vacuubrand VAC 24seven User manual

Instructions for use
Original instructions N°: 999296_EN
Installation Description
Installation &
Commissioning

Imprint
Original instructions
Keep for further use!
This manual is only to be used and distributed in its complete and original form. It is strictly the
users’ responsibility to check carefully the validity of this manual with respect to his product.
Thank you for purchasing this product from VACUUBRAND GMBH + CO KG.
You have chosen a modern and technically high quality product.
2 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
Manufacturer:
VACUUBRAND GMBH + CO KG
Alfred‑Zippe‑Str. 4
97877 Wertheim
GERMANY
Phone:
Head office: [phone]‑0
Sales: [phone]‑5550
Service: [phone]‑5660
Fax: [phone]‑5555
E‑Mail: [email protected]
Web: www.vacuubrand‑process.com

Content
3N°: 999296_EN_VAC_24seven_Assembly/06.04.17
1 About this document 5
1.1 User information ........................................... 5
1.1.1 Installation and assembly ............................... 5
1.1.2 General information ................................... 5
1.2 Safety.................................................... 6
1.2.1 Personnelqualication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 VACUUBRAND Service department ...................... 6
1.2.3 Personnel provision – operator side ....................... 6
1.3 Symbols and icons.......................................... 7
1.4 Abbreviations .............................................. 7
2 Goods arrival 9
2.1 Included materials .......................................... 9
2.2 In‑house transport .......................................... 9
2.3 Lifting gear ............................................... 10
3 Preparations at installation site 11
3.1 Preparing measures........................................ 11
3.1.1 Check installation site ................................. 11
3.1.2 Installation site requirements ........................... 11
3.2 Prepare connections ....................................... 13
3.2.1 Mechanical connections ............................... 13
3.2.2 Electrical connection.................................. 15
3.3 Recommended accessories at hand ........................... 17
4 Installation and Commissioning 19
4.1 Conditions ............................................... 19
4.1.1 Provide personnel resources ........................... 19
4.1.2 Supply working and transport equipment .................. 19
4.1.3 Ready for connection ................................. 19
4.2 Required tools ............................................ 20
4.3 Installing vacuum pumping unit ............................... 21
4.3.1 Place and install the pump module....................... 21
4.3.2 Place and position the control module .................... 27
4.3.3 Cable assignment – Pump module....................... 28
4.4 Connect vacuum pumping unit ............................... 29
4.4.1 Electrical connection (power supply) ..................... 30
4.4.2 Electrical connection of peripherals ...................... 32
4.5 Gas ballast connection ..................................... 35
4.5.1 Gas ballast pump module(s) ............................ 35
4.5.2 Ambient air for gas ballast ............................. 35
4.5.3 Inert gas for gas ballast (option) . . . . . . . . . . . . . . . . . . . . . . . . . 36
TABLE OF CONTENT

Content
4 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
4.6 Final jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6.1 Install cover......................................... 37
4.6.2 Protective earthing ................................... 38
4.6.3 Install interconnection set (Option) . . . . . . . . . . . . . . . . . . . . . . . 39
4.6.4 Vacuum and exhaust connection ........................ 40
4.6.5 Vacuum sensor connection ............................ 42
4.7 Functional check .......................................... 42
5 Decommissioning 43
5.1 Temporary shutdown ....................................... 43
5.2 Storage ................................................. 44
6 Appendix 47
6.1 Technical information....................................... 47
6.2 Index ................................................... 49

About this document
5N°: 999296_EN_VAC_24seven_Assembly/06.04.17
1 About this document
This description is part of a modularly structured operating manual
groupedinaleverarchle.
The instruction section named VAC 24seven_Assembly is intended for
skilled personnel and therefore only available in German and English.
1.1 User information
1.1.1 Installation and assembly
Inthissectionofthemanual,youwillnddescriptionsfortheassembly,
installation, start‑up and shut‑down of the vacuum pumping unit.
Instruction section Content
VAC 24seven_Assembly Assembly, installation, start‑up,
storage, shut‑down
Vacuum pumping system
VAC 24seven
Read this manual thoroughly and completely before using the product.
Observe the safety instructions in the manual part system description
VAC 24seven_System.
Observe the complementary safety instructions and warnings in this
manual.
1.1.2 General information
The illustrations in this manual are provided as examples.
VACUUBRAND GMBH + CO KG reserves the right to modify or
changetheproductdesignand/ortechnicalspecicationsatanytime
without prior notice.
General information
Instruction sections
(= manual parts)
User information

