Gardner Denver Welch VCpro 600 Series User manual

Operation Manual
(EN)
Translation of the original operation manual
Welch VCpro 600 Series
Vacuum Controller
Device models:
► VCpro 601
Vacuum control valve
► VCpro 602
Motor speed control
600100
Revision 0 2019-10-30

Manufacturer
Gardner Denver Thomas GmbH
Am Vogelherd 20
98693 Ilmenau
Germany
Imprint
© 2019
Reprint or duplication, also in excerpt,
are not permitted without written ap-
proval from Gardner Denver Thomas
GmbH.
All rights under the copyright laws are
expressly reserved by Gardner Den-
ver Thomas GmbH.
We reserve the right to make changes
and amendments.
T [phone]
F [phone]
welch.em[email protected]
www.gardnerdenver.com/welch
Customer support [phone]

Contents
Operation manual VCpro 600 3
Contents
1Important Information ..............................................................................5
1.1 Note for the user/personnel .................................................................................................5
1.2 Depiction of warning notices and information......................................................................5
1.3 Explanations of safety symbols............................................................................................6
1.4 Legend for the abbreviations ...............................................................................................7
2Safety.........................................................................................................8
2.1 General ................................................................................................................................8
2.2 Use.......................................................................................................................................8
2.2.1 Proper use............................................................................................................................8
2.2.2 Improper use........................................................................................................................8
2.2.3 Foreseeable misuse.............................................................................................................9
2.3 Target groups.......................................................................................................................9
2.3.1 Personnel qualification.........................................................................................................9
2.3.2 Overview of the responsibilities ...........................................................................................9
2.4 Protective measures..........................................................................................................10
2.5 Special hazards .................................................................................................................10
2.5.1 Hazardous materials in general.........................................................................................10
2.5.2 Explosive gases.................................................................................................................11
2.5.3 Electricity............................................................................................................................11
2.5.4 Mechanics..........................................................................................................................12
2.5.5 Vacuum..............................................................................................................................12
2.5.6 System functions................................................................................................................12
2.6 Network safety ...................................................................................................................13
3Technical data.........................................................................................14
3.1 Properties...........................................................................................................................14
3.2 Interfaces ...........................................................................................................................15
3.3 Pneumatic connections......................................................................................................16
3.4 Parts in contact with internal gas.......................................................................................16
4Description..............................................................................................17
4.1 Function .............................................................................................................................17
4.2 Set-up.................................................................................................................................17
4.3 Operating elements and navigation of the vacuum controller ...........................................18
4.3.1 Operating elements and display ........................................................................................18
4.3.2 Navigation..........................................................................................................................21
4.4 Device models ...................................................................................................................21
4.4.1 Vacuum controller VCpro 601 (vacuum control valve) ......................................................21
4.4.2 Vacuum controller VCpro 602 (motor speed control) ........................................................22
4.5 Explanation of the symbols................................................................................................23
4.6 Interfaces ...........................................................................................................................24
4.7 Accessories (options).........................................................................................................24
5Assembly and installation .....................................................................25
5.1 Unpacking..........................................................................................................................25
5.2 Set-up and connection.......................................................................................................25
5.3 Electrical connection..........................................................................................................25
5.4 Communication interfaces .................................................................................................26
5.5 Storage...............................................................................................................................26
6Operation.................................................................................................27
6.1 Start-up ..............................................................................................................................27

Contents
4 operation manual VCpro 600
6.2 Operating modes and system settings..............................................................................27
6.2.1 Operating mode 1 Manual.................................................................................................27
6.2.2 Operating mode 2 Automatic ............................................................................................28
6.2.3 Operating mode 3 Program...............................................................................................29
6.2.4 Operating mode 4 Multi-pump...........................................................................................30
6.2.5 Operating mode 5 Self-cleaning........................................................................................30
6.2.6 System settings.................................................................................................................31
6.3 Configuring the vacuum controller ....................................................................................35
6.3.1 Access control................................................................................................................... 35
6.3.2 Log files.............................................................................................................................35
6.3.3 Reset to factory settings....................................................................................................36
6.4 "PC-Control 601" PC software (Option) ............................................................................36
6.4.1 Installation .........................................................................................................................36
6.4.2 Connection settings...........................................................................................................37
6.4.3 Main screen....................................................................................................................... 38
6.4.4 File.....................................................................................................................................39
6.4.5 Log files.............................................................................................................................40
6.4.6 Settings .............................................................................................................................42
6.4.7 Calibrate............................................................................................................................43
6.4.8 Firmware update ............................................................................................................... 44
6.5 Solvents table....................................................................................................................45
7Maintenance and service....................................................................... 46
7.1 Cleaning ............................................................................................................................46
7.2 Disposal.............................................................................................................................46
7.3 Damage report .................................................................................................................. 46
8Elimination of operating faults..............................................................47
9Spare parts overview.............................................................................49
9.1 Spare parts list vacuum controller.....................................................................................49
9.2 Ordering and service contact............................................................................................50
10 Appendix.................................................................................................51
10.1 EU declaration of conformity.............................................................................................51
10.2 Notes.................................................................................................................................52

