Ulvac GCD-051X User manual

No.17700-2-01-14
Instruction Manual
for
Direct-Drive Oil Sealed Rotary Vacuum Pump
Model
GCD-051X
GCD-136X
GCD-201X
Before using the product, be sure to read this manual.
Keep this manual in a place where it can be referred to at any time
and look after it carefully.
The contents of this instruction manual are subject to change
without prior notice due to improvements in performance and the
functions of the product.
ULVAC KIKO,Inc.

- 01 -
0. Introduction
0.1 Before using the vacuum pump
Thank you for purchasing our vacuum pump (hereinafter called “pump”). When you have received
the pump, check that the delivered pump is as per your order and that it has not been damaged in
transportation, etc.
In order to use the pump for as long as possible, read this instruction manual
thoroughly before performing installation, operation, inspection and
maintenance, and sufficiently understand the cautions for safety, the
specifications and operation methods of the pump.
No part of this instruction manual may be copied for use by a third party
without our permission.
Warning
Note

- 02 -
0.2 Safety symbols
In this instruction manual and on warning labels attached to the pump, the following symbols
are used so that matters which must be strictly adhered to can be readily understood.
These symbols are divided as shown below.
When mishandled, there is an imminent danger of the operator suffering a fatal
accident or serious injury.
When mishandled, there is a possibility of the operator suffering a fatal
accident or serious injury.
When mishandled, there is a possibility of the operator suffering an injury
(light or medium injury) or of damage occurring to property.
When mishandled, there is a possibility of the pump being damaged or
malfunctioning.
Caution
Note
Warning
Danger

- 03 -
0.3 Cautions for safety
When toxic or flammable gases are exhausted from the pump, they m a y l e a k n o t
only from the pump outlet but also from the pump unit itself. Take proper
measures suitable for the type of gas.
After the pump has been used for exhausting toxic gasses, not only the pump
itself but also vacuum pump oil (hereinafter called “pump oil”) get toxic.
Keep this in mind when performing the maintenance.
Never allow people other than repair engineers to disassemble or repair the
pump. Failure to do so may result in ignition or malfunction, leading to injury
or electric shock.
Before performing inspection or repair, always turn off the power switch.
Failure to do so may result in electric shock or the unexpected start of the
pump, leading to injury.
Connect the earth wire correctly. It is recommended that a dedicated earth
leakage breaker should be installed. If the earth wire is not connected, there
is a possibility of electric shock occurring in the case of a malfunction
or electrical leakage.
There is a risk of explosion. Never block the outlet or operate the pump with
equipment mounted at the outlet side which blocks the passage of gas.
Otherwise, the internal pump pressure increases causing the pump to explode,
the oil level gauge to protrude or the motor to be overloaded.
This pump is not resistant to pressure. The internal pump pressure is limited
to 0.03 MPa (gauge pressure).
Warning
Danger
Danger
Warning
Warning
Warning

- 04 -
Do not use the pump in an explosive atmosphere. Failure to do so will result
in injury or fire.
Mount vacuum valve and leak valve between the vacuum chamber and pump.
To stop the pump, always close vacuum valve and then open leak valve. If this
procedure is neglected, the pump oil fills the cylinder, making restart
difficult or causing damage to the pump. The pump oil also may flow back to
the vacuum chamber side.
Do not insert fingers or objects into the opening of the motor. Doing so may
result in electric shock, injury, or fire.
Never touch the rotating section of the motor, shaft or coupling while the
pump is in operation. Failure to do so will result in injury.
Never place combustible materials around the motor or pump. There is a risk
of fire.
Also, do not place objects which block ventilation around the motor. Abnormal
heat generation may result in burns or fire.
Do not touch the motor while the pump is in operation or when the pump is
still hot immediately after it stops. Touching it will result in burns.
Arrange wires correctly in accordance with the “Electrical Equipment
Technical Standard” and “Wiring Regulations.” Incorrect wiring may result
in fire.
If the pump ceases operation or malfunctions, turn off the power switch
immediately to prevent acidents, and ask the company from which you purchased
the pump or the manufacturer for inspection and repair.
Caution
Warning
Caution
Caution
Caution
Caution
Caution
Warning

