Ulvac DTC-22 User manual

DTC-22
DTC-22K
No．2001700-2-01-7
User’s Manual
Diaphragm-type Dry Vacuum Pump
Model: DTC-22, 22K
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.
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.............................................................................................................. 2
1.3 Thermal Protection Relay............................................................................................ 3
2. Dimensions.......................................................................................................................... 3
3. Installation and Storage....................................................................................................... 4
3.1 Cautions for Installation and Storage .......................................................................... 4
3.2 Environmental Conditions for Installation, Storage, and Operation............................. 4
3.3 Location ...................................................................................................................... 4
3.4 Checking Operation After Installation.......................................................................... 4
3.5 Piping.......................................................................................................................... 5
3.6 Storage ....................................................................................................................... 5
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........................................................................................... 6
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 and Cleaning Consumables ....................................................................... 8
1) Replacing Diaphragms............................................................................................ 9
2) Replacing Inlet and Outlet Valves......................................................................... 12
3) Replacing O Rings................................................................................................ 13
4) Replacing Bearings............................................................................................... 13
6.5 Troubleshooting List.................................................................................................. 14
7. In Conclusion..................................................................................................................... 15
•Warranty........................................................................................................................ 15
•Usage Status Check Sheet
(used with requests for disassembly and repair)

Figures and Tables
Fig.2.1 DTC-22 Dimensions................................................................................................ 3
Fig.2.2 DTC-22KDimensions.............................................................................................. 3
Fig.3.1 Example of Piping Used When Evacuating a Vessel.............................................. 5
Table 1.1 DTC-22 Product Specifications............................................................................... 2
Table 1.2 DTC-22K Product Specifications............................................................................. 2
Table 6.1 Consumables List ................................................................................................... 7
Table 6.2 Locations for Maintenance and Inspection.............................................................. 8
Table 6.3 Troubleshooting List.............................................................................................. 14

01
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.
０１

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
･User’s manual -------------------- x 1
･Inlet and outlet caps (fitted to inlet and outlet) -------------------- x 2
･Power plug adapter (attached to power cord) -------------------- x 1
It is attached only to 100V in the motor ratings voltage.
(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.
Customers purchasing the DTC-22K
Do not hold or push the tube at the top of the pump
while removing it from the packaging.
Damage to the tube may affect performance of the
pump.
!
Note
０２

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 components reach surface temperatures in excess of 60’C during pump operation.
Burns may result if these components are touched during operation.
To prevent electric shock, always shut-off the primary power supply before working on
electrical wiring, or engaging in any electrical work.
!
Danger
!
Warning
!
Caution
!
Note
High Temperatures
Electric Shock
０３

04
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.
(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.
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 motor is freely ventilated to prevent overheating which may result in fire or
burns.
Power Supply
(4) Always remove the power cord from the wall socket before checking or repairing the pump.
Failure to do so may result in electric shock, or the pump suddenly starting and causing
injury.
(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) Remove the power cord from the wall socket before connecting any wiring. Connecting
wiring with the power on 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 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, 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) Do the wiring work after cutting the power supply, except when the power supply
code is a plug.
!
Danger
!
Warning
０４

5
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) 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
(18) The pump should be dismantled or repaired only by a repair technician trained by the
manufacturer.
(19) To prevent ingestion of microscopic particles resulting from wear of components, use a dust
mask and gloves during repair work.
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) 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 during assembly of pump.
(2) To prevent back injury, always use both hands to lift pumps.
(3) 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.
Operation
(4) Do not use in applications involving organ transplants, or contact with body fluids or living
tissue.
(5) Touching rotating components (motor, main shaft, axial joints, cooling fan) while the pump is in
operation may result in injury.
(6) The overload protector operates when the pump becomes excessively hot. Touching it in this
condition may result in burns.
(7) 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.
(8) Do not insert fingers or objects into, or peer into, the inlet or outlet during operation.
!
Warning
!
Caution
０６
０５

