi 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.
page 6 of 61 Contents Reset / Language selection......................................................................................5 Safety information!......................................................................................................7 1.1 General information.......................................................................................................................7 1.2 Intended use..........................................................................................
page 7 of 61 Safety information! 1.1 General information NOTICE Read and comply with this manual before installing or operating the equipment. 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 supplier’s invoice number.
page 8 of 61 ☞ Always provide a free and pressureless exhaust pipeline. ☞ Max. permitted pressure at the pressure transducer: 1.5 bar (absolute). ☞ Avoid overpressure of more than 0.2 bar in case inert gas is connected to the pump, the gas ballast connection or to a venting valve. • • • • NOTICE Comply with maximum permissible pressures at inlet and outlet and pressure differences, see section ”Technical data”. Do not operate the pump with overpressure at the inlet.
page 9 of 61 NOTICE • 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 temperatures! • If there 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.
page 10 of 61 • • • • NOTICE Comply with applicable regulations when disposing of chemicals. Take into consideration that chemicals may be polluted. Take adequate precautions to protect people from the effects of dangerous substances (chemicals, thermal decomposition products of fluoroelastomers), wear appropriate safety-clothing and safety glasses. Use only genuine spare parts and accessories.
page 11 of 61 1.7 Maintenance and repair NOTICE Wear parts have to be replaced regularly. In case of normal wear the lifetime of the diaphragms and valves is > 10000 operating hours. Bearings have a typical durability of 40000 h. ➨ 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.
page 12 of 61 2 Standard items and options Item ROTAVAC vario Pumping unit qty 1 P/N 200-240 V 50/60 Hz P/N 100-120 V 50/60 Hz 591-00142-00 591-00142-01 Standard items ROTAVAC vario control / ROTAVAC vario tec ROTAVAC vario control (pump) 1 Power cord 1 Instruction manual 1 01-005-005-24 Warranty card / Confirmation of condition of unit 1 01-006-002-58 14-007-003-81 14-007-003-89 Accessories (optional) Item ROTAVAC vario Pumping unit condensate cooler P/N 591-00084-00 Documents are on
page 13 of 61 3 Technical data Type ROTAVAC vario Pumping unit Maximum pumping speed (ISO 21360) m3/h 1.
page 14 of 61 Controller ceramic diaphragm (alumina), capacitive, absolute pressure, gas type independent Pressure transducer Display LCD graphic display, illuminated Pressure units / scale (selectable) mbar, Torr or hPa Measuring range (absolute) 1080 mbar - 0.1 mbar (810 Torr - 0.1 Torr) Maximum control range with internal pressure transducer (absolute)* 1060 mbar – 1 mbar (795 Torr – 1 Torr), Turbo-Mode (<1 mbar / Torr) Resolution 0.
page 15 of 61 3.
page 16 of 61 ROTAVAC vario Pumping unit 2 1 5 6 8 7 4 3 Rear side controller jacks for connection of VACUU•BUS components (e.g., coolant valve) external venting valve) rating plate connection plug of the VACUU • BUS line to VARIO pump venting connection serial interface RS 232 C vacuum connection 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.
page 17 of 61 ROTAVAC vario Pumping unit with condensate cooler (accessory) 6 12 11 9 5 7 13 4 3 10 14 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.
page 18 of 61 4 Use and operation When switching on the controller for the very first time, a menu to select the language of the controller menu is displayed. Select the desired language (e.g. ”English”) by turning the selection knob and press to confirm. Then select the pressure unit (”mbar”, ”Torr” or ”hPa”) in the same way. It is possible to access the language selection menu at any time by switching on the controller while keeping the selection knob pressed. 4.
page 19 of 61 NOTICE After switching off the pump, wait 60 sec. minimum until next switching on. Avoid throttling losses by using connecting pipes with large diameter and keep them as short as possible. In case of perturbing exhaust noise connect an exhaust hose. Install outlet pipelines always falling to avoid backflow of condensate towards the pump. When assembling, ensure vacuum-tightness. After assembly, check the complete system for leaks.
