Anest Iwata OCX-128 User manual

.
Instruction Manual
Maintenance Tools and Fixtures
OCX-128
This instruction manual includes very important warnings, cautions and operating
procedure in order to operate this pump safely and efficiently.
Be sure to read this instruction manual thoroughly and fully understand before
operation.
After reading it, store it in a convenient place for immediate and future reading.

-1-
Important information
Be sure to read this instruction manual to understand how to operate equipment
correctly. Only operators, who fully understand warnings, cautions and instructions,
are to operate the equipment. Improper operation (mishandling) can cause serious
bodily injury, death, fire or explosion.
Store this manual in a convenient place for immediate and future reference.
◆Regarding safety
・The safety instructions given in this manual are the minimum operating requirements.
Follow all national or municipal laws and regulations pertaining to fire, electricity, and
other safety regulations, as well as corporate regulations.
・Pay special attention to items which are shown by the below marks and symbols.
・Symbols and marks have the following meanings.
Examples of marks
WARNING
Indicates a potentially hazardous situation which, if not
avoided, may result in serious injury or loss of life.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury or property
damage.
Examples of symbols
Indicates [Beware]. We will explain briefly in or near the symbol.
(The example on the left is [Beware of electric shock]).
Indicates [Prohibited action]. We will explain briefly in or near the symbol.
(The example on the left is [Do not touch]).
Indicates [Required action]. We will explain briefly in or near the symbol.
(The example on the left is [Be sure to ground]).
＊We shall not be responsible for any injury or damage caused by disregard of
warnings, cautions or instructions.
Supplementary notes
Important
Indicates notes which we ask you to observe. They are helpful to
achieve full performance and functionality of the equipment.

-2-
For safe operation
Below is very important information about how to safely operate the equipment.
Before inspection and maintenance, be sure to read and fully understand the
contents.
WARNING
Conduct
periodical
maintenance and
inspection
Danger of failure and bodily injury
Conduct periodical maintenance and
inspection.
If not, it can cause insufficient
performance, failure of vacuum pump, and
bodily injury.
Be careful about
high temperature
Danger of burns
Conduct maintenance and inspection only
after vacuum pump becomes cool enough.
Maintenance and inspection soon after
vacuum pump stops can cause burn
injury.
With a thermal
protector [Only
single-phase
motor]
Danger of restart
Be sure to switch off electric source before
maintenance or inspection.
Single-phase motor has a thermal
protector.
Vacuum pump restarts become cool
without warning after vacuum pump.
.
Turn off electric
source
Danger of electric shock
Be sure to conduct maintenance and
inspection after you turn off electric
source.
If not, it can cause bodily injury from
electric shock or turning object.
CAUTION
Never use
solvent
Danger of shorter operating
lifetime and failure
Never use solvent when cleaning inside
the pump and Tip seal.
※If done, it can shorten lifetime.
Use ISP
exclusive grease
Danger of shorter operating
lifetime and Bearing failure
Be sure to use ISP exclusive grease.
※Mixing with other oil can shorten grease
life time and damage Bearings.

-3-
Contents
Important information ................................................................................................................ 1
For safe operation....................................................................................................................... 2
Contents....................................................................................................................................... 3
1. Before use ............................................................................................................................... 4
1.1 Check the product............................................................................................................. 4
1.2 Names of Fixtures and Tools........................................................................................... 4
2. How to use............................................................................................................................... 5
2.1 Maintenance standards.................................................................................................... 6
2.2 Necessary items for maintenance................................................................................... 7
2.3 Pump structure.................................................................................................................. 7
3. Annually or every 8000 hours maintenance and inspection ............................................. 8
3.1 Disassembly ...................................................................................................................... 8
3.2 Clean Tip seal.................................................................................................................. 11
3.3 Maintenance of FS(1)...................................................................................................... 13
3.4 Maintenance of FS(2)...................................................................................................... 14
3.5 Maintenance of OS.......................................................................................................... 16
3.6 Maintenance of Inlet flange............................................................................................ 17
3.7 Maintenance of Outlet flange......................................................................................... 17
3.8 Assembly ......................................................................................................................... 18
3.9 Operation ......................................................................................................................... 21
4. Every two years or every 16000 hours maintenance and inspection............................. 22
4.1 Disassembly .................................................................................................................... 22
4.2 Replace O-ring................................................................................................................. 22
4.3 Remove Tip seal.............................................................................................................. 22
4.4 Maintenance of FS(1)...................................................................................................... 23
4.5 Maintenance of FS(2)...................................................................................................... 29
4.6 Maintenance of OS.......................................................................................................... 33
4.7 Maintenance of Inlet flange............................................................................................ 36
4.8 Maintenance of Outlet flange......................................................................................... 36
4.9 Maintenance of Air flush port........................................................................................ 37
4.10 Fit new Tip seal ............................................................................................................. 38
4.11 Assembly ....................................................................................................................... 38
4.12 Break-in operation ........................................................................................................ 38
4.13 Inspect pump performance.......................................................................................... 40
4.14 Rated current chart....................................................................................................... 40
5. Fixture combination chart.................................................................................................... 40
6. Parts list.................................................................................................................................41
7. Extended drawing................................................................................................................. 42