About this document
6 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
1.2 Safety
1.2.1 Personnel qualication
This instruction section is intended for skilled personnel.
Theelectricalconnectionmayonlybecarriedoutbyqualiedelectri‑
cians.
1.2.2 VACUUBRAND Service department
In addition to the jobs that can be performed by the local staff, there are
tasks that must performed by VACUUBRAND service only.
Jobs of the VACUUBRAND Service department
Task (Job)
VACUUBRAND
Service depart-
ment
Personnel
(local staff) at
operator side
Installation X-
Start‑up X-
Function check and pilot run X-
Instructing operating personnel X-
Expanding pump module XX
Repair (overhaul) XX
Decommissioning XX
Location change XX
VACUUBRAND-Service receives from the operator the right to stay in
the entire machine environment for the duration of their activities.
For heavy works a suitable lifting gear has to be provided.
1.2.3 Personnel provision – operator side
The customer (operator) has to provide the following specialists for the
VACUUBRAND-Service:
Electrician
Mechanician
Crane and lifting gear operator
Network administrator (option)
IMPORTANT!
Personnelqualication
Jobs carried out by
VACUUBRAND service
Skilled personnel
on operator side

About this document
7N°: 999296_EN_VAC_24seven_Assembly/06.04.17
1.3 Symbols and icons
Symbols and icons are intended to aid in your understanding of the
proper use of the product.
Symbols and icons explanation
Positive example – Do!
Result – o. k.
Negative example –
Do not!
Refers to content in
this manual.
Refers to content of
other supplementary docu‑
ments.
general
mandatory sign.
 For further, detailed information about symbols and
icons, and display conventions read system description
VAC 24seven_System.
1.4 Abbreviations
Alu Aluminium
approx. approximately
awg american wire gauge,
US code for wire diameter
DN Nominal diameter
EX* Exhaust (= outlet)
Gr. Size (tool)
IN* Inlet
KF Smallange
Max. Maximum value
Min Minimum value
SW Wrench size (tool)
* Adhesive labeling on the rear side of the pump module
Icon description
Abbreviations

About this document
8 N°: 999296_EN_VAC_24seven_Assembly/06.04.17

Goods arrival
9N°: 999296_EN_VAC_24seven_Assembly/06.04.17
2 Goods arrival
2.1 Included materials
The included materials are listed in the delivery note. Check its com‑
pleteness when receiving.
Please check the delivery for completeness and damages immediately
after receipt.
Please report any missing or damaged item
immediately to our Service department.
Notify the responsible shipping company immediately if you discover any
damage to the packaging.
Please claim transport damages in written form, if possible proved
by conclusive photographs.
Proper disposal of the packaging
Comply with safety directives and with local regulations for disposal,
when disposing of the packaging.
2.2 In‑house transport
The vacuum pumping unit is delivered in individual modules. As long as
the delivery is palletized, industrial trucks can be used for in‑house trans‑
port.
When changing the installation location, make sure that the transport
safetydevicesinsideallpumpmodulesarexedcorrectly.
Without pallet, a pump module may only be lifted and transported by a
suitiable load bearing lifting gear using the eye screw set.
Do!
Pallet truck with pallet
Do not!
Pallet truck without pallet
IMPORTANT!
Correct transport
(do‑and‑don't)
Check delivery