page 20 of 61 • • • • • • • • The gas outlet (hose nozzle 10 mm) must not be blocked. The exhaust pipeline has always to be free and pressureless to enable an unhindered discharge of gases. If necessary connect the exhaust to a suitable treatment plant to prevent the discharge of dangerous gases and vapors to the surrounding atmosphere. Attention: Install hoses of the cooling system in a way to avoid flow / dropping of condensed water onto the pumping unit (especially cables and electronic parts).
page 21 of 61 4.5 Attention: Important notes regarding the use of gas ballast ➨ When using air rather than inert gas, risk of significant damage to equipment and/ or facilities, risk of personal injury or even loss of life exists due to the formation of hazardous and/or explosive mixtures if air and pumped media react inside or at the outlet of the pump. ➨ Make sure that air/gas inlet through the gas ballast valve never leads to hazardous, explosive or otherwise dangerous mixtures.
page 22 of 61 NOTICE Do not allow the catchpot to get overfilled. Maximum liquid level approx. 80% to avoid problems when removing the catchpot. Check liquid level in the catchpot regularly and drain catchpot in time. Permissible range of coolant temperature at the condensate cooler: -15°C to +20°C. Check hose connections prior to starting operation of the cooling system. Check coolant hoses regularly during operation. Removing the catchpot: Remove joint clip, remove catchpot and drain condensate.
page 23 of 61 5 Controller When switching on the controller for the very first time, a menu to select the language of the controller menu is displayed. Select the desired language e.g., ”English” by turning the selection knob and press to confirm. Then select the pressure unit (”mbar”, ”Torr” or” hPa”) in the same way. It is possible to access the language selection menu at any time by switching on the controller while keeping the selection knob pressed.
page 24 of 61 Display and symbols Function of the device: (displayed in the upper left corner) Vac control Pump down Vac control Auto mode Program Configuration 100 1013.2 mbar 100 1013.
page 25 of 61 Notes on selecting the function The controller can be adapted to the specific application by choosing the appropriate function depending on the connected components and the requirements of the application. Automatic detection of the components When switching on the controller the actual configuration of the connected components is checked automatically. Connected components are detected automatically and used and supervised until the controller is switched off.
page 26 of 61 5.1 Menu guide Vac control Pump down Speed HI Minimum Off Delay Off Duration Off - - - - - - Graphic - - - - - - - - - - - - Back - - - - - - Pump down Vac control 1013.2 1013.2 mbar mbar MODE MODE Auto mode Function Configuration Pump down Vac control Auto mode Program VACUULAN Configuration - - - - - Back - - - - Adjustment 1013 mbar RS-232... Sensors... Display...
page 27 of 61 5.2 Function Pump down ➨ Continuous pumping with pressure and time settings • Operation on demand of a speed controlled pumping unit Preselections ☞ Use the selection knob to select the parameters. All parameters can be altered even while operation control is running. ☞ Speed: Preselection of the motor speed for pump down. The selection ”HI” effects the maximum speed and best ultimate vacuum of the pump (with automatic speed reduction at ultimate vacuum).
page 28 of 61 Temporary switching from ”Pump down” to ”Vac control” or ”Auto mode” (only if control is running): ☞ Press key ”MODE”. The controller switches to function ”Vac control”, the current vacuum is used as set value. ☞ Pressing key ”MODE” again switches to function ”Auto mode”. The controller adapts the boiling pressure starting from the current vacuum. ☞ The preset function of the controller does not change due to this temporary switching.
page 29 of 61 5.3 Function Vac control ➨ Vacuum control to a preset vacuum value • Operation on demand of a speed controlled pumping unit Preselections + Use the selection knob to select the parameters. All parameters can be altered even while operation control is running. ☞ Set vacuum: The ”Set vacuum” is the set point for vacuum control with pinpoint precision. The selection ”Turbo” leads to the optimum backing pressure for a turbomolecular pump.
page 30 of 61 Temporary switching from ”Vac control” to ”Auto mode” while process control is running: ☞ Press key MODE. The controller switches to ”Auto mode” and adapts the boiling pressure starting with the actual set value. The preset function of the controller does not change due to this switching. When pressing key ”STOP” the controller is in function ”Vac control” again. Adjustment of the set vacuum during vacuum control: Dynamic, interactive adaptation: + Press the selection knob and keep pressed.
