Ulvac DOP-200S User manual

No. 28200-2-03-8
INSTRUCTION MANUAL
Oscillating Piston Dry Vacuum Pump
DOP-200S,100T,50F,100ST,50DT,50S4,50S4Ⅱ
DOP-200SV,100TV,50FV,100STV,50DTV,50S4V,50S4VⅡ
DOP-300S,150T,300SV,150TV
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.
DOP-300S DOP-300SV

Contents
Pages with a shaded background are those which contain items related to safety.
Before Using the Equipment...............................................................................................................01
Checks When Opening Packaging.....................................................................................................02
Using the Pump Safely.......................................................................................................................03
･Safety icons ............................................................................................................................03
･Cautions for Safety in Use.......................................................................................................04
1. Product Outline...............................................................................................................................1
1.1 Purpose of Use and Prohibitions..........................................................................................1
1.2 Specifications.......................................................................................................................1
1.3 Thermal Protection Relay.....................................................................................................2
2. Dimensions.....................................................................................................................................2
3. Installation and Storage ..................................................................................................................3
3.1 Cautions for Installation and Storage....................................................................................3
3.2 Environmental Conditions for Installation, Storage, and Operation.......................................3
3.3 Location...............................................................................................................................3
3.4 Operational Checks Following Installation............................................................................3
3.5 Fluctuations in the power voltage and frequency..................................................................4
3.6 Piping...................................................................................................................................4
3.7 Storage................................................................................................................................4
4. Cautions for Operation....................................................................................................................5
4.1 Cautions for Operation.........................................................................................................5
4.2 Operation of the Thermal Protection Relay...........................................................................5
4.3 Precautions when starting....................................................................................................5
5. Pump Performance.........................................................................................................................6
5.1 Pressure Achieved...............................................................................................................6
5.2 Evacuation Rate...................................................................................................................6
5.3 Power Requirements............................................................................................................6

6. Maintenance, Inspection, and Repair..............................................................................................7
6.1. Cautions for Maintenance, Inspection, and Repair...............................................................7
6.2 Maintenance ........................................................................................................................7
6.3 Regular Inspections .............................................................................................................7
6.4 Replacing Consumables and Cleaning.................................................................................9
1) Preparations for Replacing the Pump.............................................................................10
2) Removing the Head Cover.............................................................................................10
3) Removing the Cylinder...................................................................................................11
4) Removing the Holder Plate, Cup Packing, and Inlet Valve Rubber Separator................12
5) Removing Small Cylinder Components..........................................................................13
6) Detailed Holder Plate Components................................................................................14
7) Replacing and Assembling Consumables......................................................................14
6.5 Troubleshooting List...........................................................................................................17
7. Product specification of each model .............................................................................................18
8. In Conclusion................................................................................................................................22
･Warranty.................................................................................................................................22
･Usage Status Check Sheet
(used with requests for disassembly and repair)
･Product information, service bases, and contact information
Figures and Tables
Fig. 2.1 DOP-200S..........................................................................................................................2
Fig. 2.2 DOP-200SV .......................................................................................................................2
Fig. 2.3 DOP-300S..........................................................................................................................2
Fig. 2.4 DOP-300SV .......................................................................................................................2
Fig. 3.1 Change region of the voltage and frequency......................................................................4
Fig. 3.2 Example of Piping Used When Evacuating a Vessel..........................................................4
Table 1.1 Product Specifications (50 Hz/60 Hz) ...............................................................................1
Table 6.1 Consumables List...............................................................................................................8
Table 6.2 Locations for Maintenance and Inspection .........................................................................8
Table 6.3 Troubleshooting List.........................................................................................................17

01
Before Using the Equipment
Thank you for purchasing this product. Your custom is very much appreciated.
This pump is only for vacuum pumping, 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 may be refused if these circumstances are
unclear.

