Ilmvac MPC 104 Tp User manual

Operation Manual
Diaphragm pump
Type MPC 104 Tp
400082
2008-01-14

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 Mechanical Systems .................................................................................................................6
2.4 Hazardous Substances.............................................................................................................7
2.5 High Temperatures ...................................................................................................................7
2.6 Dimensioning the fine-wire fuse................................................................................................7
3Description ..............................................................................................................................8
3.1 Design .......................................................................................................................................8
3.2 Areas of Application ..................................................................................................................8
3.3 Principle of Operation ...............................................................................................................8
3.3.1 Pump head circuitry ..................................................................................................................9
3.3.2 Materials of the medium-affecting pump parts..........................................................................9
3.4 Scope of Delivery......................................................................................................................9
3.5 Accessories (optional)...............................................................................................................9
4Technical Data.......................................................................................................................10
4.1 View of device and dimensions...............................................................................................10
4.2 Intake Pressure / Pumping Speed – Diagram ........................................................................10
4.3 Device data .............................................................................................................................11
5Installation and Operation....................................................................................................12
5.1 Unpacking ...............................................................................................................................12
5.2 Installation and Connection.....................................................................................................12
5.3 Operation ................................................................................................................................13
5.4 Storage....................................................................................................................................13
5.5 Scrap Disposal ........................................................................................................................13
6Maintenance and Servicing..................................................................................................14
6.1 General Requirements............................................................................................................14
6.2 Maintenance Performed by the User ......................................................................................14
6.2.1 Disassembly............................................................................................................................15
6.2.2 Montage .................................................................................................................................15
6.2.3 Test .........................................................................................................................................16
6.3 Maintenance by the Manufacturer ..........................................................................................17
6.4 Damage Report.......................................................................................................................17
7Troubleshooting....................................................................................................................18
8Spare Parts Overview ...........................................................................................................19
8.1 Maintenance kit.......................................................................................................................19
8.2 Exploded view.........................................................................................................................20
8.2.1 Spare part list..........................................................................................................................21
400082 3

Important Information
1 Important Information
1.1 General Information
The ILMVAC Diaphragm Pumps 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 Diaphragm Pumps.
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 diaphragm pumps
The personnel operating and maintaining the diaphragm pumps must have the technical
competence required to perform the work that has to be done. 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 diaphragm pumps. The Operat-
ing Manual must be kept at the place of use and be available to the personnel when re-
quired.
1.3 Intended Use
• The layout of the diaphragm pump must be appropriate for the conditions of use. The
user bears the sole responsibility for this.
• The diaphragm pump may only be operated under the conditions stated
– in the "Technical Data" section,
– on the type plate, and
– in the technical specification for the order concerned.
• Diaphragm pumps are approved for extracting, pumping and compressing gases and va-
pours. If these gases and vapours are toxic or explosive, then the user must observe the
currently valid safety regulations for this application. Special types of diaphragm pumps
are available for aggressive and explosive gases.
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.
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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)
• Main switch
• Device fuse
• “Hot Surface" label on the pump body (warning notice).
The diaphragm pump must not be operated without these elements.
1.6 Meaning of the Warning notes
Take note of the warning notices. 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 Diaphragm Pumps 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
Observe the standards and regulations applying in your country when you use the dia-
phragm pumps.
400082 5