6
Maintenance and Repair
(9) Dispose in accordance with legislation for disposal and cleaning of waste products, handle as
industrial waste, and do not incinerate.
Toxic fluorine gas is generated by incineration of fluorine-based plastics.
(10) 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.
(11) Leave the pump for at least 30 minutes until it has cooled, and begin operation again. Touching
the pump immediately after it has stopped may result in burns.
Installation
(1) The pump may malfunction if it is subjected to shocks or
tipped over on its side.
(2) Do not hold or push the tube at the top of the pump (see
below). Damage to the tube may affect performance of
the pump.
Applications
(3) This pump is not designed to be corrosion-proof. Use it only with clean air at normal
temperature, or with gases of equivalent characteristics.
(4) This pump is designed for general corrosion resistance, however it is not resistant to molten
alkali metals such as molten sodium, to fluorine at high temperatures, and to some oxides of
fluorine.
(5) Corrosion-resistant plastic is used in the external covering of the DTC-22, however it is not
resistant to all chemicals.
Ensure that the following chemicals do not come in contact with the pump. Any chemical,
including the following, which comes into contact with the pump should be wiped off
immediately.
• Acetone •Ethyl ether •Ethyl acetate •Animal fats
!
Caution
!
Note
０６

7
Installation
(6) Ingestion of liquids or compressed and gases into the pump will result in damage and prevent
proper operation.
(7) Ingestion of rubbish and dust in the air entering the pump will interfere with its proper function. If
the air is likely to contain rubbish or dust, a filter should be fitted to the inlet to protect the pump.
(8) Ducting should always be fitted to the pump outlet if toxic corrosive gases, or steam, enters the
pump.
Operation
(9) Use the pump within an ambient temperature range of 40°C. Use at high ambient temperatures
will dramatically reduce the life of the pump.
(10) Back pressure at the outlet while the pump is starting may overload the motor.
(11) The thermal protection relay operates when the pump reaches a very high temperature.
Touching the pump in this condition may result in burns.
(12) To maintain the performance of the pump, always ensure that it is cleaned internally after use.
Clean by ingesting clean air for 3~5 minutes under no-load conditions.
Maintenance and Repair
(13) 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.
!
Note
０７

1
1.Product Outline
1.1 Purpose of Use and Prohibitions
This product is a dry vacuum pump which employs reciprocating motion of a rubber diaphragm
for vacuum discharge.
PTFE is a highly corrosion-resistant plastic and is used in components which come in contact
with gas.
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 designed for general corrosion resistance, however it
is not resistant to molten alkali metals such as molten sodium, to
fluorine at high temperatures, and to some oxides of fluorine.
(4) Corrosion-resistant plastic is used in the external covering of the
DTC-22 however it is not resistant to all chemicals.
Ensure that the following chemicals do not come in contact with the
pump. Any chemical, including the following, which comes into
contact with the pump should be wiped off immediately.
•Acetone •Ethyl ether •Ethyl acetate •Animal fats
(5) Ensure that the gas entering the pump does not contain rubbish,
dust, or water (except steam).
(6) Do not operate the pump for long periods at near-atmospheric
pressure.
!
Warning
!
Note