02
Checks When Opening Packaging
Check the following after opening the packaging.
(1) Is the product as you requested?
(2) Are the accessories and necessary parts included?
Standard accessories
・Instruction manual -------------------- x 1
・Inlet pipe protective cap and vent plug -------------------- x 1 each
・Silencer -------------------- x 1
(3) Is the pump damaged in any way?
(4) Are any external screws or inlet and outlet pipes loose? Are any components missing?
Contact your agent or the sales division of the manufacturer if there are any problems with the
pump.
1. Ensure that the tube on the side of the pump is not gripped or bent when removing
the pump from the packaging. Holding the pump by this tube may damage it, thus
reducing pump performance.
2. Always remove the vent plug before using the pump.
3. Fit an inlet filter if there is a possibility of foreign matter or dust particles entering the
pump.
4. Use ventilation holes, and fit a cooling fan, to reduce the temperature in the vicinity of
the pump. Ensure that the pump cooling fan inlet is not blocked. Ensure that a space
of at least 100mm is available on all sides of the pump.
DOP-300S DOP-300SV
!
Note

03
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.
Some parts of the pump may reach temperatures of 60°C or more during operation.
Touching such components may result in burns.
Always switch off the main power supply before installing electrical wiring or performing
any electrical work on the pump. Failure to do so may result in electric shock.
!
Danger
!
Warning
!
Caution
!
Note
Electric Shock Caution
High temperature Caution

04
・Cautions for Safety in Use
Applications
(1) This pump is not designed to be explosion-proof, and should therefore not be used to
evacuate explosive gases.
(2) In addition to discharge of gas via the pump outlet, gas may leak from the pump itself.
Do not use the pump to evacuate toxic gases. If toxic gas is evacuated 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 sending the pump to the manufacturer’s service division for dismantling and
repair, always note the type of gas that has been used on the 'Pump Usage Check
Sheet'. Note that if the pump has been used to evacuate toxic gas, it may be
contaminated and dismantling and repair may not be possible.
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. Such use may result in fire.
(3) Ensure that the motor is freely ventilated to prevent overheating which may result in fire
or burns.
Power Supply
(4) Always switch off the main power supply, and make sure that the pump has stopped,
before carrying out inspection and repair.
(5) Ensure that the relevant wiring is in accordance with technical standards for electrical
equipment and wiring regulations. Incorrect wiring may result in fire.
(6) Always switch off the main power supply before installing electrical wiring. Carrying out
work on the pump while the power is connected may result in electric shock.
(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
malfunction 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 relay, and this may result in the motor burning
out, or fire.
(9) Do not damage, modify, or pull the power cord, or place objects on it. Damage to the
cord may result in electric shock or fire. [Continued on next page]
!
Danger
!
Warning

05
Power Supply
(10)Ensure that the power cord used for the pump is appropriate for the rated voltage and
current. Use a 4-core cable, with each core wire having a cross-section area of 1.0mm2
or more. Ensure that one of the core wires is used as an earth wire. Firmly attach the 6
- 12mm diameter SKINTOP compatible cable fitted with the appropriate terminals (M4
terminal block screws) to a terminal block. Failure to follow these requirements may
result in electric shock.
(11)Switch off the main power supply, and remove the power cord from the terminal block,
before disconnecting the power cord from the pump. 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.
Operation
(14)This pump is not designed to be explosion-proof, and should therefore not be used in
the vicinity of inflammable substances (eg inflammable solvents) or in explosive
atmospheres. Failure to follow these requirements may result in injury or fire.
(15)Inserting fingers or objects into the motor inlet may result in electric shock, injury, or
fire.
(16)Operating the pump with the discharge outlet blocked, or with a device which prevents
passage of gas to the discharge outlet, may result in rupture of the pump. The internal
pressure of the pump rises and the pump body may rupture and the motor become
overloaded. This pump is not designed to be pressure-resistant. The internal pressure
of the pump is limited to 0.03 MPa (gauge pressure).
Maintenance and Repair
(17)The pump should be dismantled or repaired only by a repair technician trained by the
manufacturer.
(18)To prevent ingestion of microscopic particles resulting from wear of components, use a
dust mask and gloves when replacing cup packing, inlet and outlet valves, and gaskets.
Installation
(1) To prevent back injuries, always use at least two people when lifting and moving the
pump. Use two persons to lift the upright vertical type of pump from its base.
(2) Microscopic particles resulting from wear of components are discharged from the outlet
and contaminate the room. If necessary, connect a pipe from the discharge outlet to the
outside of the building. [Continued on next page]
!
Caution
!
Warning
Earth・W・V・U