Basic Safety Instructions
2 Basic Safety Instructions
2.1 General Information
Warning notices must be observed. Disregarding them may lead to damage to health and
property.
The diaphragm pumps must be operated by personnel who can detect impending dangers
and take action to prevent them from materialising.
The manufacturer or authorized authorised workshops will only service or maintain the dia-
phragm pump if it is accompanied by a fully completed damage report. Precise information
about the contamination (also negative information if necessary) and thorough cleaning of
the diaphragm pump are legally binding parts of the contract.
Contaminated diaphragm pumps and their individual parts must be disposed of in accor-
dance with the legal regulations.
The local regulations apply in foreign countries.
2.2 Electricity
The diaphragm pumps of operation mode S1 are supplied. When the location of operation
mode S1 devices is changed, please note that the testing must be repeated in accordance
with DIN EN 0105, DIN EN 0702 and BGV A2. The local regulations apply in foreign coun-
tries. Please note the following when connecting the plug to the electrical power supply sys-
tem:
• 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 Mechanical Systems
Improper use can lead to injuries or material damage. Observe the following instructions:
• Only operate the diaphragm pumps with hoses of the specified dimensions.
• The maximum permissible pressure of 1 bar at the suction connection must not be exceeded.
• 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
NW 8 laboratory hoses for connecting diaphragm pumps.
• The overpressure generated at the pressure port must not exceed 1 bar.
• The pump must not be used to suck up fluids. Lay the exhaust pipe so that it slopes downwards, so
allowing condensate to flow out of the pump. Collect the condensate and dispose of it in an envi-
ronmentally compatible manner.
• Prevent dyes exuding.
• Maintain near the venting slots a space of least 20 cm between the pump and adjacent parts in or-
der to enable the pump to cool.
CAUTION !
Solid particles in the pumping medium impair the pumping action and can lead to
damage. Prevent solid particles penetrating into the pump.
6 400082

Basic Safety Instructions
2.4 Hazardous Substances
The operating company bears the responsibility for the use of the diaphragm pump.
Hazardous substances in the gases to be pumped can cause personal injuries and property
damage. Pay attention to the warning notices for handling hazardous substances.
The local regulations apply in foreign countries.
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.
Explosive gases
The diaphragm pumps is not certified according to ATEX guidelines 94/9/EC.
Aggressive gases
Extracting aggressive gases is not permitted.
Poisonous gases
Use a separator when pumping poisonous or harmful gases. Prevent such substances from
leaking out of the appliance or pump. Treat these substances according to the applicable
environmental protection regulations.
Test the strength and leak-tightness of the connecting lines and the connected apparatus.
Prevent environmental poisons, e.g. mercury, getting into the diaphragm pumps.
Fulfil the requirements, for example:
• German Hazardous Substances Regulation (GefStoffV) of 23. December 2004
• Regulations 2006/121/EC (classification, packaging and identification of hazardous substances),
• Manufacturer's safety data sheets on hazardous substances.
2.5 High Temperatures
The diaphragm pump may heat up as a result of the temperature of the gas being pumped
and through compression heat. Prevent the following maximum permissible temperatures
from being exceeded.
• + 40 °C for the environment, and
• + 60 °C for the gas to be pumped.
The motor for single phase alternating current is protected against overload by a fine-wire
fuse.
2.6 Dimensioning the fine-wire fuse
Diaphragm pump model Fine-wire fuse Order no.
MPC 104 Tp - 230 V T 1 A 825366
MPC 104 Tp - 115/230 V T 3.15 A 825391
CAUTION !
Open the base plate to change the fuse. First, pull out the power plug.
400082 7