Important Information
Operation manual VCpro 600 5
1 Important Information
ATTENTION
►Read operation manual carefully before use.
►Keep operation manual for later reference.
1.1 Note for the user/personnel
Safety
The user/personnel must have read and understood the operation manual completely be-
fore starting work.
The operation manual must always be kept in the place it will be used and be available to
the user/personnel.
The product may not be transferred without the operation manual.
Safe operation can only be guaranteed with proper and correct use of the product. The
safety instructions must be heeded!
General information
For simplification, the vacuum controller (VCpro) will be called the device below.
Vacuum apparatus/vacuum system generally describes a combination of components for
vacuum applications, such as rotary evaporator with vacuum controller and vacuum
pump.
The operator is responsible for the proper use of vacuum apparatuses/vacuum systems.
1.2 Depiction of warning notices and information
The warning notices are depicted as follows:
Additional
symbols
DEGREE OF RISK
►Warning about possible hazards.
►Consequences if warning is not heeded.
►Heed note to prevent!
Degree of risk
DANGER
►Indicates a threatening risk that results in
dangerous injuries or death.
WARNING
►Indicates a possibly hazardous situation
which, if not avoided, can result in serious
injuries or life-threatening consequences.
CAUTION
►Indicates a possibly hazardous situation.If it
is not avoided, it can result in slight injuries.
Depiction of information
Additional
symbol
SIGNAL WORD
►Important information for the user/operator.

Important Information
6 operation manual VCpro 600
1.3 Explanations of safety symbols
►General warning symbol
►High voltage warning
►Explosive materials warning
►Hot surface warning
►Poisonous substances warning
►General prohibition
►General mandatory sign
►Disconnect from power
►Protective clothing –gloves
►Protective clothing –goggles
►Heed operating instructions
►Components jeopardized by electrostatic discharge ESD
►General information

Important Information
Operation manual VCpro 600 7
1.4 Legend for the abbreviations
Abbreviation
Designation or meaning
Explanation
A
Ampere - current strength
Electrical unit
abs
absolute
Value specification
AC
Alternating current
Electrical unit
ATM
Atmosphere
Pressure specification
DC
Direct current
Electrical unit
DN
Nominal diameter –inner diameter
(French: diamètre nominal)
Dimension specification
EPDM
Ethylene propylene diene rubber
Material
EX
Exhaust
Connection designation
FFKM
Perfluorinated rubber
Material
FKM
Fluorinated rubber
Material
FS
Full scale
Scale end value
FSS
Level sensor (German: Füllstandssensor)
Component
hh:mm:ss
hour / minute / second
Time specification
hPa
Hektopascal (1 hPa = 1 mbar = 0.75 Torr)
Pressure unit
Hz
Hertz - frequency
Electrical unit
IN
Intake
Connection designation
LVS
Labor vacuum system
Device model
max.
Maximum
Value specification
mbar
Millibar (1 mbar = 1 hPa = 0.75 Torr)
Pressure unit
min.
Minimum
Value specification
mm
Millimeter
Dimension specification
MPC
Diaphragm pump, chemically resistant
Device model
PP
Polypropylene
Material
PVDF
Polyvinylidene fluoride
Material
r.F.
Relative humidity (German: relative Feuch-
te)
Environmental condition
RPM
Rotation per minutes
Mechanical unit
Torr
Torr (1 Torr = 1.33 mbar = 1.33 hPa)
Pressure unit
V
Volt - voltage
Electrical unit
VCpro
Vacuum controller
Device model
W
Watt –power
Electrical unit
WV
Water valve
Component

