Pfeiffer Vacuum MVP 160-3 User manual

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

Dear Customer,
Thank you for choosing a Pfeiffer Vacuum product. Your new diaphragm pump should
support you in your individual application with full performance and without malfunctions. The
name Pfeiffer Vacuum stands for high-quality vacuum technology, a comprehensive and
complete range of top-quality products and first-class service. From this extensive, practical
experience we have gained a large volume of information that can contribute to efficient
deployment and to your personal safety.
In the knowledge that our product must avoid consuming work output, we trust that our
product can offer you a solution that supports you in the effective and trouble-free
implementation of your individual application.
Please read these operating instructions before putting your product into operation for the
first time. If you have any questions or suggestions, please feel free to contact info@pfeiffer-
vacuum.de.
Further operating instructions from Pfeiffer Vacuum can be found in the Download Center on
our website.
Disclaimer of liability
These operating instructions describe all models and variants of your product. Note that your
product may not be equipped with all features described in this document. Pfeiffer Vacuum
constantly adapts its products to the latest state of the art without prior notice. Please take
into account that online operating instructions can deviate from the printed operating
instructions supplied with your product.
Furthermore, Pfeiffer Vacuum assumes no responsibility or liability for damage resulting from
the use of the product that contradicts its proper use or is explicitly defined as foreseeable
misuse.
Copyright
This document is the intellectual property of Pfeiffer Vacuum and all contents of this
document are protected by copyright. They may not be copied, altered, reproduced or
published without the prior written permission of Pfeiffer Vacuum.
We reserve the right to make changes to the technical data and information in this document.
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Table of contents
1 About this manual 7
1.1 Validity 7
1.1.1 Related documents 7
1.1.2 Variants 7
1.2 Target group 7
1.3 Conventions 7
1.3.1 Instructions in the text 7
1.3.2 Pictographs 8
1.3.3 Stickers on the product 8
1.3.4 Abbreviations 8
2 Safety 9
2.1 General safety instructions 9
2.2 Safety instructions 9
2.3 Safety precautions 10
2.4 Usage limits of the vacuum pump 11
2.5 Proper use 11
2.6 Foreseeable improper use 12
3 Transportation and Storage 13
3.1 Transporting the vacuum pump 13
3.2 Storing the vacuum pump 13
4 Product description 14
4.1 Identifying the product 14
4.2 Shipment 14
4.3 Vacuum pump design and function 14
5 Installation 15
5.1 Installing the vacuum pump 15
5.2 Connecting the pumping stages 15
5.3 Connecting the vacuum side 16
5.4 Connecting the exhaust side 16
5.5 Establishing an electrical connection 17
6 Operation 18
6.1 Switching on and operating the vacuum pump 18
6.2 Switching off the vacuum pump 19
7 Decommissioning the vacuum pump for long periods 20
8 Maintenance 21
8.1 General 21
8.2 Maintenance intervals 21
8.3 Dismantling the distributor 21
8.4 Disassembling the diaphragm head 22
8.5 Checking and replacing parts 23
8.6 Cleaning contaminated parts 24
8.7 Replacing the diaphragm 24
8.8 Replacing the valves 26
8.9 Installing the diaphragm head 27
8.10 Installing the distributor 28
8.11 Checking vacuum pump function 28
9 Troubleshooting 30
10 Service solutions from Pfeiffer Vacuum 32
Table of contents
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11 Spare parts 34
12 Accessories 35
13 Technical data and dimensions 36
13.1 General 36
13.2 Substances in contact with the media 36
13.3 Technical data 37
13.4 Dimensions 38
13.5 Characteristics 38
Declaration of conformity 40
Table of contents
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List of tables
Tbl. 1: Abbreviations used in this document 8
Tbl. 2: Usage limits of the vacuum pump 11
Tbl. 3: Typical life with normal use 21
Tbl. 4: Diaphragm attachments 24
Tbl. 5: Troubleshooting 31
Tbl. 6: MVP 160-3 spare parts list 34
Tbl. 7: Accessories 35
Tbl. 8: Conversion table: Pressure units 36
Tbl. 9: Conversion table: Units for gas throughput 36
Tbl. 10: Materials that make contact with the process media 37
Tbl. 11: Technical data, MVP 160-3 37
List of tables
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List of figures
Fig. 1: MVP 160-3 14
Fig. 2: IN and EX connections on diaphragm heads 15
Fig. 3: Distributor: Intake side distributor (left) and pressure side distributor (right) 16
Fig. 4: Connection diagram: MVP 160-3 with single phase AC motor 17
Fig. 5: Mains switch 19
Fig. 6: Mains switch 19
Fig. 7: Loosen the compression couplings on the diaphragm head 22
Fig. 8: Dismantling both distributors 22
Fig. 9: Disconnecting diaphragm head 23
Fig. 10: Disassembling the diaphragm head 23
Fig. 11: Diaphragm key (accessory) 25
Fig. 12: Diaphragm key with inlaid diaphragm parts 25
Fig. 13: Diaphragm and associated parts 25
Fig. 14: Correct positioning of valves in diaphragm head 26
Fig. 15: Valves 26
Fig. 16: Installing the diaphragm head 27
Fig. 17: Secure diaphragm head 27
Fig. 18: Install both distributors 28
Fig. 19: Screw couplings on diaphragm head 28
Fig. 20: Dimensions in mm 38
Fig. 21: Air pumping speed at 50 Hz 38
Fig. 22: Air pumping speed at 60 Hz 39
List of figures
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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 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
These operating instructions apply to the diaphragm pump with the following part number:
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 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 an individual step 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 numerical list indicates an action with multiple necessary steps.
