vacuubrand PC 3001 basic User manual

page 1 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
PC 3001 basic
Chemistry pumping unit with speed control
Technology for Vacuum Systems
Instructions for use

page 2 of 27
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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
➨Danger! Immediate danger. Death or severe injuries as well as damage
to equipment and environment can occur.
☞Warning! Possible danger. Severe injuries as well as damage to equip-
ment and environment can occur.
• Caution! Possible danger. Slight injuries as well as damage to equip-
ment and environment can occur.
Note. Disregarding of notes may cause damage to the product.
Caution! Hot surface!
Isolate equipment from mains before removing the cover.
Dear customer,
Your VACUUBRAND diaphragm pumps should support you for many years without trouble and with
optimal performance. Thanks to our long practical experience we have much information and advice
on how you can achieve powerful application usage and personal safety through our products. Please
read these instructions for use before the initial operation of your pump. VACUUBRAND diaphragm
pumps are the result of many years of experience in design and construction and practical operation of
these pumps combined with the latest developments in material and manufacturing technology.
Our quality maxim is the „zero fault principle“: Every diaphragm pump leaving our company, is tested
intensively including an endurance run of 18 hours. Therefore faults, even those which occur rarely,
are identied and can be eliminated immediately. The achievement of the specications after the en-
durance run is tested for every pump.
Every VACUUBRAND pump achieves the specications.
We are committed to providing our customers with this high quality standard.
We know that the vacuum pump cannot replace all of your real work and hope that our products con-
tribute to an effective and trouble-free realisation of your work.
Yours VACUUBRAND GMBH + CO KG
After sales service: Contact your local dealer or call [phone].
NOTICE

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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Contents
Safety information! .....................................................................................................4
General information............................................................................................................................4
Intended use.......................................................................................................................................4
Setting up and installing the equipment .............................................................................................4
Ambient conditions .............................................................................................................................5
Operating conditions ..........................................................................................................................5
Safety during operation ......................................................................................................................6
Maintenance and repair......................................................................................................................7
Technical data .............................................................................................................8
Gas inlet temperatures ......................................................................................................................9
Wetted parts ......................................................................................................................................9
Pump parts ......................................................................................................................................10
Kits for PC 3001 basic......................................................................................................................11
Use and operation ....................................................................................................12
Installing in a vacuum system ..........................................................................................................12
During operation...............................................................................................................................13
Attention: Important notes regarding the use of gas ballast.............................................................13
Shutdown .........................................................................................................................................14
Troubleshooting .......................................................................................................15
Accessories ..............................................................................................................16
Replacing diaphragms and valves..........................................................................17
Disassembling the housing cover at the inlet side ..........................................................................18
Replacing the diaphragm ................................................................................................................19
Assembling the housing cover at the inlet side ...............................................................................21
Disassembling the housing cover at the side of the on/off switch...................................................22
Assembling the housing cover at the side of the on/off switch ........................................................23
Notes on return to the factory .................................................................................24
Health and safety clearance form ...........................................................................25
Declaration of conformity ........................................................................................26

