Ilmvac 6 Z - 101 chemvac User manual

Operation Manual
chemvac Combination Pump Systems
Types 6 Z - 101 chemvac
12 Z - 301 chemvac
23 Z - 301 chemvac
109025
2008-12-12

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 20
98693 Ilmenau, Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: http://www.ilmvac.de
http://www.ilmvac.com

Contents
Contents
1Important Information .......................................................................................................................................4
1.1 General Information.............................................................................................................................................4
1.2 Target Groups......................................................................................................................................................4
1.3 Intended Use .......................................................................................................................................................4
1.4 Use for an Unauthorized Purpose .......................................................................................................................4
1.5 Safety Devices.....................................................................................................................................................5
1.6 Meaning of the Warning notes.............................................................................................................................5
1.7 Product Standards, Safety Regulations ..............................................................................................................5
2Basic Safety Instructions..................................................................................................................................6
2.1 General Information.............................................................................................................................................6
2.2 Electricity .............................................................................................................................................................6
2.3 High Temperatures..............................................................................................................................................6
2.4 Mechanical Systems............................................................................................................................................7
2.5 Hazardous Substances .......................................................................................................................................8
3Description .........................................................................................................................................................9
3.1 Design..................................................................................................................................................................9
3.2 Function .............................................................................................................................................................10
3.2.1 Diagram of the layout of a chemvac pump system ...........................................................................................10
3.3 Applications .......................................................................................................................................................11
3.4 Scope of Delivery...............................................................................................................................................11
4Technical Data .................................................................................................................................................12
4.1 Dimensions ........................................................................................................................................................12
4.2 Intake Pressure / Pumping Speed - Diagram....................................................................................................12
4.3 Device data - chemvac Combination Pump Systems .......................................................................................13
4.3.1 Device data - Rotary vane pump .......................................................................................................................14
4.3.2 Device data - Diaphragm pumps.......................................................................................................................15
5Installation and Operation ..............................................................................................................................16
5.1 Unpacking..........................................................................................................................................................16
5.2 Installation and Connection ...............................................................................................................................16
5.3 Operation ...........................................................................................................................................................16
5.4 Storage ..............................................................................................................................................................17
5.5 Scrap Disposal...................................................................................................................................................17
6Maintenance and Servicing ............................................................................................................................18
6.1 General Requirements ......................................................................................................................................18
6.2 Maintenance Performed by the User.................................................................................................................18
6.2.1 Maintenance of the rotary vane pump...............................................................................................................19
6.2.1.1 Oil check ............................................................................................................................................................19
6.2.1.2 Oil change..........................................................................................................................................................20
6.2.1.3 Changing the oil type.........................................................................................................................................21
6.2.2 Maintenance of the diaphragm pump................................................................................................................21
6.2.2.1 Disassembly - MPC 101 Zp...............................................................................................................................22
6.2.2.2 Assembly - MPC 101 Zp....................................................................................................................................22
6.2.2.3 Disassembly - MPC 301 Zp...............................................................................................................................23
6.2.2.4 Assembly - MPC 301 Zp....................................................................................................................................23
6.2.2.5 Test....................................................................................................................................................................23
6.3 Maintenance by the Manufacturer.....................................................................................................................24
6.3.1 Servicing ............................................................................................................................................................24
6.4 Damage Report .................................................................................................................................................24
7Troubleshooting ..............................................................................................................................................25
8Overview of spare parts..................................................................................................................................26
8.1 Gasket set - rotary vane pumps ........................................................................................................................26
8.2 Maintenance kit - rotary vane pumps ................................................................................................................27
8.3 Maintenance kit - diaphragm pumps .................................................................................................................27
8.4 Complete view - chemvac combination pump system ......................................................................................28
8.4.1 List of spare parts - chemvac combination pump system .................................................................................29
8.5 Spare part view - P 6 Z......................................................................................................................................30
8.5.1 List of spare parts - rotary vane pump P 6 Z .....................................................................................................31
8.6 Spare part view - P 12 Z, P 23 Z .......................................................................................................................32
8.6.1 List of spare parts - rotary vane pump P 12 Z ...................................................................................................33
8.6.2 List of spare parts - rotary vane pump P 23 Z ...................................................................................................34
8.7 Spare part view - MPC 101 Zp ..........................................................................................................................35
8.7.1 List of spare parts - diaphragm pump MPC 101 Zp ..........................................................................................35
8.8 Spare part view - MPC 301 Zp ..........................................................................................................................36
8.8.1 List of spare parts - diaphragm pump MPC 301 Zp ..........................................................................................36
109025 3

