MP 2401 E, MP 1801 Z, MP 1201 T

Transcription

1 Operation Manual Diaphragm pumps 8-headed Types MP 2401 E, MP 1801 Z, MP 1201 T MPC 2401 E, MPC 1801 Z, MPC 1201 T

2 We are constantly working on the further development of all our product types. Reprinting or reproduction of this manual, including extracts, is not allowed without the prior written permission of ILMVAC GmbH. All rights under the copyright laws are expressly reserved by ILMVAC GmbH. We reserve the right to make changes and amendments. ILMVAC GmbH Am Vogelherd Ilmenau, Germany Telephone: Fax: Homepage:

3 Contents Contents 1 Important Information General Information Target Groups Intended Use Use for an Unauthorized Purpose Safety Devices Meaning of the Warning notes Product Standards, Safety Regulations Basic Safety Instructions General Information Electricity Mechanical Systems Hazardous Substances High Temperatures Description Design Areas of Application Principle of Operation Models Gas ballast Scope of Delivery Accessories Accessories optional Technical Data Dimensions Intake Pressure / Pumping Speed Diagram Device Data Order Numbers Installation and Operation Unpacking Installation and Connection Operation Storage Scrap Disposal Maintenance and Servicing General Requirements Maintenance Performed by the User Disassembly Assembly Test Maintenance by the Manufacturer Troubleshooting Spare Parts Overview Maintenance kit Diaphragm pump - Exploded view Complete unit - MP Parts list complete unit MP Complete unit - MPC Parts list complete unit MPC Damage Report

4 Important Information 1 Important Information 1.1 General Information The diaphragm pumps conform to the following directives: 93/68/EEC Low Voltage Directive 98/37/EU Machinery Directive 89/336/EEC Electromagnetic Compatibility Directive The CE sign is located on the rating plate. Observe the binding national and local regulations when fitting the pump into installations. Our products are sold worldwide and can therefore be equipped with the typical national plugs and for the various voltages. You will find more information about the available pump designs under Target Groups This Operating Manual is intended for the personnel planning, operating and maintaining ILMVAC diaphragm pumps. This group of people includes: Designers and fitters of vacuum apparatus, Employees working on commercial laboratory and industrial vacuum technology applications and Service personnel for diaphragm pumps The personnel operating and maintaining the diaphragm pumps must have the technical competence required to perform the work that has to be done. We recommend that the user appoints the personnel who are to perform this work. The personnel must have read and understood the complete Operating Manual before using the diaphragm pumps. The Operating Manual must be kept at the place of use and be available to the personnel when required. 1.3 Intended Use The layout of the diaphragm pump must be appropriate for the conditions of use. The u- ser bears the sole responsibility for this. The diaphragm pump may only be operated under the conditions stated - in the "Technical Data" section, - on the type plate, and - in the technical specification for the order concerned. Diaphragm pumps are approved for extracting, pumping and compressing gases and vapours. If these gases and vapours are toxic or explosive, then the user must observe the currently valid safety regulations for this application. Special types of diaphragm pumps are available for aggressive and explosive gases

5 1.4 Use for an Unauthorized Purpose Important Information It is forbidden to use the pump for applications deviating from the technical data stated on the type plate or the conditions stated in the supply contract, or to operate it with missing or defective protective devices. 1.5 Safety Devices Measures such as the following are for the safety of the operating personnel: Operation mode S1 (with grounding connector) Motor protection switch (thermal) and Hot Surface" label on the pump body (warning notice). 1.6 Meaning of the Warning notes Take note of the warning notices. They are in the following box: WARNING! Hazard which may lead to serious injuries or material damage. 1.7 Product Standards, Safety Regulations ILMVAC diaphragm pumps meet the following product standards: DIN EN 292-1, DIN EN DIN EN DIN EN EN (DIN VDE ) Safety of machines, basic terminology Compressors and vacuum pumps Electrical equipment of machines Operation of electrical installations. The following additional safety regulations apply in the FR Germany: BGV A2 VBG 5 BGR 120 BGI 798 Electrical equipment and operating materials Power-driven machines Guidelines for laboratories BG hazard assessment in the laboratory Observe the standards and regulations applying in your country when you use the diaphragm pumps