page 4 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Safety information!
General information
Read and comply with this manual before installing or operating the equipment.
Transport the pump at the provided handle.
Remove all packing material, remove the product from its packing-box, remove the
protective covers from the inlet and outlet ports and keep, inspect the equipment.
If the equipment is damaged, notify the supplier and the carrier in writing within three
days; state the item number of the product together with the order number and the
supplier’s invoice number. Retain all packing material for inspection.
Do not use the equipment if it is damaged.
If the equipment is not used immediately, replace the protective covers. Store the
equipment in suitable conditions.
Intended use
☞The pump and all system parts must not be used on humans or animals.
☞Prevent any part of the human body from coming in contact with vacuum.
☞Ensure that the individual components are only connected, combined and oper-
ated according to their design and as indicated in the instructions for use.
☞Comply with notes on correct vacuum and electrical connections, see section
”Use and operation”.
• The pumps are designed for ambient temperatures during operation between
+10°C and +40°C. Check the maximum temperatures if installing the pump in a
cabinet or a housing and make sure ventilation is adequate. Install an external
automatic ventilation system if necessary. If pumping hot process gases make
sure that the maximum permitted gas inlet temperature, which depends on sev-
eral parameters like inlet pressure or ambient temperature (see ”Technical data”),
is not exceeded.
• Particles and dust must not be aspirated.
Use the equipment for the intended use only, i.e. for generation, control and meas-
urement of vacuum in vessels designed for that purpose.
Setting up and installing the equipment
➨Equipment must be connected only to a suitably fused and protected electri-
cal supply and a suitable earth point. Failure to connect the motor to ground may
result in deadly electrical shock.
The mains cable may be tted with a moulded European IEC plug or a plug suit-
able for your local electrical supply. If the plug has been removed or has to be
removed, the cable will contain wires colour coded as follows: green or green and
yellow: earth; blue or white: neutral; brown or black: live.
☞Due to the high compression ratio of the pump, the pressure at the outlet port
might get higher than the maximum permissible pressure compatible with the
mechanical stability of the system.
☞Do not permit any uncontrolled pressurizing (e. g. make sure that the exhaust
pipeline cannot become blocked). If there is an exhaust isolation valve, make
sure that you cannot operate the equipment with the valve closed. Risk of burst-
ing!
☞Always provide a free and pressureless exhaust pipeline.
NOTICE
NOTICE

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Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
☞Avoid overpressure of more than 0.2 bar in case inert gas is connected to the
pump, the gas ballast connection or to a venting valve.
• Comply with maximum permissible pressures at inlet and outlet and pressure
differences, see section ”Technical data”. Do not operate the pump with overpres-
sure at the inlet.
• Check that mains voltage and current conform with the equipment (see rating
plate).
• Connect pipes gas tight at inlet and outlet of the pump.
• Attention: Flexible elements tend to shrink when evacuated.
Provide a rm level platform for the equipment and check that the system to be
evacuated is mechanically stable and that all ttings and hose connections are se-
cure. Ensure a stable position of the pump without any mechanical contact except of
the pump feet. Comply with all applicable safety regulations.
Keep a distance of minimum 20 cm between fan and ambient parts (e.g. housing,
walls, ...). Check fan regularly for dust/dirt, clean if necessary to avoid a cutback of
ventilation.
If the equipment is brought from cold environment into a room for operation, allow
the equipment to warm up (pay attention to water condensation on cold surfaces).
The diameter of the inlet and outlet pipeline should be at least as large as the diame-
ter of the pump connection pipelines.
Comply with all applicable and relevant safety requirements (regulations and
guidelines), implement the required actions and adopt suitable safety meas-
ures.
Ambient conditions
To the best of our knowledge the equipment is in compliance with the requirements
of the applicable EC-directives and harmonized standards (see ”Declaration of con-
formity”) with regard to design, type and model. Directive IEC 1010 (EN 61010) gives
in detail conditions under which the equipment can be operated safely (see also IP
degree of protection).
Adopt suitable measures in case of differences, e. g. using the equipment outdoors,
installation in altitudes of more than 1000 m above mean sea level, conductive pol-
lution or bedewing.
Pay attention to the permissible maximum ambient and gas inlet temperatures
(see ”Technical data”).
Operating conditions
➨The pumps have no approval for operation in or for pumping of potentially
explosive atmospheres.
➨The pumps are not suitable to pump
-unstable substances and substances which react explosively under
impact (mechanical stress) and/or when being exposed to elevated
temperatures without air,
- self inammable substances,
- substances which are inammable without air and
-explosive substances.
NOTICE
NOTICE