Goods arrival
10 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
2.3 Lifting gear
In order to avoid damage during assembly, the lifting devices have to be
installed correctly on the machine.
NOTICE
Damage due to improper lifting.
 Place the hoisting slings for a preferably vertical load lift.
 Avoid shear forces on the eye screws;
max. permissable shear only higher than > 45°.
 Usehoistingslingswithsufcientloadcarryingcapacityofup
to 350 kg (772 lb) per hoisting sling.
< 45°
Do!
Correctly placed hoist
Do not!
Incorrectly placed hoist
Weight specication
Number Type Weight
(kg) (lb)
1x Pump module 106 234
2x Pump module 212 467
3x Pump module 318 701
1x Control module 15,6 kg 34
How to lift correctly
(do‑and‑don't)
Weightspecication

Preparations at installation site
11N°: 999296_EN_VAC_24seven_Assembly/06.04.17
3 Preparations at installation site
3.1 Preparing measures
For installation by VACUUBRAND service, the operator has to prepare
the following in advance:
3.1.1 Check installation site
The following measures must be taken before assembly:
Check door openings, other openings and room heights to ensure
they are high enough to transport the parts of the vacuum pumping
unit safely to the installation site.
Asufcientlyweight-bearing,atsurfaceisrequiredfortheinstalla‑
tion site.
Number Design (with control module) Distributed load
(kN/m2)
1x Pump module 1,65
2x Pump module 3,37
3x Pump module 4,56
3.1.2 Installation site requirements
Ambient conditions
Ambient conditions (US)
Ambient temperature 10–45 °C 50 – 113 °F
Max. Relative humidity
(non condensing) 30 – 85 % 30 – 85 %
Ambient pressure Atmosphere
Location/Installation site dry, sheltered from rain
EX zone no
Floor/Ground at,horizontalandcleaninstallation
surface
Vibrations preferably devoid of external shocks
Minimum distance to
Side
Rear
100 mm
200 mm
0,33 ft
0,66 ft
Ceiling distance, above 100 mm 0,33 ft
Preparations on
customer side
Check installation site
Specicationsfor
ambient conditions

Preparations at installation site
12 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
Observe the minimum distances at the installation site
Top view
Side view
Leave enough space around the maintenance doors in order to remove
adiaphragmpumpeasily,ifnecessary.Alsoensuresufcientspacefor
maintenance or extension of the machine, e. g., lateral access and also
to connections on the rear.
Consider thermal load
Depending on operation conditions, connections, pipes, and connecting
elements may have to resist high thermal loads.
Use pipes and connection elements which can resist thermal loads
of media and exhaust gas temperature.
Ensuresufcientairsupplyatthesitetoavoidoverheatingoftheunit.
Max. permissible medium temperature (US)
Continuous operation – high gas load
>100 mbar (75 Torr) 10–45 °C 50–113 °F
Continuous operation – low gas load
<100 mbar 0–60 °C 32–140 °F
short‑time <5 Min
<100 mbar ‑10–80 °C ‑14–176 °F
Detected exhaust gas temperature for air
at 45 °C ambient temperature (US)
Outlet pipe behind KF, normal operation 125 °C 257 °F
Outlet pipe behind KF, during
maintenance 133 °C 271 °F
Sketches
Recommended
minimum distances
Thermal load

Preparations at installation site
13N°: 999296_EN_VAC_24seven_Assembly/06.04.17
3.2 Prepare connections
3.2.1 Mechanical connections
Due to the connection of pipes and tubes, no mechanical stress must
be transferred to the vacuum pumping unit.
Vacuumtubesmustmeetthespecicationsforvacuum,e.g.,
sufcientstability.
There must be no foreign objects inside the suction line. Objects
sucked into the machine could cause damage to the vacuum pumps.
The nominal diameter of the connecting tubes must correspond
atleasttothecross-sectionofthesuctionangeofthevacuum
pumping unit.
No shut‑off devices must be installed in the exhaust line.
Constrictions in the connection lines may result in performance
losses.
Supply lines
Supplylinesandconnectionsuptotheconnectionangesofthevac‑
uum pumping unit have to be provided by the customer.
Supplylinesincludepipelinesorexibletubelinesforvacuum1, exhaust
gas2,andinertgas.Supplylinesmustbedimensionedsufciently.
Supply lines to Connection
Pump module
Chemically resistant, vacuum‑tight
exiblehose
or
Chemically resistant, vacuum‑tight pipe‑
line
Suction line – vacuum,
KF DN 40 (Ø 40 mm)
Heat‑resisting tube
or
Heat‑resisting tube
Outlet pipe – exhaust gas,
KF DN 25 (Ø 25 mm)
Control module
gas-tight,exiblehose *Gas ballast – Inert gas sup‑
ply ID/OD 4/6 mm
* Option: Inert gas is mandatory when pumping media reacting with air.
1 -> Vacuum connection: IN = Inlet
2 -> Exhaust connection: EX = Exhaust
IMPORTANT!
Supply lines
Mechanical connections