-4-
1. Before use
1.1 Check the product
・Check that the package is right-side-up before opening.
・Check that the model of the product is the same as the one you ordered.
・Check that there is no shortage or damage.
If there is any damage, contact either the dealer who sold it to you or us.
・Check the following accessories.
Instruction manual (this one)
1.2 Names of Fixtures and Tools
Washer M10, M12
Hex. nut M10, M12
Hex. socket head bolt
M10 L110 Whole thread
M12 L120 Whole thread
Fixture 11
Fixture 20-E
Fixture 22-E
Fixture 21-E
Hex. bar spanner
Wrench flat 10 Long type
Wrench flat 8 Long type
Wrench flat 6 Ball at tip, long type
Wrench flat 5 Ball at tip, long type
Wrench flat 4 Ball at tip, long type
Wrench flat 3 Ball at tip, long type
Wrench flat 2.5 Ball at tip, long type
Fixture 12
Fixture 10, 13, 14
Fixture 8
Fixture 5
Fixture 2-2
Fixture 1-E, 15-E
Fixture 9B, 17, 18
OS Insert guide

-5-
2. How to use
These are exclusive tools for doing the maintenance and inspection of Oil-Free Scroll
Vacuum Pumps, ISP-250E.
WARNING
Danger of failure and bodily injury
Conduct periodical maintenance and inspection.
If not, it can cause insufficient performance, failure of vacuum pump, and bodily injury.
Conduct periodical
maintenance and
inspection
Danger of burns
Conduct maintenance and inspection only after vacuum pump becomes cool
enough.
Maintenance and inspection soon after vacuum pump stops can cause burn injury.
Be careful about
high temperature
Danger of restart
Be sure to switch off electric source before maintenance or inspection.
Single-phase motor has a thermal protector.
Vacuum pump restarts become cool without warning after vacuum pump.
With a thermal
protector
[Only single-phase
motor]
Danger of electric shock
Be sure to conduct maintenance and inspection after you turn off electric source.
If not, it can cause bodily injury from electric shock or turning object.
Turn off electric
source

-6-
2.1 Maintenance standards
Do the maintenance according to maintenance standards which are shown in time
and period, whichever comes first.
The following parts are consumable and need to be replaced periodically.
Whenever something goes wrong with them, replace them immediately.
Parts
No.
Where to inspect
Maintenance standards
Every400
timesvapor
pumping
Remarks
Annuallyor
every8,000
hours
Bienniallyor
every16,000
hours
31
Ballbearing
[FS(1)(2)]
△
○
△
Supply with
Bearing kit
21
Needle bearing
[OS]
Grease/ △
○
△
298
O-ring
[FS(2)]
△
○
△
37
O-ring
[Pin crank]
△
○
△
38
Miniature ball bearing
[Pin crank]
△
○
△
53
Spider
△
○
△
28-1
Shaftseal
[FS(1)(2)]
△
○
△
Supply with
Seal set
28-2
G-seal
[FS(1)(2)]
△
○
△
20
G-seal
[OS]
△
○
△
214
O-ring
[FS(1)]
△
○
△
Supply with
O-ring set
23
O-ring
[FS(2)]
△
○
△
25
O-ring
[Inlet flange]
△
○
△
202
O-ring
[Outlet flange]
△
○
△
297
O-ring
[Inner ring]
△
○
△
295
Inlet gasket
[Inlet]
△
○
△
101
Tip seal set(1)
△
○
△
Supply with
Tip seal set
103
Tip seal set(2)
△
○
△
107
Exhaust valve set
△
○
△
Supply with
Exhaust valve set
306
Air flush set
△
○
△
Supply with
Air flush kit
104
Pin crank set
△
△
△
Supply with
Pin crank kit
○・・・Replace
△・・・Replace if something goes wrong.
Note 1：Maintenance interval should be shorter than either the period or operating hours.
Note 2：When you want further maintenance and inspection after either the 6th year or 48,000 operating
hours, please contact our dealer who sold it to you.
Important
Causes of failure
Shorten maintenance interval if conditions of installation or operation are unfavorable.
In particular, ambient temperature has a great influence on failure. Maintenance interval is based on an ambient
temperature 5~40℃and a yearly average ambient temperature 25℃.
Shorten the maintenance interval if temperature exceeds the foregoing. If not, it can cause failure.
Maintenance interval is not a guarantee period.