6 Basic Safety Instructions 2 Basic Safety Instructions 2.1 General Information Warning notices must be observed. Disregarding them may lead to damage to health and property. The diaphragm pumps must be operated by personnel who can detect impending dangers and take action to prevent them from materialising. The manufacturer or authorized authorised workshops will only service or maintain the diaphragm pump if it is accompanied by a fully completed damage report. Precise information about the contamination (if present) and thorough cleaning of the diaphragm pump are legally binding parts of the contract. Contaminated diaphragm pumps and their individual parts must be disposed of in accordance with the legal regulations. The local regulations apply in foreign countries. 2.2 Electricity Only diaphragm pumps of operation mode S1 are supplied. When the location of operation mode S1 devices is changed, please note that the testing must be repeated in accordance with DIN EN 0105, DIN EN 0702 and BGV A2. The local regulations apply in foreign countries. 2.3 Mechanical Systems Improper use can lead to injuries or material damage. Observe the following instructions: Only operate the diaphragm pumps with hoses of the specified dimensions. The maximum permissible pressure of 1 bar at the suction connection must not be exceeded. Solid particles in the pumping medium impair the pumping action and can lead to damage. Prevent solid particles penetrating into the pump. Hazardous substances must be separated out as far as this is technically possible before they reach the pump. External mechanical stresses and vibrations must not be transmitted to the pump. Only use flexible laboratory hoses for connecting diaphragm pumps. The overpressure generated at the pressure port must not exceed 1 bar. The pump must not be used to suck up fluids. Lay the exhaust pipe so that it slopes downwards, so allowing condensate to flow out of the pump. Collect the condensate and dispose of it in an environmentally compatible manner. Prevent dyes exuding. Maintain a space of least 20 cm between the pump and adjacent parts in order to enable the pump to cool

7 2.4 Hazardous Substances Basic Safety Instructions The operating company bears the responsibility for the use of the diaphragm pump. Hazardous substances in the gases to be pumped can cause personal injuries and property damage. Pay attention to the warning notices for handling hazardous substances. The local regulations apply in foreign countries. Explosive gases Before switching on, check whether the gas to be pumped is explosive or can form explosive mixtures. In such a case, use a diaphragm pump with an explosion-proof motor. In addition, the following regulations must be observed: Explosion Protection Directive 94/9/EU, EC Directive 1999/92 and the DIN 57165/DIN VDE Aggressive gases The MPC series is designed for extracting aggressive gases. The use of diaphragm pumps of the series MP cannot be recommended for such cases of application! Poisonous gases Use a separator when pumping poisonous or harmful gases. Prevent such substances from leaking out of the appliance or pump. Treat these substances according to the applicable environmental protection regulations. Test the strength and leak-tightness of the connecting lines and the connected apparatus. Prevent environmental poisons, e.g. mercury, getting into the diaphragm pumps. Fulfil the requirements, for example: German Hazardous Substances Regulation (GefStoffV) of 15 November 1999 Regulations 67/548 EEC and 88/379 EEC (classification, packaging, and identification of substances), 11th GSGV explosion protection regulation (regulation of 12 December 1996 covering putting devices and protective systems on to the market which are intended for areas at risk of explosion) Manufacturer's safety data sheets on hazardous substances. 2.5 High Temperatures The diaphragm pump may heat up as a result of the temperature of the gas being pumped and through intrinsic heating. The temperature of the diaphragm pump heads can reach 70 C during operation. Prevent the following maximum permissible temperatures from being exceeded C for the environment, and + 80 C for the gas to be pumped. The motor for single phase alternating current is protected against overload by an integrated motor protection switch. Pumps with EEx design motors do not have any such overload protection. They must be retrofitted by the user with a protective device that is suitable for the relevant use