Preparations at installation site
14 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
Sensor connection
Provide a connection port for the vacuum sensor at or near the applica‑
tion for pressure measurement.
Vacuum sensor Connection
Connectionange KF DN 16 (Ø 16 mm)
Permissible pressure ranges
Max. permissible pressure (US)
at the inlet (IN), absolute 1,1 bar 825 Torr
at the exhaust (EX), absolute 1,1 bar 825 Torr
Differential pressure between inlet
and outlet 1,1 bar 825 Torr
at gas ballast, absolute 1,2 bar 900 Torr
Sensor connection, mechanical
Pressure ranges

Preparations at installation site
15N°: 999296_EN_VAC_24seven_Assembly/06.04.17
3.2.2 Electrical connection
For electrical connection the mains supply must be available at the
installation site of the vacuum pumping unit. The mains supply must be
sufcientlydimensioned.
The installation of electrical equipment shall only be performed by a
qualiedelectrician.
The mains voltage must correspond to the voltage and frequency
specicationsontheratingplate.
The vacuum pumping unit has to be protected against overload with
a pre‑fuse.
Forelectricalconnectionsaqualiedelectricianisrequiredonthe
day of installation.
Mains connection
Preparing mains connection (US)
Electrical connection 400 V/60 Hz,
3 phase, 16 A
208 V/60 Hz,
1 phase, 30 A
Pre‑fuse 16 A 30 A
Mains cable,
maximum 50 m 5x 2.5 mm23x AWG 8
Sensor connection
Vacuum sensor
Plug connection VACUU·BUS®
Standard cable length 2 m
VACUU·BUS®Order N°
Extension cable 2 m 612552
Extension cable 10 m 2618493
At a distance longer than 2 m to the vacuum pumping unit, a
VACUU·BUS®extension cable is required. The maximum length of the
sensor cable including extension cable is 30 m.
Order a VACUU·BUS®extension cable for longer distances and
keep it ready on the day of installation.
IMPORTANT!
IMPORTANT!
Sensor connection, electrical
Data for mains connection

Preparations at installation site
16 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
Additional connection options
For data exchange with customer systems, e. g., PLC, the control mod‑
ule provides the following connection options:
Connecting additional VACUU·BUS® components (1),
e. g., in‑line isolation valve.
Ethernet (2) for integration into the local network and remote control
via end device (PC, tablet etc.) or
RS 232 (3) for connection of a PC , e.g., to read out data.
Connection (4) to a monitoring system on operator side, e. g., bi‑direc‑
tional error interface from/to PLC.
Option: Connection to the operator's control system, e.g.,
to preset speed or set vacuum via PLC.
Standard interfaces
4
21 3
VACUUBRAND‑BUS system Connection for ...
1*VACUU·BUS®VACUU·BUS®components
Interface
2Ethernet Patch cable, min. Cat.5e RJ45
or
3Sub‑D 9 poles (max. 25 m)
from 3 m
RS‑232 null modem cable
shielded
Digital I/O module VACUU·BUS®
– External error indication (1 = no error / 0 = error)
4*Signal cable, bis 30 m 4x 0.5 mm2(or 5x 0.5 mm2),
e.g.,Ölex
Fault indication input – IN: 5 – 75 VDC / 5 – 50 VAC
Fault indication output – OUT: 60 VDC / 40 VAC (max. 2.5 A)
* Maximum cable length of the signal cable = 30 m!
Connections and Interfaces