06
Installation
(3) 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 relative humidity of 85% or less during
operation.
2. Other conditions for storage and operation
a) Level floor of sufficient strength
b) No condensation
c) Dust-free environment
d) Well ventilated
e) Environment free of corrosive or explosive gas
f) Not subject to direct sunlight
g) No danger of fire
h) Maximum ambient temperature of 40°C when
connecting the pump.
Operation
(4) Touching rotating components (eg motor, main shaft, axial joints, cooling fan) while the
pump is in operation may result in injury.
(5) When the overload protection relay operates the pump will be extremely hot. Touching
the pump in this condition may result in burns.
(6) 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.
(7) Inserting fingers or objects, or peering, into, the inlet or outlet during operation may
result in injury or malfunction.
Maintenance and Repair
(8) If the pump ceases operation, switch off the main power supply immediately to prevent
accidents, remove the power cord from the wall outlet, and contact your dealer or the
manufacturer for inspection and repair.
(9) After stopping the pump, leave it for 30 minutes or more and begin work on it only after
checking that it has cooled sufficiently. The interior of the pump is extremely hot
immediately after it has been switched OFF, and burns may result if it is touched in this
condition.
!
Caution
Use two persons
to hold here with
both hands.

07
Installation
(1) Application of shock to the pump, or allowing it to fall over, may result in a malfunction.
(2) Do not grip or bend the tube on the side of the pump. Any damage to this tube may
reduce the performance of the pump.
(3) Fit an inlet filter if there is a possibility of foreign matter or dust particles entering the
pump.
(4) Use ventilation holes, and fit a cooling fan, to reduce the temperature in the vicinity of
the pump. Ensure that the pump cooling fan inlet is not blocked. Ensure that a space of
at least 100mm is available on all sides of the pump.
Application
(5) This pump is not designed to be corrosion-resistant. It should only be used with clean
air at normal temperatures, or gases with equivalent characteristics.
(6) This pump is only for vacuum pumping. Use at near-atmospheric pressures for long
periods of time may result in a malfunction.
(7) In addition to discharge of gas via the pump outlet, gas may leak from the pump itself.
Do not use the pump to evacuate toxic gases. If the pump is used to evacuate toxic
gas, appropriate care is required during maintenance.
(8) The pump will not often operate normally if it is used with corrosive gases, organic
solvents, liquids, or condensed gases (eg steam).
(9) The pump will not often operate normally if it is used with gases containing particles or
dust etc. Always fit a filter to the inlet.
Operation
(10)Use the pump at an ambient temperature of 0-40°C. The life of the pump will be
severely reduced if it is operated at high temperatures.
(11)Application of back pressure at the pump outlet will overload the motor and may
prevent the pump starting.
(12)When the thermal protection relay operates the pump will be extremely hot. Touching
the pump in this condition may result in burns.
Maintenance and Repair
(13)This pump operates with precision clearances and therefore requires particular skill for
assembly. If a repair technician is not available, contact the manufacturer's service
division for replacement of consumables.
!
Note

