Pfeiffer Vacuum KS 0.5 User manual

PD 0012 BEN/B (1507)
OPERATING INSTRUCTIONS
KS 0.5 ... 12.0
Condensers
Translation of the original instructions
EN

Table of contents
2
Table of contents
1 About this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Range of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Connecting the cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Draining the condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3 Condensate re-evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.4 Sequence control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10.1 Spare parts packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

About this manual
3
1 About this manual
1.1 Validity
This operating manual is for customers of Pfeiffer Vacuum. It describes the functioning
of the designated product and provides the most important information for safe use of
the unit. The description follows applicable EU guidelines. All information provided in this
operating manual refers to the current state of the product's development. The documen-
tation remains valid as long as the customer does not make any changes to the product.
Up-to-date operating instructions can also be downloaded from
www.pfeiffer-vacuum.com.
1.2 Conventions
Safety instructions The safety instructions in Pfeiffer Vacuum operating instructions are the result of risk
evaluations and hazard analyses and are oriented on international certification stan-
dards as specified by UL, CSA, ANSI Z-535, SEMI S1, ISO 3864 and DIN 4844. In this
document, the following hazard levels and information are considered:
Pictogram definitions
DANGER
Imminent danger
Indicates an imminent hazardous situation that will result in death or serious injury.
WARNING
Possibly imminent danger
Indicates an imminent hazardous situation that can result in death or serious injury.
CAUTION
Possibly imminent danger
Indicates an imminent hazardous situation that can result in minor or moderate injury.
NOTICE
Command or note
Command to perform an action or information about properties, the disregarding of
which may result in damage to the product.
Prohibition of an action or activity in connection with a source of danger,
the disregarding of which may result in serious accidents
Warning of a displayed source of danger in connection with operation of
the unit or equipment
Command to perform an action or task associated with a source of dan-
ger, the disregarding of which may result in serious accidents

4
Safety
Instructions in the
text
Work instruction: here you have to do something.
Abbreviations KS: Condensor
2Safety
2.1 Safety precautions
Installation, operating and maintenance regulations must be complied with.
Before carrying out any work read and observe the operating and safety instructions
of the pumping station and the individual components.
Observe the safety and accident prevention regulations.
Check regularly that all safety precautions are being complied with.
When returning the components to us please note the instructions in the Service sec-
tion.
Important information about the product or this document
Duty to inform
Each person involved in the installation or operation of the unit must read and observe
the safety-related parts of these operating instuctions.
The operator is obligated to make operating personnel aware of dangers originating
from the unit or the entire system.

Safety
5
2.2 Protective equipment
Determined situations concerning the handling of vacuum pumps require wearing of per-
sonal protective equipment. The owner, respectively the employer are obligated to pro-
vide adequate equipment to any operating persons.
2.3 Proper use
●The pumping of condensable vapors
●Application for obtaining distillate
●Application in drying systems
2.4 Improper use
Improper use will cause all claims for liability and warranties to be forfeited. Improper use
is defined as usage for purposes deviating from those mentioned above, especially:
●pumping of corrosive or explosive media
●operation in potentially explosive areas
●connection to pumps or units which are not suitable for this purpose according to their
operating instructions
●connection to units which have exposed voltage-carrying parts
●use of accessories or spare parts, which are not named in this manual
DANGER
Danger to health by hazardous substances during maintenance or installation
Depending on the process vacuum pumps, components or operating fluids can be con-
taminated by toxic, reactive or radioactive substances.
Wear adequate protective equipment during maintenance and repairs or in case of
reinstallation.
DANGER
Frostbite, severe eye damage and suffocation hazard!
Contact with coolant causes frostbite and severe eye damage. Liquid coolants, in par-
ticular, have the tendency to spray explosively when filled too quickly or when the cool-
ing container is warm. Coolant passing into a gaseous state can, in high concentrations,
displace oxygen and lead to suffocation hazard by accumulating in the inhaled air.
Wear safety glasses with adequate side protection; wear protective gloves (special
cryo-gloves or leather gloves).
Secure liquid gas tanks from falling over, and protect them against shock, impact and
heat; ventilate rooms adequately.

6
Transport and storage
3 Transport and storage
3.1 Transport
Parts of the system are dismounted prior to transport, so these much be re-installed
according to the installation drawing.
4 Product description
4.1 Product identification
To correctly identify the product when communicating with Pfeiffer Vacuum, always have
the information from the rating plate available.
Scope of delivery The condensers can be delivered in the following designs:
– Cooling surface between 0.5 and 12 m2
– Housing in normal and stainless steel design
– Condensate drainage either through manual valves or automatic drainage control
Other special application-specific designs are possible.
4.2 Function
The purpose of the condenser is to condense steam before it enters the vacuum pump,
in order to protect the vacuum pump against damaging condensates and to ensure the
permitted partial pressure of the vacuum pressure is not exceeded. This preserves the
lubricity of the operating materials and the achievable ultimate pressure of the vacuum
pump.
The effectiveness of the condenser is limited by the cooling water temperature and the
procedure used. Steam condensation is in principle only possible up to the saturation
pressure of the respective substance. In order to maintain an optimum performance of
the condenser, the cooling water inlet temperature should not normally exceed 15°C.
In condensation compartment 3, the cooling surface is formed by a stainless steel coiled
tube through which water flows. The steam exiting from the vacuum chamber condenses
on the cooling surface and flows as condensate into the collection container 4.
Thanks to the set-up of the non-return valve V3, the use of a ventilation valve V4 and a
condensate outlet screw V5, the condensate produced can be drained off without inter-
rupting batches.
WARNING
There is a risk of injury if the system is not transported properly.
Danger to life from falling or protruding loads if the system is not properly secured to lift-
ing devices or is not transported properly.
Use suitable lifting devices and tools.
Ensure that the weight is distributed evenly (danger of tipping!).
Test the hanging for high center of gravity.
The set-up and size of the gas intake and exhaust nozzles is based on the cus-
tomer's requirements.
These can sometimes differ considerably from the illustrations shown in these operating
instructions. The component drawing with the respective article number of the condens-
er is the authoritative reference for the position of the nozzles and connectors.