Description
3 Description
3.1 Design
The diaphragm pump consists of a
pump body and a drive motor in casing.
The diaphragm pump is also available
as a special "MPC 104 Tp build-in model"
without casing.
The pump body consists of an eccentric
shaft, four connecting rod and four pump
heads.
Each pump head contains a diaphragm
and two work valves. Both pump heads
are arranged in 180° opposite each other.
The pump heads are driven via the motor
and the eccentric shaft with a connecting
rod.
The suction (2) and the exhaust connec-
tion (1) are located directly on the pump
head and are designed as hose nipple
for an inner hose diameter of 8 mm.
The pump is electrically connected via the
ICE connection cable (3).
Fig. 1 Diaphragm pump MPC 104 Tp
( 1 )
( 2 )
( 3 )
3.2 Principle of Operation
Motor, eccentric shaft and connecting rod set the diaphragms in stroke movement. This
changes the size of the space between the diaphragms and pump head (pump chamber).
Increasing the size of the pump chamber opens the inlet valve while the outlet valve is clo-
sed (gases are sucked in).
Decreasing the size of the pump chamber switches the valves over and ejects the gas
through the exhaust outlet.
The valves are actuated by the gas being pumped.
A large proportion of condensate in the diaphragm pump minimizes the suction performance
and the ultimate pressure that can be achieved.
3.3 Areas of Application
ILMVAC diaphragm pumps are intended for:
• Pumping and compressing neutral and aggressive gases and vapours.
• Generating a vacuum down to an ultimate pressure < 2 mbar.
• Use in physical and chemical laboratories in trade and industry.
• Use for vacuum filtration, vacuum distillation and vacuum drying, and other vacuum tech-
nology applications.
• These can also be used in stripped down form for OEM applications (for example without
a casing).
8 400082

Description
3.4 Pump head circuitry
Three stage (T): Two pump heads are in parallel, the other two in series.
Ultimate pressure: < 2 mbar
Type: MPC 104 Tp
Special designs:
• Special diaphragm pumps can be supplied after consultation with the manufacturer or for
a corresponding supply contract.
• Motors for different voltages.
3.5 Materials of the medium-affecting pump parts
Component Material
Chemical model MPC type (resistant to aggressive gases)
Connection- / pump head PTFE with carbon-fibre reinforcing
Seal EPDM
Screw fitting PVDF / PP
Valves PEEK
Diaphragm fabric reinforced with a PTFE layer
Connecting elements PP
Hose PTFE
Notes:
PTFE with carbon-fibre reinforcement, electrically conductive (manufacturer's certificate of
electrical conductivity available on request).
Material resistance to aggressive media see:
“Kunststoff Kautschuk Produkte“, Jahreshandbuch der Verarbeiter 2000/2001 ("Plastic,
Rubber Products“, Annual Handbook of the Processor 2000/2001), Publisher Hoppenstedt
Darmstadt, Vienna, Zurich.
3.6 Scope of Delivery
The scope of delivery is specified in the supply contract.
3.7 Accessories (optional)
Designation Usage Order no.
Vacuum Control Box VCB 424 cv For measuring and regulation of vacuum. 600037
Straight clamping ring screw fitting
PVDF, 8 – 1/8“
Connecting element for
vacuum hose 8 / 6 x 1 mm 829919
400082 9

Technical Data
4 Technical Data
4.1 View of device and dimensions
(D)
(H)
(W)
Fig. 2 View of device and dimensions (see chapter 4.3)
4.2 Intake Pressure / Pumping Speed – Diagram
Fig. 3 Intake Pressure / Pumping Speed – Diagram
10 400082

Technical Data
4.3 Device data
Parameter Unit Data
m3/ h 0.8 / 0.9
Pumping speed 50/60 Hz
DIN 28432
at speed of 1350 rpm l / min 13 / 15
Ultimate pressure
at speed of 1350 rpm mbar <2
Max. inlet pressure bar 1
Max. outlet pressure bar unpressurised
Intake and pressure ports - Hose nozzle
for vacuum hose NW 8
Max. ambient temperature °C + 10 to + 40
Max. operating gas temperature °C + 60
Bearing - maintenance-free
Reference surface sound
pressure level
DIN 45635 part 13
dB (A) <45
Voltage / Frequency V, Hz 230, 50/60 (115/230, 50/60)
Power kW 0.06
Operating mode - S 1
Type of protection DIN EN 60529 - IP 42
Class of insulation DIN EN 600034-1 - F (160°C)
Weight for :
- Diaphragm pump 230 V 7.1
- Diaphragm pump 115/230 V
kg
7.9
Dimensions (W/D/H) mm 235 / 140 / 340
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 :
- Diaphragm pump 230 V
without mains connection cable 400082
- Diaphragm pump 115/230 V
without mains connection cable
-
400082-03
400082 11