1
1. Product Outline
(Product specification of each model is put on P.18-21.)
1.1 Purpose of Use and Prohibitions
This product is a piston dry vacuum pump employing reciprocating motion of cup packing.
Observe the following prohibitions to ensure normal operation of the pump.
Prohibitions
(1) This pump is only for vacuum pumping, 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 evacuate gases containing particles, dust, water, or corrosive gases.
(5) Do not operate the pump for long periods at near-atmospheric pressure.
1.2 Specifications
Table 1.1 Product Specifications (50Hz/60Hz)
Model
DOP-200S
DOP-200SV
DOP-300S
DOP-300SV
Evacuate rate (L/min)
200/220
300/330
Pressure achieved
(kPa)
8
8
Motor
3φ200V280W4P 50/60Hz
3φ220V280W4P 60Hz
Fitted with thermal protection relay
(automatic reset type)
3φ200V400W4P 50/60Hz
3φ220V400W4P 60Hz
Fitted with thermal protection relay
(automatic reset type)
Voltage, frequency
200V･50Hz
200V･60Hz
220V･60Hz
200V･50Hz
200V･60Hz
220V･60Hz
Rated current (A)
1.8
1.7
1.6
2.5
2.3
2.2
Speed (r.p.m)
1382
1651
1692
1401
1672
1701
Inlet pipe
O.D.φ16×I.D.φ12 (R1/2)
Weight (kg)
20
22
20
22
Air temperature (°C)
0-40
Dimensions (mm)
315W×434L×231H
216W×460.5L×353H
315W×443L×231H
225W×469.5L×353H
Over voltage
category
Ⅱ
Ⅱ
Pollution degree
2
2
Insulation Category
Class 1
Class 1
!
Warning
!
Note

2
Fig.2.1 DOP-200S
Fig.2.2 DOP-200SV
Fig.2.3 DOP-300S
Fig.2.4 DOP-300SV
1.3 Thermal Protection Relay
1) This pump is fitted with an automatic reset thermal protection relay for overload protection.
This device shuts off the motor power supply circuit automatically to prevent burn-out if the
motor temperature rises due to overloading, or there is a pump fault which prevents
rotation.
2) Always fit other protective devices (eg earth leakage breaker, motor breaker) in addition to
the overload protection relay.
See "Warning" (8) on p.04.
See "Caution" (5) on p.06.
2. Dimensions
(Product specification of each model is put on P.18-21.)
!
Warning
!
Caution

3
3.Installation and Storage
3.1 Cautions for Installation and Storage
See "Warning" (1), (2), (3), (5), (6), (7),
(8), (9), (10), (11), (12) and (13) on p.04
and p.05.
See "Caution" (1), (2) and (3) on p.05
and p.06.
See "Note" (1), (2), (3) and (4) on p.07.
3.2 Environmental Conditions for Installation, Storage, and Operation
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 (during storage and operation)
a) Level floor of sufficient strength
b) No condensation
c) Dust-free environment
d) Well ventilated
e) Environment free of corrosive or explosive gas
f) Not subject to direct sunlight
g) No danger of fire
h) Maximum ambient temperature of 40°C when connecting the pump.
i) Sufficient space is available on all sides of the pump, and the pump cooling fan inlet is
not blocked.
3.3 Location
The pump should be installed level in a location with minimal dust and humidity. This location
should be selected in consideration of ease of installation and removal, inspection, and
cleaning.
Particular attention should be paid to ambient temperature when fitting the pump to equipment.
Use anti-vibration rubbers to isolate the pump from vibrations in the equipment. See 3.2
Environmental Conditions for Installation, Storage, and Operation for details.
3.4 Operational Checks Following Installation
1) Remove the rubber cap and vent plug on the inlet pipe.
2) Remove the four screws in the terminal box cover, pass the power cord through the
SKINTOP, and connect to the terminal block. Fit the appropriate crimped connectors to the
end of the cord.
Caution: Ensure that the power cord is appropriate for the rated voltage and current.
Caution: Use a 4-core cable, with each core wire having a cross-section area of 1.0 mm2or
more. Use one of the core wires as an earth wire.
Caution: Use M4 terminal block screws with SKINTOP compatible cable of 6 - 12 mm
diameter.
!
Warning
!
Caution
!
Note