page 31 of 61 5.4 Function Auto mode ➨ Control of a pump in function auto mode: Automatic determination of the boiling vacuum and automatic adaptation of the boiling vacuum in case of changing process parameters. Preselections ☞ Use the selection knob to set the parameters. ☞ Sensitivity: The ”Sensitivity” of the control effects the control speed. High sensitivity leads to a reduced pumping down speed, e. g. for small amounts of solvents or foaming processes.
page 32 of 61 5.5 Function Program ➨ Ten programs with up to ten program steps with preset values for vacuum and time can be set and stored. ➜ ☞ Edit: Preset values for the process run can be edited: Time: Process runtime for each program step to reach a preset vacuum level or if setting ”Step” runtime after having achieved the vacuum level. The summed up total process runtime is shown in the base line.
page 33 of 61 The last process is stored in the temporary data memory as long as the controller stays switched on. This program can be transferred to a storage space and edited. Once the program is finished, the clock symbol starts to flash. Confirm the end of the program by pressing START/STOP (clock symbol will disappear). Attention: If ”Autostart” is set to ”On”, the program will start again (time will be reset to 00:00:00) after a power failure or after switching the controller off/on.
page 34 of 61 5.6 Function VACUULAN ➨ Optimised vacuum control for vacuum networks • Operation on demand of a speed controlled pump (VARIO) Preselections ☞ Use the selection knob to select the parameters. ☞ Set vacuum (lower switch-off value): If the pressure drops below the ”Set vacuum” a time-meter starts to run; additionally the motor speed is reduced. The time-meter is reset, if the pressure exceeds the pressure value for switching on again (”Switch on”).
page 35 of 61 5.7 Examples for use Assembly of a vacuum system ☞ Assemble vacuum connection lines between controller, vacuum pump and apparatus. ☞ Assemble electrical connections. ☞ Connect coolant if necessary. 5.7.1 Vacuum for filtration and suction ☞ Select function ”Pump down”. ☞ If necessary set value for ”Speed” (high or low pumping speed). Reduce the speed in case of fast sedimentation (formation of a filter cake). ☞ Set ”Minimum” to a value which still does not lead to evaporation of the solvent.
page 36 of 61 5.7.3 Vacuum for distillation and evaporation (e. g. rotary evaporator) Semi-automatic distillation and evaporation ☞ Select function ”Pump down”. ☞ Start process by pressing key ”START/STOP”. ☞ Observe process. As soon as evaporation starts, press key ”MODE” (switching to ”Vac control”). The vacuum level is kept constant (at the boiling pressure). Fine tuning of the vacuum value is possible by turning the selection knob.
page 37 of 61 5.8 Function Configuration In the menu ”Configuration” the device parameters are preselected. Preselections ☞ Use the selection knob to select the parameters. ☞ Adjustment: Adjustment of the pressure transducer under vacuum and/or at atmospheric pressure, see also section ”Readjustment the controller”. Adjustment at atmospheric pressure is carried out at an absolute pressure value between 1060 - 700 mbar and under vacuum at an absolute vacuum value between 0 - 20 mbar.
page 38 of 61 6 Readjustment of the controller NOTICE The vacuum gauge was adjusted using factory standards, which are traceable through regular calibration in an accredited laboratory (German Calibration service) to the German national pressure standard. Depending on the process and/or accuracy requirements, check the adjustment and readjust if necessary.
page 39 of 61 7 Interface parameters The controller is equipped with a serial interface (RS 232C, nine-pole Sub-D-plug). ☞ Plug-in or remove the cable (cable RS 232C) from the interface only if the equipment is switched off. ☞ The interface is not electrically isolated from the measuring circuit. ☞ For optimal electromagnetic compatibility assemble an interface filter (cat. no.: 638235). The controller is fully operable via the serial interface.
page 40 of 61 7.2 Read commands Response Description current IN_PV_1 pressure XXXX.X mbar/Torr/hPa unit according to preselections current speed IN_PV_2 XXX% 1-100% or HI time IN_PV_3 XX:XX h:m process runtime pressure IN_PV_X operation time IN_PV_T of the controller XXXX.X XXXX.X ...