-7-
2.2 Necessary items for maintenance
Prepare the following items before maintenance.
1. Block（large）2pcs.
(55mm×55mm×length 250mm wood which does not damage pump)
2. Block（small）1pc.
(20mm×10mm×length 250mm wood which does not damage pump)
3. Clean cloth
4. Spanners (･14mm wrench flat ･17mm wrench flat ･19mm wrench flat)
5. Thin spanners (･12mm wrench flat)
6. Torque wrench for bolt with Hex. Socket head
・for 4mm wrench flat which can measure 3.0N･m (30kgf･cm) torque
・for 5mm wrench flat and 6mm wrench which can measure15N･m (150kgf･cm) torque
7. Rubber mat which can prevent sliding
8. Straight edge screwdriver
9. Cross head screwdriver
・M3（tip shape No.1）
・M4（tip shape No.2）
10. Cutter (Sharp knife)
11. Threadlocker (medium strength) e.g. LOCTITE 242
12. Tweezers（more than 150 mm）
13. Bamboo spatula, Brass brush
14. ISP exclusive grease
15. Snap ring pliers
16. Vernier caliper
17. Ampere meter (Clamp meter)
18. Air compressor etc.
19. Pirani vacuum gauge
20. Leak detector
2.3 Pump structure
This Pump is a scroll type vacuum pump. An orbiting scroll (OS) rotates
between a fixed scroll FS(1) and a fixed scroll FS(2) and the set of scrolls
compresses air. FS(1) is on Motor side and FS(2) is on Fan cover side.
FS(2)
OS
FS(1)

-8-
3. Annually or every 8000 hours maintenance
and inspection
WARNING
Danger of failure and bodily injury
Conduct periodical maintenance and inspection.
If not, it can cause insufficient performance, failure of vacuum pump, and bodily injury.
Conduct periodical
maintenance and
inspection
Danger of burns
Conduct maintenance and inspection only after vacuum pump becomes cool
enough.
Maintenance and inspection soon after vacuum pump stops can cause burn injury.
Be careful about
high temperature
Danger of restart
Be sure to switch off electric source before maintenance or inspection.
Single-phase motor has a thermal protector.
Vacuum pump restarts become cool without warning after vacuum pump.
With a thermal
protector
[Only single-phase
motor]
Danger of electric shock
Be sure to conduct maintenance and inspection after you turn off electric source.
If not, it can cause bodily injury from electric shock or turning object.
Turn off electric
source
3.1 Disassembly
3.1.1 Remove Fan cover
Remove 4 Hex. socket head bolts which hold Fan cover, and remove Fan cover and
Cover plate.
Important
Before disassembly, open Inlet to atmospheric pressure, repeat close-open operation for a
couple of times in order to clean inside the pump, and cut off electric source.
Important
Rotate Fan by hand and check smooth rotation, and remember the feeling of rotating
resistance.
When reassembling, check the slightly heavier rotating resistance. If rotation is not smooth, something will go
wrong inside the pump. Check each Bearing and replace it if something goes wrong.
Washer
Hex. socket head bolt
Fan cover
Cover plate
Hex. wrench
(Size 4mm)

