Ulvac DAP-6D Series User manual

No.29100-2-03-13
INSTRUCTION MANUAL
Diaphragm-type Dry Vacuum Pump
Model: DAP-6D, 12SSeries
Request to Users
Please read this manual thoroughly to ensure safe
and effective use of the equipment.
Keep this manual in a safe place.
Due to periodic improvements in performance, the
equipment described in this manual is subject to
changes in dimensions and specifications without
prior notice.
ULVAC KIKO, Inc.

Contents
Pages with a shaded background are those, which contain items related to safety.
1.Before Using the Equipment..........................................................1
2. Using the Pump Safely.................................................................2
・Safety icons ...........................................................................2
・Cautions for Safety in Use.....................................................2
3. Product Outline.............................................................................7
4.Dimentional Drawing......................................................................8
5.Installation and Operation..............................................................9
6.Cautions in Operation..................................................................11
6.1 Cautions in Operation....................................................................... 11
6.2 Startup in Cold Season..................................................................... 11
6.3 Thermal Protector…......................................................................... 11
7.Maintenance, Inspection, and Repair..........................................12
7.1 Cautions for Maintenance, Inspection, and Repair ........................... 12
7.2 Maintenance..................................................................................... 12
7.3 Regular Inspections.......................................................................... 12
7.4 Replacing and Cleaning Consumables............................................. 13
7.5 TROUBLESHOOTING ..................................................................... 19
8. Storage.......................................................................................19
9.Conclusion...................................................................................20
・Warranty ......................................................................................... 20
・Usage Status Check Sheet

－1－
1. Before Using the Equipment
Thank you for purchasing this product. Your custom is very much appreciated.
This pump is designed solely for vacuum discharge, and may malfunction or cause
accidents if not handled appropriately. Read the manual thoroughly, and pay due attention
to inspections, maintenance, and safety.
Personnel Handling the Equipment
Only persons who have read this manual thoroughly, and have sufficient understanding of
safety, pump specifications, and method of operation, may operate this pump.
Read the Manual Thoroughly
Read the manual thoroughly in order to use the equipment correctly. Read the section on
Safe Use particularly closely.
Keep This Manual in a Safe Place
After reading this manual, be sure to keep it in a safe place, which is readily accessible to
others needing to use it.
Copying This Manual Is Prohibited
No part of this manual may be copied for use by a third party without the express
permission of the manufacturer.
Statutory Requirements for Disposal
Follow all statutory and local authority regulations when disposing of this pump.
Safety During Repair
Please provide a full description of the circumstances of use (particularly the use of
dangerous materials) for the safety of repair personnel when requesting the manufacturer
for repairs to the pump. Your request for repair of may be refused if these circumstances
are unclear.

－2－
2. Using the Pump Safely
To ensure that the pump is handled correctly, read this section thoroughly before use.
This manual and the warning labels on the pump include safety icons as an aid to
understanding safety requirements.
These safety icons warn the operator and others of possible dangers and damage and
should always be followed.
・Safety icons
The meanings of the safety icons are as follows.
Incorrect handling of the equipment is very likely to result in death or
serious injury to the operator.
Incorrect handling of the equipment may result in death or serious injury
to the operator.
Incorrect handling of the equipment may result in light or medium
injuries to the operator or damage to the equipment.
Incorrect handling of the equipment may result in damage to the
equipment and hinder its correct operation.
・Cautions for Safety in Use
Applications
(1) This pump is not designed to be explosion-proof, and should therefore not be used to
discharge explosive gases. Such use may result in injury and fire.
(2) In addition to discharge of gas via the outlet, gas may also leak from other parts of
the pump, and it should therefore not be used with toxic gases. If toxic gas is
discharged for any reason it is important to note that the interior of the pump will be
contaminated by the gas, requiring appropriate caution during maintenance.
Maintenance and Repair
(3) When requesting the manufacturer’s service division to dismantle and repair the
pump, always note the gas which the pump has been used with on the Usage Check
Sheet. Note that if it has been used to discharge toxic gas for any reason it will be
contaminated. Please be aware that use with some gases will preclude dismantling
and repair.
!
Warning
!
Caution
!
Note
!
Danger
!
Danger