page 41 of 61 Read commands Operation Command Status process control IN_STAT Fault status IN_ERR Response Description XXXXXX 0 control off 1 pump down/ determining boiling point 2 set vacuum reached/ boiling pressure found 3 current pressure below set vacuum/ automatic switch-off 0 VACUULAN 1 Pump down 2 Vac control 3 Auto mode 4 Program 5 measurement device 0: venting valve closed 1: venting valve open 0: coolant valve closed 1: coolant valve open 0: in-line valve closed 1: in-line va
page 42 of 61 Read commands Operation Command Response Description IN_SP_1 XXXX mbar or XXXX Torr or XXXX hPa set vacuum IN_SP_2 XXX% maximum speed (100% = ”HI”) IN_SP_3 XXXX mbar or XXXX Torr or XXXX hPa switching on pressure for VACUULAN or two point control IN_SP_4 XX:XX h:m delay (00:00 = Off) IN_SP_5 XXXX mbar or XXXX Torr or XXXX hPa switch off pressure (”Maximum” for ”Vac control”, ”Minimum” for ”Pump down”) IN_SP_6 XX:XX h:m process runtime time pressure IN_SP_P1y IN_SP_P2y
page 43 of 61 7.3 Write commands Operation Command Parameter Description function OUT_MODE X 0: VACUULAN 1: Pump down 2: Vac control 3: Auto mode 4: Program Attention: If control is running only switching from 1 to 2, 2 to 3 and 3 to 2 is possible with takeover of the set vacuum.
page 44 of 61 Write commands Operation mode * Command Parameter Description START X 1 started STOP X 0 Stop and delete fault 1 Stop 2 Stop with adopting the set vacuum REMOTE* X ECHO** X OUT_VENT X STORE X OUT_SENSOR X 0 Remote off 1 Remote on 0 Echo off 1 Echo on, write command with return value 0 venting valve closed 1 venting valve open 2 venting until atmospheric pressure store settings permanently, if Echo ”1” after realisation 1 internal sensor 2-9 external sensors (if connected)
page 45 of 61 8 Assembling the condensate cooler (accessory) ➨ Unscrew the hose nozzle at the outlet of the pump using an open-ended wrench. ➨ Screw hose connection of the condensate cooler to the outlet of the pump using an open-ended wrench. ☞ Align the square of the hose connection so that the mounting angle for the condenser can be assembled (see figure). ➨ Unscrew both Phillips screws at the fixing plate of the controller. ➨ Remove catchpot at the condenser.
page 46 of 61 9 Troubleshooting Fault Possible cause Remedy ❑ ➨ Mains not plugged in? ✔ Plug in mains plug. ➨ Controller or pumping unit switched off? ✔ Switch device on. ➨ BUS cable to internal power supply not plugged in? ✔ Plug in BUS cable at controller. ➨ Other causes (device defective)? ✔ Contact local distributor. ➨ Short circuit at connected valves? ✔ Replace valves. ➨ Short circuit at the RS 232 plug? ✔ Check plug and cable.
page 47 of 61 Fault Possible cause Remedy ❑ Internal venting valve does not respond, valve symbol is not displayed. ➨ External pressure transducer connected and active? ✔ Select internal pressure transducer or connect external venting valve. ❑ ➨ Venting valve does not respond, valve symbol is displayed. Valve soiled? ✔ Clean valve. ❑ ➨ Function ”Vac control”: Control stops, ”arrow up” is flashing. Preset maximum pressure exceeded? ✔ Confirm by pressing key START/STOP.
page 48 of 61 Fault Possible cause Remedy ❑ ➨ Wrong settings at controller? ✔ ➨ Centring ring at a small flange ✔ connection not correctly positioned or leak in the pipeline or vacuum system? ➨ Long, narrow vacuum line? ✔ Use lines with larger diameter, length as short as possible. ➨ Pump has been exposed to condensate? ✔ Allow pump to run for some minutes with atmospheric pressure at the inlet. ➨ Deposits have been formed inside the pump? ✔ Clean and inspect the pump heads.