Important Information
1 Important Information
1.1 General Information
The ILMVAC Combination Pump Systems conform to the following directives:
• 2006/95/EC Low Voltage Directive
• 2006/42/EC Machinery Directive
• 2004/108/EC 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 http://www.ilmvac.de.
1.2 Target Groups
This Operating Manual is intended for the personnel planning, operating and maintaining
ILMVAC Combination Pump Systems.
This group of people includes:
• Designers and fitters of vacuum apparatus,
• Employees working on commercial laboratory and industrial vacuum technology applica-
tions and
• Service personnel for combination pump systems.
The personnel operating and maintaining the rotary vane pumps must have the technical
competence required to perform the work that has to be done.
The user must authorize the operating personnel to do the work that has to be done.
The personnel must have read and understood the complete Operating Manual before using
the rotary vane 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 chemvac Combination Pump System must be appropriate for the condi-
tions of use. The user bears the sole responsibility for this.
The chemvac Combination Pump System 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.
1.4 Use for an Unauthorized Purpose
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.
4 109025

Important Information
1.5 Safety Devices
Measures such as the following are for the safety of the operating personnel:
• electrical connection with a protective conductor (operating mode S1) and an earthing
plug,
• Motor protection switch (thermal),
• “Hot Surface" label on the pump body (warning notice),
• glass components with a transparent plastic coating which protects them against bursting
and cracking
The chemvac Combination Pump System must not be operated without these elements.
1.6 Meaning of the Warning notes
Take note of the warning notes. They are in the following box:
CAUTION ! / WARNING !
Hazard which may lead to serious injuries or material damage.
1.7 Product Standards, Safety Regulations
ILMVAC chemvac Combination Pump Systems meet the following product standards:
DIN EN 292-1, DIN EN 292-2 Safety of machines, basic terminology
DIN EN 1012-2 Compressors and vacuum pumps
DIN EN 60204-1 Electrical equipment of machines
EN 50110-1 (DIN VDE 0105-100) Operation of electrical installations
EN 61010-1 Safety for laboratory devices
EN 50081-1-2 Electromagnetic compatibility (EMC)
Generic specification - Interference resistance
for residential, business and industrial areas, and small businesses
EN 50082-1-2 Electromagnetic compatibility (EMC)
Generic specification - Interference emission
for residential, business and industrial areas, and small businesses
EN 55014 Radio disturbance characteristics of electrical equipment and
systems
EN 61000-3-2/3 Electromagnetic compatibility (EMC)
Directive 2006/42/EC Law and Administration Regulations relating to Machinery
Directive 2002/95/EC RoHS Restriction of use of certain hazardous substances
The following additional safety regulations apply in the FR Germany:
BGV A2 Electrical equipment and operating materials
VBG 5 Power-driven machines
BGR 120 Guidelines for laboratories
BGI 798 BG hazard assessment in the laboratory
BGG 919 Accident prevention regulations for "compressors"
BGR 189 (BGR 195; 192; 197) Use of protective working clothes
Observe the standards and regulations applying in your country when you use the chemvac
Combination Pump Systems.
109025 5

