Ulvac OMT-100A User manual

MODEL NO OMT-100A/OMT-200A
OIL MIST TRAP
INSTRUCTION MANUAL
Be sure to read this manual before using this instrument
and keep it in your file for future reference.
The contents of this manual are subject to change without
notice for improvement.
ULVAC KIKO , Inc.
1-10-4, Kitashinyokohama,
Kohoku-ku, Yokohama, 223-0059, Japan
TEL [phone] FAX [phone]
0. INTRODUCTION
0.1 Before Using This Unit
Upon receipt of this unit, check that the delivered unit is the correct model you ordered and that
there is no damage in transit.
For the names of components of the oil mist trap in this manual, refer to "8. EXPLODED
VIEW".
!
WARNING
Before installation, inspection and maintenance, carefully read this manual and fully
understand the specifications, operating procedure and safety cautions.
!
NOTE
No part of this manual may be reproduced for use by a third party without written
consent by ULVAC KIKO.
0.2 Denotations in This Manual
The following denotations are used throughout this manual to call operator's attention to
safety.
The denotations are classified into the following categories.
!
DANGER
Failure to comply with DANGER involves the possibility of impending loss of life or
serious personal injury.
!
WARNING
Failure to comply with WARNING involves the possibility of loss of life or serious
injury.
!
CAUTION
Failure to comply with CAUTION involves the possibility of medium degree of personal
injury or serious damage to the equipment.
!
NOTE
Failure to comply with NOTE involves the possibility of damage to the equipment or
malfunction of the equipment.
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0.3 Safety Cautions
!
DANGER
If the vacuum pump is used to pump toxic gas, the pump oil will be toxic, not to
mention oil mist trap itself. Take care in maintenance.
!
WARNING
Do not use the oil mist trap in an explosive atmosphere. Injury or fire can result.
!
WARNING
Always use the oil mist trap at below the maximum flow rate. Otherwise, the internal
pressure will rise and the oil mist trap will fail. The maximum flow rate is 120 L/min for
the OMT-100A and 240 L/min for the OMT-200A.
!
WARNING
Do not use the oil mist trap for inflammable gas. Injury or fire can result.
!
WARNING
Do not touch or replace an element during vacuum pump operation or immediately
after the pump is shut down. It is very hot and can cause burn.
!
WARNING
Do not plug the exhaust port nor attach a device that interferes with the passage of gas
to the exhaust port when the unit is operated. The pressure in the oil mist trap will rise
and the unit may be damaged or fail. Note that the unit is not explosion-proof.
!
CAUTION
If the oil mist trap is damaged, immediately turn off the switch for the vacuum pump
and remove the power plug. If a damaged oil mist trap is used, oil mist may come out or
internal pressure may rise. For safety, contact your local distributor.
!
CAUTION
Do not use the oil mist trap for corrosive gas. Damage or failure can result.
-02-
!
CAUTION
Do not modify the oil mist trap. If modified, troubles of the oil mist trap will not be
covered by warranty. Also it can generate oil mist or cause internal pressure rise.
0.4 Receipt and Storage of Oil Mist Trap
0.4.1 Receipt of oil mist trap
Every care has been taken before shipping the oil mist trap, but check the following
after unpacking it.
(1) Is the unit the correct mode you ordered?
(2) Are the prescribed accessories (O-ring P-41) supplied?
(3) Is any part damaged in transit?
(4) Is any part off position?
If any problem is found, contact your local ULVAC KIKO representative.
0.4.2 Storage, installation and environmental conditions during operation
Meet the following conditions during storage, installation and operation.
(1) Ambient temperature during operation : 7°C to 40°C
(2) Surface temperature during operation : Cannot be used at
above 80°C
(3) Others (during storage and operation)
a) To be free from corrosive or explosive gas
b) Not to be condensing dew on the oil mist trap
c) To be free from dust and dirt
d) To be indoors
e) Do not turn the oil mist trap sideways.
f) Do not expose to direct sunlight.
g) To be away from heat source
h) Not dry atmosphere
(Store the unit at a relative humidity of 10% or more.)
!
NOTE
Do not give impact to the oil mist trap. Damage or failure can result.
-03-