- 05 -
Fluoride rubber material is used for the internal parts of a pump.
There are some for which the chemical resistance of Fluoride rubber material
is not suitable.
Especially, be careful of the following chemical.
Ammonia, Acetone, Ethylene oxide, Ethylene diamine, Zinc acetate,
Amyl acetate, Aluminum acetate, Isopropyl acetate, Ethyl acetate,
Lead acetate, Calcium acetate, Cellosolve Acetate, Nickel acetate,
Butyl acetate, Propyl acetate, Methyl acetate, Nitroethane, Nitropropane,
Nitromethane, Freon
Do not operate the pump without adding pump oil. If it is operated in an
oil-less condition, the pump will be damaged.
Note
Caution

- 06 -
0.4 Acceptance and storage of the pump
0.4.1 Acceptance of the pump
Although the pump is delivered with great care, check the following after unpacking.
①The delivered pump is in accordance with your request.
②The specified accessories (enough pump oil to use the pump once; optional equipment) have
been provided.
③No parts have been damaged in transportation.
④Neither screws nor nuts have become loose nor were lost in transportation.
If there are any problems, contact the company from which you purchased the pump or the sales
department of the manufacturer.
0.4.2 Environmental conditions for storage, installation and operation
Since this pump is precisely engineered, ensure that the following conditions be satisfied during
storage, installation and operation.
①Ambient temperature, relative humidity: 7℃~ 40℃, 85% RH or less
②Height above sea level during storage and installation: 1,000 m or less
③Other conditions for storage and operation
a) Free from corrosive and explosive gases
b) No condensation
c) Dust-free environment
d) Indoors
e) Do not place pumps on top of each other or place a pump on its side.
f) Not subject to direct sunlight
g) Far from heat sources
Do not subject the pump to shocks or place the pump on its side. Doing so
may damage the pump.
0.5 Protective device
The pump is provided with a single-phase 100V 50/60Hz (GCD-051X, 136X), three-phase
200V 50/60Hz (GCD-201X) motor.
An overload protector (manually reset thermal protector) is incorporated.
The use of another protective device (such as an earth leakage breaker) in addition to the
overload protector is recommended.
Use the pump only at the rated voltage. Use at other than the rated voltage
will interfere with correct operation of the overload protector, and result
in the motor burning out, or fire.
Note
Note

Contents - 1
Contents
0. Introduction ·························· 01
0.1 Before using the vacuum pump ·························· 01
0.2 Safety symbols ·························· 02
0.3 Cautions for safety ·························· 03
0.4 Acceptance and storage of the pump ·························· 06
0.4.1 Acceptance of the pump ·························· 06
0.4.2 Environmental conditions for storage, installation and operation ·· 06
0.5 Protective device ·························· 06
1. For Safe Operation ·························· 1
1.1 Hazards peculiar to the pump and safety measures ······················· 1
1.1.1 Danger Leakage of hazardous gases and substances ············ 1
1.1.2 Warning Electric shock ·························· 1
1.1.3 Warning Explosion ·························· 2
1.1.4 Caution High temperature ·························· 2
1.2 Safety Data Sheet (SDS) ·························· 2
2. Outline of the Pump ·························· 3
2.1 Specification ·························· 3
2.2 Dimensional drawing ·························· 4
3. Installation ·························· 7
3.1 Installation ·························· 7
3.2 Lubrication ·························· 7
3.3 Vacuum piping ·························· 9
3.4 Electric wiring ·························· 10
3.4.1 GCD-051X･136X（in the case of GCD-201X single phase motor specification） ····· 10
3.4.2 GCD-201X（in the case of GCD-136X three phase motor specification）··········· 10
3.5 Fluctuation in the power voltage and frequency ························· 11
4. Operation ·························· 13
4.1 Cautions for operation ·························· 13
4.2 Start of operation ·························· 14
4.3 Stopping the operation ·························· 14
4.4 Operation in cold climates ·························· 15
4.5 Backflow preventer ·························· 15
4.6 Thermal protector ·························· 15
4.7 Gas ballast valve ·························· 16
4.8 Installation of the oil mist separators (Option) ······················ 17
4.9 Restriction on operation when the oil mist separators is installed ···· 17