Basic Safety Instructions
2 Basic Safety Instructions
2.1 General Information
WARNING !
Warning notices must be observed. Disregarding them may lead to damage to health
and property.
The chemvac Combination Pump Systems must be operated by personnel who can detect
impending dangers and take action to prevent them from materialising.
The user/operator is responsible for correct installation and safe operation.
The manufacturer or authorized authorised workshops will only service or maintain the
chemvac combination pump systems if it is accompanied by a fully completed damage re-
port. Precise information about the contamination (also negative information if necessary)
and thorough cleaning of the laboratory vacuum system are legally binding parts of the con-
tract.
Contaminated chemvac Combination Pump Systems and their individual parts must be dis-
posed of in accordance with the legal regulations.
The local regulations apply in foreign countries.
2.2 Electricity
The chemvac Combination Pump Systems are supplied for operating mode S1. Please note
that the testing must be repeated in accordance with DIN EN 0105, DIN EN 0702 and BGV
A2 in case of portable devices.
The local regulations apply in foreign countries.
Please note the following when connecting to the electrical power supply system:
• The electrical power supply system must have a protective connector according to DIN
VDE 0100-410 (IEC 60364-4-41).
• The protective connector must not have any breaks.
• The connecting cable must not be damaged.
2.3 High Temperatures
The pumps of the chemvac combination pump system can become heated by the tempera-
ture of the gas being pumped and the heat of compression.
Prevent the following maximum permissible temperatures from being exceeded.
• + 40 °C for the environment, and
• + 20 °C for the gas to be pumped.
The motor for single phase alternating current is protected against overload by an integrated
motor protection switch.
6 109025

Basic Safety Instructions
2.4 Mechanical Systems
Improper use can lead to injuries or material damage. Observe the following instructions:
• Only operate the chemvac combination pump systems with hoses of the specified dimen-
sions.
• 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 chemvac combination pump systems.
• Pressure must not be allowed to build up at the pressure port.
• The pump system 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 conden-
sate and dispose of it in an environmentally compatible manner.
• Maintain a space of least 20 cm between the pumps and adjacent parts in order to enable
the pumps to cool.
WARNING !
Solid particles in the pumping medium impair the pumping action and can lead to
damage.
Prevent solid particles penetrating into the pump.
When handling glass vessels, pay attention to:
• Only use glass vessels with a plastic coating for splinter protection.
• Only use vessels which are suitable for use with vacuums (e.g. round-bottomed flasks).
We recommend that only glass components supplied by the manufacturer are used.
Do not use Erlenmeyer flasks.
• Before each evacuation, check glass vessels for damage which might impair their streng-
th, replace them if any such damage is found.
• Do not heat glass vessels on one side only.
• Retardation of the boiling of the gases to be pumped can lead to a sudden pressure in-
crease. Prevent retardation of boiling by means of suitable measures (e.g. turbulent agi-
tation).
109025 7

Basic Safety Instructions
2.5 Hazardous Substances
ACHTUNG !
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 operating company bears the responsibility for the use of the chemvac combi-
nation pump system.
Harmful substances must be effectively prevented from escaping.
Ensure that all lines and connections are leak tight.
Handle exhaust gases in accordance with the requirements of the emission protection regu-
lations.
Do not operate the chemvac combination pump system without a separator. The separator
can only be emptied after the apparatus has been vented.
Dispose the condensate in an environmentally compatible manner!
The local regulations apply in foreign countries.
Combustible Gases
Examine before switching on whether that can form gas combustible gas/air mixtures which
can be promoted! Consider the regulations of the guideline 1999/92/EC.
It is not permitted to pump gases that are combustible or prone to explosion.
Explosive gases
The chemvac Combination Pump Systems is not certified according to ATEX guidelines
94/9/EC.
Aggressive gases
For the chemvac combination pump system, an MPC series diaphragm pump is used for ex-
tracting vapors and aggressive gases.
The warranty shall lapse if the chemvac combination pump system is used with diaphragm
pumps from other manufacturers than those stated.
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.
The pumps and hose lines can be damaged by poisonous or aggressive gases.
Test the strength and leak-tightness of the connecting lines and the connected apparatus.
Prevent environmental poisons, e.g. mercury, getting into the pumps.
Fulfil the requirements, for example:
• German Hazardous Substances Regulation (GefStoffV) of 23. December 2004
• Regulations 2006/121/EC (classification, packaging and identification of hazardous sub-
stances),
• Manufacturer's safety data sheets on hazardous substances.
8 109025