2
1.2 Specifications
Table 1.1 Product Specifications
Model
DTC-22
Discharge rate
50Hz
20L/min
60Hz
24L/min
Pressure achieved
1.0kPa
Motor
Single phase,
AC 100 V
(±10%)
Single phase
,AC 115 V
(±10%)
Single phase
,AC 200 V
(±10%)
Single phase
,AC 220 V
(±10%)
Single phase,
AC 230 V
(±10%)
50 W, 4P, with condenser-run thermal protection relay (automatic reset)
Rated current
1.3/1.3A
(50/60Hz)
1.2/1.32A
(50/60Hz)
0.73/0.65A
(50/60Hz)
0.6/0.72A
(50/60Hz)
0.6A
(50Hz)
Speed
1290/1560rpm
(50/60Hz)
1260/1580rpm
(50/60Hz)
1310/1610rpm
(50/60Ｈｚ）
1275/1570rpm
(50/60Hz)
1270rpm
(50Hz)
Inlet and outlet piping
O.D.Φ10 ×I.D.Φ6(G1/4)
Weight
7.3kg
Air temperature
0～40℃
Dimensions
(W refers to the distance
to the tip of the intake or
exhaust pipe)
142mm(W) ×272mm(L) ×202mm(H)
Ｏｖｅｒ Voltage Category
Ⅱ
Pollution Degree
２
Table 1.2 Product Specifications
Model
DTC-22K
Discharge rate
50Hz
20L/min
60Hz
24L/min
Pressure achieved
1.0kPa
Motor
Single phase,
AC 100 V
(±10%)
Single phase
,AC 115 V
(±10%)
Single phase
,AC 200 V
(±10%)
Single phase
,AC 220 V
(±10%)
Single phase,
AC 230 V
(±10%)
50 W, 4P, with condenser-run thermal protection relay (automatic reset)
Rated current
1.3/1.3A
(50/60Hz)
1.2/1.32A
(50/60Hz)
0.73/0.65A
(50/60Hz)
0.6/0.72A
(50/60Hz)
0.6A
(50Hz)
Speed
1290/1560rpm
(50/60Hz)
1260/1580rpm
(50/60Hz)
1310/1610rpm
(50/60Hz)
1275/1570rpm
(50/60Hz)
1270rpm
(50Hz)
Inlet and outlet piping
O.D.Φ9 ×I.D.Φ6(G1/4)
Weight
7.0kg
Air temperature
0～40℃
Dimensions
(W refers to the distance
to the tip of the intake or
exhaust pipe)
125mm(W) ×247mm(L) ×184mm(H)
Over Voltage Category
Ⅱ
Pollution Degree
２

3
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 a pump fault which prevents rotation, or if load becomes
excessive.
2) It is recommended that additional protective devices (eg. earth leakage breaker, motor
breaker) be fitted.
See Warning (8), P04
See Caution (5), P05
2.Dimensions
Top (width 142mm)
Front (length 272mm) Front (height 202mm)
Fig.2.1 DTC-22
Top (width 125mm)
Front (length 247mm) Front (height184mm)
Fig.2.2 DTC-22K
!
Warning
!
Caution

4
3.Installation and Storage
3.1 Cautions for Installation and Storage
See Warning
(1)(2)(3)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14), P04
See Caution (1)(2)(3), P05
See Note (1)(2) , P06
(7), P07
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 during assembly of pump.
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 Checking Operation After Installation
1) Remove the rubber caps from the inlet and outlet.
2) Check that the pump switch is OFF (set to O), and insert the plug into the 100 V wall socket.
Note:Ensure that the power plug is sufficient for the rated voltage and current.
Note:Extension cords should be 3-wire, with lead wires having a cross-sectional area of at
least 0.75 mm2.
3) Please intercept the power supply and connect it, except when the power strip is a plug.
4) Turn the switch ON (set to l) and check that gas is being drawn into the inlet.
5) When this check is complete, turn the power switch OFF (set to O) to stop the pump.
!
Warning
!
Caution
!
Note

5
3.5 Piping
1) Install piping carefully to prevent leaks.
2) Piping connected to the inlet should be at least 6 mm inside diameter.
3) Use rubber hoses, etc. to ensure that pump vibrations do not reach between the pump and
piping, otherwise the pump or piping may be damaged.
4) Ensure that piping connected to the outlet does not cause back pressure. Maximum back
pressure is 0.03 MPa (gauge pressure).
5) 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.
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.
7) When evacuating a vessel, ensure that a shut-off valve is placed between the pump inlet pipe
and the vessel (see Fig.3.1).
Fig.3.1 Example of Piping Used When Evacuating a Vessel
3.6 Storage
Turn the switch OFF (set to O), remove the power plug from the outlet, place the rubber caps
over the inlet and outlet, and store the pump in an area of low humidity.
4.Cautions for Operation
4.1 Cautions for Operation
See Danger (1)(2),P04
See Warning (8),P04
(15)(16)(17), P05
See Caution (4)(5)(6)(7)(8), P05
See Note (3)(4)(5),P06
(6)(7)(8)(9)(10)(11)(12), P07
1) To maintain the performance of the pump, always ensure that it is cleaned internally after use.
Clean by ingesting clean air for 3~5 minutes under no-load conditions.
2) Consult the manufacturer if the pump is to be used in a special application.
4.2 Operation of the Thermal Protection Relay
1) When the thermal protection relay operates, switch the pump power supply OFF (set to O),
remove the power cord from the outlet, and contact the manufacturer. Note that the pump will
be very hot and should not be touched.
Vacuum pump
Filter
Leak valve
Shut-off valve
Vessel
!
Caution
!
Note
!
Warning
!
Danger