4
Fig.3.1 Change region of the
voltage and frequency
3) Switch power ON, check the direction of rotation, and check for suction.
4) When checks are complete, switch off the main power supply and stop the pump. Check
that the pump has stopped.
3.5 Fluctuations in the power voltage and frequency
Standard: Rotating electric machine general rules IEC
60034-1:2004.
There is no problem to main parts when operated continuously
under the voltage and frequency fluctuations in area A, and no
problem to main parts when operated under the voltage and
frequency fluctuations in area B.
Here, “no problem” means that the pump can be operated
safely
and without the life of the parts being shortened, and does not
refer to the pump characteristics or the rated conditions such
as a rise in temperature.
The ratings are the rated torque (N.m).
3.6 Piping
1) Ensure that all piping is installed without leaks, and fit a filter
on the pump inlet.
2) Use inlet piping with an internal diameter of 12 mm or more.
3) Ensure that piping connected to the outlet does not cause back pressure. Maximum back
pressure is 0.03 MPa (gauge pressure).
4) 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.
5) When evacuating a vessel, ensure that a shut-off valve is placed between the pump inlet
pipe and the vessel (see Fig. 3.2).
Fig. 3.2 Example of Piping Used When Evacuating a Vessel
6) When starting the pump, it may not start if the intake-side pressure is lower than the
atmospheric pressure.
Attach an atmospheric release leak valve between the pump intake pipe and vessel, and set
the intake-side pressure to atmospheric pressure when starting the pump.
After starting the pump, always close the leak valve.
3.7 Storage
Switch off the main power supply and check that the pump has stopped.
Remove the power cord connected to the pump, place the rubber cap on the inlet pipe,
remove the silencer from the outlet and fit the vent plug, and store in a location with low
humidity
Vacuum pump
Filter
Leak valve
Shut-off valve
Vessel

5
4. Cautions for Operation
4.1 Cautions for Operation
See "Danger" (1) and (2) on p.04.
See "Warning"(8), (14), (15) and (16)
on p.04 and p.05.
See "Caution" (4), (6) and (7) on p.06.
See "Note" (3), (4), (5), (6), (7), (8), (9),
(10), and (11) on p.07.
4.2 Operation of the Thermal Protection Relay
1) If the thermal protection relay operates, switch off the main power supply immediately and
contact the manufacturer. The motor will be extremely hot and should not be touched
under any circumstances.
2) When the cause of the problem has been eliminated, check that the motor has cooled,
switch on the main power supply, and check that the pump is operating.
See "Caution" (5) on p.06.
4.3 Precautions when starting
1) Starting in cold weather
The bearing grease and cup packing may harden under cold conditions, and the pump
may be difficult to start. Use the following procedure in this case.
(1) Open the inlet to atmosphere, and switch power ON-OFF two or three times until the
pump starts. If the pump still does not start, raise the ambient temperature above 0°C.
(2) With the inlet open to atmosphere, run the pump for a few minutes to warm it.
(3) Commence normal operation once the pump has warmed.
2) Precautions regarding the intake-side pressure
Set the intake-side pressure to atmospheric pressure when starting the pump.
If the pressure is lower than atmospheric pressure, it will apply a load on the motor and
may prevent the pump from starting.
If it is necessary to maintain a vacuum, attach a shut-off valve or three-way valve between
the pump and vessel. Refer to fig.3.2 for a piping example using a shut-off valve.
!
Danger
!
Caution
!
Note
!
Warning
!
Caution