Contents - 2
5. Pump Performance ·························· 18
5.1 Ultimate pressure ·························· 18
5.2 Pumping speed ·························· 18
5.3 Power requirement ·························· 18
6. Maintenance, Inspection and Repair ·························· 20
6.1 Maintenance ·························· 20
6.2 Periodic inspection ·························· 20
6.3 Replacement of the pump oil ·························· 22
6.4 Replacement of the coupling spider ·························· 24
6.5 Trouble check list ·························· 25
7. Disposal ·························· 27
8. Maintenance prats ·························· 28
8.1 Maintenance parts list ·························· 28
8.2 Disassembly drawing ·························· 31
Warranty
Safety Data Sheet (SDS)
Usage Status Check Sheet (for use in Instruction Manual)
Contact address of sales and service departments

Contents - 3
Figures and Tables
Fig. 1 Dimensional drawing of GCD-051X oil sealed rotary vacuum pump ········ 4
Fig. 2 Dimensional drawing of GCD-136X oil sealed rotary vacuum pump ········ 5
Fig. 3 Dimensional drawing of GCD-201X oil sealed rotary vacuum pump ········ 6
Fig. 4 Lubrication of the oil sealed rotary vacuum pump ······················ 8
Fig. 5 Basic piping diagram to the vacuum chamber ·························· 9
Fig. 6 Electric wiring diagram ·························· 10
Fig. 7 Change region of the voltage and frequency ·························· 11
Fig. 8 Pumping speed curve ·························· 19
Fig. 9 Replacement of the coupling spider ·························· 24
Fig. 10 Disassembly drawing of GCD-051X oil sealed rotary vacuum pump ········ 31
Fig. 11 Disassembly drawing of GCD-136X oil sealed rotary vacuum pump ········ 32
Fig. 12 Disassembly drawing of GCD-201X oil sealed rotary vacuum pump ········ 33
Table 1 Specification ·························· 3
Table 2 Electric capacity of motor fault load protection equipment ············ 10
Table 3 Characteristics of the thermal protector ·························· 15
Table 4 Periodic inspection table ·························· 21
Table 5 Trouble check list ·························· 25
Table 6 GCD-051X Maintenance parts list ·························· 28
Table 7 GCD-136X Maintenance parts list ·························· 29
Table 8 GCD-201X Maintenance parts list ·························· 30
Attached table: Safety Data Sheet (SDS)

-1-
1. For Safe Operation
1.1 Hazards peculiar to the pump and safety measures
Before operating or inspecting the pump, read this section carefully to fully understand potential
hazards and prevention methods.
1.1.1 Danger Leakage of hazardous gases and substances
Cause Prevention method and measures
Leakage of toxic and
flammable gases
⇒Dilute hazardous gases to a safe concentration before they
enter the pump inlet.
Injury due to touching toxic
pump oil in the pump or
harmful substances attached
to the pump during
inspection or disposal
⇒ ① Wear protective equipment suitable for toxic substances
when carrying out inspection.
②Before overhauling and disposing of the pump, ask a
waste disposal specialist to make it safe.
③Ask an authorized waste disposal specialist to carry out
disposal.
1.1.2 Warning Electric shock
Cause Prevention method and measures
The energized part of the
motor was touched.
⇒ ① When connecting electric wires, always turn off the
power and be sure to connect the earth wire.
②When inspecting and transferring the pump, always turn
off the power.
③Never insert hands, fingers, or thin objects through the
motor opening.

-2-
1.1.3 Warning Explosion
Cause Prevention method and measures
The pressure in the pump
increased causing the pump
to explode.
⇒The maximum internal pump pressure is 0.03 MPa (gauge
pressure).
Measure the pressure at the outlet side and, if the pressure
is 0.03 MPa or more (gauge pressure), remove objects
which block the passage of gas from the outlet side. When
an oil mist trap is adopted, replace or clean it so that it will
not block the passage of gas.
1.1.4 Caution High temperature
Cause Prevention method and measures
High temperatures caused
burns.
⇒ ① The pump reaches a high temperature during operation.
pump body →50 ～80 ℃
motor →40 ～80 ℃
②Since the surface temperature is hot, touching the
surface accidentally may result in burns. Never touch
the pump during operation. When carrying out
inspection, wait until the pump has cooled down
completely after it stops.
1.2 Safety data sheet (SDS)
The attached “Safety Data Sheet (SDS)” shows chemical materials which may be used or
touched when operating the pump. Read the SDS carefully in order to understand the harmful
properties of these materials.
Contact us before using chemical materials (vacuum pump oil) other than those mentioned in
this instruction manual.
The SDS is provided as reference information for safe use of dangerous and toxic
chemicals. Persons handling pump oil are, on their own responsibility, required
to implement the necessary safety measures in use. The SDS is therefore not to
be considered as a guarantee of safety.
Caution