6
2) The pump operates automatically when temperature drops. Shut-off the power supply, and
determine the cause of operation of the thermal protection relay.
3) Once the cause of the fault has been removed, wait until the motor cools and restart
operation.
See Caution (6), P05
4.3 Precautions when starting
1) Starting in cold weather
Cold weather will increase the viscosity of bearing grease and harden diaphragms, resulting in
the pump being difficult to start. Follow the procedure below in such conditions.
a) Turn the switch ON/OFF 2~3 times with the inlet open to atmosphere until the pump starts. If
the pump still does not start, raise the ambient temperature to beyond 0°C.
b) With the inlet open to atmosphere, run the pump for a few minutes to warm it.
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.3.1 for a piping example using a shut-off valve.
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 (ie 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 maximum rate of evacuation is reached when air is introduced, and decreases slightly 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 ~4 x 104Pa. At
pressures below this range the compression work is considerably reduced and power is
expended in mechanical work.
!
Caution

7
6.Maintenance, Inspection, and Repair
6.1. Cautions for Maintenance, Inspection, and Repair
See Danger (3), P04
See Warning (4),P04
(17)(18), P05
See Caution (9)(10)(11), P06
See Note (12), P07
Maintenance and repair by the customer’s repair technician is limited to the following procedures.
Do not undertake other repairs, or make modifications other than the standard options supplied
by the manufacturer.
1) Replacing diaphragms
2) Replacing inlet and outlet valves
3) Replacing O rings
6.2 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 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 Replacement and Cleaning Guide on the following page. Refer to 6.4
Replacing and Cleaning Consumables for procedures.
Request replacement by the manufacturer’s service division if a repair technician is not available.
Table 6.1 Consumables List
Components
Quantity
Material
Average life
Diaphragms
2
Synthetic rubber (EPDM)
In contact with gas: PTFE
6,000hr
Inlet and outlet valves A
2
Perfluoropolyetherrubber
6,000hr
Inlet and outlet valves B
2
Perfluoropolyetherrubber
6,000hr
Valves holder
2
PTFE
6,000hr
O rings (P-10A)
2
Fluorine rubber (FPM)
6,000hr
O rings (S-24)
4
Fluorine rubber (FPM)
6,000hr
O rings (AS568-110)
4
Fluorine rubber (FPM)
6,000hr
Bearings
1 set
―――
15,000hr
Note that the average life for a component varies with the conditions of use.
Always follow 4.1 Cautions for Operation, and remember that life is extended by running the
pump at minimal load (running the pump at minimal load is operation at the achieved pressure
(inlet closed)).
Bearings are replaced by the manufacturer’s service division.
!
Danger
!
Warning
!
Caution
!
Note

8
<Replacement Guide>
Replace or clean components if performance is reduced or the following symptoms become
apparent. Table 6.2 Locations for Maintenance and Inspection
Period of
operation
Inspection item
Replacement guidelines
Method of
inspection
3000 hours
Diaphragms
Wear of PTFE components,
deformation, hardening, or
cracking of rubber components
Visual
inspection
Inlet and outlet valves
Valves holder
Deformed, hard, or cracked
Visual
inspection
O rings
Hard, cracked, or stretched
Visual
inspection
Bearings
Abnormal noises
Listen
6.4 Replacing and Cleaning Consumables
See Caution (11), P06
Always use a mask and gloves when replacing components to prevent ingestion of microscopic
particles resulting from wear of components.
Use the following tools, and refer to the photographs, when replacing cleaning components.
Contact the manufacturer’s service division for this work if the necessary tools are not available.
1) Phillips screwdriver : No.2
2) Hex socket wrench : (1)3mm (2) 5mm
3) Torque wrench : 5mm hexagonal socket, set to 11 N.m torque
4）Phillips Torque screwdriver : Set to 0-4 N.m torque.
5) Spanners : 14mm or equivalent adjustable spanner
6) Vacuum grease : For replacing O rings.
7) Solvent : Use a solvent such as ethyl alcohol which has no effect on
rubber components.
8) Paper towels etc
!
Caution

