page 1 of 25 Instructions for use Technology for vacuum systems PC 2002 VARIO / PC 2004 VARIO (without controller) Chemistry pump unit 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 25 Dear customer, Your VACUUBRAND diaphragm pump shall support you at your work for a long time without any trouble and with full load output. Thanks to our large practical experience we attained much information how you could add to an efficient application and to personal safety. Please read these instructions for use prior to the initial start-up of your pump.
page 3 of 25 Contents Safety information! .................................................................................................... 4 Technical data ............................................................................................................ 8 Notes on operation .................................................................................................. 12 Troubleshooting ......................................................................................................
page 4 of 25 Safety information! 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. Retain all packing material for inspection. Do not use the equipment if it is damaged.
page 5 of 25 ☞ Provide a firm level platform for the equipment and check that the system to be evacuated is mechanically stable and that all fittings are secure. Attention: Flexible elements tend to shrink when evacuated. Due to the high compression ratio of the pumps, pressure at the outlet port might be generated being higher than the max. permitted pressure compatible with the mechanical stability of the system.
page 6 of 25 ☞ Attention: In case of supply voltage below 100V, the lock of the cutout might be restricted and the pump might restart on its own after sufficient cooling down. Take suitable precautions, if an automatic restart of the pump may lead to a critical dangerous situation. ☞ Avoid high heat supply (e. g. due to hot process gases). ☞ Ensure sufficient air admittance if pump is installed in a housing.
page 7 of 25 ☞ Attention: The pump might be contaminated with process chemicals which have been pumped during operation. Ensure that the pump is decontaminated before maintenance and take adequate precautions to protect people from the effects of dangerous substances if contamination has occurred. ☞ Before starting maintenance vent the pump, isolate the pump and other components from the vacuum system. Allow sufficient cooling of the pump. Drain condensate, if applicable.
page 8 of 25 Technical data PC 2002 VARIO without Controller PC 2004 VARIO without C o n t ro l l e r m 3/ h 2,5** 3,8** Ultimate vacuum* (absolute) mbar 9 2 Ultimate vacuum* (absolute) with gas ballast mbar 15 9 Type M a x i mu m p u m p i n g s p e e d * ( I S O 2 1 3 6 0 ) Max. per missible outlet pressure (absolute) bar 1,1 Max.
page 9 of 25 Components Pumping unit Outlet Inlet Hose Fitting O-r ings at the catchpot Over pressure safety relief device Catchpot cover plate Exhaust waste vapour condenser, collecting flask Pump Housing cover inser t Head cover D i a p h ra g m c l a m p i n g d i s c Valve D i a p h ra g m O-r ing Wetted par ts PET ETFE/ECTFE (PC 2002 VARIO), PP (PC 2004 VARIO) PTFE ETFE / ECTFE FPM silicon r ubber / PTFE foil PP borosilicate glass PTFE carbon reinforced ETFE carbon fibre reinforced ETFE carbon fibre
page 10 of 25 PC 2002 VARIO without controller exhaust waste vapour condenser with cover overpressure safety relief device at the exhaust waste vapour condenser pump MZ 2C VARIO with frequency converter inlet (vacuum connection) round bottom flask to collect condensate outlet: gas! (hose nozzle 10 mm) cooling water outlet (hose nozzle 6 mm) cooling water inlet (hose nozzle 6 mm) handle rating plate gas ballast valve Documents are only to be used and distributed completely and unchanged.
page 11 of 25 PC 2004 VARIO without controller exhaust waste vapour condenser with cover overpressure safety relief device at the exhaust waste vapour condenser pump MD 4C VARIO with frequency converter inlet (vacuum connection) round bottom flask to collect condensate outlet: gas! (hose nozzle 10 mm) cooling water outlet (hose nozzle 6 mm) handle rating plate cooling water inlet (hose nozzle 6 mm) gas ballast valve Documents are only to be used and distributed completely and unchanged.
page 12 of 25 Notes on operation Installing in a vacuum system: ☞ Avoid throttling losses by using connecting pipes with large diameter and keep them as short as possible. ☞ Reduce the transmission of vibration and prevent loading due to rigid pipelines. Insert elastic hoses or flexible elements as couplings between the pump and rigid pipes. Attention: Flexible elements tend to shrink when evacuated.