8 Description 3 Description 3.1 Design The diaphragm pump consists of a pump body and a drive motor. The pump body consists the in pairs of the A and B-laterally put on eccentric cam drives in the housing as well as put on-pump-cuts back. Each pump head contains a diaphragm and the work valves. Two pairs of pump heads are arranged opposite each other. 1 to 3 stage pumps are supplied, depending upon the circuitry of the pump heads. The pump heads are driven via an eccentric shaft with a connecting rod. Fig. 1 diaphragm pump type MPC 1201 T 3.2 Areas of Application ILMVAC diaphragm pumps are intended for: Pumping and compressing neutral and aggressive gases and vapours. Generating a vacuum down to an ultimate pressure < 2 mbar. Use in physical and chemical laboratories in trade and industry. Use for vacuum filtration, vacuum distillation and vacuum drying, and other vacuum technology applications. 3.3 Principle of Operation Motor, eccentric shaft and connecting rod set the diaphragms in stroke movement. This changes the size of the space between the diaphragms and pump head (pump chamber). Increasing the size of the pump chamber opens the inlet valve while the outlet valve is closed (intake process). Decreasing the size of the pump chamber ejects the gas through the outlet valve. The valves are actuated by the gas being pumped. A large proportion of fluid in the diaphragm pump minimizes the pumping efficiency

9 Description 3.4 Models Pump head circuitry: One-stage (E): Final vacuum: Types: Four pump heads are connected in parallel. < 75 mbar MP 2401 E and MPC 2401 E Two-stage (Z): Final vacuum: Types: Three pump heads are in parallel, the fourth in series. < 8 mbar MP 1801 Z and MPC 1801 Z Three stage (T): Final vacuum: Types: Two pump heads are in parallel, the other two in series. < 2 mbar MP 1201 T and MPC 1201 T Materials of the medium-affecting pump parts: Component Standard design MP type Chemical model MPC type (resistant to aggressive gases) Cylinder- / pump head Aluminium PTFE with carbon-fibre reinforcing Seal EPDM EPDM Screw fitting PA PVDF Valves PEEK PEEK Diaphragm NBR fabric reinforced with a PTFE layer Connecting elements PP PP NBR fabric reinforced with a PTFE layer Notes: PTFE with carbon-fibre reinforcement, electrically conductive (with manufacturer's certificate of electrical conductivity). Material resistance to aggressive media see: "Plastic, Rubber Products, Annual Handbook of the Processor 2000/2001 ( Kunststoff Kautschuk Produkte, Jahreshandbuch der Verarbeiter 2000/2001), Publisher Hoppenstedt Darmstadt, Vienna, Zurich. Special designs: Special diaphragm pumps can be supplied after consultation with the manufacturer or for a corresponding supply contract. Explosion protection motors in the EEx e and Eex de designs. Motors for different voltages

10 Description 3.5 Gas ballast When condensable vapours are pumped, they may be compressed above the saturated vapour pressure and condense. Opening the gas ballast valve (1) in the suction line of the last pump stage allows air to flow into the pump chamber. This prevents condensation and flushes the pump clear. (1) Operation leads to: - Increasing the ultimate pressure and - Increasing the operating temperature. Fig. 2 MPC 1201 T with gas ballast valve The gas ballast valve is only provided as standard for MPC type diaphragm pumps. The fitting into other pump types is an option or must be specified in the supply contract. 3.6 Scope of Delivery The scope of delivery is specified in the supply contract. 3.7 Accessories Ventilation valve, Order No Electromagnetic valve for venting the apparatus Gas ballast valve, Order No For diaphragm pumps of type MP, manually operated Vacuum controller VCZ 324, order no Accessories optional Intake pipe valve, Order No (intake port valve) solenoid valve for regulating the working pressure in the connected apparatus. Control valve VVB G, Order No For measuring and regulating the operating pressure

11 Technical Data 4 Technical Data 4.1 Dimensions The main dimensions are identical for all pump types specified here. (1) (2) (H) (D) (W) 1 - Intake port 2 - Pressure port Fig. 3 Dimensions type MP 2401 E (see point 4.3) 4.2 Intake Pressure / Pumping Speed Diagram Fig. 4 Intake Pressure, Pumping Speed

