Gardner Denver WELCH GEMINI 2050 User manual

OWNER’S MANUAL
FOR
GEMINI™ VACUUM SYSTEM
MODELS:
2050 & 2060
CAUTION
GEMINI vacuum pumps are designed for intermittent use with aqueous based, mildly
acidic / basic, or select organic media. Use with acid, base or organic vapors or
gases is limited by compatibility with pump materials of construction. Always verify
vapor chemical compatibility prior to pump use and utilize proper cleaning methods to
remove chemical residuals from the pump after use.
Part No. 642853B
Printed in USA
Welch-Ilmvac
5621 W. Howard Street
Niles, IL 60714
Phone: [phone] (Technical Support)
Fax: [phone]
E-Mail: [e-mail]
Web-Page: www.welchvacuum.com
Model 2050 Model 2060

INSTRUCTION
WARNING AND CAUTION
PLEASE READ BEFORE OPERATION
While reading your manual, please pay close attention to areas labeled:
WARNING AND CAUTION.
The description of each is found below.
WARNING
Warnings are given where failure to observe instruction could result
in injury or death to people.
CAUTION
Cautions are found where failure to observe the instruction could result
in damage to the equipment, associated equipment and process.
These units confi rm to the SI International system of units of measurement.
The following symbols (with recommendation of IEC1010 ) of warning will be found on the pump.
Caution - refer to accompanying documents
Caution - risk of electrical shock
Caution - hot surface
2

TABLE OF CONTENTS
Section 01 - SAFETY INFORMATION
1.10 To Prevent Injury
1.20 To Reduce Risk Of Electrical Shock
1.30 To Reduce Risk Of Electrocution
1.40 To Reduce Risk Of Explosion Or Fire
Section 02 - INSTALLATION
2.10 Introduction
2.20 Unpacking
2.30 Pump Location
2.40 Application Connection
Section 03 - OPERATION
3.10 Starting Procedures / Applications Qualifi cation
3.20 Leak Detection
3.30 Pump Cleaning / Shutdown Procedures
Section 04 - MAINTENANCE
4.10 Maintenance Procedures
Section 05 - TROUBLESHOOTING
5.10 Vacuum Problems
Section 06 - SPECIFICATION
6.10 Specifi cation Table
Section 07 - WARRANTY
3

SECTION 1: SAFETY INFORMATION
1.10 To Prevent Injury...
1.11 Never operate this product if it has a damaged cord or plug. If it is not working properly, has
been dropped, damaged or has fallen into water, please contact a Gardner Denver Welch
service center to arrange return for examination and repair.
1.12 Keep the cord away from heated surfaces. All electrical products generate heat. To avoid seri-
ous burns never touch unit during or immediately after operation.
1.13 Never block any pump case ventilation openings or place it on a surface where the ventilation
openings may be blocked.
The air openings are for ventilation of the motor inside the housing. Keep all air openings free
of lint, dirt and other foreign objects.
1.14 Always disconnect power source before servicing.
1.15 Never insert fi ngers or any other object into any openings.
1.16 Do not operate this product where oxygen is being administered.
1.17 Wear safety glasses and goggles when operating this product. Never point any air nozzle or air
sprayer toward another person or any part of the body.
1.18 Use only in well ventilated areas.
1.19 Never block pump exhaust. Serious injury can result from pressure build up.
1.20 To Reduce Risk Of Electrical Shock...
1.21 Do not disassemble. Disassembly or attempted repairs if accomplished incorrectly can create
electrical shock hazard. Refer servicing to qualifi ed service agencies only.
1.22 Unit is supplied with a three pronged plug. When using theAC adapter, be sure to connect
pump to a properly grounded outlet only.
1.30 To Reduce Risk Of Electrocution...
1.31 Do not use this product in or near area where it can fall or be pulled into water or other liquids.
1.32 Do not reach for this product if it has fallen into liquid. Unplug immediately.
1.33 Never operate this product outdoors in the rain or in a wet area.
1.40 To Reduce Risk Of Explosion or Fire...
1.41 Do not use this pump in or near explosive atmospheres or where aerosol (spray) products are
being used.
1.42 Do not pump combustible liquids or vapors with this product or use in or near an area where
fl ammable or explosive liquids or vapors may exist.
1.43 Do not use this product near fl ames.
WARNING
Failure to observe the above safety precautions could result
in severe bodily injury, including death in extreme cases.
4