－3－
Installation
(1) Do not use the pump in an explosive atmosphere. Such use may result in injury and
fire.
(2) Ensure that there are no inflammable materials such as solvents in the vicinity when
using the pump.
(3) Ensure that the pump is freely ventilated to prevent overheating, which may result
in fire or burns.
Power Supply
(4) Always check the pump and install wiring with the power cord disconnected. Working
with power connected may result in electric shock, or the pump starting
unexpectedly.
(5) Ensure that wiring is installed by persons qualified in accordance with regulations for
wiring (e.g. technical standards for electrical equipment, requirements for internal
wiring). Incorrect wiring with may result in fire.
(6) Ensure that lead wiring is properly connected and insulated with insulation tape (or
an insulating cap).
(7) Always ensure that the pump is correctly earthed. A dedicated earth leakage breaker
is recommended. Failure to earth the pump correctly may result in electric shock if a
fault or earth leakage occurs.
(8) Use the pump only at the rated voltage. Use at other than the rated voltage will
interfere with operation of the overload protection device, and this may result in the
motor burning out, or fire.
(9) Do not damage, modify, and pull the power cord, or place objects on it. Damage to the
cord may result in electric shock or fire.
(10)Always fully insert the power cord into the socket. Partial insertion may result in
electric shock.
(11)Remove the cord from the socket while holding the plug. Failure to do so may result
in electric shock.
(12)Touching the power cord with wet hands may result in electric shock.
(13)Touching electrical wiring etc while inserting the power plug may result in electric
shock.
(14)The electric motor fitted to this pump incorporates a thermal protector, however it is
not guaranteed to be open when it eventually fails at some time after the guaranteed
6000 cycles. For safety reasons therefore, it is necessary to fit an overload (over
current), protection device and an earth leakage breaker.
!
Warning

－4－
Operation
(15) This pump is not designed to be explosion-proof. When using the pump, ensure that
there are no inflammable materials such as solvents, or explosive gases, in the
vicinity. Use under such conditions may result in injury or fire.
(16) Inserting fingers or objects into the motor inlet may result in electric shock, injury,
or fire.
(17) Do not operate the pump with the outlet blocked, or with equipment which may
impede the flow of air placed in front of the outlet. Operation under such conditions
will result in an increase in the internal pressure of the pump, and may result in
rupture of the pump itself.
This pump is not pressure resistant, and may be used at a maximum internal
pressure of 30.0 kPa (gauge pressure).
Operation at a discharge resistance equivalent to 30.0 kPa (gauge pressure) may
result in the motor being overloaded.
Ensure that cooling and load conditions for the particular application are considered
thoroughly, and that the temperature increase for each motor component is within
the requirements for class of motor insulation as legally required in your country.
Installation
(1) The fine clearances used in this pump require that the following conditions be
satisfied during storage, installation, and operation.
1. Ambient temperature of 0 - 40°C and maximum relative humidity of 85% during
operation.
2. Other conditions for storage and operation.
a) Horizontal floor of sufficient strength.
Do not install the pump either vertically or facing downwards.
b) No condensation.
c) Free of dust.
Ensure that water or dust does not enter the pump or motor during
assembly.
d) Free of soot and oil.
e) Free of splashing or flooding.
f) Environment free of explosive gas.
g) Not subject to direct sunlight.
h) No danger of fire.
i) When storing the pump, or when operating it within other equipment, ensure
that the temperature in the vicinity of the pump does not exceed 40°C.
j) When installing the pump, avoid mounting a vacuum pump directly on the
base. Employ anti-vibration rubber between the base and the vacuum pump.
k) Install it in the place where a moving object does not come in contact with.
l) Keep it indoor ventilated.
!
Warning
!
Caution