12 Technical Data 4.3 Device Data Parameter Unit 2401 E (single-stage) Diaphragm pump types 1801 Z (two-stage) 1201 T (three-stage) Pumping performance 50/60 Hz DIN (at speed of 1500 rpm) Final vacuum (at speed of 1500 rpm) Final vacuum with gas ballast (at speed of 1500 rpm) (with MPC only) m 3 / h 15.5 / / / 9.1 l / min mbar < 75 < 8 < 2 mbar Max. inlet pressure bar 1 Max. outlet pressure bar 1 Intake and pressure ports - Small flange DN 16 KF (optional: Hose nipple for vacuum hose NW 8) Max. ambient temperature C + 40 Max. operating gas temperature Bearing Reference surface sound pressure level DIN part 13 Voltage / Frequency (Different data upon customer request) C + 80 maintenance-free db (A) < 48 V, Hz AC asynchronous motor 230, 50 (50/60) (generally with motor protection switch, switch and cable) Three-phase asynchronous motor 230/400, 50/60 (generally with motor protection switch, switch and cable) Power kw 0.37 Operating mode S 1 Type of protection DIN EN Class of insulation DIN EN IP 54 F (160 C) Dimensions (W/D/H) mm 540 / 300 / 240 Weight kg 24.0 Motor in EEx design DIN EN 60034/IEC 34, DIN VDE 0530, DIN EN to DIN EN Type of protection: e II T4 and de II c T4 - on request - (Motors are supplied with terminal box but without motor protection switch)

13 Technical Data Order Numbers Diaphragm pump Voltage/ Frequency Plug Order No. MP 2401 E MPC 2401 E MP 1801 Z MPC 1801 Z MP 1201 T MPC 1201 T 230V, 50Hz CEE /400V, 50Hz CEE V, 50Hz UK V, 50Hz CH V, 60Hz US V, 50/60Hz US V, 50Hz CEE /400V, 50Hz CEE V, 50Hz UK V, 50Hz CH V, 60Hz US V, 50/60Hz US V, 50/60Hz CEE /400V, 50Hz CEE V, 50/60Hz UK V, 50/60Hz CH V, 60Hz US V, 50/60Hz US V, 50/60Hz CEE /400V, 50Hz CEE V, 50/60Hz UK V, 50/60Hz CH V, 60Hz US V, 50/60Hz US V, 50Hz CEE /400V, 50Hz CEE V, 50Hz UK V, 50Hz CH V, 60Hz US V, 50/60Hz US V, 50Hz CEE /400V, 50Hz CEE V, 50Hz UK V, 50Hz CH V, 60Hz US V, 50/60Hz US

14 Installation and Operation 5 Installation and Operation 5.1 Unpacking Carefully unpack the diaphragm pump. Check the pump for: Transport damage, Conformity with the specifications of the supply contract (type, electrical supply data), Completeness of the delivery. Please inform Ilmvac GmbH without delay if there are discrepancies between the delivery and the contractually agreed scope of delivery, or if damage is detected. Please take note of the general terms of business of ILMVAC GmbH. The pump must be returned in the original packaging in order to make a claim under warranty. 5.2 Installation and Connection 1. Set the diaphragm pump on a flat and horizontal surface. 2. Remove the protective caps on the suction and pressure ports. 3. Prepare the connections. 4. Connect the NW 8 vacuum connector to the suction port. 5. Connect the exhaust pipe to the pressure connection. 6. Connect the diaphragm pump to the electrical supply. 5.3 Operation Observe the basic safety instructions when using the pump. The diaphragm pump is switched on and off at the operating switch. The operating company must install a main switch for pumps with terminal boxes. 5.4 Storage The pumps are to be stored in a low-dust, interior room within the temperature range from + 5 to + 40 C and at a relative air humidity < 90%. Leave the protective elements on the suction and pressure ports. Another equally good protection may be used. 5.5 Scrap Disposal The diaphragm pumps must be disposed of in accordance with the specific national regulations. If the pumps are contaminated, we recommend separating its parts for disposal as follows: Pump body, hose lines and other parts as hazardous waste, (cleaned as scrap or household waste) Motor and power cables as electrical scrap, Plastics go for plastic recycling

15 Maintenance and Servicing 6 Maintenance and Servicing 6.1 General Requirements The maintenance / inspection interval is around 1,000 operating hours. The bearings of the drive motors and the eccentric shaft are life-long lubricated and so maintenance-free. 6.2 Maintenance Performed by the User WARNING! Only perform the work that is described here, and that which is permitted to be done by the user. All other maintenance and service work may only be performed by the manufacturer or a dealer authorized by him. Beware of the pump parts being possibly contaminated by hazardous substances. Wear protective clothing if there is contamination. Scope of permissible work: Open the pump heads. Inspect the pump chambers, diaphragms and valves. Clean the interior of the pump, change the diaphragms and valves. Tools required: The tool kit, order No consists of: Pin type face wrench, adjustable, size 3, Allan key, size 3 (for types MPC), Allan key, size 4 (for types MP), Open spanner, size