-9-
3.1.2 Remove Inlet flange
①Remove Hex. socket head bolts which hold Inlet flange, and remove Inlet flange,
O-ring, Inlet filter, Inlet adapter, Inlet gasket.
3.1.3 Remove Body set
①Place the pump vertically with Motor downwards.
②Remove Hex. socket head bolts which hold Motor set and FS(1), lift Body set and
separate it from Motor set.
Important
Rotate Motor shaft by hand and check the smooth rotation.
If rotation is not smooth with some resistance, check Motor bearings and Motor, and replace it if something goes
wrong.
Inlet flange
Hex. socket head bolt
O-ring
Inlet filter
Inlet adapter
Inlet gasket
Hex. wrench
(Size 5mm)
FS(1)
Hex. socket head bolt
Hex. wrench
(Size 5mm)
Motor set

-10-
3.1.4 Disassembly of Body set
①Place Body set with FS(1) downwards on 2 blocks (wood which height is over
55mm).
②Remove Hex. socket head bolt which fixes Fan(2) on FS(2) side, and remove
Washer, Fan(2), Parallel key and Fan spacer.
③Loosen Hex. socket head bolts diagonally by
turns which fix FS(2), and remove them.
④Pull FS(2) towards axis and remove it.
⑤Pull O-ring and Inner ring towards axis and
remove it.
⑥Pull OS towards axis and remove it.
Important
・When pulling FS(2) and OS, pay attention not to damage Inner ring, Shaft seal, or Needle
bearing with angle of key groove of Crank shaft.
・When you cannot pull OS due to damaged OS Needle bearing, first do ⑦item, pull Crank
shaft and OS at the same time, and separate OS and Crank shaft from FS(2) side.
Fan(2)
Hex. wrench
(Size 5mm)
Hex. socket head bolt
Parallel key
Fan spacer
Washer
Hex. wrench
(Size 5mm)
O-ring
Inner ring
FS(2)
OS
Hex. socket head bolt
Crank shaft

-11-
⑦Remove Hex. socket head bolt which holds Fan(1) on FS(1) side, and remove a
Washer and Fan(1).
⑧Remove Parallel key and pull Crank shaft, O-ring and Inner ring.
3.2 Clean Tip seal
Important
・Check that top of Tip seal comes out from the groove of FS(1),
FS(2) and OS (by about 0.1mm) at any point.
・If extrusion is less than 0.1mm at any point, replace all Tip seal at
the same time (refer to 4.10).
・Tip seal height: 2.20~2.30mm
・If it is not replaced, tip of scroll wrap contacts counter surface
(bottom) and damages it, resulting in failure.
Hex. wrench
(Size 5mm)
Fan(1)
Parallel key
Hex. socket head bolt
FS(1)
Washer
Crank shaft
Crank shaft
Inner ring
O-ring
FS(1)

-12-
3.2.1 Remove Tip seal
Gradually remove old Tip seal from end of outer periphery edge.
3.2.2 Clean Tip seal
Lightly wipe out both sides of Tip seal while black sliding material facing upwards.
CAUTION
Never use solvent when cleaning inside the pump and Tip seal.
※If done, it can shorten lifetime.
Never use solvent
Important
・If you feel resistance when removing Tip seal, dust will attach to side and groove of Tip seal.
Wipe out dust from the groove and Tip seal by using clean cloth and bamboo spatula.
・Remember each Tip seal position to return it to original position.
Important
・If you feel resistance when removing Tip seal, dust will attach to side and groove of Tip seal.
Wipe out dust from the groove and Tip seal by using clean cloth and bamboo spatula.
・Never use solvent.
・It makes tip seal expand to clean too hard, which results in making it difficult to insert it into
the groove.