Description
3 Description
3.1 Design
The chemvac Combination Pump System consists of a two-stage, oil-combined rotary vane
pump (1) and a two-stage chemical diaphragm pump (2). The two pumps are functionally
connected to each other by suitable separators (3; 5) and a pressure control valve (4) to
form a compact unit. It is still possible to connect suction-side accessories, such as filters
and coolers.
The chemical durability of the chemvac combination pump system derives from the way it
works and the materials selected to make the individual components. The rotary vane vac-
uum pumps (1) have a good, basic resistance to corrosion as standard. Among other things,
the PTFE pump heads and PTFE- diaphragms ensure that the chemical diaphragm pumps
(2) have high durability. The connecting elements are made of high-quality PVDF and PP
plastics.
The different volumes pumped by the rotary vane pump (1) and the diaphragm pump (2) at
high intake pressures and the pressure back up which this causes between the pumps is
compensated for by the pressure control valve (4) integrated into the valve block (3). The
separator AKD (3) catches condensates forming on the pressure side. The exhaust filter in-
tegrated into the AKD reduces the emission of oil mist. Connect the pressure-side connector
(4.2) to the laboratory-side extraction system.
The required pressure in the oil casing of the rotary vane vacuum pump can be monitored by
a mechanical vacuum gauge (tube spring manometer) (6).
The rotary vane pump has a bubbler (gas purging apparatus) (7) instead of a gas ballast
system.
An mechanical main stream oil filter (8) can be flange-mounted onto the rotary vane pump if
solid particles are expected in the pump during the evacuation process.
1 Rotary vane pump
with bubbler set in the works
1.1 Suction port - rotary vane pump
1.2 Pressure port - rotary vane pump
2 Diaphragm pump
2.1 Suction port - diaphragm pump
2.2 Pressure port - diaphragm pump
3 Separator AKD (exhaust filter)
4 Pressure relief valve
4.1 Relief valve outlet
4.2 Pressure port – pump system
5 Separator (bottle)
6 Mechanical vacuum gauge
(tube spring manometer)
7 Bubbler (gas purging apparatus)
8 Main stream oil filter OPF 40 C
(Option : order no. 700153-01)
9 Connecting line (Item 4 –> 5)
Fig. 1 Vacuum connection
109025 9

Description
3.2 Function
The outstanding feature of chemvac Combination Pump Systems in comparison to conven-
tional rotary vane pumps is that this special pump combination can pump solvent or acid va-
pors for long periods, even at low intake pressures, with hardly any problems.
The field of applications for the chemvac Combination Pump Systems can be extended by
such special options as condensers on the pressure side, separators and filter.
Acidic or solvent vapors entering a vacuum pump are first compressed, but either do not or
only slightly condense because of the pump operating temperature and the under pressure
created in the oil casing via the diaphragm pump. (The under pressure is indicated by the
manometer that on the rotary vane pump is.).
The pressure at the manometer should be < 100 mbar. This significantly lengthens the main-
tenance intervals.
This, in turn, substantially reduces the problems of disposing of contaminated pump oil.
Condensing vapors are captured in the downstream condensate separators.
CAUTION !
Because of the design of the chemvac combination pump system, the rotary vane
pump is supplied with the gas ballast valve closed and blocked.
3.2.1 Diagram of the layout of a chemvac pump system
1 -
2 -
3 -
4 -
5 -
6 -
Pressure port
Relief valve
Suction port
Diaphragm pump
Clearance space
Rotary vane pump
Fig. 2 Function scheme
10 109025