－5－
Operation
(2) Do not close the outlet while the pump is in operation.
(3) Touching rotating components (ex motor, main shaft, axial joints, cooling fan) while
the pump is in operation may result in injury.
(4) The overload protector operates when the pump becomes excessively hot. Touching it
in this condition may result in burns.
(5) Touching the motor while the pump is in operation or while it is still hot immediately
after having been switched off may result in burns.
(6) Ensure that the customer installs a trap if steam is generated. Ensure that
condensate does not enter the vacuum pump. A malfunction may result if condensate
enters the pump.
(7) Do not approach or touch rotating components (e.g. cooling fan) under any
circumstances while the pump is in operation.
(8) Stop the pump before lifting and carrying it to another location.
(9) Do not give a fan cover part a shock. if give a shock , stop driving promptly, and
confirm that a fan cover and a fan do not have damage. When a fan cover runs in a
damaged state, you may result in injury.
Maintenance and Repair
(10) Ensure that the pump is discarded in accordance with appropriate legislation
related to the treatment and cleaning of waste products. Ensure that the pump is
discarded as an industrial waste product, and is not incinerated.
(11) If the pump ceases operation, turn power OFF (set switch to O) immediately to
prevent accidents, remove the power cord from the wall outlet, and contact your
dealer or the manufacturer for inspection and repair.
Installation
(1) Ensure that the pump is not dropped, subjected to physical shock, or tipped over. A
malfunction may result if the pump is handled in this manner.
(2) Do not place objects on, or stand on, the pump. A malfunction may result if the pump is
handled in this manner.
(3) As the pump is not protected against entry of water, it is not guaranteed against
splashing or flooding.
(4) When carry a pump, do not have a fan cover. A fan cover may be damaged.
Applications
(5) This pump is solely for use in vacuum extraction, and should not be run for long periods
of time at near-atmospheric pressure. A malfunction may result if the pump is operated
in this manner.
(6) Do not use the pump for pressurization (Do not use the pump with a pressurized air
supply).
!
Caution
!
Note

－6－
Operation
(7) Ensure that the pump is used within an ambient temperature range of 0 - 40°C.
Use at high temperatures will dramatically reduce the life of the pump.
Install cooling equipment (e.g. a fan) if the pump is to be used at an ambient
temperature in excess of 40°C, and set ambient temperature to 40°C or less.
(8) Ensure that the pump outlet is free of back pressure when the pump is started. Back
pressure at the pump outlet will result in overload on the motor, and may prevent
starting.
(9) The overload protector operates when the pump becomes excessively hot. Touching it in
this condition may result in burns.
Maintenance and Repair
(10) The pump is manufactured to precise clearances, and should not be dismantled or
modified under any circumstances.
(11) Miscellaneous
* Problems (e.g. faults) with the vacuum pump shall be resolved by consultation
between the two parties.
!
Note

－7－
3.Product Outline
3.1 Purpose of Use and Prohibitions
This product is a dry vacuum pump which employs reciprocating motion of a rubber
diaphragm for vacuum discharge.
Observe the following prohibitions to ensure normal operation of the pump.
Prohibitions
(1) This pump employs only vacuum operation, and must not be pressurized.
(2) Do not re-sell, repair, or modify this pump without the approval of the
manufacturer.
(3) This pump is not designed to be corrosion-proof. Use it only with clean air at
normal temperature, or gases of equivalent characteristics.
(4) Do not attempt to discharge gases containing particles, dust, water, or corrosive
gases.
(5) Do not operate the pump for long periods at near-atmospheric pressure.
3.2 Specifications
Table 3.1 Product Specifications (50/60 Hz)
Model
DAP-6D
DAP-12S
Pumping Speed
50Hz
6L/min
12L/min
60Hz
7L/min
14L/min
Ultimate Pressure
6.65×103 Pa
24.0×103Pa
Motor
single phase, 10 W, 4P, capacitor operation
Rated Current
100V
0.5/0.5 A
200V
0.25/0.25 A
220V
0.25/0.25 A
Revolution
100V
1275/1530 r/min
200V
1320/1600 r/min
220V
1320/1600 r/min
Weight
1.9 kg
Suction/Exhaust Pipe
Rc1/8
Operating Ambient Temperature
0°C to 40°C
Outside dimensions (mm)
91(W) 163(L) 100.6(H)
!
Warning
!
Note

－8－
4. Dimensional Drawing
Fig.-1 DAP-6D Dimensions
Fig.-2 DAP-12S Dimensions
※Motor specifications
200V,220V is
attached to Power
supply cord without
switch and plug.