Safety
8 operation manual VCpro 600
2 Safety
2.1 General
Anyone who will use the device must have read and understood the following safety and
warning notices.
All activities may only be performed by trained personnel who are familiar with the special
hazards and heed them and who have understood the functioning and operation manual
of the vacuum controller.
The device may only be used if it is in technically perfect condition.
2.2 Use
2.2.1 Proper use
The vacuum controller is a device, which with adjustable parameters, is used for control of
an absolute pressure between normal pressure and 1 mbar for vacuum applications in the
industrial sector and laboratories.
The device is only to be used indoors and may not be used in potentially explosive atmos-
phere.
Operation of the device is only permissible under the conditions described
in Chapter 3 Technical data,
on the type plate,
and in the technical specification for the order in question.
Furthermore, proper use includes:
Heeding the warning/safety measures in this operation manual and of the connected de-
vices
Heeding the operation manual
Adherence to the operation manuals for connected vacuum pumps and laboratory vacu-
um systems from Gardner Denver Thomas GmbH
Use of approved spare parts and accessories from Gardner Denver Thomas GmbH
►Any other use will be regarded as improper!
2.2.2 Improper use
CAUTION
►With proper use, personal injury or property damage can occur.
►The operator must ensure proper operation!
The following is regarded as improper use:
Use that does not correspond to the proper use
Use outside of the specifications of the technical data, the type plate or the conditions
named in the delivery contract
Operation in less-than-perfect technical condition
Operation with missing or defective protective equipment
Operation outdoors
Uses that are improper must be prevented by the operator or measures must be taken that
ensure proper operation!

Safety
Operation manual VCpro 600 9
2.2.3 Foreseeable misuse
ATTENTION
►Misuse is generally FORBIDDEN. It also counts as improper!
Regarded as foreseeable misuse are the following:
Operation in explosive atmospheres
Conveying of critical gas (outside of the specifications in section 6.5 Solvents table)
Manipulation of the software and hardware, such as impermissible attachments and mod-
ifications
Leaving critical applications unsupervised
Operation of the device with tools or other impermissible objects
2.3 Target groups
ATTENTION
►There can be misuse due to use by untrained personnel.
►The operator must ensure that the personnel is trained properly and all
necessary safety measures are adhered to!
2.3.1 Personnel qualification
Target group
Area of activity
User
Laboratory personnel, e.g. chemists
Specialized personnel
Person with professional qualification
as a mechanic, electrician and/or with laboratory devices
Manufacturer or
authorized workshop
Service and maintenance / service only by manufacturer or
authorized workshops / service providers
2.3.2 Overview of the responsibilities
Activity
User
Specialized
personnel
Manufacturer /
workshop
Set-up
x
x
x
Bringing into service
x
x
x
Operation
x
x
x
Calibration of sensors
x
x
x
Calibration of sensors at the factory
x
Factory settings
x
x
Fault message
x
x
x
Troubleshooting
x
x
x
Elimination of pneumatic faults
x
x
x
Elimination of electrical faults
x
x
Network integration
x
x
Software update
x
x
Data import/export
x
x
x
Data logger download
x
x
x
Repair order
x
x

Safety
10 operation manual VCpro 600
Activity
User
Specialized
personnel
Manufacturer /
workshop
Service (cleaning)
x
x
x
Replacement of spare parts
x
x
x
Decommissioning
x
x
Decontamination *
x
x
*or having this done by qualified and authorized service providers
2.4 Protective measures
All protective measures must be the highest priority in order to protect the life and health of
personnel. In case of potential safety hazards, these must be assessed and measures taken
to avoid hazards. Uses that endanger health and life are not permitted.
Applicable operating instructions from the operator and the national regulations for accident
prevention, safety and occupational safety must be heeded.
PROTECTIVE CLOTHING
►For applications that require protective clothing, this clothing must be
worn for personal safety.
►The operator must specify the type and manner of protective clothing!
2.5 Special hazards
EMERGENCY SWITCH OFF
►In dangerous situations, de-energize the device by pressing the power
switch or disconnecting the power plug.
DE-ENERGIZED
When de-energized:
►VCpro 601 model: all valves are closed
►VCpro 602 model: motor stops
2.5.1 Hazardous materials in general
WARNING
►Hazardous materials in the medium to be conveyed can cause personal
injuries and property damage.
►Heed the warning and safety instructions for handling hazardous
materials!
HAZARDOUS MATERIALS
►For applications with materials with H and P classes, measures must
be taken to protect the health of people and the environment.
►The operator must –taking into account the applicable regulations –
assess the possible hazards in order to prevent personal injuries and
damage to the environment and property. The operator bears
responsibility for this!