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Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
• The pumps are not suitable for pumping substances which may form deposits
inside the pump. Deposits and condensate in the pump may lead to increased
temperatures even to the point of excessing the maximum permitted tempera-
tures!
• If there is a danger of formation of deposits in the pump chamber (check inlet
and outlet of the pump), inspect the pump chambers regularly and clean if neces-
sary.
• The pumps are not suitable for pumping dust and have no approval for opera-
tion below ground.
If pumping different substances, it is recommended to purge the pump with air or
inert gas prior to changing the pumped media in order to pump out residues and to
avoid reactions of the pumped substances with each other and with the pump ma-
terials.
Take into consideration interactions and chemical reactions of the pumped me-
dia. Ensure that the materials of the wetted parts are compatible with the pumped
substances, see section ”Technical data”.
Safety during operation
➨Adopt suitable measures to prevent the release of dangerous, toxic, explosive,
corrosive, noxious or polluting uids, vapours and gases. In case install an ap-
propriate collecting and disposal system and take protective action for pump and
environment.
➨Prevent any part of the human body from coming into contact with vacuum.
➨The user must take suitable precautions to prevent any formation of explosive
mixtures in the expansion chamber or at the outlet. In case of e.g. a diaphragm
crack, mechanically generated sparks, hot surfaces or static electricity may ignite
these mixtures. Use inert gas for gas ballast or venting if necessary.
➨Potentially explosive mixtures at the outlet of the pump have to be drained ap-
propriately, sucked off or diluted with inert gas to non-explosive mixtures.
☞Pay attention to the symbol ”hot surfaces” on the equipment. Adopt suitable
measures to prevent any danger arising from the formation of hot surfaces or
electric sparks. Provide a suitable protection against contact if necessary.
☞Ensure that the exhaust pipeline is always free and pressureless.
☞Pumping at high inlet pressure may lead to overpressure at the gas ballast
valve. Pumped gases or condensate might be pushed out in case the valve is
open. If an inert gas supply is connected, ensure that the inlet pipeline is not con-
taminated.
• Comply with applicable regulations when disposing of chemicals. Take into con-
sideration that chemicals may be polluted.
Take adequate precautions to protect people from the effects of dangerous sub-
stances (chemicals, thermal decomposition products of uoroelastomers), wear
appropriate safety-clothing and safety glasses.
• Use only genuine spare parts and accessories. Otherwise safety and perform-
ance of the equipment as well as the electromagnetic compatibility of the equip-
ment might be reduced.
Possibly the CE mark or the C/US conformity becomes void if not using genuine
spare parts.
NOTICE

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Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
• Due to the residual leak rate of the equipment, there might be an exchange of
gas, albeit extremely slight, between the environment and the vacuum system.
Adopt suitable measures to prevent contamination of the pumped substances or
the environment.
Provide appropriate protective measures (i.e precautions which allow for the require-
ments of the respective application) even for the case of failure and malfunction.
Failure of the pump (e.g. due to power failure) or of connected components, of parts
of the supply or change of parameters must not lead to a critical dangerous situa-
tion under any circumstances. In case of diaphragm cracks or leaks in the manifold
pumped substances might be released into the environment or into the pump hous-
ing or motor. Comply especially with notes on operation and use and maintenance.
The motor is protected by a temperature sensor at the circuit board: Current
limitation if the temperature at the circuit board is higher than 70°C, switching off the
pump if the temperature is higher than 85°C. In case of blockade of the motor (after
10 attempts to start-up) the pump is switched off.
If the pump is switched off due to safety measures, manual reset is necessary. Isolate
the pump from mains. Eliminate the cause of failure before restarting the pump.
Do not start the pump if the pressure difference between inlet and outlet port ex-
ceeds 1.1 bar at maximum.
Prevent any backpressure of gases and the backow of condensates.
Never suck liquids or dust into the pump.
The A-weighed emission sound pressure level of the pump does not exceed 70
dB(A). Measurement according to EN ISO 2151:2004 and EN ISO 3744:1995 with
standard silencer or exhaust tube at outlet.
Maintenance and repair
Wear parts have to be replaced regularly. In case of normal wear the lifetime of
the diaphragms and valves is > 10000 operating hours. Bearings have a typical du-
rability of 40000 h.
➨Isolate equipment from mains and wait two minutes before starting mainte-
nance to allow the capacitors to discharge.
☞Ensure that the pump cannot be operated accidentally. Never operate the pump
if covers or other parts of the pump are disassembled. Never operate a defective
or damaged pump.
☞Attention: The pump might be contaminated with process chemicals which have
been pumped during operation. Ensure that the pump is decontaminated before
maintenance and take adequate precautions to protect people from the effects of
dangerous substances if contamination has occurred.
• Before starting maintenance vent the pump, isolate the pump and other compo-
nents from the vacuum system. Allow sufcient cooling of the pump. Drain con-
densate, if applicable.
Ensure that maintenance is done only by suitably trained and supervised techni-
cians. Ensure that the maintenance technician is familiar with the safety procedures
which relate to the products processed by the pumping system.
In order to comply with law (occupational, health and safety regulations, safety at
work law and regulations for environmental protection) vacuum pumps, components
and measuring instruments returned to the manufacturer can be repaired only when
certain procedures (see section ”Notes on return to the factory”) are followed.
NOTICE