Installation
7
Fig. 1: KS 1.5 M ... 6 M
4.3 Range of application
While, through the condensation, the condenser considerably speeds up the pre-drying
process when used in drying systems, in distillation systems it is used to obtain distillate.
If a condenser is used in a pumping station, the condenser should be installed between
the Roots vacuum pump and the backing pump. With this set-up, steam can still be con-
densed in the condenser through the compression of the Roots vacuum pump, even if
the saturation pressure of the steam is significantly below the required level in the vacu-
um chamber.
5 Installation
Prior to installation, check the load-bearing capacity of the installation base.
Position the condenser vertically and anchor it to the installation base.
1Gasintake
2 Gas exhaust
3 Condensation compart-
ment
4 Collection container
5 Cooling water inlet
6 Cooling water outlet
10 Sight glass
LS1 Level monitor
V3 Non-return valve (conden-
sate overflow)
V4 Ventilation valve
V5 Condensate outlet
2
3
5/6
4
V5
V3
LS1
V4
10
1
WARNING
Tilting danger!
Product may tilt over and may cause serious injury.
Do not climb on the product to make installations.
Use ladders and steps.
When mounting components (e.g. vacuum pumps) pay attention to the relocation of
the product’s center of gravity.
Fix the product to the floor with appropriate screws.

8
Installation
5.1 Assembling
Remove the protective caps from the connection flanges.
Make the connection between the vacuum chamber and condenser or vacuum pump
as short as possible with a nominal width as wide as possible.
Clear welded lines of any welding scales, loose parts etc. before installation.
Connect the pipes free of tension;
– Ensure that mating flanges are in a parallel position,
– if necessary, integrate suspension components into the piping.
Lay the piping to the condenser so that it is directed downwards to enable the conden-
sate from the cold pipe to flow into the condenser.
Always install KS 0.5 ... 12.0 vertically to maintain the required through flow direction.
PI
P1
V1
V2
V3
V5
V4
P2
LS 1
LS 2
14
12
1
2
LS 3
5
6
10

Operation
9
5.2 Connecting the cooling water
Connect the cooling water lines:
– Cooling water inlet (5).
– Cooling water outlet (6); must be pressure-free.
Open cooling water supply and ensure sufficient flow; adjust if necessary.
To save cooling water at times of fluctuating steam production, the condenser can be fit-
ted with a cooling water control valve. When the maximum amount of condensate is be-
ing produced, the permitted water outlet temperature can be adjusted manually on this
valve. If the amount of steam being produced goes down and therefore the amount of
heat to be discharged, the control valve automatically reduces the amount of cooling wa-
ter until the set water outlet temperature is reached.
5.3 Electrical connection
Versions with an electric cabinet have the electrical components of the condenser and
the drive motors of the pumping station wired in the cabinet. The electrical connection is
implemented according to the applicable circuit diagrams (see appendices).
6Operation
6.1 Commissioning
Prior to putting the condenser into operation, check that the ventilation valve V4 and con-
densate outlet V5 are closed.
Open the non-return valve V3.
Open the cooling water inlet and check the flow.
– The condensate produced now flows out of the condensation compartment 3,
through the non-return valve V3 and sight glass 10, and into the collection container
4.
– If the level of condensate produced goes above the middle of the sight glass 10,
the condensate must be drained.
DANGER
Voltage-bearing elements
Danger to life from electric shock.
The electrical connection can be carried out only by trained and authorised electri-
cians.
Disconnect the power supply and secure it against being switched back on.
Ensure the system is adequately earthed.
CAUTION
Excess voltage!
Danger of destroying the unit.
Power connections must comply with local regulations. Voltage information given on
the rating plate must correspond to the mains voltage values.
Use only cable with protective earth conductor.
To protect the electronics and the power supply cable in case of failure provide an
appropriate network safety device.

10
Operation
6.2 Draining the condensate
During batch processes, if the amount of condensate produced does not fill the collection
container, the condensate can be drained after the end of the batch.
Close the non-return valve V3.
Vent the collection container 4 by opening the ventilation valve V4.
Open the condensate outlet V5.
Drain off condensate and dispose of in accordance with the relevant valid legal regu-
lations.
Once the condensate has drained out, close the outlet valve V5 and ventilation valve
V4.
Carefully open the non-return valve V3.
6.3 Condensate re-evaporation
If during batch drying processes, the required saturation pressure of the steam produced
in the condenser was not reached, re-evaporated condensate will come out of the col-
lection container. The steam produced also loads the vacuum pump and extends the dry-
ing time up to the ultimate vacuum.
Closing the non-return valve V3 at the end of the condensate production prevents re-
evaporation from occurring.
Electric valve control
The re-evaporation prevention integrated in the control closes the non-return valve when
a pre-set pressure is reached V3. This pressure should be slightly higher than the steam
pressure of the medium being condensed. This prevents any re-evaporation from the
collection container 4.
WARNING
Contamination of parts and operating fluid by pumped media is possible.
Poisoning hazard through contact with materials that damage health.
In the case of contamination, carry out appropriate safety precautions in order to pre-
vent danger to health through dangerous substances.
Decontaminate affected parts before carrying out maintenance work.
Electric valve control!
The processes described for manual operation are largely undertaken by the control in
the electric cabinet for versions with electric valve control (see corresponding function
description of relevant control).