Safety
Operation manual VCpro 600 11
For applications with hazardous materials, the following must be heeded:
Adhere to the requirements of the manufacturer's safety data sheets for hazardous mate-
rials.
Prevent the escape of poisonous and environmentally-damaging substances from the
apparatus.
To protect the environment and the apparatus, use a separator (e.g. condenser).
Check the strength and leak tightness of the connecting lines.
Check the proper installation of the sensor in the vacuum apparatus.
SERVICE / REPAIR
►Service and repair by the manufacturer or in authorized facilities only
with transfer of the completely filled-out damage report with
decontamination declaration.
The damage report form is available for download from our website
www.gardnerdenver.com/welch on the "Service" menu"Damage reports".
2.5.2 Explosive gases
The device is not suited for operation in areas subject to explosion or the conveying of media
that can form explosive mixtures.
The device is not certified according to ATEX directive 2014/34/EU.
When using the device in areas subject to explosion, the system operator is obligated to ad-
here to the ATEX 137 directive 1999/92/EC.
DANGER
►Caution, risk of explosion due to critical applications.
►With use of the device in an atmosphere subject to explosion or in
applications where explosive mixtures can form, there is danger to life.
►The operator must ensure that the application may not be used in
potentially explosive atmosphere!
2.5.3 Electricity
DANGER
►There is danger to life when opening the device. Touching exposed
electrical conductors can cause immediate death.
►Opening the device is generally forbidden; this may only be done by
specialists.
►Before opening the device, disconnect the power plug!
Heed the following instructions:
Operating the device without the housing is forbidden.
Only the manufacturer, authorized workshops or trained personnel may change the pow-
er supply, display or printed circuit board.
If the device is defective, switch it off and disconnect the power plug.
Use only the included standardized power plug in accordance with IEC 60320-C13. The
power plug and cable must be in perfect condition.
The electrical network must have protective conductors in accordance with IEC 60364-4-
41. The protective conductor may not be interrupted.
Note that the controller must be regarded as a portable tool.

Safety
12 operation manual VCpro 600
2.5.4 Mechanics
ATTENTION
►In case of improper use of manipulation of the device, there can be
property damage to the connected vacuum pump or vacuum
apparatus!
Operate the device only according to the operation manual and the instructions in the opera-
tion manuals for the connected devices!
Operation with overpressure is not permitted with the device.
Solid and liquid materials in the gas to be conveyed can compromise the function of the sen-
sor. Prevent the penetration of solid particles into the vacuum apparatus.
2.5.5 Vacuum
WARNING
►Hazard due to sudden ventilation of the vacuum apparatus.
►Due to sudden ventilation, the vacuum apparatus can explode.
►Prevent sudden ventilation. Check the pressure in the vacuum
apparatus before you disconnect the pneumatic connections.
The vacuum apparatus can also be under vacuum when the device is
switched off.
Glass equipment is especially at risk. Make sure that it is vacuum-proof and non-breakable!
2.5.6 System functions
The following settings for the "control systems" must be assessed separately for particular
vacuum applications, see Chapter 6.2.6 System settings:
"Allow ventilation"
When this function is activated, it is possible that ambient air will get into the applications.
This can cause uncontrolled reactions.
Note that an inert gas must be connected to the ventilation valve if necessary.
By activating the function, gas, possibly ones damaging to health, can escape from the
application into the environment!
"Auto Start"
If the "Auto Start" function is activated, the device starts automatically after
a power failure or when the power switch is pressed. This can cause undesired after-
effects in your application.
An automatic start only occurs if an operating mode was started previously.
Make sure that critical applications are not unsupervised!
WARNING
►Activating the "Auto start" parameter in the system setting can result
in hazards for the user and his environment.
►Check system settings with automatic start-up function and assess
possible hazards for your application!
Both system settings are not activated in the factory setting. Before you activate the func-
tions, make sure that there is no hazard with your application. The operator must assess
possible hazards in order to guarantee the safety of users!
Unauthorized activation of the functions can be prevented with the ADMIN password, see
Chapter 6.3.1 Access control.

