Pfeiffer Vacuum MVP 160-3 User manual

OPERATING INSTRUCTIONS
EN
Translation of the Original
MVP 160-3
Diaphragm vacuum pump

PU0077BEN_A PU0077 2017-12-12

Table of contents
1 About this manual 5
1.1 Validity 5
1.1.1 Related documents 5
1.1.2 Variants 5
1.2 Target group 5
1.3 Conventions 5
1.3.1 Pictographs 5
1.3.2 Symbols used 6
1.3.3 Product sticker 6
1.3.4 Instructions in the text 6
2 Safety 7
2.1 General safety instructions 7
2.2 Safety instructions 7
2.3 Safety precautions 10
2.4 Proper use 10
2.5 Foreseeable improper use 11
3 Transporting the pump 12
4 Storing the pump 13
5 Product description 14
5.1 Identifying the product 14
5.2 Shipment 14
5.3 Pump design and function 14
6 Installation 15
6.1 Installing the pump 15
6.2 Connecting the pumping stages 15
6.3 Connecting the vacuum side 16
6.4 Connecting the exhaust side 16
6.5 Establishing an electrical connection 17
7 Operation 18
7.1 Switching on and operating the pump 18
7.2 Switching off the pump 19
8 Decommissioning the pump for long periods 20
9 Maintenance 21
9.1 General 21
9.2 Maintenance intervals 21
9.3 Dismantling the distributor 22
9.4 Disassembling the diaphragm head 23
9.5 Checking and replacing parts 24
9.6 Cleaning contaminated parts 24
9.7 Replacing the diaphragm 24
9.8 Replacing the valves 26
9.9 Installing the diaphragm head 27
9.10 Installing the distributor 28
9.11 Checking pump function 29
10 Troubleshooting 30
11 Service solutions from Pfeiffer Vacuum 32
12 Spare parts 34
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13 Accessories 35
14 Technical data and dimensions 36
14.1 Technical data 36
14.2 Dimensions 37
14.3 37
Declaration of conformity 39
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1 About this manual
IMPORTANT
Read carefully before use.
Keep the manual for future consultation.
1.1 Validity
These operating instructions are for customers of Pfeiffer Vacuum. They describe the function of the
designated product and provide the most important information for a safe usage of the product. The de-
scriptions comply with applicable directives. All information provided in these operating instructions refer
to the current development status of the product. The documentation remains valid as long as the cus-
tomer does not modify the product in any way.
1.1.1 Related documents
Designation Document
Declaration of conformity A component of these instructions
Current documents are available from the Pfeiffer Vacuum Download Center.
1.1.2 Variants
This operating manual applies to pumps with the following part numbers:
Part number Designation
PK T01 400 MVP 160-3
1.2 Target group
This operating instructions are aimed at all persons performing the following activities on the product:
●transport,
●setup (installation),
●usage and operation,
●decommissioning,
●maintenance and cleaning,
●storage or disposal.
The work described in this document is only permitted to be performed by persons with the appropriate
technical qualifications (expert personnel) or who have received the relevant training from Pfeiffer Vac-
uum.
1.3 Conventions
1.3.1 Pictographs
Pictographs used in the document indicate useful information.
Note
Tip
About this manual
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1.3.2 Symbols used
Vacuum connection
Power connection
Pressure connection (exhaust)
Tbl. 1: Symbols used
1.3.3 Product sticker
This section describes all the stickers on the product along with their meaning.
Rating plate
The rating plate is located on the housing panel.
General warning signs
The label provides a general warning of potential hazards, in this case
in relation to the hot surfaces warning.
Warning of hot surfaces
The label warns of hot surfaces during operation or immediately after
switching off the pump.
1.3.4 Instructions in the text
Usage instructions in the document follow a general structure that is complete in itself. The required ac-
tion is indicated by a individual or multi-part action steps.
Individual action step
A horizontal, solid triangle indicates the only step in an action.
►This is an individual action step.
Sequence of multi-part action steps
The numbering indicates an action with multiple action steps required.
1. Action step 1
2. Action step 2
3. ...
About this manual
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2 Safety
2.1 General safety instructions
This document includes the following four risk levels and one information level.
DANGER
Imminent danger
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
►Instructions on avoiding the hazardous situation
WARNING
Possibly imminent danger
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
►Instructions on avoiding the hazardous situation
CAUTION
Possibly imminent danger
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
►Instructions on avoiding the hazardous situation
NOTICE
Danger of property damage
Notice is used to address practices not related to physical inrury.