SECTION 2: INSTALLATION
2.10 Introduction
2.11 This manual has been compiled not only for the care and maintenance of the Welch GEMINI
Vacuum System now in your possession, but as a helpful reference and guide to prevent
operating problems, enable troubleshooting, and ensure maximum pump life.
2.20 Unpacking
2.21 Carefully remove the Welch GEMINI™Vacuum System from the shipping case. Preserve all
paperwork for future reference. If damage has occurred from shipment a claim must be fi led
with the carrier immediately; preserve the shipping carton for inspection by the carrier. If
you are required to communicate with your dealer of Welch Vacuum, be sure to include your
order numbers for quick identifi cation. Do not return the pump to Welch without fi rst calling for
a returned goods number.
2.30 Pump Location
2.31 Physical Location
The Aspiration/Filtration Vacuum System should be located preferably in a clean, dry, and well
ventilated area. The system should be placed where the surrounding temperature remains
between 10°C and 40°C (50°F and 104°F). Always check to insure the location chosen
is protected from direct or indirect moisture contact.
2.32 Electrical Source
GEMINI™pumps operate at 12 VDC. Locate the pump near a source of AC power
(115V/60Hz, 230V/50Hz) to utilize the AC power adapter. The pump may also be used
with the 12 VDC power lead plugged into a standard automotive accessory socket or other
12VDC source.
2.33 Proximity to Vacuum Application
Welch recommends that the pump be installed at the highest point within the system to prevent
possible water condensate form entering the pump. The pump should be located close to
the vacuum application system in order to maximize effi ciency.
2.34 Proximity to Ventilation
Locate pump to achieve proper ventilation of exhaust fumes, particularly if the vacuum
application evolves fumes that are dangerous or malodorous. Exhaust ventilation to a hood
is recommended for all applications that could pass organic or acid base fumes through
the vacuum pump.
5
WARNING
Do not pump fl ammable or explosive gases or vapors or operate this
pump in an atmosphere containing fl ammable or explosive gases or
vapors.

2.35 Pump Placement
Rubber feet are attached to the pump. Rubber feet help to isolate noise and eliminate
creeping. All Aspiration/Filtration Vacuum Systems should be placed on a clea, horizontal
surface. Do not block the ventilation holes located on the case.
WARNING
Always vent pump exhaust to a hood or dilute exhaust gases
appropriately when pumping potentially hazardous fumes.
2.40 Application Connection
2.41 Vacuum ports
Vacuum ports and other GEMINI™ pump components are identifi ed in Figure 1. Be certain to
connect vacuum application to the vacuum pump inlet. See below identifi cation signs
for inlet and exhaust ports.
INLET SIGN EXHAUST SIGN
CAUTION
Never plug or impede the vacuum pump exhaust port.
Pressure build-up in the pump will cause pump to stall.
2.42 Tubing Connection
Use non-collapsible tubing for all vacuum connections. Connect to pump inlet using 3/8”
(10mm) ID tubing, keeping tubing length as short as possible. Tubing should be chemically
resistant to any vapors potentially evolved by the vacuum application.
2.43 Traps
GEMINI™pumps are designed to work with aqueous vapors and select organic or acid/base
fumes. Always utilize a trap to minimize chemical fume contact with pump surfaces. Empty
the trap as needed to prevent fl uid ingestion into the vacuum pump.
CAUTION
Always check pump compatibility to potential application
fumes prior to using your GEMINI™pump with acid, base,
or organic vapors / gases. Serious damage to the pump
can result from use with fumes that chemically compromise
pump contact surfaces.
WARNING
Pumping fl ammable vapors or gases can result in fi re or
explosion.
6