Installation and Operation
5 Installation and Operation
5.1 Unpacking
Carefully unpack the diaphragm pump.
Check the pump for:
• Transport damage,
• Conformity with the specifications of the supply contract (type, electrical supply data),
• Completeness of the delivery.
Please inform Ilmvac GmbH without delay if there are discrepancies between the delivery
and the contractually agreed scope of delivery, or if damage is detected.
Please take note of the general terms of business of ILMVAC GmbH.
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
1. Set the diaphragm pump on a flat and
horizontal surface.
2. Remove the protective caps on the
suction (2) and pressure ports (1).
3. Connect the NW 8 vacuum
connector to the suction port (2).
4. Voltage selector 115/230 V (3)
Label on pump:
5. Connect the diaphragm pump to the
electrical supply (earthing plug).
6. Power switch (4)
Fig. 4 Diaphragm pump MPC 104 Tp
rear side
( 3 )
( 2 )
( 1 )
( 4 )
12 400082

Installation and Operation
5.3 Operation
CAUTION!
Before the device is switched on, the voltage selector must be set with a screwdriver
to the voltage of the local power supply, either 115 or 220 V (+/-10%).
The diaphragm pump is switched on and off at the ON/OFF switch.
CAUTION !
Observe the basic safety instructions when using the pump.
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. The interior of the pump heads must be dry and free of condensates.
The interior of the pump heads must be dry and free of condensates.
5.5 Scrap Disposal
CAUTION !
The diaphragm pumps must be disposed of in accordance with the 2002/96/EC gui-
deline and the specific national regulations.
Contaminated diaphragm pumps must be decontaminated according to the laws.
400082 13

Maintenance and Servicing
6 Maintenance and Servicing
6.1 General Requirements
• Check the 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 electrical and vacuum connections daily.
6.2 Maintenance Performed by the User
WARNING !
Only perform the work that is described here, and that which is permitted to be done
by the user.
All other maintenance and service work may only be performed by the manufacturer
or a dealer authorized by him.
Beware of the pump parts being possibly contaminated by hazardous substances.
Wear protective clothing if there is contamination.
Scope of permissible work:
• Inspect the pump chambers, diaphragms and valves,
• Deposits in the inside of the pump must be cleaned out,
• Change the diaphragms, valves and seals.
WARNING !
Before opening the pump unplug it from the mains.
Tools required:
The tool kit, order No. 402107
consists of:
• 826801-4 Cross-head screwdriver, size 2,
• 826801-2 Open spanner, size SW 14,
• 826801-9 Open spanner, size SW 7.
14 400082

Maintenance and Servicing
6.2.1 Disassembly
1. Disconnect the power supply and ensure that it cannot be switched on again.
2. Open the cover of the casing.
3. Open the screw clamps of the hose bridge on the pump body with the open spanner, size 14.
4. Remove 2 x 4 screws (1) from each connecting head (2) with a cross-head screwdriver, size 2.
5. Lift off the connecting head (2) and the pump head (5). The diaphragm is now freely exposed.
6. Loosen the defective diaphragm (6) by turning it anticlockwise.
7. Valves (4) (see fig. 6) and o-rings (3) are located between the connecting and the pump head.
When dismounting both heads these parts are accessible.
8. Clean the valves (4) (see fig. 6), o-rings (3) and diaphragm (6) with a soft cloth and acetone and re-
place defective items if necessary.
Fig. 5 Disassembly - Montage
WARNING !
Renew defective parts, if necessary ! Wear protective gloves!
Parts must be renewed at the intervals stated in this Operating Manual or as speci-
fied by the user internally.
Do not clean with compressed air !
6.2.2 Montage
(Fig. 5 and 6)
1. Place the pump so that the diaphragm (6) is lying in a horizontal position.
2. Tighten the diaphragm (6) with the torque of 2 - 4 Nm.
3. Bring the connecting rod (see fig. 7) and the diaphragm (6) into the central position.
4. Replace the pump head (5).
5. Insert the valves (4) (see fig. 6) and the o-rings (3).
Ensure that they are lying completely flat. Do not insert the burred side facing the sealing surface.
6. Replace the connecting head (2) and tighten the 2 x 4 cross head screws (1) with a torque of
3 - 4 Nm.
7. Use an analog assembly sequence for all heads.
8. Reattach the hose connections with clamping ring screw fittings.
9. Close the casing by shutting the cover.
400082 15