Contents
Page
0. INTRODUCTION....................................................................................01
0.1 Before Use of This Instrument............................................................01
0.2 Denotations in This Manual................................................................01
0.3 Safety Cautions...................................................................................03
0.4 Receipt and Storage of Oil Mist Trap.................................................03
0.4.1 Receipt of oil mist trap................................................................03
0.4.2 Storage, installation and environmental
conditions during operation ........................................................03
1. FOR SAFE OPERATION ..........................................................................1
1.1 Danger Inherent to This Instrument and Safety Measures....................1
1.1.1 DANGER Hazardous gas, hazardous material............................1
2. OVERVIEW OF OIL MIST TRAP............................................................1
2.1 Design Basis..........................................................................................1
2.2 Functions of Relief valve......................................................................1
2.3 Dimensional Drawing...........................................................................2
3. INSTALLATION .......................................................................................2
3.1 Installation.............................................................................................2
3.2 Installing the Unit on ULVAC KIKO Vacuum Pump..........................3
3.3 Installation and Removal ......................................................................3
4. PERFORMANCE OF OIL MIST TRAP................................................................4
4.1 Limit of Pump Operation Hours ...........................................................4
5. INSPECTION AND MAINTENANCE........................................... 5
5.1 Maintenance..........................................................................................5
5.2 Scheduled Inspection ............................................................................5
5.3 Consumables.........................................................................................6
5.4 Replacement of Element.......................................................................6
5.5 Troubleshooting....................................................................................9
6. DISPOSAL ...............................................................................................10
7. EXPLODED VIE .................................................................................10
WARRANTY
1. FOR SAFE OPERATION
1.1 Danger Inherent to This Unit and Safety Action
Before operating or checking this unit, carefully read this section and fully understand
potential hazards and preventive actions.
1.1.1
!
DANGER Hazardous gas, hazardous material
Hazard Preventive actions
You may be injured by
contact with pump oil
that has been turned
toxic in the oil mist trap
or with toxic substance
on the unit.
1) Put on protective wear a
g
ainst toxic
substances when inspecting the unit.
2) When repairin
g
the unit or discardin
g
toxic substances, have a wastes treatment
specialist render it non-toxic.
3) Have wastes disposed of b
y
authorized
waste treatment specialist.
2. OVERVIEW OF OIL MIST TRAP
2.1 Design Basis
The Model OMT-100A/OMT-200A oil mist trap separates oil mist discharged from
an oil rotary pump during operation to reduce the discharge of oil mist. The oil that
has collected in the oil mist trap is returned into the pump case. Being small in size,
light in weight, and simple in structure, the unit can be easily maintained and repaired.
Table.1 Design Basis
Model No OMT-100A OMT-200A
Name Oil mist trap
Weight (kg) 0.43 0.55
Outside dimensions (mm) 113 diameter ×135 H
Mounting position Vertical
Connecting screw G-1
2.2 Functions of Relief valve
Clogged element will narrow the flow path and increase the inner pressure of the
pump. If the inner pressure rises to 9.8×10-2MPa(G), the relief valve will
automatically be opened to prevent pressure rise.
-1-

If the relief valve is opened, it means that the element is not functioning properly. In
this case, oil mist will be generated. Replace the element.
!
NOTE
Replace the element if it is clogged with dust or the like. Otherwise, oil mist may be
discharged.
2.3 Dimensional Drawing
Fig. 1 Dimensional drawing for OMT-100A/OMT-200A
3. INSTALLATION
3.1 Installation
Select a place as free from dust and moisture as possible, where the oil mist trap can
be easily installed, removed, checked, and cleaned, and install the unit perpendicularly
to the pump.
The connecting screw for this unit is G1 by the ISO standard. Select a pump of which
exhaust port connection is compatible with this standard.
Refer to "0.4.2 Storage, installation and environmental conditions during operation"
for environmental conditions.
!
WARNING
The unit may be ruptured if the maximum flow rate of the unit is exceeded. The
maximum flow rate for the OMT-100A is 120 L/min and that for the OMT-200A is 240
L/min.
-2-
!
WARNING
Do not plug the exhaust port nor operate the unit with a device that interferes with the
passage of a gas connected to the exhaust port. The internal pressure of the oil mist trap
will rise and the unit may be damaged or fail.
This unit is not explosion proof.
!
NOTE
If the oil mist trap is tilted or turned sideways or installed upside down, oil may
overflow or gush out. Install it perpendicularly to the pump exhaust port.
3.2 Installing the Unit on ULVAC KIKO Vacuum Pump
Table 2 gives ULVAC KIKO vacuum pumps on which the OMT-100A/
OMT-200A can be mounted.
Table 2 ULVAC KIKO Vacuum Pumps to which
OMT-100A or OMT-200A can be Attached
Model No OMT-100A OMT-200A
Model No of ULVAC
KIKO pump G-101S/D GHD-100A/B/C/D GLD-136A/C GLD-201A/B
3.3 Installation and Removal
(1) Make sure that the pump is at stop.
(2) Mount an O-ring (P-41, accessory) in the connection of the oil mist trap.
(3) Attach the oil mist trap to the pump exhaust port of which connection is
compatible with the oil mist trap and turn it clockwise holding the case at the side.
(See Fig. 2.)
(4) Before removing the oil mist trap, make sure that the pump is at stop
and turn it counterclockwise holding the case at the side.
!
NOTE
When installing and removing the oil mist trap, do not turn it by holding the
top cover. Damage or failure can result.
-3-