►Instructions on avoiding property damage
Notes, tips or examples identify important information on the product or on this
document.
2.2 Safety instructions
All safety instructions in this document are based on the results of the risk assessment carried out in
accordance with Machinery Directive 2006/42/EC Annex I and EN ISO 12100 Section 5. As far as appli-
cable, all unit life cycle phases have been considered.
Risks during transport
WARNING
Danger of serious injury due to falling objects
Due to falling objects there is a risk of injuries to limbs through to broken bones.
►Take particular care and pay special attention when transporting products manually.
►Do not stack the products.
►Wear protective equipment, e.g. safety shoes.
NOTICE
Damage caused during transport
Transport in unsuitable packaging or failure to install all transport locks can damage the product.
►Observe the transport instructions.
►Always transport the pump in its original packaging.
►Transport the pump using only the transport handles provided.
►Always use dense and impact-proof packaging for the pump.
►Seal inlet and outlet ports (for example using transport caps).
►Reattach transport locks prior to every transport.
Safety
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Risks during storage
NOTICE
Damage caused by improper storage
Improper storage damages the pump.
►Store the pump in a cool, dry, dust-free place, where it is protected against impacts.
►Seal inlet and outlet ports (for example using transport caps).
►Maintain the permissible storage temperature. (See technical data)
Risks during installation
DANGER
Danger to life from improperly earthed unit
An improperly earthed unit is a potential threat to life in the event of a fault.
►Conduct the electrical connection in accordance with locally applicable regulations.
►Make sure that the local mains voltage and frequency match rating plate specifications.
►Use only a 3-pin mains cable and extension cables with properly connected protective earthing
(earthed conductor).
►Plug the mains plug into a socket with earthing contact only.
–Protection must not be impaired by an extension with no earthed conductor.
►Always connect the mains cable prior to all other cables, to ensure continuous protective earth-
ing.
–In reverse: always disconnect all other cables prior to disconnecting the mains cable.
CAUTION
Risk of injury from bursting due to high pressure in the exhaust line
Faulty or insufficient exhaust lines cause hazardous situations, e.g. increase in exhaust pressure.
There is a risk of bursting. It is not possible to rule out the risk of injuries due to broken pieces flying
around, high escaping pressure and damage to the equipment.
►Lay the exhaust line without shut-off units.
►Observe the permissible pressures and pressure differentials of the product.
►Check the exhaust line regularly for correct function.
NOTICE
Pump damage caused by overpressure
Mixing up the connections causes overpressure overload. The pump can be started only against
max. 1 bar differential pressure between inlet and outlet, otherwise the motor jams and sustains dam-
age.
►Make sure that the distributor is installed correctly on the diaphragm heads, before connecting
the pump to the vacuum equipment.
►Before commissioning, make completely sure that the pressure side pressure is below the per-
missible limit.
Risks during operation
WARNING
Danger of poisoning due to emission of toxic process gases from the exhaust
During operation with no exhaust line, the vacuum pump allows exhaust gases and vapors to escape
freely into the air. In processes involving toxic media, there is a risk of injury and danger to life due to
poisoning.
►Observe the relevant regulations for handling toxic substances.
►Safely purge toxic process gases via an exhaust line.
►Use suitable filter equipment to separate toxic substances.
Safety
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WARNING
Risk of burns on hot surfaces
During pump operation, exposed surfaces reach high temperatures. There is a risk of burning.
►Allow the pump to cool down before carrying out any work.
►Wear protective gloves (in accordance with EN 420).
NOTICE
Damage caused by water hammer
The sudden ingress of condensate can cause water hammer, as the pump cannot pump the addition-
ally formed steam down quickly enough. Water hammer destroys the pump.
►Install a capacitor between the vacuum system and pump.
–This intercepts the fluid upstream of the pump.
NOTICE
Damage caused by fluids and dust
Fluids and dust damage diaphragms and valves.
►Prevent ingress of particles and dusts to the pump.
►Install a suitable filter upstream of the pump if necessary.
►Avoid condensation in the pump and water hammer.
►Observe the intended use.
NOTICE
Damage caused by silencer contamination
After a long period of operation at high intake pressures or with dust-laden gases, the silencer can
become congested. If the silencer becomes contaminated, an internal overpressure builds that dam-
ages bearings, diaphragms, and valves.
►Replace a contaminated silencer.
►Make sure that the exhaust line is unobstructed.
►Ideally, use a hose nozzle as an outlet.