Maintenance and Servicing
CAUTION !
Please pay attention to the valve arrangements (C) and (D)!
(A) – Connection suction side
(B) – Connection pressure side
(C) – Valve (400656)
(D) – Valve with hole (400656-4)
(E) – Gas ballast valve
Fig. 6 Valve arrangement
6.2.3 Test
• Connect the pump to the electrical supply.
• Connect a vacuum measuring device to the suction connector and measure the ultimate
pressure.
If the device is working properly, then the figure stated in the technical data must be at-
tained within a maximum of one minute.
• The pump must not make any abnormal noises.
• Moving parts must not touch each other.
16 400082

Maintenance and Servicing
6.3 Maintenance by the Manufacturer
Repairs and maintenance going beyond the extent of the work described in chapter 6.2 or
reconditioning or modification may only be performed by the manufacturer or authorized
workshops.
WARNING !
The user shall be liable for the consequences of an incorrect damage report or a
contaminated pump. The statements in the damage report are legally binding.
6.4 Damage Report
You find the form of the damage report to the Download on our web page
http://www.ilmvac.de and/or. http://www.ilmvac.com in the menu "service" and "Downloads".
If you should not have an entrance to the Internet, you can request the form also gladly with
us, company Ilmvac GmbH.
WARNING !
Incomplete or incorrectly completed damage reports may endanger the service per-
sonnel!
Give full information in the damage report, in particular regarding a possible con-
taminating of the sensor.
400082 17

Troubleshooting
7 Troubleshooting
Only ILMVAC GmbH and authorized service workshops may work on (carry out repairs,
modifications etc.) the diaphragm pump during the warranty period.
Trouble Cause Action
No power supply to the
motor
Electrical system to be
checked
by a qualified electrician.
Motor defective Exchange by service shop.
Diaphragm pump
does not start
Pump body defective Exchange or repair by service
shop.
Connected apparatus
leaks,
connecting elements
leak
Identify and seal the leak, re-
place the seals and hoses if
necessary.
Diaphragm pump leaks
(pipes or hoses)
Check the hose connections
between the pump heads,
replace the hoses and screwed
clamping rings if necessary.
Pump head Repair by service shop.
Diaphragm defective
Repair by the service work-
shop
or the user.
Valves are dirty Clean condensates and foreign
objects out of the valves.
The diaphragm pump
does not generate a
vacuum or only
an inadequate one
Valves defective Replace valves
18 400082

Spare Parts Overview
8 Spare Parts Overview
The spare parts lists contain all the spare parts and all the information necessary for order-
ing.
When ordering, please quote the description, quantity, serial number and order number!
CAUTION !
Ilmvac is not liable for any damage caused by the installation of any parts not sup-
plied by the manufacturer.
8.1 Maintenance kit
Designation Order no.
Maintenance kit 402044
The maintenance kit consists of:
Designation Piece Order no.
O-ring ø 25 x 2 8 829250-1
O-ring ø 8 x 2 5 829210-3
Form diaphragm 4 828929-1
Valve 8 400656
Valve (with hole) 2 400656-4
Caution, the number of supplied construction units in the maintenance set
corresponds to the maximum need of the series!
400082 19

Spare Parts Overview
8.2 Exploded view
Fig. 7 Exploded view MPC 104 Tp
20 400082