Description
3.3 Applications
The chemvac combination pump system is intended for:
• pumping out aggressive vapours and gases with low ultimate pressure
• pumping out solvent vapours
• pumping out vapours (including those soluble in oil)
• ceramic sintering plants with aggressive by-products and plasma etching plants
• freeze drying
Special designs:
• Special chemvac combination pump systems can be supplied after consultation with the
manufacturer,
• Rotary vane pumps with special oils are possible.
3.4 Scope of Delivery
The scope of delivery is specified in the supply contract.
109025 11

Technical Data
4 Technical Data
4.1 Dimensions
B T H
chemvac types Order no. (mm)
6 Z - 101 109023 500 300 340
12 Z - 301 109024 590 310 420
23 Z - 301 109025 590 310 420
Fig. 3 Dimensions
4.2 Intake Pressure / Pumping Speed - Diagram
Fig. 4 Intake Pressure / Pumping Speed – Diagram
12 109025

Technical Data
4.3 Device data - chemvac Combination Pump Systems
chemvac
Parameter Unit
6 Z - 101 12 Z - 301 23 Z - 301
Pumping speed 50/60 Hz
DIN 28432 at speed of 1500 rpm m3/ h 5.8 / 6.6 11 / 13.2 21 / 25.2
Ultimate pressure
at speed of 1500 rpm
- partial 1.5 x 10-4
- total
mbar
2 x 10-3
Max. inlet pressure bar 1
Max. outlet pressure bar 1
Max. Leak rate of inlet valve 7 x 10-5
Suction- / pressure port small flange DN 16 KF DN 25 KF DN 25 KF
Ambient temperature °C + 20 to + 40
Max. operating gas temperature °C + 40
Noise level
DIN 45635 part 13 dB (A) <53 <54 <54
Water vapour tolerance mbar 70 80 45
Oil filling ml 1000 1400 1000
Voltage / Frequency V, Hz 230, 50/60
Power complete kW 0.4 0.9 0.9
Operating mode - S 1
Type of protection
DIN EN 60529 - IP 54
Class of insulation
DIN EN 600034-1 - F (160°C)
Dimensions (W/D/H) mm 500/300/340 590/400/310 590/400/310
Weight kg 25.5 42.5 46
Order numbers for :
- Mains connection cable CEE 825885
- Mains connection cable UK 825878
- Mains connection cable CH 825877
- Mains connection cable US 825903
Order numbers for :
- chemvac 230 V
Combination pump system
without mains connection cable
109023 109024 109025
- chemvac 115 V
Combination pump system
without mains connection cable
-
109023-01 109024-01 109025-01
109025 13

Technical Data
4.3.1 Device data - Rotary vane pump
Parameter Unit P 6 Z P 12 Z P 23 Z
Pumping speed 50/60 Hz
DIN 28432 at speed of 1500 rpm m³ /· h-1 5.8 / 6.6 11 / 13.2 21 / 25.2
Ultimate pressure
at speed of 1500 rpm (50 Hz)
- without gas ballast partial 2 x 10-4 1.5 x 10-4 1.5 x 10-4
- without gas ballast total 2 x 10-3 2 x 10-3 2 x 10-3
- with gas ballast total
mbar
1 x 10-2 3 x 10-3 3 x 10-3
Max. inlet pressure bar 1
Max. outlet pressure bar 1
Max. Leak rate of inlet valve mbar l/s 7 x 10-5
Suction- / pressure port small flange DN 16 KF DN 25 KF DN 25 KF
Ambient temperature °C + 20 to + 40
Max. operating gas temperature °C + 40
Noise level
DIN 45635 part 13 dB (A) <53 <54 <54
Water vapour tolerance mbar 60 35 35
Oil filling ml 1000 1400 1000
Voltage / Frequency V, Hz 230, 50/60
Motor power kW 0.37 0.55 0.75
Operating mode - S 1
Type of protection
DIN EN 60529 - IP 54
Class of insulation
DIN EN 600034-1 - F (160°C)
Dimensions (W/D/H) mm 415/150/215 522/166/256 522/171/256
Weight kg 19.5 30.0 335
Order numbers for :
- Rotary vane pump 230 V
without mains connection cable - 302103-05 302314-05 302316-05
- Rotary vane pump 115 V
without mains connection cable - 302103-03 302314-07 302316-07
14 109025