Fig. 2 Installation of oil mist trap
4. PERFORMANCE OF OIL MIST TRAP
4.1 Limit of Pump Operation Hours
The pump operating time is limited when the pump is operated continuously at a high
suction pressure.
Table 3 gives the relationship between the continuous operating time and the suction
pressure of the pump.
Stop the pump once for more than five minutes within this time so that oil returns to
the pump.
If the pump is continuously operated at a high pressure, oil may gush out through the
exhaust port.
Table 3 Relationship between Continuous Operating Time
and Suction Pressure of Vacuum Pump
Continuous suction pressure Maximum operating time
13.3 to 12 KPa Within 3 hours
12 to 10 KPa Within 5 hours
10 to 8 KPa Within 8 hours
8 to 6 KPa Within 15 hours
6 to 4 KPa Within 22 hours
4 to 2 KPa Within 33 hours
2 to 1 KPa Within 55 hours
-4-
NOTE : This table gives reference values, which vary with the pump throughput and
operating conditions.
When the vacuum pump is pumped to below 40 Pa, the oil collected in the oil mist
trap automatically returns to the pump case. The time required for the oil to return to
the pump is more than 10 minutes.
5. INSPECTION AND MAINTENANCE
5.1 Maintenance
Check the following once a day during operation.
(1) Oil leak in the connection with the vacuum pump.
(2) Oil mist or oil gushing out from the case.
(3) Unusual sound.
If any problem is found, take actions according to Table 6 Troubleshooting Checklist.
5.2 Scheduled Inspection
Check items should be changed according to the operating conditions of the oil mist
trap, but check the following periodically. Scheduled inspection will serve to
prevent troubles and prolong the life of the oil mist trap.
!
NOTE
Be sure to turn off the power to the vacuum pump before inspection.
Never turn on the power during inspection. The vacuum pump may generate oil mist or
cause injury.
(1) Checking the oil mist trap
If there is an oil leak in the connection with the pump or a large volume of oil mist
or oil gush out from the case, stop the pump and restart it more than 30 minutes later.
If a large volume of oil mist or oil gush out from the case again, replace the element
with a new one.
(2) Scheduled replacement of element
The oil mist separating capacity of the element is limited. Replace the element
before it fails referring to Table 4. Scheduled replacement will serve to reduce oil
mist.
If gas containing dust, dirt water or the like is pumped for an extended time, the
element will be clogged and will not function.
-5-

Table 4 Frequency of Element Replacement
Model No Frequency of element replacement
OMT-100A 1500 to 2000 hours
OMT-200A 1000 to 1500 hours
If pumping is continued for a long time or if the oil mist trap is severely contaminated
with suction gas, it is recommended to disassemble and clean it, in addition to the above
checks, to maintain performance. For disassembly, contact your local ULVAC KIKO
representative.
5.3 Consumables Table 5 List of Consumables
Description Q'ty
Element 1
OMT-100A Relief valve spring 1
Element 1
OMT-200A Relief valve spring 1
Check valve spring 1
Common parts O-ring (P-41) 1
5.4 Replacement of Element
If the element is clogged, the trap cannot separate oil mist completely. If much oil
mist is discharged when restarting the pump after a pause for more than 30 minutes,
replace the element. Scheduled replacement is recommended according to the element
replacement frequency in Table 4.
!
DANGER
If the vacuum pump is used to pump toxic gas, pump oil as well as oil mist trap will be
toxic. Beware of it in maintenance.
!
CAUTION
When replacing the element, wear rubber gloves, goggles and other protective wear. If
your hand is stained with vacuum pump oil, wash the stained portion with water and
soap. If oil is admitted into your eye, wash your eye with clean water for at least 15
minutes and then see doctor for treatment.
-6-
<Replacement of element>
Refer to "7. EXPLODED VIEW" for the names of components.
(1) Make sure that the pump is shut down.
(2) Remove the top cover as shown in Fig. 3.
Fig. 3 Removal of top cover
(3) Remove the relief valve spring, OMT retainer and element from the case in that
order.
(4) Replace the element with a new one and center it with the OMS receiver to install
it.
Fig. 4 Installation of element
-7-