page 8 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
We reserve the right for technical modications without prior note!
Technical data
* Information: In a motor speed range between 0 and 200 rpm the pump is running automatically in a
cycled interval operation.
Type PC 3001 basic
Maximum pumping speed (ISO 21360) m3/h 1.7
Ultimate vacuum (absolute) without gas ballast mbar 2
Ultimate vacuum (absolute) with gas ballast mbar 4
Maximum permissible inlet pressure (absolute) bar 1.1
Maximum permissible outlet pressure (abso-
lute) bar 1.1
Maximum permissible pressure (absolute) at
gas ballast valve bar 1.2
Permissible ambient temperature storage / op-
eration °C -10 to +60 / +10 to +40
Permissible relative atmospheric moisture dur-
ing operation (no condensation) % 30 to 85
Rated power (electric) kW 0.16
No-load speed* min-1 0 - 2400
Maximum permissible range of supply voltage
( ±10% ) Attention: Observe specications
of rating plate!
100-120 V~ 50-60 Hz
200-230 V~ 50-60 Hz
Maximum rated current at:
100-120 V~ 50/60 Hz
200-230 V~ 50/60 Hz
A
A
1.6
0.7
Device fuse 1x 7A
1x 0.5A self-resetting (VACUU•BUS)
Motor protection temperature sensor on the pcb
(current limitation)
Degree of protection IEC 529 IP 20
Inlet hose nozzle DN 6/10 mm
Outlet hose nozzle DN 10 mm / silencer
Dimensions L x W x H approx. mm 251 x 256 x 400
Weight approx. kg 6.4

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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Wetted parts
Gas inlet temperatures
Operating condition Inlet pressure Permitted range of gas
temperatures at inlet
Continuous operation > 100 mbar (high gas load) +10°C to +40°C
Continuous operation < 100 mbar (low gas load) 0°C to +60°C
Short-time (< 5 minutes) < 100 mbar (low gas load) -10°C to +80°C
Components Wetted materials
Pump
Housing cover PTFE
Head cover ETFE carbon bre reinforced
Diaphragm clamping disc ETFE carbon bre reinforced
Diaphragm PTFE
Valves FFKM
Pumping unit
Inlet PP
Outlet PTFE (hose nozzle) // PVC/PP (silencer)
Tubing PTFE
Screw-in ttings ETFE/ECTFE

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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
PC 3001 basic
Position Component
1Chemistry diaphragm pump
MD 1C VARIO
2 knob to select motor speed
3 Mains connection
4 ON/OFF switch
Position Component
5 Inlet
6Outlet
(supplementary: with silencer)
7 Gas ballast valve
8 Handle
1
5
2
7
4
3
6
8
Pump parts

page 11 of 27
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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Notes regarding the knob and the motor speed
Turning the knob to the left reduces the motor speed, turning the knob to the right increases the motor
speed.
A high motor speed reduces the lifetime of diaphragms and valves.
Pumping at high motor speed increases the pumping speed of the pump. Ensure sufcient cooling
of the pump!
Pumping at low motor speed increases the ultimate vacuum of the pump and also the lifetime of
diaphragms and valves.
Kits for PC 3001 basic
Kit AK + CVC 3000.......................................................................................................................699921
Kit EK 500.....................................................................................................................................699922
PC 3001 basic with
kit AK + CVC 3000
PC 3001 basic with
kit EK 500
PC 3001 basic with
kit AK + CVC 3000
and
kit EK 500
corresponds with
PC 3001 VARIO