Risks during maintenance
CAUTION
Risk of injury on hot surfaces, due to the vacuum or on sharp edges due to improperly per-
formed maintenance work
Improper handling of the pump before maintenance work causes hazardous situations involving a risk
of injury. There is a risk of burning injuries on hot surfaces. There is a risk of injury due to the vacuum
when switching off. There is a risk of cutting injuries due to the access to sharp-edged, rotating parts
when removing the pump.
►Ensure that the pump has come to a complete standstill before performing any work on the
pump.
►Switch off the pump correctly.
►Vent the pump to atmospheric pressure.
►Secure the pump against being switched back on.
►Allow the pump to cool down.
►Seal open connections with the original protective covers immediately after removing the pump.
NOTICE
Damage caused by pointed or sharp-edged tools
Sharp-edged tools damage pump parts during maintenance.
►Never disconnect pump parts such as diaphragm heads using pointed or sharp-edged tools.
►Never use pointed or sharp-edged tools to lift diaphragms.
►If necessary, use a rubber mallet to loosen parts.
Safety
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NOTICE
Damage caused by unsuitable cleaning agents
Unsuitable cleaning agents damage pump parts.
►Use only approved cleaning agents to clean pump parts.
►Never use soluble detergents.
NOTICE
Damage caused by unsuitable auxiliary tool
Using unsuitable tools damage the diaphragm and associated components.
►Never use the diaphragm key with auxiliary tools (for example pliers or an Allen key without tor-
que limitation).
2.3 Safety precautions
The product is designed according to the latest technology and recognized safety engineering rules.
Nevertheless, improper use can result in danger to operator all third party life and limb, and product
damage and additional property damage.
Information requirement on possible hazards
The owner or operator of the product is required to make all operating personnel
aware of hazards arising from the use of this product.
Every person who is involved in the installation, operation or maintenance of the
product must have read and understood the safety-relevant parts of this documen-
tation.
Infringement of EU conformity due to modifications to the product
The Declaration of Conformity from the manufacturer is no longer valid if the opera-
tor changes the original product or installs additional equipment.
●Following installation into a system, the operator is required to check and re-
evaluate as necessary the conformity of the overall system in the context of the
relevant EU Directives before commissioning that system.
General safety precautions for working with the pump
►Observe all applicable safety and accident prevention regulations.
►Check that all safety measures are observed at regular intervals.
►Do not expose body parts to the vacuum.
►Always ensure a secure connection to the earthed conductor (PE).
►Never disconnect plug connections during operation.
►Observe the above shutdown procedures.
►Keep lines and cables away from hot surfaces (> 70°C).
►Never fill or operate the unit with cleaning agents or cleaning agent residues.
►Do not carry out your own conversions or modifications on the unit.
►Observe the unit protection class prior to installation or operation in other environments.
►Observe statutory and local regulations regarding solvents handling.
►Never operate an open or faulty unit.
►Before carrying out any maintenance, first allow the unit to cool and disconnect it from the vacuum
equipment.
►Disconnect the pump from the mains prior to every intervention, and wait an additional five sec-
onds until the capacitors have discharged.
►Implement suitable safety precautions where unintentional pump venting can cause hazards.
–Power failures can cause unintentional venting.
2.4 Proper use
●You may use the pump exclusively for vacuum generation.
●You may not operate the pump with accessories not recommended by Pfeiffer Vacuum.
Safety
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●Always observe installation, commissioning, operating, and maintenance instructions.
2.5 Foreseeable improper use
Improper use of the product invalidates all warranty and liability claims. Improper use is any, even unin-
tended, use, which is contrary to the product purpose; and in particular:
●pumping corrosive media
●pumping explosive media
●pumping corrosive, explosive, radioactive, or volatile media
●pumping gases that introduce an ignition source to the suction chamber
●pumping gases that contain impurities such as particles, dust, or condensate
●pumping fluids
●pumping FPM-solubilizing media
●pumping vapors from combustible liquids
●pumping pressurized media (> atmospheric pressure)
●pumping media that can condense or cause adhering deposits to form in the suction chamber
●using the pump outside the specified area of application
●using the pump below ground
●using the pump to generate pressure
●using the pump in systems in which sporadic loads and vibrations or periodic forces act on the
unit
●using the pump in strong electrical, magnetic, or electromagnetic fields
●connecting to pumps and equipment that are not intended for this purpose according to their oper-
ating instructions
●connecting to equipment with exposed live parts
●connecting to sockets without earthing contact
●using lubricants not specified by Pfeiffer Vacuum
●using pipes to lift the pump
●using accessories or spare parts not listed in this manual
●using the pump as a climbing aid
●using the connection lines between the diaphragm heads as carrying handles
●using the pump in ambient conditions that do not meet the specified IP protection class limits
Safety
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3 Transporting the pump
WARNING
Danger of serious injury due to falling objects
Due to falling objects there is a risk of injuries to limbs through to broken bones.