16 Maintenance and Servicing 6.3 Disassembly 1. Disconnect the power supply and ensure that it cannot be switched on again. 2. Open the screw clamps of the hoses on the pump body with the SW 17 open spanner. Fig. 5 Disassembly, assembly 3. Remove four machine screws (1) from each pump head with an Allan key, size Lift off the pressure plate (2), the cylinder head (3) and the pump head (6). The valve gasket (5) and diaphragm (8) are now freely exposed. 5. Loosen the diaphragm (8) at the strain washer (7) by turning the size 3 pin type face wrench anticlockwise. 6. Clean the valve gasket (5) and the diaphragm (8) with a soft cloth and acetone. Wear protective gloves! Renew these parts if necessary. Do not clean with compressed air. 6.4 Assembly 1. Place the pump so that the diaphragm is lying in a horizontal position. 2. Use the size 3 pin-type face wrench to tighten the pressure disc (9), the diaphragm (8) and the strain washer (7) with the correct torque of 6-7 Nm. 3. Bring the connecting rod (5) (see fig. 9) and the diaphragm (8) into the central position. 4. Replace the pump head (6). 5. Insert the valve (5) and the O-ring (4). Ensure that they are lying completely flat. Do not insert the burred side facing the sealing surface. Align the cylindrical head flush with the pin. 6. Replace the pressure plate (2) and insert and tighten the 4 machine screws with a torque of 4-5 Nm. 7. Reattach the hose connections with clamping ring screw fittings

17 Maintenance and Servicing 6.5 Test Connect a vacuum measuring device to the suction connector and measure the ultimate pressure. If the device is working properly, then the figure stated in the technical data must be attained within a maximum of one minute. 6.6 Maintenance by the Manufacturer WARNING! Incomplete or incorrectly completed damage reports may endanger the service personnel! Provide full information about contamination, and clean the pump thoroughly before handing it over to third parties. Repairs and maintenance going beyond the extent of the work described in section 6.2 or reconditioning or modification may only be performed by the manufacturer or authorized workshops. The prerequisites for a handover are a complete and factually correct damage report, and a clean pump. Note: The user shall be liable for the consequences of an incorrect damage report or a contaminated pump. The statements in the damage report are legally binding

18 Troubleshooting 7 Troubleshooting During the warranty period, intervention in the diaphragm pumps and accessory components may only be made by ILMVAC GmbH. Trouble Cause Action Diaphragm pump does not start The diaphragm pump does not generate a vacuum or only an inadequate one. No power supply to the motor Motor defective Pump body defective Connected apparatus leaks, connecting elements leak Diaphragm pump leaks (pipes or hoses) Pump head Diaphragm defective Valves are dirty Valves defective Diaphragm pump is dirty Electrical system to be checked by a qualified electrician. Exchange by service shop. Exchange or repair by service shop. Identify and seal the leak, replace the seals and hoses if necessary. Check the hose connections between the pump heads, replace the hoses and screwed clamping rings if necessary. Repair by service shop. Repair by the service workshop or the user. Clean condensates and foreign objects out of the valves. Replace valves Cleaning by the service workshop or the user

19 Spare Parts Overview 8 Spare Parts Overview The spare parts lists contain all the spare parts and all the information necessary for ordering. When ordering, please quote the description, quantity, serial number and order number! 8.1 Maintenance kit Designation Order No. Maintenance kit The maintenance kit consists of: Designation Piece Order No. O-ring ø 28 x O-ring ø 12 x Valve Diaphragm Attention, the number of supplied construction units in the maintenance set corresponds to the maximum need of the series!