(5) Mount the OMS retainer on the element with the surface on which the model no
of the oil mist trap is inscribed facing upward, as shown in Fig. 5.
Fig. 5 Mounting the OMS retainer
(6) Center the relief valve spring with the OMS retainer to mount it.
(7) To mount the top cover, match the stops on the inside wall of the top cover with
the fitting notches on the outer periphery of the case as shown in Fig. 6 and mount
it by reversing the removing procedure.
Fig. 6 Mounting the top cover in position
-8-
5.5 Troubleshooting
Table 6 Troubleshooting Checklist
Symptom Cause Corrective action See
Much oil mist and oil
are discharged. 1) Element life is expired. 2) The element is clogged
with dust and dirt.
1) Replace element.
2) Replace or clean the
element.
5.4
5.4
3) The element is not
reassembled properly. 3) Replace the element by reassembling the oil
mist trap.
5.4
4) The maximum flow
rate of the oil mist trap
is exceeded.
4) Lower the pump
throughput to below the
max. flow rate of oil
mist trap.
5) The check valve is not
functioning properly. 5) Repair or clean the check valve.
Oil is not recovered into
the pump case. 1) The pump is running continuously at a high
suction pressure.
1) Stop the pump
temporarily (for five
minutes). Or lower the
p
ump intake pressure to
below 40 Pa.
4.1
2) Foreign matter is
contained in the check
valve area.
2) Repair or clean the
check valve area.
Unusual sound is heard. 1) Foreign matter is
tra
p
ped in the oil mist
trap.
1) Repair or clean the oil
mist trap.
2) Element is not
properly reassembled. 2) Replace the element by reassembling the oil
mist trap.
5.4
Oil leaks from the oil
mist trap. 1) The O-ring is deteriorated. 1) Replace the O-ring.
2) The oil mist trap is not
securely mounted to
the pump.
2) Securely mount the oil
mist trap to the pump. 3.3
3) The maximum flow
rate of the oil mist trap
is exceeded.
3) Lower the pump
throughput to below the
max. flow rate of the oil
mist trap.
4) The element life is
expired or the element
is clogged.
4) Replace or clean the
element. 5.4
5) The oil mist trap was
not reassembled
p
roperly when the
element was replaced.
5) Replace the element by
reassembling the oil
mist trap.
5.4
-9-

6. DISPOSAL
Dispose of the oil mist trap in accordance with your local applicable laws and regulations.
!
CAUTION
If the oil mist trap was used to pump toxic gas that can be hazardous to human body,
not only the oil mist trap, but also pump oil will be toxic. In that event, have it
disposed of by specialist in waste treatment.
7. EXPLODED VIEW
-10-
Warranty
(1) The warranty period of this oil mist trap is one year from shipment.
(2) Any malfunctions or defects which occur under normal usage conditions during the
warranty period will be repaired free of charge. Note, the warranty stated here is an
individual warranty covering the oil mist trap. In addition, the scope of the warranty
coverage concerning repairs is limited to the repair and/or replacement of parts.
Normal usage conditions refer to the following:
a) Ambient temperature and humidity during operation: 7 - 40°C, below 85% RH
b) Operation in accordance with the user manual
(3) Repair fees will incur during the warranty period for the following cases:
a) Malfunctions due to a natural disaster or fire.
b) Malfunctions caused by special atmospheric conditions, such as salt damage,
inflammable
c) Malfunctions caused by usage conditions that differ from those stated in the user
manual
(performance specifications, maintenance and inspection, etc.).
d) Malfunctions caused by modifications or repairs carried out by a party other than the
manufacturer, or by a service company not approved by the manufacturer.
h) Malfunctions that occur, when the oil mist trap is damaged as a result of being
dropped or falling, etc.
i) Malfunctions which are determined by the manufacturer’s technical personnel to be
caused by conditions that do not comply with the usage conditions for this vacuum
pump.
j) Malfunctions due to the replacement of consumables.
(4) Disclaimer
a) We shall not be liable for any malfunctions of our products caused by the customer,
regardless if the malfunction does not fall within the warranty period, nor shall we be
liable for any loss of opportunity for the customer’s clients or for compensation for
any damages to other products, labor costs, production loss, transportation expenses
and other related work.
b) We shall not be liable for any claims and patent infringements, including secondary
damages, filed a claim by a third party against the customer.