page 12 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Use and operation
Installing in a vacuum system
• Connection lines at the pump inlet have to be gas tight. Particles and dust must
not be aspirated, the user has to provide appropriate lters if necessary. The user
must ensure their suitability concerning gas ow, chemical resistance and safe-
ness against clogging prior to use.
• Connect an exhaust line gas tight at the pump outlet if necessary. Always dispose
of exhaust gases appropriately (e.g. into a fume hood). If there is risk of release of
dangerous or polluting uids, install an appropriate system to catch and dispose
of those uids.
• The gas outlet (hose nozzle 10 mm / silencer) must not be blocked. The exhaust
pipeline has always to be free and pressureless to enable an unhindered dis-
charge of gases.
• When using the silencer: Check the silencer regularly for chemical attack and
deposits, replace if necessary or use an exhaust pipeline without silencer.
• Reduce the transmission of vibration and prevent loading due to rigid pipelines.
Insert elastic hoses or exible elements as couplings between the pump and rigid
pipes. Attention: Flexible elements tend to shrink when evacuated.
• Especially if the gas ballast valve is open, a power failure may cause uninten-
tional ventilation of the pump and the vacuum system. In case this constitutes a
potential source of danger, take appropriate safety measures.
• Make sure ventilation is adequate if the pumping unit is installed in a housing or
if ambient temperature is elevated. Provide external venting if necessary. Keep a
distance of minimum 20 cm between device and ambient parts.
The mains switch is at the left side of the pumping unit.
After switching off the pump, wait 60 sec. minimum until next switching on.
Avoid throttling losses by using connecting pipes with large diameter and keep them
as short as possible.
Install outlet pipelines always falling to avoid backow of condensate towards the
pump.
When assembling, ensure vacuum-tightness. After assembly, check the complete
system for leaks.
Secure hose connections at the pump appropriately against accidental detaching.
NOTICE

page 13 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
During operation
•Maximum ambient temperature: 40 °C
• Make sure ventilation is adequate if pump is installed in a housing or if ambient
temperature is elevated.
• Potentially dangerous gases or vapours at the outlet of the pump have to be
drained and disposed appropriately.
• Due to the high compression ratio of the pumps, pressure at the outlet port might
be generated being higher than the maximum permissible pressure compatible
with the mechanical stability of the system. Ensure that the pump outlet cannot
become blocked or restricted.
If pump is installed in altitudes of more than 1000 m above mean sea level check
compatibility with applicable safety requirements, e. g. IEC 60034 (motor may over-
heat due to insufcient cooling).
Do not start the pump if the pressure at outlet port exceeds maximum 1.1 bar
(absolute). Attempts to start the pump at higher pressures may cause blockade and
damage of the motor.
Check compatibility with maximally permitted pressure at inlet and outlet.
Prevent internal condensation, transfer of liquids or dust. The diaphragm and valves
will be damaged, if liquids are pumped in signicant amounts.
Check the pump regularly for external soiling and deposits, clean if necessary to
avoid an increase of the pump‘s operating temperature.
If pumping condensable vapours (water vapour, solvents, ....), let the pump run with
gas ballast to reduce condensation in the pump.
The motor is protected by a temperature sensor at the circuit board: Current
limitation if the temperature at the circuit board is higher than 70°C, switching off the
pump if the temperature is higher than 85°C. In case of blockade of the motor (after
10 attempts to start-up) the pump is switched off.
If the pump is switched off due to safety measures, manual reset is necessary. Iso-
late the pump from mains. Eliminate cause of failure before restarting the pump.
Avoid high heat supply (e. g. due to hot process gases).
A warm up period (approx. 15 min.) is required to ensure that rated ultimate vacuum
and pumping speed are attained.
Attention: Important notes regarding the use of gas ballast
➨ When using air rather than inert gas, risk of signicant damage to equipment and/
or facilities, risk of personal injury or even loss of life exists due to the formation
of hazardous and/or explosive mixtures if air and pumped media react inside or
at the outlet of the pump.
☞Make sure that air/gas inlet through the gas ballast valve never leads to hazard-
ous, explosive or otherwise dangerous mixtures. If in doubt, use inert gas.
NOTICE