Technical Data
4.3.2 Device data - Diaphragm pumps
Parameter Unit MPC 101 Zp MPC 301 Zp
m3/ h 1 / 1.1 2.3 / 2.5
Pumping speed 50/60 Hz
DIN 28432
at speed of 1500 rpm l / min 16.7 / 18 38 / 41
Ultimate pressure
at speed of 1500 rpm mbar <8
Ultimate pressure
with gas ballast
at speed of 1500 rpm
mbar 18
Max. inlet pressure bar 1
Max. outlet pressure bar 1
Suction- / pressure port - Hose nozzle for vacuum hose NW 8
Ambient temperature °C + 10 to + 40
Max. operating gas temperature °C + 60
Bearing - maintenance-free
Noise level
DIN 45635 part 13 dB (A) <44
Voltage / Frequency V, Hz 230, 50/60
Motor power kW 0.06 0.18
Operating mode - S 1
Type of protection
DIN EN 60529 - IP 54
Class of insulation (motor)
DIN EN 600034-1 - F (160°C)
Dimensions (W/D/H) mm 195 / 235 / 145 230 / 265 / 169
Weight kg 6.5 11.2
Order numbers for :
- Diaphragm pump 230 V
without mains connection cable 400171-3 -
- Diaphragm pump 115 V
without mains connection cable 400171-13 -
- Diaphragm pump 115/230 V
without mains connection cable
-
- 4000482-27
109025 15

Installation and Operation
5 Installation and Operation
5.1 Unpacking
Carefully unpack the chemvac Combination Pump System.
Check the system 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.
In case of a claim under warranty, the device must be returned in packaging that is
suitable for protecting it during transport.
5.2 Installation and Connection
• Set the chemvac Combination Pump System on a flat and horizontal surface.
• Remove the protective caps on the connections.
• Connect it to the vacuum apparatus by means of the small flange DN 16 KF or DN 25 KF.
• Connect the pressure port to the central laboratory air evacuation duct. Ensure that the
substances fed in are absolutely safe and harmless.
• Check that the connections are properly seated.
• Connect the pump system to the electric supply mains and switch on.
5.3 Operation
CAUTION !
Observe the basic safety instructions when using the chemvac combination pump
system !
In order to avoid pumping speed losses, all the vacuum connecting hoses used should have
a large nominal diameter and should be laid out so that the lengths are as short as possible.
Avoid rigid connections. They must be assembled carefully in order to achieve a low leak
rate.
Do not start extracting aggressive media or solvent vapours until the rotary vane pump of the
chemvac combination pump system has reached its operating temperature. Also check at
the oil level gauge for intermittent formation of foam. Operation with a "bubbler" is an excep-
tion, as flushing the gas through the oil casing is intentional in this case.
Also check the oil level against the relevant markings during operation. Top up the oil if nec-
essary.
The separator must be emptied when it becomes half full. For this purpose, vent the system
and remove the union nut from the glass vessel. Please comply with the disposal regula-
tions.
16 109025

Installation and Operation
CAUTION !
The gas ballast valve of the rotary vane pump must always remain closed while the
chemvac combination pump system is running.
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 pro-
tection may be used.
5.5 Scrap Disposal
CAUTION !
The chemvac combination pump system must be disposed of in accordance with the
2002/96/EC guideline and the specific national regulations.
Contaminated pump systems must be decontaminated according to the laws.
109025 17