-3-
2. Outline of the Pump
2.1 Specification
This oil sealed rotary vacuum pump is a rotary vane pump (hereinafter called Gaede type pump)
in which the pump is directly driven by the motor. Since the pump is small, light, and quite
simply constructed, it is easily maintained and repaired.
Table 1 Specification
GCD-051X GCD-136X GCD-201X
50Hz 60Hz 50Hz 60Hz 50Hz 60Hz
Model Rotary vane (2 vanes)
Pumping speed
(L/min) 50 60 135 162 200 240
G.V. close 6.7×10-1
Ultimate
pressure (Pa) G.V. Open 6.7
V 100 100/110 100 100/110 100 100
1-phase W(Pole) 200(4) 400(4) 550(4)
V 200 200/220 200 200/220
Motor 3-phase W(Pole) 400(4) 700(4)
1-phase 5.6(100V)
4.8(100V)
5.1(110V) 5.6(100V) 5.4(100V)
5.1(110V) 7.5(100V) 7.2(100V)
7.0(110V)
Full-load
current (A) 3-phase 1.9(200V) 1.8(200V)
1.7(220V) 3.5(200V) 3.0(200V)
2.9(220V)
1-phase 1,440(100V)
1,730(100V)
1,740(110V) 1,425(100V) 1,715(100V)
1,725(110V) 1,420(100V) 1,715(100V)
1,725(110V)
Revolution
(r/min) 3-phase 1,440(200V) 1,730(200V)
1,740(220V) 1,430(200V) 1,705(200V)
1,730(220V)
Standard
oil SO-M
Oil Oil amount
(mL) 500～800 1,000 1,100
Note 1: The ultimate pressure values in the above table are indicated by a Pirani gauge.
Note 2: Vacuum pump oils have different steam pressures, viscosities, and oil properties depending
on the type. Always use the oil sealed rotary vacuum pump oil specified by us. The use of
other oils will affect the pump’s performance.
Specified oil: SO-M
Note 3: “G.V.” is an abbreviation for gas ballast valve.

-4-
2.2 Dimensional drawing
Motor ; Single phase, 100V 50/60Hz,110V 60Hz, 200W, 4Poles
Weight ; 14.1kg
Fig. 1 Dimensional drawing of GCD-051X oil sealed rotary vacuum pump

-5-
Motor ; Single phase, 100V 50/60Hz,110V 60Hz 400W, 4Poles,
capacitor start and run
Weight ; 25.4kg
Motor ; three phase, 200V 50/60Hz,220V 60Hz, 400W, 4Poles
Weight ; 22.8kg
Fig. 2 Dimensional drawing of GCD-136X oil sealed rotary vacuum pump

-6-
Motor ; Single phase, 100V 50/60Hz,110V 60Hz 550W, 4Poles,
capacitor start and run
Weight ; 29.4kg
Motor ; three phase, 200V 50/60Hz,220V 60Hz, 700W, 4Poles
Weight ; 27.0kg
Fig. 3 Dimensional drawing of GCD-201X oil sealed rotary vacuum pump