7
SECTION 3: OPERATION
Starting Procedures
Qualifying your Application
Welch GEMINI™pumps are designed for intermittent use in a variety of aqueous and organic
solvent-based applications. Proper GEMINI™pump operation and service life are dependent
upon use withcompatible application fumes, use of a trap to minimize chemical pull-through, and
prompt cleanup to purge chemicals from the pump.
Fumes that will be compatible with your GEMINI™ pump include neutral pH aqueous
applications as well as certain alcohols (ethanol, isopropanol ) and carboxylic acids (acetic acid).
It is important to check for pump material compatibility with potential fumes that can be drawn
off your vacuum application. Failure to follow chemical compatibility guidelines can result in
severely reduced pump service life.
The critical materials to check for chemical compatibility are the surface contact materials in your
GEMINI™ pump. These materials are:
1. Viton
2. Polyarylamide
For handling harsh chemical fumes, Welch recommends use of pumps with PTFE-based
contact surfaces. Contact your Welch representative for information about D F ™,
D F U ™, and Self-Cleaning Dry Vacuum Systems™.
3.10
3.11

GEMINI™System Components 2050 and 2060
2050 2060
Figure 1
Vacuum Inlet and Exhaust Port
The vacuum inlet and exhaust port for both GEMINI™models are identifi ed in Figure 1. Be
certain to follow the guidelines in the Section 2: Installation.
WARNING
Never plug pump exhaust. Resulting pressure buildup will
cause pump to stall
On / Off Switch
Identify the On / Off switch for your Model in GEMINI™ Figure 1.
Vacuum Gauge and Regulator (Model 2060 only)
The vacuum gauge reads negative pressure - pressure below atmospheric. The reference point
for the gauge is atmospheric pressure. The vacuum level can be adjusted anywhere between
atmospheric pressure and maximum pump vacuum (230 Torr / 300 mBar).
GEMINI™Start-Up
After verifying that your vacuum application is correctly confi gured per Section 2: Installation,
turn on the pump On / Off switch. Welch recommends running the pump for a few minutes to
warm it up, before use. The warm-up improves the pumps ability to handle humid air.
Closing off the vacuum inlet line on Model 2060 will give gauged verifi cation of full vacuum
operation and will help in identifying the presence of leaks in the application system. Set
vacuum level by turning the regulator knob counter-clockwise to increase vacuum or clockwise
to decrease vacuum. Note: This procedure should be performed each time you use this device.
Be sure to call Welch technical service prior to start up at [phone] if you have any
questions.
8
3.12
3.121
3.122
3.123
3.13
Inlet On/Off Switch
Outlet
On/Off Switch
Vacuum
Gauge
Inlet
Vacuum
Pressure
Regulator
Outlet

Leak Detection
Pump effi ciency is compromised by pumping an added volume of leaked gas to maintain
the desired vacuum. System leaks can be inferred by noticing vacuum gauge (Model 2060)
differences when vacuum inlet tube is blocked from when the tube is opened for a time to the
application system. System leaks can be located by slightly pressurizing the system and painting
the suspected area with a thick soap solution. Escaping air will produce soap bubbles.
Pump Cleaning and Shutdown Procedure
Cleaning Contaminants
If application may have exposed the GEMINI™pumps to acidic / base or water miscible organic
compounds, pull warm water vapors through the pump for 5 minutes to clean pump contact
surfaces.
GEMINI™System Shutdown Procedures
After use, Welch recommends the pump be run for about 2 minutes disconnected from the
vacuum process. The air pumped through the mechanism will purge out water vapor or droplets
of water condensate that may have formed on the inside of the pump.
SECTION 4: MAINTENANCE
Maintenance Procedures
Maintaining a WelchAspiration/Filtration Vacuum System
Theseunitsare100%oil-free.Thepumpemploysanon-lubepistonandcylinder.Nomaintenance
is necessary for the bearings. All bearings are sealed and permanently lubricated. Lubrication
should not be attempted. The units are built for intermittent duty operation with the quietness and
durability of a diaphragm, but with piston performance.
9
3.20
3.21
3.30
3.31
3.40
3.41
4.10
4.11