Maintenance and Servicing
6 Maintenance and Servicing
6.1 General Requirements
Repairs of the chemvac combination pump system may only be performed by the manufac-
turer or authorized workshops. The prerequisites are a complete and factually correct dam-
age report, and a clean and, if necessary, a decontaminate device.
• Check the diaphragm pump daily for unusual running noises and heat building up on the
surface of the pump. We recommend changing the diaphragm after 10,000 operating
hours. The user may specify that the exchange be made earlier, depending upon the
application process.
• Check the level and quality of the oil in the rotary vane pump every day. Comply with
the oil change intervals, if necessary they can be defined by the user.
• Check the electrical and vacuum connections daily.
• Check the screw connections and hoses for leaks every day, and exchange if necessary.
• Check the glass vessels of the separator AKD separator for integrity and exchange if
necessary. Empty the glass vessel in good time, comply with the regulations for the dis-
posal of hazardous substances. Check that the filter cartridge is in good working order.
The filter cartridge must be exchanged if the in-built valve is actuated during operation.
• Check that the pressure control valve is in good working order, open the valve (4
screws) and clean the seating if necessary.
6.2 Maintenance Performed by the User
The user can perform maintenance work as described below.
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.
A regeneration phase is required after pumping aggressive media or solvent vapours in or-
der to maintain the serviceability and reliability of the chemvac combination pump system.
This means that you let the chemvac combination pump system run for one hour at ultimate
pressure. The bubbler on the rotary vane pump must remain open. The ultimate pressure at
the suction port must be checked by means of a vacuum gauge. The regeneration process
has been completed when the maximum possible improvement of the ultimate pressure has
been attained.
18 109025

Maintenance and Servicing
6.2.1 Maintenance of the rotary vane pump
Scope of permissible work:
• Check the oil level.
The oil consumption variesaccording to the operating conditionsof the rotary vanepump.
The oil level must be checked on the oil level gauge to ensure that the vacuum pump al-
ways remains in optimal operating condition. The oil level must always be kept within the
given markings on the oil level gauge. The oil must be topped up if the oil level falls to the
lower mark.
• Change the oil when its quality falls.
Tools required:
• 826801-10 Open spanner SW 22
• 826801-6 Allan key SW 5
1 - screw-plug for oil-filling
2 - oil drain screw plug
3 - Oil sight glass
4 - lower marking MIN
5 - upper marking MAX
Fig. 5 Oil level control
6.2.1.1 Oil check
CAUTION !
The condition and quality of the pump oil have a substantial effect upon the per-
formance and operational readiness of the vacuum pump!
Comparing the colour of a sample of the pump oil with fresh oil provides an indication of the
contamination of the pump oil.
You obtain the oil needed for testing from the oil drain aperture with the vacuum pump
switched off and at operating temperature.
Brown or black oil, or oil smelling as if it has burnt must be removed from the vacuum pump.
Flush the vacuum pump and fill up with fresh oil.
109025 19

Maintenance and Servicing
6.2.1.2 Oil change
WARNING !
If the vacuum pump has been used to pump media which are dangerous to health
then all measures must be taken to protect the service and operating personnel!
Working sequence
Topping-up the oil:
• Remove the oil filler plug
• Pour in the oil until it reaches the upper mark
• Screw in the oil filling plug together with the seal once again
• Switch on the vacuum pump and let it work for about 2 minutes
• Check the oil level when the pump is switched off, repeat if necessary
Draining the oil:
• Unscrew the oil drain plug from the pump casing while the pump is at operating tempera-
ture.
• Tilt the vacuum pump slightly, catch the oil in a suitable vessel and dispose of it in accor-
dance with the applicable regulations.
WARNING !
Avoid skin contact with the oil!
Dispose of the oil in accordance with the valid environmental protection regulations!
Filling up with oil:
• Remove the oil filler plug
• Pour in the oil until it reaches the upper mark
• Screw in the oil filling plug together with the seal once again
• Switch on the vacuum pump and let it work for about 2 minutes
• Check the oil level when the pump is switched off, repeat if necessary
Flushing:
If the oil is heavily contaminated, the vacuum pump must be flushed, e.g.
• heavy clouding by condensates
• suspended particles such as dust, fibres, abraded particles
• dark coloration of the oil.
The flushing liquid should be the type of oil which is currently being used.
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