Safety
Operation manual VCpro 600 13
2.6 Network safety
ATTENTION
►The vacuum controller is network-capable via the LAN connection.
This introduces the possibility of external access to the vacuum
controller. Unauthorized access can cause manipulation of the
applications.
The operator must guarantee network security in order to prevent
undesired access to the vacuum controller.

Technical data
14 operation manual VCpro 600
3 Technical data
3.1 Properties
Parameters
Data
Unit
Device model
VCpro 601
VCpro 602
Item number
600100
600101
Whole device
Degree of protection
IP 20
-
Operating temperature
+ 15 … + 30
°C
Rated voltage
115 … 240
V AC
Rated power
40
W
Frequency
50 / 60
Hz
Output voltage power supply
24
V DC
Device fuse
T 630
mA
Dimensions (W/D/H)
195 / 178 / 105
mm
Weight
1.5
kg
Storage temperature
+ 10 … + 40
°C
Storage humidity
max. 90 %
r.F.
Vacuum controller (internal)
Switching/regulation precision
± 1
digit
- Vacuum control valve
Voltage / power / resolution
24 / max. 16 / 1
-
V / W /
bits
- Motor speed control
Voltage / resolution
-
0 –10 / 8
V / bits
- Pressure sensor
Voltage / resolution
5 / 12
V / bits
- Ventilation valve
Voltage / power / resolution
24 / 2 / 1
V / W /
bits
- Water valve
Voltage / power / resolution
24 / max. 4 / 1
V / W /
bits
- Level sensor
Voltage / resolution
24 / 1
V / bits

Technical data
Operation manual VCpro 600 15
Parameters
Data
Unit
Pressure sensor (internal)
Sensor type
capacitive
-
Measurement range
1 - 1100
mbar
Precision in total
linearity, hysteresis and
reproducibility
< ± 0.3 % FS
-
3.2 Interfaces
Control connections
Connection type
Pin assign-
ment
IN/
OUT:
Serial
RS 232, 9-pin D-Sub plug
-
IN/
OUT:
LAN
RJ 45, min. CAT 6
OUT:
Vacuum
control valve
With the VCpro 601 model, the vacuum
control valve is integrated.
-
OUT:
Water valve
Binder
outlet
4-pin
1 +24 V
2 GND
3 N/A
4 N/A
OUT:
Level sen-
sor
Binder
outlet
7-pin
1 Signal
sensor
2 N/A
3 GND (L-)
4 N/A
5 +24 V (L+)
6 Teach
7 N/A
OUT:
Motor
speed
control
Binder
outlet
4-pin
1 N/A
2 N/A
3 0-10 V
4 GND
NOTE Control connection only for the
VCpro 602 model.

Technical data
16 operation manual VCpro 600
3.3 Pneumatic connections
Connections
Connection type
Connection:
Inert gas (ventilation valve)
Hose nozzle DN 4
Connection:
Vacuum apparatus
Hose nozzle DN 8
Connection:
Vacuum pump
3.4 Parts in contact with internal gas
Components
Material
Valve block including hose nozzles
PP
Vacuum control valve
PVDF, PTFE
Ventilation valve
including inert gas hose nozzle
FKM,
stainless steel
Backflow-stop valve (internal)
FFKM
Pressure sensor
Including seal
Aluminum oxide ceramic, EPDM
ATTENTION
►The user must ensure that the application is not critical with the
installed materials.
►Heed the safety instructions see Chapter 2.5.1 Hazardous materials in
general.