20 Spare Parts Overview 8.2 Diaphragm pump - Exploded view Fig. 6 Exploded view - Diaphragm pump without connections

21 Spare Parts Overview 8.3 Complete unit - MP ; 11; 15 1g; 25; 26 12; ; Fig. 7 Complete unit MP

22 Spare Parts Overview Parts list complete unit MP MP 2401 E MP 1801 Z MP 1201 T Item no. Designation Piece Order No. Piece Order No. Piece Order No. 1 Basic pump complete (consisting of position: 1a 1k) a Piston rod b Close tolerance spacer 25x35x c Eccentric shaft d Ball bearing Z e Ball bearing Z f Mass balance g Motor 230V; 50/60Hz; 0.37/0.44 kw Motor 400/480V; 50/60Hz; 0.37/0.44 kw Motor 115V; 60Hz; 0.44 kw Motor 100V; 50/60Hz; 0.44 kw h Casing j Casing k O-ring ø x Diaphragm Valve Pump head Cylinder head Cylinder head Cylinder head Pressure washer Tightening washer Straight coupling PA; 10 ¼ T-threaded joint PA; ¼ Elbow union PA; 10 ¼ Pebax hose 10 / 8x1 1.4m m m O-ring ø 28 x O-ring ø 12 x Manifold; Al Manifold PP; 3 x ¼ Suction-/pressure port Al; DN 16 KF ¼ Foot complete Spacer distance piece Foot Air duct Fan 230V; 50/60Hz Fan 115V; 60Hz Fan 100V; 50/60Hz Spacer for fan Time controlling VAPU Motor operating condenser 16µF Motor operating condenser 12µF Handle Rubber-metal pad Mains connection cable with : - plug CEE (for 230 V) plug CEE (for 400 V) plug U plug CH plug US

23 Spare Parts Overview 8.4 Complete unit - MPC ; 11; 15 1g; 25; ; ; Fig. 8 Complete unit MPC

24 Spare Parts Overview Parts list complete unit MPC MPC 2401 E MPC 1801 Z MPC 1201 T Item no. Designation Piece Order No. Piece Order No. Piece Order No. 1 Basic pump complete (consisting of position: 1a 1k) a Piston rod b Close tolerance spacer 25x35x c Eccentric shaft d Ball bearing Z e Ball bearing Z f Mass balance g Motor 230V; 50/60Hz; 0.37/0.44 kw Motor 400/480V; 50/60Hz; 0.37/0.44 kw Motor 115V; 60Hz; 0.44 kw Motor 100V; 50/60Hz; 0.44 kw h Casing j Casing k O-ring ø x Diaphragm Valve Pump head Cylinder head Cylinder head Cylinder head Pressure washer Tightening washer Pressure plate Gas ballast valve Straight coupling PVDF; 10 ¼ T-threaded joint PVDF; ¼ Elbow union PVDF; 10 ¼ Vacuum hose PTFE; 10 / 8x1 1.4m m m O-ring ø 28 x O-ring ø 12 x Manifold; Al Manifold PP; 3 x ¼ Suction-/pressure port PP; DN 16 KF ¼ Foot complete Spacer distance piece Foot Air duct Fan 230V; 50/60Hz Fan 115V; 60Hz Fan 100V; 50/60Hz Spacer for fan Time controlling VAPU Motor operating condenser 16µF Motor operating condenser 12µF Handle Rubber-metal pad Mains connection cable with : - plug CEE (for 230 V) plug CEE (for 400 V) plug U plug CH plug US

25 9 Damage Report Company Customer s Order No: Type: Type-No: Damage Report ILMVAC GmbH Am Vogelherd 20 D Ilmenau Telephone: Fax: Date: Warranty: Yes/No Ser-No.: 1. Description of Fault a) Was the pump/ components in use?* yes no b) Which oil was used?* c) Is the pump/ component free of hazardous substances? yes continue at section 3 2. Type of contamination of pump/ component no continue at section 2 a) toxical** yes no b) etching** yes no c) micro-biological** yes no d) explosive** yes no e) radio-active** yes no f) other contaminates** yes no * in rotary vane vacuum pumps and roots pumps ** pumps/ components can only be accepted with proof of correct decontamination or cleaning resp. If agreed the decontamination/ cleaning work can be carried- out at ILMVAC GmbH. Type of contaminates or dangerous process reaction products the pumps/ components were in contact with Trade name Product name Manufacture 3. Official declaration Chemical description (formula if possible) Hazardclass Measures in case of escape of contaminates First aid in case of accidents I/ we ensure that the data/ information given is correct and complete. The despatch of the pump/ component is performed in accordance with the prevailing law. Contact s name: Phone: Dept.: Fax: Date: Company stamp: Official signature: The repair can only be carried-out, if the Damage Report duly completed is submitted. Otherwise the repair work might be delayed. Our General/ Conditions of Sale apply