►Take particular care and pay special attention when transporting products manually.
►Do not stack the products.
►Wear protective equipment, e.g. safety shoes.
NOTICE
Damage caused during transport
Transport in unsuitable packaging or failure to install all transport locks can damage the product.
►Observe the transport instructions.
►Always transport the pump in its original packaging.
►Transport the pump using only the transport handles provided.
►Always use dense and impact-proof packaging for the pump.
►Seal inlet and outlet ports (for example using transport caps).
►Reattach transport locks prior to every transport.
Instructions for safe transport
1. Observe weight specified on the rating plate.
2. Where possible, always transport or ship the pump in its original packaging.
3. Always carry the pump with both hands.
4. Remove the protective cover only immediately prior to installation.
Transporting the pump
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4 Storing the pump
NOTICE
Damage caused by improper storage
Improper storage damages the pump.
►Store the pump in a cool, dry, dust-free place, where it is protected against impacts.
►Seal inlet and outlet ports (for example using transport caps).
►Maintain the permissible storage temperature. (See technical data)
Storing the pump
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5 Product description
5.1 Identifying the product
You will need all the data from the rating plate to safely identify the product when communicating with
Pfeiffer Vacuum.
Recording rating plate data
1. Read the data on the product rating plate.
2. Record this data.
3. Always have all rating plate specifications to hand.
5.2 Shipment
●MVP 160-3 diaphragm vacuum pump
●Operating manual (German/English)
5.3 Pump design and function
4
8
6
5
9
3
2
1
7
Fig. 1: MVP 160-3
1 Vacuum connection (inlet, DN 25 ISO-KF) 6 Mains switch
2 Distributor, intake side 7 Pressure connection (with silencer)
3 Handle (2x) 8 Rating plate on housing panel
4 Mains plug 9 Motor fan
5 Distributor, pressure side
The diaphragm vacuum pump is a three stage, dry compressing pump. This means that the supplied
medium does not come into contact with any lubricant.
The pump is a positive displacement pump with a periodic change in suction chamber size, produced by
the movement of the diaphragm. The gas flow causes the valves to open and close automatically.
The pump units are connected directly to the drive motor (AC motor).
The pump is equipped with a pressure side silencer as standard.
Product description
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6 Installation
6.1 Installing the pump
Notes on installing the pump
1. Place the pump on a flat, horizontal surface.
2. Make sure that the pump is stable and secure, with no additional mechanical contact other than
the pump feet.
3. Make sure that the system to be evacuated and all hose connections are mechanically stable.
4. Never install the pump on a soft surface (such as foam), as this impairs air supply to the fan.
5. Ensure adequate air supply if you install the pump in an enclosed housing or at a high ambient
temperature. Provide external forced ventilation if necessary.
–Minimum 5 cm between fan (on pump underside) and adjacent parts (for example housing,
walls, etc.)
6. If you install the pump at an installation altitude of > 1000 m AMSL, you must implement meas-
ures in accordance with DIN VDE 0530 to ensure an adequate cooling air supply.
7. Anchor the pump to the supporting surface in the event of stationary installation.
8. Use elastic hose pieces or bellows for anchoring.
–This prevents mechanical forces resulting from rigid connection lines.
9. Maintain ambient conditions.
10. Before switching on, allow the pump to acclimatize.
–If the pump is brought into the operating area from a cold environment, condensation can
form.
6.2 Connecting the pumping stages
NOTICE
Pump damage caused by overpressure
Mixing up the connections causes overpressure overload. The pump can be started only against
max. 1 bar differential pressure between inlet and outlet, otherwise the motor jams and sustains dam-
age.
►Make sure that the distributor is installed correctly on the diaphragm heads, before connecting
the pump to the vacuum equipment.
►Before commissioning, make completely sure that the pressure side pressure is below the per-
missible limit.
The intake connections of the pumps are marked "IN" and the outlets "EX" on the individual diaphragm
heads.
Fig. 2: IN and EX connections on diaphragm heads
IN Intake connection EX Outlet
Installation
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Fig. 3: Distributor: Intake side distributor (left) and pressure side distributor (right)
6.3 Connecting the vacuum side
Preventing pressure losses
Using the shortest possible vacuum connection lines with large nominal diameter
prevents pressure losses.