SECTION 5: TROUBLESHOOTING
Vacuum Problems
Manyvacuumproblemsareattributabletosystemleakageorcontamination.See LeakDetection
(section 3.21) and Cleaning Contaminants (section 3.31) to address system problems. Pump
operation may be verifi ed by isolating the vacuum inlet from the system and using a gauge (built
in for Model 2060) to verify vacuum vis-à-vis Specifi cations.
Power Failure
If pump does not turn on, the power adapter can be replaced. Contact your Welch representative
for information.
10
SECTION 6: SPECIFICATION
6.10 SPECIFICATION TABLE
5.10
5.11
5.20
5.21
Parameter Model 2050 Model 2060
Vacuum Pressure - Torr (mbar) 230 (300) 230 (300)
Flow - cfm (lpm) 0.38 (10.7) 0.38 (10.7)
Operating Voltage 12VDC 12VDC
Power Rating 2.2W 7.0W
Tubing ID 1/4” (7mm) 1/4” (7mm)
Dimensions (W x H x L) inch (mm) 4.66x8.41x9.05
(118x215x230) 7.6x8.41x9.15 193x214x232
Operating Temperature - C 10-40 10-40
Power Supply 100-240V/50/60Hz 100-240V/50/60Hz
Weight - lbs (kg) 7 (3.2) 13 (5.9)

11
SECTION 7: WARRANTY
7.10 WARRANTY
Please Read Carefully Before Operating This Welch® Vacuum Pump
Unpacking
Inspect the pump carefully. If any damage has occurred, fi le claim with the freight carrier immediately.
Save the shipping container for carrier to inspect.
Operating Pump
Refer to the Instruction/Operation Manual for all information to properly operate and maintain the pump.
Warranty
The Welch Vacuum product is warranted to be free from defects, in material and workmanship. The
liability of Gardner Denver Welch Vacuum Technology, Inc. under this warranty is limited to servicing,
adjusting, repairing or replacing any unit or component part which in the judgement of Welch Vacuum
has not been misused, abused or altered in any way causing impaired performance or rendering it
inoperative. No other warranties are expressed or implied. The method of executing this warranty:
servicing, adjusting, repairing or replacing shall be at the discretion of Welch Vacuum. Vacuum pumps
that have been used for any period, however short, will be repaired under this warranty rather than
replaced.
The warranty is effective for one year from the date of original purchase when:
1. The warranty card has been completed and returned.
2. The product with RMAis returned to the factory or other designated service centers, freight
prepaid.
3. The product, in our judgement, is defective through no action or fault of the user.
Iftheproduct hasbecomedefectivethroughmisuse,abuse,or alteration,repairswill bebilled regardless
ofthe ageof theproduct. Inthisevent,an estimateof therepaircostswillbesubmittedand authorization
of these charges will be required before the product is repaired and returned.
Toreducetheadditionalchargesanddelayseitherwithinoroutsideofthewarrantyperiod,contactWelch
Vacuum at [phone] for a return authorization number. Products without a return authorization
number will be returned by our receiving department. Before shipping, pack the pump properly and
insure it against loss or damage. Mark the outside of the carton and the packing slip with the return
authorization number. Pumps damaged due to improper packaging are the customer’s responsibility.

12
Welch-Ilmvac
5621 W. Howard Street
Niles, IL 60714
Phone: [phone] (Technical Support)
Fax: [phone]
E-Mail: [e-mail]
Web-Page: www.welchvacuum.com
Copyright© 2007 Gardner Denver Thomas Inc., Welch Vacuum Technology
Welch is a registered trademark of Gardner Denver Thomas Inc., Welch Vacuum Technology
USA, Canada, Latin America
Gardner Denver Thomas, Inc.,
Welch Vacuum Technology
5621 W. Howard St.
Niles, IL 60714 USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Asia
Rietschle Thomas Asia Pacifi c, Ltd.
Unit 2503, Metropole Square
No. 2 On Yiu St., Siu Lek Yuen
Shatin, New Territories, Hong Kong, P.R.C.
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Europe
Gardner Denver UK
Waterbrook Estate, Waterbrook Road
Alton Hampshire
GU342UD United Kingdom
Phone: [phone]
Fax: [phone]
Email: webinf[email protected]
SALES AND SERVICE OFFICES