page 14 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
In case of low boiling solvents when the formation of condensate is unlikely, the use
of gas ballast might be unnecessary.
Shutdown
Short-term:
Has the pump been exposed to condensate?
- Allow the pump to continue to run at atmospheric pressure for a few minutes.
Has the pump been exposed to media which may damage the pump materials or
forms deposits?
- Check and clean pump heads if necessary.
Long-term:
- Take measures as described in section short-term shutdown.
- Separate pump from the application.
- Close gas ballast.
- Drain catchpots (if using with upgrade kits)
- Close inlet and outlet port (e. g. with transport caps).
- Store the pump in dry conditions.
In case of condensable vapours (water vapour, solvents,
...):
☞Do not pump vapour until the pump has reached its opera-
ting temperature.
☞Open gas ballast valve. The gas ballast valve is open if the
arrow on the gas ballast cap shows towards the pump.
☞With gas ballast valve open ultimate vacuum will be re-
duced, pumping speed is decreased.
☞Use inert gas at the air inlet to avoid the formation of explo-
sive mixtures.
☞Close gas ballast valve by turning 180°.
gas ballast
NOTICE

page 15 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Troubleshooting
Fault Possible cause Remedy
❑Pump does not start or
stops immediately.
➨Knob for motor speed is
turned to the left stop?
✔Turn the knob to the right.
➨Supply voltage is missing or
too low?
✔Check or connect the supply
voltage; check the mains
fuse.
➨Overpressure in the exhaust
line?
✔Open exhaust line, ensure a
free (pressureless) outlet line
➨Motor overloaded? ✔Allow motor to cool. Identify
and eliminate the cause of
failure.
➨VACUU•BUS fuse has been
triggered, e.g. load in the
VACUU•BUS system too high
or short circuit in valves?
✔Remove VACUU•BUS com-
ponents (e.g. valves). The
fuse is self-resetting.
❑Pump does not achieve
ultimate vacuum or nor-
mal pumping speed.
➨Centring ring at a small ange
connection not correctly posi-
tioned or leak in the pipeline
or vacuum system?
✔Check pump directly - con-
nect vacuum gauge directly
at pump inlet - then check
connection, pipeline and
vacuum system if necessary.
➨Long, narrow vacuum line? ✔Use lines with larger dia-
meter, length as short as
possible.
➨Pump has been exposed to
condensate?
✔Allow pump to run for some
minutes with atmospheric
pressure at the inlet.
➨Deposits have been formed
inside the pump?
✔Clean and inspect the pump
heads.
➨Diaphragms or valves defec-
tive?
✔Replace diaphragms and/or
valves.
➨Outgassing substances or
vapour generated in the pro-
cess?
✔Check process parameters.
➨Pump temperature too high
(reduced motor speed)?
✔Ensure sufcient cooling
of the pump or reduce inlet
pressure.
❑Pump too noisy. ➨Loud exhaust noise? ✔Connect hose or silencer to
pump outlet.
➨Diaphragm crack or dia-
phragm clamping disc loose?
✔Perform maintenance.
➨Other than above mentioned
causes?
✔Contact local distributor.
❑Pump seized. ✔Contact local distributor.