1. Step 1
2. Step 2
3. ...
About this manual
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1.3.2 Pictographs
Pictographs used in the document indicate useful information.
Note
Tip
1.3.3 Stickers on the product
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 sign
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 vacuum pump.
1.3.4 Abbreviations
Abbreviation Meaning in this document
DN Nominal diameter (from the French: diamètre nominal)
FPM Fluoropolymer rubber
MVP Diaphragm vacuum pump
NN Mean sea level
PA Polyamide
PE Earthed conductor (protective earth)
Polyethylene
WAF width across flats
Tbl. 1: Abbreviations used in this document
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 injury.
►Instructions on avoiding property damage
Notes, tips or examples indicate 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.
Safety
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Risks during installation
DANGER
Risk to life due to electric shock
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.
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.
WARNING
Risk of burns on hot surfaces
During vacuum pump operation, exposed surfaces reach high temperatures. There is a risk of burn-
ing.
►Allow the vacuum pump to cool down before carrying out any work.
►Wear protective gloves (in accordance with EN 420).
Risks during maintenance
WARNING
Risk of burns on hot surfaces
During vacuum pump operation, exposed surfaces reach high temperatures. There is a risk of burn-
ing.
►Allow the vacuum pump to cool down before carrying out any work.
►Wear protective gloves (in accordance with EN 420).
2.3 Safety precautions
The product is designed according to the latest technology and recognized safety engineering rules.
Safety
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Nevertheless, improper use can result in danger to operator all third party life and limb, and product
damage and additional property damage.
Duty to provide information on potential dangers
The product holder or user is obliged to make all operating personnel aware of dangers
posed by this product.
Every person who is involved in the installation, operation or maintenance of the product
must read, understand, and adhere to the safety-related parts of this document.
Infringement of conformity due to modifications to the product
The Declaration of Conformity from the manufacturer is no longer valid if the operator
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 Europe-
an Directives before commissioning that system.
General safety precautions for working with the vacuum 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 vacuum pump from the mains prior to every intervention, and wait an additional
five seconds until the capacitors have discharged.
►Implement suitable safety precautions where unintentional vacuum pump venting can cause haz-
ards.
–Power failures can cause unintentional venting.
2.4 Usage limits of the vacuum pump
Operations condition, status Intake pressure Permissible gas temperature range
Continuous operation > 100 hPa (high gas load) +10°C to +40°C
Continuous operation < 100 hPa (low gas load) 0°C to +60°C *
Short-term (< 5 minutes) < 100 hPa (low gas load) -10°C to +80°C *
Tbl. 2: Usage limits of the vacuum pump
2.5 Proper use
●The vacuum pump may only be used for vacuum generation.
●It is not permissible to operate the vacuum pump with accessories not recommended by Pfeiff-
er Vacuum.
●Always observe installation, commissioning, operating, and maintenance instructions.
Safety
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2.6 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 of corrosive media
●Pumping explosive media
●Pumping corrosive, explosive, radioactive, or volatile media
●Pumping of gases that introduce an ignition source to the suction chamber
●Pumping of gases that contain impurities such as particles, dust, or condensate
●Pumping of 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
●Use of the vacuum pump outside the specified area of application
●Using the vacuum pump below ground
●Using the vacuum pump to generate pressure
●Using the vacuum pump in systems in which sporadic loads and vibrations or periodic forces act
on the unit
●Using the vacuum pump in strong electrical, magnetic, or electromagnetic fields
●Connection to vacuum pumps or equipment which are not suitable for this purpose according to
their operating instructions
●Connection to devices with exposed live parts
●Connecting to sockets without earthing contact
●Using lubricants not specified by Pfeiffer Vacuum
●Using pipes to lift the vacuum pump
●Use of accessories or spare parts that are not listed in these instructions
●Using the vacuum pump as a climbing aid
●Using the connection lines between the diaphragm heads as carrying handles
●Using the vacuum pump in ambient conditions that do not meet the specified IP protection class
limits
Safety
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3 Transportation and Storage
3.1 Transporting the vacuum 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 vacuum pump in its original packaging.
►Transport the vacuum pump using only the transport handles provided.