-13-
3.3 Maintenance of FS(1)
3.3.1 Clean FS(1)
①Wipe out dust on wall and bottom of scroll wrap and inside the Inlet with clean cloth.
②Wipe out dust on side and bottom of Tip seal groove by using clean cloth and
bamboo spatula.
③Blow out the whole unit with air.
④Wipe out dust Pin crank.
・Turn Pin crank by hand and check if it turns lightly and smoothly.
・If you feel rumble when it is turning by hand, replace Pin crank set with new one.
⑤When Pin crank set is replaced, remove two screws located aside of Pin crank set
and remove Pin crank set.
・Wipe out adhesive and dust around screws. Blow out the whole unit with air.
・Fit Pin crank set and tighten by screw with slight amount of Threadlocker (medium
strength) e.g. LOCTITE 242.
⑥Turn inner ring of the Ball bearing by hand and check that it turns lightly and
smoothly.
⑦If you feel some rumble, replace the Ball bearing according to 4.4.1～4.4.2 and
4.4.7～4.4.8.
Important
・When cleaning, protect it with masking tape to prevent foreign matter such as wear debris and
waste lint from entering the bearing and shaft seal.
・If you feel some resistance to remove Tip seal, be sure to wipe out dust.
・Be sure to clean Tip seal groove with soft bamboo spatula since groove is fragile.
・Always use clean cloth. Mixing with other grease can greatly deteriorate its performance.
・Pay attention not to leave the waste thread in the Bearings.
Important
・Use threadlocker (medium strength) e.g. LOCTITE 242.
・Apply slight amount of threadlocker to thread section.
・Wipe out extruded threadlocker with clean cloth.
Ball bearing
Shaft seal(1)
G-seal

-14-
⑧Fill ISP exclusive grease [0.1ml (0.2g)] between 2 lips of Shaft seal(1) and G-seal
with syringe evenly around whole periphery.
CAUTION
Danger of shorter operating lifetime and Bearing failure.
Be sure to use ISP exclusive grease.
※Mixing with other oil can shorten grease lifetime and damage Bearings.
Use ISP exclusive
grease
3.3.2 Fit Tip seal
①Place white soft back-up part facing downwards and black hard sliding material
facing upwards.
②Fit Tip seal from the center of FS(1).
③Internally extruded section near the center of wrap functions as a stopper to hold
Tip seal. Completely push sliding material side by hand into the groove.
3.4 Maintenance of FS(2)
3.4.1 Clean FS(2)
①Wipe out dust on wall and bottom of scroll wrap and inside the Inlet with clean cloth.
②Wipe out dust on side and bottom of Tip seal groove by using clean cloth and
bamboo spatula.
③Blow out the whole unit with air.
Important
・When cleaning, protect it with masking tape to prevent foreign matter such as wear debris and
waste lint from entering the bearing and shaft seal.
・If you feel some resistance to remove Tip seal, be sure to wipe out dust.
・Be sure to clean Tip seal groove with soft bamboo spatula since groove is fragile.
・Always use clean cloth. Mixing with other grease can greatly deteriorate its performance.
・Pay attention not to leave the waste thread in the Bearings.
Extruded section
Shaft seal(1)
G-seal
2 lips
2 lips

-15-
④Turn inner ring of the Ball bearing by hand and check that it turns lightly and
smoothly.
⑤If you feel some rumble, replace the Ball bearing according to 4.5.1 and 4.5.6.
⑥Fill ISP exclusive grease [0.1ml (0.2g)] between 2 lips of Shaft seal(1) and G-seal
with syringe evenly around whole periphery.
CAUTION
Danger of shorter operating lifetime and Bearing failure.
Be sure to use ISP exclusive grease.
※Mixing with other oil can shorten grease lifetime and damage Bearings.
Use ISP exclusive
grease
3.4.2 Fit Tip seal
①Place white soft back-up part facing downwards and black hard sliding material
facing upwards.
②Fit Tip seal from the center of FS(2).
③Internally extruded section near the center of wrap functions as a stopper to hold
Tip seal. Completely push sliding material side by hand into the groove.
Extruded section
Ball bearing
Shaft seal(1)
G-seal
Shaft seal(1)
G-seal
2 lips
2 lips