6
5.Pump Performance
5.1 Pressure Achieved
The term “pressure achieved” as employed in the catalogue and in this manual is defined as
“the minimum pressure obtained by the pump without introduction of gas from the pump inlet
(i.e. the no-load condition)”.
Note that the indicator values for pressure may differ between types of vacuum gauges.
The pressure achieved in practice is higher than that noted in the catalogue for the following
reasons.
(1)The fact that the vacuum gauge is mounted a distance from the pump, the steam
generated by water droplets and rust etc on the inside walls of the pump and piping, and a
variety of gases present in the system result in increased pressure.
(2)Leaks into the vacuum system introduce other gases, resulting in increased pressure.
5.2 Evacuation Rate
The rate of evacuation varies with the type of gas used, and its pressure. The maximum rate
of evacuation is reached when air is introduced, and slowly decreases as pressure is reduced.
The resistance of the piping system increases with small bore piping which extends over long
distances, and this reduces the rate of evacuation.
The declared rate of evacuation for this pump is the maximum value achieved with dry air.
5.3 Power Requirements
The power required to drive the pump is the total of the work required to overcome the
rotational resistance of the pump (mechanical work), and the work required to compress the
air (compression work), and is at a maximum at an inlet pressure of 2.7 x 104- 6 x 104Pa.
If pressure drops below this level, compression work is considerably reduced and power is
expended in mechanical work.

7
6. Maintenance, Inspection, and Repair
6.1 Cautions for Maintenance, Inspection, and Repair
See "Danger" (3) on p.04.
See "Warning" (4), (17) and (18) on
p.04 and p.05.
See "Caution" (8) and (9) on p.06.
See "Note" (13) on p.07.
Customer repair technicians are able to perform the following maintenance and repairs. Other
repairs and modifications (except for the standard options available from the manufacturer)
should not be performed by the customer.
1) Replacing cup packing
2) Replacing inlet and outlet valves
3) Replacing gaskets
4) Replacing inlet valve rubber separator
5) Replacing backup inlet and outlet valves
6) Replacing connecting tubes
6.2 Maintenance
Ensure that the following checks are conducted at least once every three days while the pump
is in operation.
1) Does the pump emit abnormal noises?
2) Is the pump abnormally hot?
3) Is gas evacuated normally?
4) Is the silencer blocked?
Resolve any problems in accordance with "6.5 Troubleshooting List."
6.3 Regular Inspections
Inspect consumables after the first 3000 hours of operation, and replace and clean in
accordance with the " Guidelines for Replacement and Cleaning "on the following page. Refer
to 6.4 Replacing Consumables and Cleaning for procedures.
Request replacement by the manufacturer’s service division if a repair technician is not
available.
!
Danger
!
Caution
!
Note
!
Warning

8
<Consumables List> Table 6.1 Consumables List
Components
Quantity
Material
Average life
200(※1)
300(※2)
Inlet and outlet valves(Other than ※3)
12
12
SUS
―――
DOP-50S4,50S4V,
50S4Ⅱ,50S4VⅡ(※3)
Inlet valves(t=0.2)
4
SUS
―――
outlet valves
4
Backup inlet and outlet valves
8
8
PTFE
6000 h
Cup packing
4
4
PTFE
6000 h
Inlet valve rubber separator
4
4
Silicon
6000 h
Gaskets
4
4
NBR
6000 h
Connecting tubes
1 set
1 set
Nylon
6000 h
Bearings
1 set
1 set
―――
15000 h
※1DOP-200S,200SV,100T,100TV,50F,50FV,100ST,100STV,50DT,50DTV,50S4,50S4V,50S4Ⅱ,50S4VⅡ
※2 DOP-300S,300SV,150T,150TV
※3DOP-50S4,50S4V,50S4Ⅱ,50S4VⅡ：Quantity 4
Life of these components tends to be extended when the requirements in "4.1 Cautions for
Operation" are followed, and the pump is operated under a light load. The term 'light load'
refers to operation at achieved pressure (inlet closed).
Bearings are replaced by the manufacturer’s service division.
< Guidelines for Replacement and Cleaning >
Replace or clean components if performance is reduced and/or the following symptoms
appear.
Backup inlet and outlet valves:
Replace in the event of abnormal wear, hardening, or cracking.
Cup packing: Replace in the event of abnormal wear, hardening, or cracking.
Inlet and outlet valves:
Replace in the event of deformation, hardening, or chipping.
Bearings: Contact the manufacturer for repair in the event of abnormal noises or
abnormal motor vibration (chattering).
Inlet valve rubber separator:
Replace in the event of deformation, wear, hardening, or cracking.
Connecting tubes: Replace in the event of deformation, wear, hardening, or cracking.
Gaskets: Replace in the event of deformation, hardening, or cracking.
<Locations for Maintenance and Inspection>
Table 6.2 Locations for Maintenance and Inspection
Period of
operation
Inspection item
Inspection details
Method of
inspection
Every 3000
hours
Backup inlet and
outlet valves
Abnormal wear, hardening,
cracking.
Visual
inspection
Cup packing
Abnormal wear, hardening,
cracking.
Visual
inspection
Inlet and outlet
valves
Deformation, hardening, chipping.
Visual
inspection
Inlet valve rubber
separator
Deformation, wear, hardening,
cracking.
Visual
inspection
Gaskets
Deformation, hardening, cracking.
Visual
inspection
Connecting tubes
Deformation, hardening, cracking.
Visual
inspection
Bearings
Abnormal noises.
Listen