Condensate separator
We recommend using a condensate separator in cases where the system to be
evacuated contains fluid, resulting in steam being generated during evacuation.
Connecting the vacuum side
1. Remove the locking cap from the vacuum connection.
2. Install the connection between pump and vacuum system so that it is as short as possible.
3. Install a condensate separator upstream of the pump.
4. Connect the pump to the vacuum system using the vacuum connection.
6.4 Connecting the exhaust side
Condensate separator
We recommend using a condensate separator in cases where the system to be
evacuated contains fluid, resulting in steam being generated during evacuation.
Connecting the exhaust side
1. Observe the official accident prevention regulations.
–This applies in particular where you install a shut-off unit for internal operating reasons, mean-
ing that overpressure can build in the line.
2. Remove protective caps.
3. Install the line downward from the pump, so that condensation does not flow back into the pump.
4. Connect pump and vacuum chambers with the shortest possible connection, with a minimum
nominal diameter equal to that of the vacuum connection.
5. Make sure that no piping system forces are acting on the pump.
6. Support or hang the pipes.
7. Only use the silencer at low gas throughput, and check it regularly to ensure that it is unobstruct-
ed.
Installation
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6.5 Establishing an electrical connection
Fig. 4: Connection diagram: MVP 160-3 with single phase AC motor
Installation
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7 Operation
7.1 Switching on and operating the pump
WARNING
Danger of poisoning due to emission of toxic process gases from the exhaust
During operation with no exhaust line, the vacuum pump allows exhaust gases and vapors to escape
freely into the air. In processes involving toxic media, there is a risk of injury and danger to life due to
poisoning.
►Observe the relevant regulations for handling toxic substances.
►Safely purge toxic process gases via an exhaust line.
►Use suitable filter equipment to separate toxic substances.
CAUTION
Risk of injury from bursting due to high pressure in the exhaust line
Faulty or insufficient exhaust lines cause hazardous situations, e.g. increase in exhaust pressure.
There is a risk of bursting. It is not possible to rule out the risk of injuries due to broken pieces flying
around, high escaping pressure and damage to the equipment.
►Lay the exhaust line without shut-off units.
►Observe the permissible pressures and pressure differentials of the product.
►Check the exhaust line regularly for correct function.
NOTICE
Damage caused by water hammer
The sudden ingress of condensate can cause water hammer, as the pump cannot pump the addition-
ally formed steam down quickly enough. Water hammer destroys the pump.
►Install a capacitor between the vacuum system and pump.
–This intercepts the fluid upstream of the pump.
NOTICE
Damage caused by fluids and dust
Fluids and dust damage diaphragms and valves.
►Prevent ingress of particles and dusts to the pump.
►Install a suitable filter upstream of the pump if necessary.
►Avoid condensation in the pump and water hammer.
►Observe the intended use.
NOTICE
Damage caused by silencer contamination
After a long period of operation at high intake pressures or with dust-laden gases, the silencer can
become congested. If the silencer becomes contaminated, an internal overpressure builds that dam-
ages bearings, diaphragms, and valves.
►Replace a contaminated silencer.
►Make sure that the exhaust line is unobstructed.
►Ideally, use a hose nozzle as an outlet.
Achieving throughput and ultimate pressure
The pump achieves the specified throughput and ultimate pressure values once the
operating temperature has been reached (after approx. 15 minutes).
Operation
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1
Fig. 5: Mains switch
1 Mains switch
Switching on and operating the pump
You can switch on the pump at any time.
1. Press the mains switch.
7.2 Switching off the pump
1
Fig. 6: Mains switch
1 Mains switch
Switching off the pump
You can switch off the pump at any time.
1. Allow the pump to run on for a few more minutes with the intake port open.
2. Press the mains switch.
3. Clean and check the diaphragm heads when working with pump media that are corrosive to pump
materials or can cause formation of deposits.
Operation
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8 Decommissioning the pump for long periods
Observe the following procedure before shutting down the pump for a longer period of time:
Decommissioning the pump for long periods
1. Switch pump off.
2. Vent pump and allow to cool.
3. Disconnect pump from vacuum equipment.
4. Clean suction chamber.
5. Seal flanges and any other openings.
6. Store the pump in dry, dust-free areas, within the specified ambient conditions:
–In areas with damp or aggressive atmospheres, we recommend packaging the pump in a
plastic bag with a drying agent, and sealing it so that it is airtight.
–For storage durations longer than 2 years, we recommend you carry out maintenance and a
lubricant change prior to recommissioning.
Decommissioning the pump for long periods
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