Description
Operation manual VCpro 600 17
4 Description
4.1 Function
The VCpro 600 series vacuum controller is a measurement and control/regulation device for
vacuum processes. The regulation and control is done by inputting parameters for "set-
points" and the querying of the "actual values“. This allows a regulation and monitoring of the
vacuum processes in various operation modes:
Vacuum pressure regulation in a pressure range from 1100 to 1 mbar
Vacuum pressure regulation VCpro 601: via an electromagnetic vacuum control valve
Vacuum pressure regulation VCpro 602: via an external motor speed controlled vacuum
pump
Ventilation of the system via the sensor ventilation valve subassembly as component of
the vacuum controller, if necessary also with inert gas (inert gas connection DN4 on the
device rear)
4.2 Set-up
The vacuum controller has a metal housing (3). The operating and display elements (9) are
arranged on the front of the device.
On the rear are the ventilation valve with inert gas connection and for the device models:
VCpro 601, the electromagnetic vacuum control valve
VCpro 602, the control wire connection for the motor speed control
On the right side of the device are the power socket (7) with device main switch I/O (8), the
RS 232 PC connection (5) and the RJ 45 LAN connection (6).
The vacuum pump (2) and vacuum apparatus (1) are connected using the hose nozzles.
Depending on the device model (VCpro 601 or VCpro 602), the outputs are assigned for
electromagnetic vacuum control valve for regulating the vacuum, or for the vacuum pump
motor, using an analog voltage for motor speed regulation (0 –10 V).
3
9
7
8
5
6
2
4
1

Description
18 operation manual VCpro 600
Pos.
Designation
1
Vacuum apparatus –connection
2
Vacuum pump –connection
3
Metal housing
4
Electromagnetic vacuum control valve (only VCpro 601 model)
5
RS 232 PC connection
6
RJ 45 LAN connection
7
Power socket
8
Device main switch I/0
9
Operating and display elements
OPERATING ELEMENTS: see Chapter 4.3.1 Operating elements and display
EXPLANATION OF THE SYMBOLS: see Chapter 4.5 Explanation of the symbols
OPTIONALLY available: see Chapter 4.7 Accessories (options)
Water valves WV
Level sensor FSS
The optional units can be connected using the following connection sockets see Chapter 3.2
Interfaces:
Water valve connection WV
Connection for level sensor FFS
The optional units are controlled with the vacuum controller.
4.3 Operating elements and navigation of the vacuum controller
4.3.1 Operating elements and display
4
3
2
1
5

Description
Operation manual VCpro 600 19
Pos.
Symbol
Designation /
function
Explanation
1
Toolbar
Vacuum control valve
Lights up if valve is open.
Ventilation valve
Lights up if valve is open.
Motor
Device model VCpro 602:
The relative motor speed is displayed in
percent on the motor symbol.
Cooling water valve
Lights up if valve is open.
Fluid catchpot
Lights up if the level sensor (optional)
is triggered.
Serial interface
Lights up when the device is connected to
the PC software via RS232.
LAN interface
Lights up when the device is connected to
the PC software via LAN.
Warning
When maintenance is due
2
Display - display field
▼0
Pressure –setpoint
Depiction in real time (top left)
44.0
Pressure –actual value
Depiction in real time
≤ / ≥
Less than-equal to
Greater than-equal to
Actual value is outside of the range depict-
ed (bottom left)
00:00
Time
hh:mm (top middle)
3
Navigation bar
Manual
See Chapter 6.2 Operating modes and sys-
tem settings
Automatic
Program
Multi-pump
Self-cleaning
System settings
4
Button bar
VENT
Ventilation of the system:
Opens the ventilation valve if the oper-
ating mode is not active
Opens the ventilation valve for the time
when pressed, in active operating
mode

Description
20 operation manual VCpro 600
Pos.
Symbol
Designation /
function
Explanation
PMIN
Primary function:
Device model VCpro 601:
Vacuum control valve opens.
Device model VCpro 602:
Maximum pressure drop at
100 % motor speed.
Secondary function:
Pressure input: table with solvents appears
on the screen.
NOTE See Chapter 6.5 Solvents table
START / STOP
Start and stop the active operating mode
selected.
BACK
Primary function:
Input: back
Navigation: one level up
Secondary function:
Change between numeric and graphic dis-
play in active operating mode.
5
Rotary encoder
TURN
Primary function:
Selection of operating mode
Selection of row/column in the
parameter table
Secondary function:
Adjust parameter value
Change pressure setpoint in active
operating mode manual
PRESS
Primary function:
Selection of selected operating mode
Selection of parameter value
Secondary function:
Confirmation of set parameter value
Confirmation <OK> dialog field
Change pressure setpoint in active
operating mode manual