page 13 of 25 ☞ Connect the exhaust to a suitable treatment plant to prevent the discharge of dangerous gases and vapours to the surrounding atmosphere. During operation: Do not start pump if pressure difference between inlet and outlet port exceeds max. 1 bar. Attempts to start pump at higher difference may cause blockade and damage of the motor. ☞ Check compatibility with max. permitted pressure at outlet and max. pressure difference between inlet and outlet ports.
page 14 of 25 Attention: Notes concerning the operation of the exhaust waste vapour condenser ➨ Check hose connections prior to starting operation of the cooling system. ➨ Check coolant hoses regularly during operation. ☞ Ensure that the coolant outlet pipeline is always free and that it cannot get blocked. ☞ Maximum permissible coolant pressure at the exhaust waste vapour condenser: 6 bar (absolute) ☞ Comply with the maximum permissible coolant pressures of additional components in the coolant circuit (e.
page 15 of 25 Troubleshooting Please read also instructions for use for the controller! Fault Possible cause R e m e dy Pump fails to star t or stops immediately. Î Pump has been exposed to condensate? ) A l l ow t h e p u m p t o r u n w i t h inlet por t open for some minutes at max. frequency. Pump does not achieve ultimate vacuum or nor mal pumping speed.
page 16 of 25 Replacing diaphragms and valves All bearings are encapsulated and are filled with long-life lubricant. Under normal operating conditions, the pump is maintenance free. The valves and the diaphragms 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.
page 17 of 25 Disassembling the pump from the pumping unit ➨ Use an open-ended wrench (w/f 17) to remove the union nut of the fitting of the cover plate. ➨ Use open-ended wrench (w/f 15) to turn elbow fitting 1/4 of a turn, remove hose. Do not remove the elbow fitting from the cover plate. ☞ Through reassembly a leak might result. ➨ Remove union nut at the exhaust waste vapour condenser and remove hose from the inlet of the condenser. PC 2002: ➨ Do not disassemble pump from pump support.
page 18 of 25 ➨ Use open ended wrench (w/f 14) to turn elbow fitting 1/4 of a turn, remove hose. Do not remove the elbow fitting from the pump head. ☞ Through reassembly a leak may result. ➨ Use hex key to remove four socket head screws from pump head and remove upper housing (housing cover with housing cover insert and head cover). ☞ 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).
page 19 of 25 ➨ Remove head cover from housing cover insert and check valves. Note position of valves and remove. ☞ Replace valves if necessary. ➨ Use petroleum ether or industrial solvent to remove deposits. Do not inhale. ➨ Check diaphragm for damage and replace if necessary. Use Phillips screw driver to remove four countersunk head screws and lift off housing plate. Replacing the diaphragm ➨ Use face wrench to remove diaphragm support disc. ➨ Check for washers.
page 20 of 25 Reassemble in reverse order. ➨ Install head cover (with O-ring if applicable), valves and housing cover. ☞ Make sure that the valves are correctly seated: Valves at the outlet with round centred opening under valve, valves at the inlet with kidney-shaped opening beside valve. ➨ By turning eccentric bushing, bring connecting rod into upper turning point position (Max. stroke of the rod).
page 21 of 25 Assembling the pumping unit PC 2003 / PC 2004: ➨ Assemble pump at pump support. Support pump appropriately. ➨ Screw in at each case two socket head screws at the front of the pump an underneath the terminal box with hex key size 5. Pay attention to washers. ➨ Position pump with pump support on the base plate and tighten the four hexagon nuts on the feet of the pump support (open-ended wrench w/f 10). ➨ Reconnect hose to the inlet of the condenser and tighten union nut.
page 22 of 25 Cleaning and assembling components Overpressure safety relief device ............................. 638821 (at the exhaust waste vapour condenser) ☞ Remove union nut at the condenser and remove hose from the inlet of the condenser. ☞ Pull off old overpressure safety relief device and install new one. ☞ Connect hose to the inlet of the exhaust waste vapour condenser and tighten union nut. Round bottom flask 500 ml, coated .......................... 638497 O-ring 28 x 2,5 ......................
page 23 of 25 Notes on return to the factory Repair - return - DKD calibration Safety and health of our staff, laws and regulations regarding the handling of dangerous goods, occupational health and safety regulations and regulations regarding safe disposal of waste require that for all pumps and other products the “Health and safety clearance form“ must be send to our office duly completed and signed before any equipment is dispatched to our premises.
page 24 of 25 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.
page 25 of 25 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.