－9－
5. Installation and Operation
(1) Install the pump in a place as free from dust and moisture, where the pump can be
easily checked and maintained.
(2) Install the pump tightly in a stable horizontal position.
(3) Use the pump at an ambient temperature of 0°C to 40°C,equal to or less than
meters above the sea level 1000m, and humidity 85% RH (relative humidity).
(4) In case of assembling the pump in a system
Pay an attention particular to the ambient temperature: 0°C - 40°C.
Float the pump from the system using a rubber shock absorber;
install the pump so that vibration is not transmitted to the system.
By removing the fixed rubber legs, do not install the pump directly to the system.
There would be a case that the pump casing is deformed and a load occurs to the
motor bearing.
The base region installation hole position can be open in reference to Fig 3 in a long
hole.
Fig.-3 DAP-6D,12S Holes position and size for installation
For 4－M4
For 4－M3

－10－
(5) After verifying that the power switch of the pump is turned OFF, connect the
power cord or the motor lead to the power supply according to the motor rating.
(6) Turn ON the pump to check that pump is pumping.
(7) After that, turn OFF the power to stop the pump.
(8) Install either a circuit protector or a glass pipe fuse.
(9) Make piping arrangement ensuring that no leakage occurs in the suction pipe.
Use as short a hose as possible. If a long hose is used, it will take longer to pump.
(10) When attaching the pipe to the exhaust or suction opening, tighten the pipe to a
torque of 6 N･m. Too much tightening force could damage the exhaust or suction
opening.
(11) Make piping arrangement so that the exhaust port tree tram is a backing pressure.
(12) In case of selecting the inlet pipe and exhaust pipe that are not from our products,
please select the exhaust pipe that has same or larger inner diameter length with
the inlet pipe.
(13) Typical vacuum pumping diagram is as shown in Fig-4. (Timing valve )Pump vent
valve to start easily the pump is attached close by the pump. Also, isolation valve
to keep the chamber in vacuum is equipped between the pump and the chamber.
(When pump is operating: Isolation valve is open, timing valve is closed)
(When the pump is at a stop: Isolation valve is closed, timing valve is open)
Fig.-4 Vacuum pumping diagram
VACUUM
PUMP
FILTER
PUMP VENT VALVE
(TIMING VALVE)
ISOLATION VALVE
CHAMBER

－11－
6. Cautions in Operation
For safe and trouble-free operation, please pay attentions for the following items in
operating pump.
6.1 Cautions in Operation
(1) This pump is designed exclusively for vacuum pumping. So a backing pressure
of the pump is needed to keep lower than 30 kPa (Gauge pressure) by a
reasonable means.
(2) Use the pump at an ambient temperature of 0°C to 40°C.
(3) Do not use the pump to suck corrosive gas, organic solvent, liquids, or
condensable gas (water vapor, etc.).
(4) Use the pump in an environment where it is not likely that dust, dirt, etc. are
admitted into the pump.
(5) This pump is not designed as an explosion-proof. So do not use it in the vicinity
of inflammable solvent or the like, which can be very dangerous.
(6) Start the pump with the suction side and exhaust side under atmospheric
pressure. Otherwise, it is not so easy to start the pump.
(7) If the pump is stopped under reduced pressure and is started immediately after
that, the pump may not restart. To restart it, vent the pump to atmospheric
pressure.
If the pump is used for other applications, consult with us.
6.2 Startup in Cold Season
In a cold season, it may sometimes be difficult to start the pump due to hardened
bearing grease, diaphragm or others. In that event, proceed as follows.
(1) Vent the suction port to atmospheric pressure and turn ON/OFF the power
switch until the pump starts.
(2) Operate the pump for several minutes with the suction port vented to
atmospheric pressure to warm up the pump.
(3) Operate the pump as usual after the pump is warmed up.
6.3 Thermal Protector
(1) This pump incorporates a manual reset type thermal protector. It automatically
cuts off the motor power circuit to prevent the motor from being damaged by
burning when the pump stops rotating due to trouble or when the pump is
energized with an over current due to overload during operation.
(2) If the thermal protector is activated, turn OFF the power switch and contact our
representative or ULVAC KIKO. Never touch the motor, which is still very hot.
(3) Restart operation after eliminating the cause of trouble and verifying that the
motor temperature has lowered.