9
6.4 Replacing Consumables and Cleaning
See "Caution" (9) on p.06.
(1) The interior of the pump is extremely hot immediately after operation. After stopping
the pump, leave it for 30 minutes or more and begin replacing consumables and
cleaning only after checking that it has cooled sufficiently.
(2) To prevent ingestion of microscopic particles in the air, use a dust mask and gloves
when replacing components and cleaning.
(3) To prevent injury, wear gloves when replacing consumables.
Prepare the following tools, and refer to photographs, before replacing components and
cleaning. Contact the manufacturer's service division if the required tools are not available.
* Tools
1. Hex wrenches: 5 mm and 3 mm across flats
2. Torque wrench: Hexagon socket, 5 mm across flats (torque settable to 8Nm)
3. Philips screwdriver: No. 2
4. Cleaning solvent: Solvent which does not affect rubber components (eg ethyl alcohol)
5. Paper: Soft cloth or paper to remove contamination
6. Dust mask, gloves, oil-based pen, air compressor
※Wipe components which is contaminated during replacement with 4. and 5. above.
Procedure for exchanging the article of consumption of this product..
This product is comprised of four head pump chambers. This description includes the
procedure for replacing consumables for a single head. It is recommended that the
consumables for the remaining three heads are also replaced using this procedure. The
replacement procedure is described using the DOP-200S. Remove the angle when
replacing consumables in the vertical type of pump.
* Replaceable Consumables
·Backup inlet and outlet valves ·Inlet valve rubber separator
·Inlet and outlet valves ·Cup packing
·Gaskets ·Connecting tubes
!
Caution

10
1) Preparations for Replacing the Pump
(1) Switch off the pump primary power supply, and remove the piping connected to the inlet
pipe.
(2) Remove the pump from the equipment.
(3) Open the terminal box, and remove the wiring connected to the terminal block.
(4) Using the 5 mm hex wrench, loosen the M6x20 hex-headed bolt holding the handle.
(5) Remove the handle and panel.
(6) Stand the pump up so that the head may be removed vertically.
2) Removing the Head Cover
(1) Using the hex wrench, loosen the four M6xL30 hex-headed bolts holding the head
cover, and remove them.
(2) Pull the fitting joint forwards with both hands and remove from the connecting tube. Pull
the left and right fitting joints alternately until they are removed.
(3) Remove the connecting tube, and remove the head cover.
(1),(2) Remove from the equipment. (3) Remove wiring.
(4),(5) Loosen the bolt. (6) Stand the pump up so that
the head may be removed vertically.