►Always use sealed and impact-proof packaging for the vacuum 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. Wherever possible, always transport or ship the vacuum pump in its original packaging.
3. Always carry the vacuum pump with both hands.
4. Remove the protective cover only immediately prior to installation.
3.2 Storing the vacuum pump
NOTICE
Damage caused by improper storage
Improper storage leads to damage to the vacuum pump.
►Store the vacuum pump in a cool, dry, dust-free place, where it is protected against impacts.
►Seal inlet and outlet ports (e.g. using transport caps).
►Maintain the permissible storage temperature. (See technical data)
Transportation and Storage
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4 Product description
4.1 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.
4.2 Shipment
●Diaphragm vacuum pump
●Operating instructions
4.3 Vacuum 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 vacuum pump. This means that the
supplied medium does not come into contact with any lubricant.
The vacuum 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 auto-
matically.
The pump units are connected directly to the drive motor (AC motor).
The vacuum pump is equipped with a pressure side silencer as standard.
Product description
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5 Installation
5.1 Installing the vacuum pump
Procedure
1. Place the vacuum pump on a flat, horizontal surface.
2. Make sure that the vacuum 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 vacuum pump on a soft surface (such as foam), as this impairs air supply to
the fan.
5. Ensure for sufficient air supply if you install the vacuum 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 vacuum pump at an installation altitude of > 1000 m AMSL, you must imple-
ment measures in accordance with DIN VDE 0530 to ensure an adequate cooling air supply.
7. Anchor the vacuum 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 vacuum pump to acclimatize.
–If the vacuum pump is brought into the operating area from a cold environment, condensation
can form.
5.2 Connecting the pumping stages
NOTICE
Vacuum pump damage caused by overpressure
Mixing up the connections causes overpressure overload. The vacuum pump can be started only
against max. 1 bar differential pressure between inlet and outlet; otherwise the motor jams and sus-
tains damage.
►Make sure that the distributor is installed correctly on the diaphragm heads, before connecting
the vacuum 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 vacuum pump are marked “IN” and the outlets “EX” on the individual dia-
phragm 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)
5.3 Connecting the vacuum side
Preventing pressure losses
Using the shortest possible vacuum connection lines with large nominal diameter prevents
pressure losses.
Condensate separator
Pfeiffer Vacuum recommends the installation of a condensate separator in case vapors are
formed from moisture during evacuation.
Procedure
1. Remove the locking cap from the vacuum connection.
2. Install the connection between vacuum pump and vacuum system so that it is as short as possi-
ble.
3. Install a condensate separator upstream of the vacuum pump.
4. Connect the vacuum pump to the vacuum system using the vacuum connection.
5.4 Connecting the exhaust side
Condensate separator
Pfeiffer Vacuum recommends installing a condensate separator, with condensate drain at
the lowest point of the exhaust line.
Procedure
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 vacuum pump so that condensation does not flow back into the
pump.
4. Connect the vacuum 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 vacuum 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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5.5 Establishing an electrical connection
Fig. 4: Connection diagram: MVP 160-3 with single phase AC motor
Installation
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6 Operation
6.1 Switching on and operating the vacuum 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 vacuum pump cannot pump the
additionally formed steam down quickly enough. Water hammer destroys the vacuum pump.
►Install a capacitor between the vacuum system and the vacuum pump.
–This intercepts the fluid upstream of the vacuum pump.
NOTICE
Damage caused by fluids and dust
Fluids and dust damage diaphragms and valves.
►Prevent ingress of particles and dusts to the vacuum pump.
►Install a suitable filter upstream of the vacuum pump if necessary.
►Avoid condensation in the vacuum 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 vacuum 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
1Mains switch
Procedure
You can switch on the vacuum pump at any time.
1. Press the mains switch.
6.2 Switching off the vacuum pump
1
Fig. 6: Mains switch
1Mains switch
Procedure
You can switch off the vacuum pump at any time.
1. Allow the vacuum 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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7 Decommissioning the vacuum pump for long periods
Procedure
1. Switch off the vacuum pump.
2. Vent the vacuum pump and allow it to cool down.
3. Disconnect the vacuum pump from the vacuum equipment.
4. Clean suction chamber.
5. Seal flanges and any other openings.
6. Store the vacuum pump in dry, dust-free rooms, within the specified ambient conditions.
–In areas with damp or aggressive atmospheres, we recommend packaging the vacuum 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 vacuum pump for long periods
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