-7-
3. Installation
3.1 Installation
The pump should be installed on a level surface in a location with minimal dust, dirt and
humidity and be arranged with consideration given to ease of installation, removal, inspection
and cleaning.
Particular attention should be paid to the ambient temperature when building the pump into
equipment. Use a rubber vibration isolator to separate the pump from other equipment and to
isolate the pump from the vibrations of other equipment. See “0.4.2 Environmental conditions
for installation, storage and operation” for details.
If the pump is operated whilst it is tilted, placed on its side or upside-down,
the pump will be damaged. Install the pump level with the inlet facing up
as shown in Fig. 1,2,3.
3.2 Lubrication
Remove the lubrication plug from the lubrication port, and add the pump oil which has been
delivered together with the pump or the pump oil specified by us (SO-M) up to the range
marked with the line on the oil level gauge. When making the first lubrication, add oil near to
the upper oil level limit shown on the oil level gauge. After lubrication, mount the lubrication
plug to the pump (see Fig. 4).
Always keep the oil level of the pump within the oil limit range shown on the oil level gauge
during operation. If the amount of oil is incorrect, the performance of the pump will deteriorate
resulting in the malfunctioning of the pump. When the amount of oil has reduced and the oil
level has reached an area below the lower line which shows the lower limit on the oil level
gauge such that the level cannot be seen, the ultimate pressure increases and exhausting sound
may not cease.
Note

-8-
(1) Oil level shown on the oil level gauge (2) Lubrication method
Fig. 4 Lubrication of the oil sealed rotary vacuum pump
① Wear protective equipment such as rubber gloves and safety goggles.
② Be sure to read the attached “Safety Data Sheet” before adding oil. If the oil
accidentally comes into contact with your hands or enters your eyes, take proper
measures in accordance with the section “First-aid treatment” shown in “Safety
Data Sheet.”
Use only oils specified by us. If other oils are used, the pump performance will
deteriorate or its life will be shortened.
Caution
Note

-9-
3.3 Vacuum piping
(1) Before connecting the pipe to the pump, clean the inner walls of the vacuum chamber,
piping and vacuum valve to completely eliminate moisture, fine particles, dust, dirt and rust.
If fine particles, dust or dirt, etc are evacuated, the pump may malfunction.
If moisture is evacuated, not only does the ultimate pressure increase but
also the inside of the pump becomes rusty causing the pump to malfunction.
(2) Mount vacuum valve (A) and leak valve (B) between the vacuum chamber and pump as
shown in Fig. 5.
Fig. 5 Basic piping diagram to the vacuum chamber
(3) Use a KF-25 (NW-25) flange for the connection to the inlet pipe.
The wire mesh in the inlet pipe has been adopted to prevent foreign matter
from entering the pump. Do not remove the wire mesh.
Mount vacuum valve (A) and leak valve (B) between the vacuum chamber and
pump
To stop the pump, always close vacuum valve (A) and then open leak valve
(B). If this procedure is neglected, the pump oil fills the cylinder,
making restart difficult or causing damage to the pump. The pump oil also
may flow back to the vacuum chamber side.
Note
Vacuum chamber
Vacuum valve
(A)
Leak valve (B)
Pump
Note
Warning
(see Fig.5).

-10-
3.4 Electric wiring
3.4.1 GCD-051X･136X（in the case of GCD-201X single phase motor specification）
(1) This pump has performed beforehand electric wiring by the side of a pump.
(2) Please insert the plug of the power cord of a pump in the wall socket of single phase 100V.
(3) Fault load protection equipment (manual return type thermal protector) is built in this motor.
3.4.2 GCD-201X（in the case of GCD-136X three phase motor specification）
(1) The rotation direction of this pump is seen from the pump front (level gauge side), and is a
clockwise rotation.
(2) If it wiring like fig.6, the rotation direction of a pump will be seen from the pump front
(level gauge side), and will be rotated clockwise. When you rotate in the opposite direction,
please shut off a power supply immediately, replace wiring connected to U and W, and
check rotating in the right direction anew.
(3) Fault load protection equipment (manual return type thermal protector) is built in this motor.
(4) When you form fault load protection equipment in the exterior of a 3-phase motor, please
refer to table 2.
A motor side grounding terminal is the screw with a display of "E" of the main part rear of
a motor.
AC 200V 50Hz/60Hz Ground E
3-phase Power supply R W
AC220V60Hz S VPump・Motor
3-phase Power supply T U
Fig. 6 Electric wiring diagram
Table 2 Electric capacity of motor fault load protection equipment
Thermal relay(A)
Model (W) 200V,50Hz 200V,60Hz 220V,60Hz
Motor breaker
(A)
GCD-136X 400 1.9 1.8 1.7 1.9
GCD-201X 700 3.5 3.0 2.9 3.5