9
1) Replacing Diaphragms
(It is recommended that both diaphragms be replaced simultaneously.)
Caution! Where gloves when attaching or removing the diaphragms.
There is a danger of injuries. Use toolsNo.1,2,3,4,5,6､7 and8 listed above
1) -1. DTC-22
Photo 1 Photo 2 Photo 3
Photo 4 Photo 5
(1) Remove the inlet and outlet pipes, and lay the pump on a soft cloth. See Photo 1.
(2) Remove the six truss screws (M4x10) in the base of the pump, and remove the front
panel (white). See Photo 2.
(3) Stand the pump up, remove the four truss screws (M4x10), and remove the top panel.
See Photo 3.
(4) Remove the eight hex socket head bolts (M6x25), and remove the pump head as
shown in Photo 4.
Note: Gripping or bending the connecting tube will damage it and reduce
performance of the pump.
Note: After removing the pump head, lay it on a soft cloth.
Note: There is a thing that the pump head spacer has been inserted under the pump
head. ( Photo 6 and 7) After Diaphragms is exchanged, the pump head spacer is
installed in the same part. Identify it so as not to confuse it.
Note: It marks the pump head spacer. Marking is used to identify the thickness, and
there are each red, blue, and a black. Note that it influences the performance
when making a mistake as former position.
Photo 6 Photo 7
Pump head spacer
Inlet or outlet pipe
Truss head screw
(M4x10)
Hex socket head bolt
(M6x25)
Top panel
Truss head
screw
(M4x10)
Slide backwards
Cross recessed Pan Head
Screw (M4x16)
Valve retainer
Tube
Marking

10
(5) Withdraw the connecting tube from the valve retainer, and disassemble the left and right
pump heads. See Photo 5.
Photo 8 Photo 9 Photo 10
(6) When one diaphragm is pushed downwards (to bottom dead center), the other
diaphragm rises (to top dead center). It is then possible to grip the edge of the
diaphragm. See Photo 8.
(7) While holding the edge of the diaphragm, turn it in the anti-clockwise direction and
remove it. See Photo9. Remove the other diaphragm in the same way.
Note: Use two persons to grip the diaphragm if it is difficult to remove.
Note: A spacer (washer) is inserted between the diaphragm and connecting rod. Ensure
that this spacer does not fall into the pump. See Photo10.
Note: The connecting rod may drop into the pump.
After removing the diaphragm, insert a hex head bolt (M6x25) into the tapped
portion of the connecting rod to hold the pump head cover in place.
(8) Clean the tapped portion of the connecting rod by wiping with a cloth impregnated with
solvent.
(9) Apply a small amount of vacuum
grease to the threads on the new
diaphragm, and to the spacer, and
screw it onto the connecting rod
clockwise. See Photo 11.
Note: Check that the spacer（see
Photo 10）removed in (7) is returned
to its original position.
Photo11
Note: To prevent wrinkles in the PTFE sheet, hold the diaphragm and fit it firmly as
shown in Photo 11
(10) Fit the other diaphragm in the same way.
Photo 12 Photo 13
(11) Apply a small amount of vacuum grease over a distance of 5mm at both ends of the
connecting tube, and place the tube fully over the nipples to connect the two pump head
covers. See Photo 12.
(12) Place the connected pump heads over the casing, and bolt in place with hex socket
head bolts (M6x25).
Note: Ensure that the pump heads are in the correct orientation. See Photo 13.
Diaphragm
Bottom dead center
Top dead
center
×
Bad
Edges up
○
Good
Almost flat
Spacer
Connecting rod
Hex socket head
bolts
(M6x25)
Fan
Switch