－12－
7. Maintenance, Inspection, and Repair
7.1. Cautions for Maintenance, Inspection, and Repair
When requesting the manufacturer’s service division to dismantle and repair the pump,
always note the gas, which the pump has been used with on the Usage Check Sheet. Note
that if it has been used to discharge toxic gas for any reason it will be contaminated.
Please be aware that use with some gases will preclude dismantling and repair.
The fine clearances used in this pump require skill in its assembly. If a repair technician is
unavailable, replacement of all consumables should be left to the manufacturer’s service
division.
7.2 Maintenance
The following checks are required at least once every three days during operation.
(1) Check for abnormal noises.
(2) Check for abnormal heating of the pump.
(3) Check that gas is discharged normally.
If a problem is found, take the measures described in 7.5 TROUBLESHOOTING.
7.3 Regular Inspections
Inspect consumables after 10,000 hrs of operation, and replace and clean in
accordance with the Replacement and Cleaning Guide on the following page. Refer
to 7.4 Replacing and Cleaning Consumables for procedures.
Request replacement by the manufacturer’s service division if a repair technician is
not available.
<Consumables List>
Table 2 Consumables List
Description
Qty
Material
Life expectancy
Diaphragm
2 paces
EPDM
10,000 hrs
Suction/exhaust valve
4 paces
FPM
10,000 hrs
Head gasket
2 paces
EPDM
10,000 hrs
Bearing
1 set
–
10,000 hrs
!
Danger
!
Note

－13－
Guideline for replacement:
•Diaphragm
Replace the diaphragm if a small crack, wear, hardening or deformation is
found on the surface.
•Suction/exhaust valve
Replace the valve if deformation, breakage, bend or the similar is found.
•Head gasket
Replace the pump head cover gasket if hardening, crack, elongation or the
similar is found.
•Bearing
If grease runs out or unusual sound or vibrating sound of the motor is perceived,
contact our representative for repair.
Table 3 Locations for Maintenance and Inspection
Operating hours
Location
Check
Checking method
10,000 hrs
Diaphragm
Deformation, crack and hardening
Visual check
Suction/
exhaust valve
Deformation and crack
Visual check
Head gasket
Damage and leak
Visual check
Bearing
Unusual sound
Auditory check
•disposal
When dispose of a pump , obey to a law of a country and a regulations of local
autonomy, dispose of a pump.
7.4 Replacing and Cleaning Consumables
※The pump becomes very hot after operation. After stopping the pump, leave it
for 30 minutes to cool, and replace and clean components only after it has
cooled to a safe temperature.
※Always put on dust mask and gloves before replacing diaphragms and valves.
Any fine particles produced by mechanical wearing may become airborne
causing a health risk if inhaled.
※Always use gloves to prevent injury when replacing diaphragms.

－14－
Tools Required for Setup
Have the following tools on hand and perform the replacement while referring to the diagram.
If there is no repair technician available, or if you do not have access to the required tools,
please make the appropriate request to our repair services department.
・Required Tools
1. Phillips head (+) screwdriver- No.2
2. Torque screwdriver- No.2 (0.25-0.30 Nm, 1.2 Nm, 4.0 Nm)
3. Tri-wing bit (special tool)
* This bit is to be used with the torque screwdriver (0.25-0.30 Nm).
Please see the pictures below. Use this to fasten/loosen the tri-wing screws.
4. Anti-loosening agent for screws
Replacing diaphragm : Loctite 242 or Loctite 243
Replacing valve : Loctite 262 or Loctite 263
5. Rag
6. Solvent for wiping (something that has no effect on rubber, such as ethanol)
7. Dust mask (for nose and mouth), gloves, protective eyewear
*Use items No.5 and 6 to wipe down any dirty area when replacing the part.
Part Replacement Procedure
Definition of Terms
In the replacement procedure, the terms “primary side”and “secondary side”shall be used to refer
to specific locations.
Refer to the terms and diagram below when performing the replacement.
Tri-wing bit
Tri-wing screw
DAP-6D
DAP-12S
Secondary side
Primary side
Primary side
Secondary side
Suction
inlet
Exhaust outlet
Exhaust outlet
Suction inlet
Rc 1/8 tap
Rc 1/8
tap
Rc 1/8 tap
Rc 1/8 tap