-16-
3.5 Maintenance of OS
3.5.1 Clean OS
①Wipe out dust on wall and bottom of scroll wrap with clean cloth.
②Wipe out dust on side and bottom of Tip seal groove by using clean cloth and
bamboo spatula.
③Blow out the whole unit with air.
④Fully wipe out old grease attached to Needle bearings in the center of OS with clean
cloth while turning roller until no more comes out.
3.5.2 Needle bearing grease up
①Fill ISP exclusive grease to roller section of Needle bearing. Apply ISP exclusive
grease between roller and cage while turning roller.
②Evenly fill ISP exclusive grease [0.2ml (0.4g) / 1section] between 2 lips of G-seal.
CAUTION
Danger of shorter operating lifetime and Bearing failure.
Be sure to use ISP exclusive grease.
※Mixing with other oil can shorten grease lifetime and damage Bearings.
Use ISP exclusive
grease
3.5.3 Fit Tip seal
①Place white soft back-up part facing downwards and black hard sliding material
facing upwards.
②Fit Tip seal in accordance with shape at the center of OS and insert gradually
further towards outside.
Important
・If you feel some resistance to remove Tip seal, be sure to wipe out dust.
・Be sure to clean Tip seal groove with soft bamboo spatula since groove is fragile.
・Always use clean cloth. Mixing with other grease can greatly deteriorate its performance.
・Pay attention not to leave the waste thread in the Bearings.
Important
・Be sure to use clean rubber gloves when applying grease to Needle bearing.
・Apply grease a bit more to both roller and cages which are somewhat worn, different
from new Bearing.
Start here at the
center of OS

-17-
3.6 Maintenance of Inlet flange
①Clean Inlet filter, Inlet adapter, Inlet gasket and inside the Inlet flange.
②Clean the Inlet filter with air blow.
3.7 Maintenance of Outlet flange
①Loosen Nut and remove Outlet flange.
②Remove O-ring inside the exhaust hole of FS(2), and clean the exhaust hole inner
diameter and outlet flange by using cloth and brass brush.
③Remove C-type snap ring in the Outlet flange with snap ring pliers. Remove
Exhaust guide, Exhaust spring and Exhaust valve.
④Clean exhaust flange and the exhaust hole of the exhaust flange and the sealing
surface against the exhaust valve by using clean cloth and bamboo spatula so as
not to damage, and blow out with air.
⑤Fit Exhaust valve, Exhaust spring, and Exhaust guide into the Exhaust flange, and
hold it with a C-type snap ring. Make sure that the Exhaust valve is at the center.
⑥Fit O-ring in the exhaust hole O-ring groove.
⑦Fit Outlet flange with Nut to FS(2),and tighten Nut and fix it.
Important
Exhaust valve should be at center.
O-ring
Nut
Outlet flange
Exhaust guide
Exhaust spring
Exhaust valve
C-type snap ring
Nut
Outlet flange
Exhaust guide
Exhaust spring
Exhaust valve
C-type snap ring

-18-
3.8 Assembly
Assemble in reverse order of disassembly.
3.8.1 Assemble Body set
①Place 2 blocks (wood which height is over 55mm) on horizontal workbench and
FS(1) on the top of them.
②Fit Crank shaft, O-ring and Inner ring vertically to FS(1).
③Turn eccentric section of both Crank shaft and Pin crank in the same direction. Put
the OS Insert guide on the Crank shaft as shown in the drawing.
④Fit OS to FS(1).
Important
When fitting Crank shaft to FS(1), pay attention not to damage Bearing and shaft seal with the
angle of Key groove of Crank shaft.
Important
Pay attention that Tip seal does not come off when fitting OS.
Crank shaft
Inner ring
O-ring
FS(1)
Make sure that this surface
matches that of crank shaft.
OS Insert guide
Crank shaft
○
×
Crank shaft
OS Insert guide
OS
FS(1)

-19-
⑤Fit the Inner ring and O-ring into the Crank
shaft.
⑥Fit O-ring to FS(2) and assemble to FS(1).
⑦Tighten the Hex. socket head bolts
alternately in the diagonal direction.
⑧Fit Fan spacer, Parallel key and Fan(2) to FS(2), apply slight amount of
threadlocker (medium strength) e.g. LOCTITE 242 to Hex. socket head bolts
and fully tighten along with Washer.
Tightening torque
14.7±0.7Nm (150±7kg･cm)
Tightening torque
7.8±0.7Nm (80±7kg･cm)
Important
・Check that there is no dust or damage on the surface of O-ring for FS(1), FS(2) and O-ring
surface.
・Check that O-ring does not come off from mating side and Tip seal does not come off from the
groove.
・Diagonally tighten Hex. socket head bolts fixing FS(2) by turns in order to tighten evenly.
Hex. wrench
(Size 5mm)
O-ring
Inner ring
FS(2)
Hex. socket head bolt
Crank shaft
O-ring
Fan(2)
Hex. wrench
(Size 5mm)
Hex. socket head bolt
Parallel key
Fan spacer
Washer