page 49 of 61 10 Cleaning the pressure transducer The controller itself is maintenance free. Contamination of the pressure transducer or deposits will influence the accuracy of measurement. NOTICE Attention: Never use a spiky or sharp-edged tool to clean the pressure transducer. Clean a contaminated pressure transducer as follows: ➨ Disconnect vacuum connection. ➨ Fill the measurement chamber with a solvent (e. g. benzene) and allow sufficient cleaning time.
page 50 of 61 11 Replacing diaphragms and valves ☞ 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. ☞ 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.
page 51 of 61 Tools required (metric): - diaphragm key w/f 46 (enclosed in the set of seals) open ended wrench w/f 14 / 17 hex key size 4 Phillips screw driver size 2 ☞ Please read section ”Replacing diaphragms and valves” completely before starting maintenance. Partially the pictures show pumps in other versions. This doesn’t influence replacing diaphragms and valves of the pump. 11.1 Cleaning and inspecting the pump heads ➨ Remove control cable at the rear side of the controller.
page 52 of 61 ➨ Use open ended wrench (w/f 14) to turn the elbow fitting 1/4 of a turn, disconnect the hose. Do not remove the elbow fitting from the pump head. ☞ Through reassembly a leak may result.
page 53 of 61 ➨ Use a hex key size 4 to loosen the six socket head screws at the pump head and remove the upper housing (housing cover with housing cover insert). ☞ Never remove parts 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). ➨ Take the head covers carefully off the housing to check the valves. Note the position of the valves and remove them. ☞ Replace valves if damaged.
page 54 of 61 ➨ Lift diaphragm at the side and position carefully together with diaphragm clamping disc and diaphragm support disc in the diaphragm key. ☞ Avoid damaging the diaphragm: Do not bend diaphragm too much. ➨ Check for washers. Do not mix the washers from the different heads. Assemble the original number of washers between support disc and connecting rod at the individual pump head. ☞ Smaller number of washers: The pump will not attain final vacuum.
page 55 of 61 It is absolutely essential to comply with the positions and orientations of the head covers and valves! Scheme of pump head with head covers and valves ”side with hose connection” valves at the outlet (round centred opening under valve) valves at the inlet (kidney-shaped opening beside valve) ”motor side” ➨ Position housing cover. ☞ Move housing cover slightly to make sure that the head covers are correctly positioned.
page 56 of 61 ➨ Tighten union nut first by hand and then tighten one full turn using open ended wrench. ➨ Assemble controller: Use Phillips screw driver to screw both screws through the fixing plate in the square nuts in the housing cover. ➨ Connect hose to the connection at the inlet of the pump. Tighten union nut first by hand and then tighten one full turn using open ended wrench. ➨ Connect control cable to the rear side of the controller.
page 57 of 61 11.4 Replacing the overpressure safety relief device at the condenser Overpressure safety relief device......................................... ........................................................................ 23-30-01-04-98 Round bottom flask 500 ml, coated...................................... .......................................................................... 514-83000-02 ➨ Remove joint clip at the catchpot.
page 58 of 61 12 Warranty, liability, copyright Warranty Heidolph Instruments provides a three-year warranty on the products described here (with the exception of glass and consumable parts) if registered with enclosed warranty card or via internet (www.heidolph. com). Warranty starts with the date of registration. Without registration warranty starts according to serial number. This warranty covers defects in materials and workmanship. Transit damage is excluded from this warranty.
page 59 of 61 13 FAQ / repair work If any aspect of installation, operation or maintenance remains unanswered in the present manual, please contact the following address. For repair services please call Heidolph Instruments or your local, authorized Heidolph Instruments Dealer. Note: You will receive approval for sending your defective item to the following address: Heidolph Instruments GmbH & Co. KG Lab Equipment Sales Walpersdorfer Str.
page 60 of 61 14 Confirmation of condition of unit In case of repair 1. Details about the unit Model _________________________ Serial number _________________________ Reason for repair _________________________ 2. Has the unit been cleaned or decontaminated / sterilized? yes no 3.
page 61 of 61 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.