－15－
i. Parts Removal
*First unplug the pump’s power cable from the main
power supply.
Step 1: Remove the pump head. First, remove the 8
small pan head screws (M4×12) shown in the picture on
the left, and then remove the pump head.
Pump head
Small pan head
screw
Step 2: Remove the valve. First remove (1) the small
flat head screw (M4×6), and then you can remove (2)
the pump head cover and (3) the head gasket. Next, use
the tri-wing (bit) screwdriver to remove (4) the tri-wing
screw, (5) the valve holder and (6) the valve.
* The picture shown is the primary side of the
DAP-12S, but the procedure is the same for the
secondary side of the DAP-12S and both the primary
and secondary sides of the DAP-6D.
Step 3: Remove the diaphragm. First, remove (1) the
small flat head screw (M5×12) as shown in the diagram,
then remove (2) the push plate for the diaphragm and (3)
the diaphragm.
*The procedure is the same for both primary and
secondary sides of all models.
* Please be careful when removing (2) the push plate for
the diaphragm and (3) the diaphragm, as they tend to
adhere to each other and they are therefore hard to
remove.
This step completes the parts removal procedure. The
next section is the assembly.
Small pan head
screw

－16－
ii. Attaching Parts & Assembly
Step 4: Attach the diaphragm. Put the new diaphragm on the
connecting rod to replace the old one removed in Step 3. The
connecting rod, diaphragm and the push plate for the
diaphragm have either a concave or a convex part to help
provide a correct assembly. Align those positioning guides on
the same position. Make sure that there is no space on either
front and rear sides of the push plate for the diaphragm, as
this implies misalignment.
Connecting rod
Concave positioning guide
Convex positioning guide
Step 5: Using the torque screwdriver (4.0 Nm) and the small
flat head screw (M5×12), fasten the diaphragm and the push
plate for the diaphragm aligned in Step 4. Before fastening
tightly, check the alignment of the diaphragm. Also, apply the
Loctite 242 or Loctite 243 onto 2-4 threads from the screw tip
for the small flat head screws.
*Be careful when applying Loctite, as too much or too little
can cause damage.
*Be sure to always follow the appropriate tightening torque.
Failure to do so can lead to product damage.
2-4 threads
Loctite 242 or Loctite 243
Perfectly aligned
Small flat
head
screw
Concave positioning guide

－17－
Step 6: Attach the valve. Put the new valve on the pump head to replace the old one removed in Step 2. As
shown in the pictures below, make sure that the valve is fully pushed in on both the suction and the exhaust
sides. Also ensure that there is no gap between the valve and the pump head. In addition, align the position of
the valve so its sides do not touch the inner wall of the dent on the pump head.
No gap
Exhaust side
Not touching the inner wall of the dent
No gap
Suction side
Step 7: Using the torque screwdriver
(0.25-0.30 Nm) with the tri-wing bit attached,
fasten the valve aligned in Step 6 with the
tri-wing screw (M3×4). Apply the Loctite 262
or Loctite 263 onto 2-4 threads from the screw
tip for the tri-wing screw.
After tightening the tri-wing screw, re-check
the alignment of the valve.
*Be careful when applying Loctite, as too
much or too little can cause damage.
*Be sure to always follow the appropriate
tightening torque. Failure to do so can lead to
product damage.
2-4 threads
Loctite 262 or Loctite 263
Tri-wing screw
Not touching the inner wall of the dent
Not touching the inner wall of the dent

－18－
Step 8: Place the head gasket on the pump head. The
head gasket has notches on both sides as positioning
guides. Align the notches to the pins on the pump head.
Align the notches to the pins
Step 9: Place the pump head cover on the head gasket. As
with the head gasket, the pump head cover has notches on
both sides as positioning guides. Align the notches to the
pins on the pump head.
Once they are aligned correctly, using the torque
screwdriver (1.2 Nm), fasten them with the small flat head
screw (M4×6).
Do the same for Steps 6 through 9 on the opposing pump
head.
*Be sure to always follow the appropriate tightening
torque. Failure to do so can lead to product damage.
Align the notches to the pins
Small flat head screw
Step 10: Attach the pump head. First, using connecting
tubes, connect the primary and secondary side pump
heads. DAP-6D has one connection point and
DAP-12S has two. (The picture on the left is of
DAP-6D.)
After connecting the two pump heads, fasten them by
tightening the screws at their corners in order (1)
through (4), going over them three times, gradually
tightening each one of them.
Finally, use the torque screwdriver (1.2 Nm) to tighten.
*Be sure to always follow the appropriate tightening
torque. Failure to do so can lead to product damage.
The parts replacement procedure is now complete.
(1)
(2)
(3)
(4)
(1)
(2)
(3)
(4)
Connecting tube