Preparations at installation site
17N°: 999296_EN_VAC_24seven_Assembly/06.04.17
Optional interface
Analog I/O Module VACUU·BUS®
– external vacuum or motor speed control
*Signal cable, bis 30 m 4x 0.5 mm2(or 5x 0.5 mm2),
e.g.,Ölex
Signal input – IN: 0 – 10 VDC
Signal output – OUT: 0 – 10 VDC
Analog I/O Module VACUU·BUS®, Order N° #636229.
3.3 Recommended accessories at hand
The VAC 24seven accessory program includes components which are
not part of the delivery scope but which are nevertheless required for the
installation of the vacuum pumping unit.
Keep the required accessories at hand on the day of installation.
Recommended accessories for installation
1
2
Accessories for VAC 24seven Order N°
1Set adjustable feet 649913
2Set eye screws, with thread M 10 649917
Accessories if required
Find below a list of accessories for a handy expansion of your vacuum
pumping unit.
If required, order the accessories to expand your vacuum pumping
unit and keep it at hand on the day of installation.
IMPORTANT!
Optional interface
Recommended accessories
Accessories if required

Preparations at installation site
18 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
1x for 2 pump modules
2x for 3 pump modules
1
2
3
4
5
6
7
Accessories for VAC 24seven Order N°
1Interconnection set to connect 2 pump modules 745010
2Set changing pump outlet for
placing the pump outlet downwards 649912
3Ball valve VKE 40 as in‑line isolation valve 675506
4Catchpot for condensate, 2 liter glass bottle 649916
5Analog I/O Module VACUU·BUS®636229
6Cleaningsetforushingthepumpingunit 649914
7Tool kit 649918
Accessories if required

Installation and Commissioning
19N°: 999296_EN_VAC_24seven_Assembly/06.04.17
4 Installation and Commissioning
4.1 Conditions
4.1.1 Provide personnel resources
The customer (operator) must provide the following personnel resources
for the installation works:
Specialist for Job/Function
Electric ►Mains connection control module
Mechanic ►Preparation and mechanical con‑
nection of the supply lines
Crane and
lifting gear operator
►in‑house transport and lifting jobs
Network administrator ►Integration of VACUU·CONTROL
into
enterprise network
4.1.2 Supply working and transport equipment
The customer (operator) must provide thefollowing working and trans‑
port equipment for the installation works:
Accessories: Set eye screws; Order N° #649917
Set adjustable feet; Order N° #649913
Industrial truck for palett transport, e. g., lift truck, fork lift
Lifting gear, e. g., crane, lifting strap, lifting belt, fork lift
4.1.3 Ready for connection
The customer (operator) meets all installation requirements and all sup‑
ply lines are installed at the installation site:
Suction tube
Outlet pipe
Supply line mains connection
Option: Control line for interfaces, e. g., fault indication, control sig‑
nals, Ethernet etc..
see also chapter:
Preparations at installation site on page 11
If all requirements are met, VACUUBRAND-Service will install, assem‑
ble and commission the vacuum pumping unit.
Installation requirements

Installation and Commissioning
20 N°: 999296_EN_VAC_24seven_Assembly/06.04.17
4.2 Required tools
The followings tools are required for installation and assembly of the
vacuum pumping unit:
12 3 4
5
N° Tool Size
1Allen key
Fastening screws of cable duct, pump module Gr. 2.5
Cover screws, control module Gr. 3
Strain relief (cable), control module Gr. 4
2Open‑end wrench
Grounding connection SW10
Fastening screws to connect pump modules SW15
Attaching and aligning adjustable feet SW17
Cable connection, control module SW32
3Phillips screwdriver
Interconnection set for pump modules Gr. 2
Connection to catchpot for condensate Gr. 2
4Insulated Phillips screwdriver
Terminal block mains supply, control module Gr. 2.5
5Spirit level 40 cm /
60 cm
Adjustable feet – align pump module
Required tools