page 16 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
Kits
Kit AK + CVC 3000.......................................................................................................................699921
Kit EK 500.....................................................................................................................................699922
Accessories for vacuum controller CVC 3000
External pressure transducer VSK 3000,
capacitive, ceramic diaphragm sensor 1080-0.1 mbar..................................................................636657
Coolant valve VKW-B, 24 V= ...................................................................................................674220
Air admittance valve VBM-B / KF 16 / hose nozzle 6/10 mm, 24 V= .......................................674217
Y-type adapter VACUU•BUS ......................................................................................................636656
Extension cable VACUU•BUS, 2m .............................................................................................612552
Cable RS 232C, 9-pole, Sub-D ...................................................................................................637837
Accessories

page 17 of 27
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the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
☞Please read section ”Replacing diaphragms and valves” completely before
starting maintenance.
Partially the pictures show pumps in other versions. This doesn´t inuence replacing diaphragms and
valves of the pump.
Tools required (metric):
- diaphragm key w/f 46
- open ended wrench w/f 14/17
- hex key size 4/5
- at-bladed screw driver 2.5 mm
- at pliers
Set of seals MD 1C (4 diaphragms, 8 valves, diaphragm key) ...................................................696828
Replacing diaphragms and valves
All bearings are encapsulated and are lled with long-life lubricant. Under normal
operating conditions, the pump is maintenance free. The valves and diaphragms are
wear parts. If the rated ultimate vacuum is no longer achieved or in case of increased
noise level, the pump interior, the diaphragms and the valves must be cleaned and
the diaphragms and valves must be checked for cracks or other damage. Depend-
ing on individual cases it may be efcient to check and clean the pump heads on a
regular basis. In case of normal wear the lifetime of the diaphragms and valves is >
10000 operating hours.
- Prevent internal condensation, transfer of liquids or dust. The diaphragm and
valves will be damaged, if liquids are pumped in signicant amount.
If the pump is exposed to corrosive gases or vapour or in case of deposits, mainte-
nance should be carried out frequently.
- Regular maintenance will improve the lifetime of the pump and also protect both
man and environment.
Ensure that maintenance is done only by suitable trained and supervised techni-
cians.
☞Ensure that the pump cannot be operated accidentally. Never operate the pump
if covers or other parts of the pump are disassembled. Never operate a de-
fective or damaged pump.
☞Before starting maintenance isolate the pump from the electrical supply and
wait two minutes after isolating the equipment from mains to allow the capaci-
tors to discharge. Avoid the release of pollutants. Allow sufcient cooling of the
pump.
• Attention: The pump might be contaminated with the process chemicals that
have been pumped during operation. Ensure that the pump is decontaminated
before maintenance and take adequate precautions to protect people from the
effects of dangerous substances if contamination has occurred. Ensure that the
maintenance technician is familiar with the safety procedures which relate to the
products processed by the pumping system.
• Wear appropriate safety-clothing when you come into contact with contaminated
components. Avoid the release of pollutants.
Before starting maintenance vent the pump and isolate it from the vacuum system.
NOTICE
NOTICE

page 18 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
➨Use an open-ended wrench (w/f 17) to loosen the union
nut at the hose connection next to the gas ballast.
➨ Use an open ended wrench (w/f 14) to turn the elbow t-
ting 1/4 of a turn, disconnect the hose. Do not remove the
elbow tting from the pump head.
☞Through reassembly a leak may result.
➨Use hex key size 5 to unscrew the handle from one side of
the housing cover.
Disassembling the housing cover at the inlet side
➨Lay the pumping unit down with the housing cover at the
side of the pump inlet facing upwards (support pumping
unit appropriately).
➨Use a hex key size 4 to loosen the six socket head screws
at the pump head and remove the upper housing (housing
cover with housing cover insert). Do not kink hoses.
☞Never remove parts using a spiky or sharp-edged tool (e.
g. screw driver), we recommend to use a rubber mallet or
compressed air (to be blown carefully into port).
➨Take the head covers carefully off the housing cover to
check the valves.
Note the position of the valves and remove them.
☞Replace valves if damaged.
Use petroleum ether or industrial solvent to remove de-
posits. Do not inhale.

page 19 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
View of the disassembled pump head parts
Replacing the diaphragm
10
1
9
3
2
5
6
7
8
4
1: housing cover
2: valve
3: head cover
4: diaphragm clamping disc with connect-
ing screw
5: diaphragm
6: diaphragm support disc
7: washers
8: rod
9: housing
10:bearing plate
➨Check the diaphragms for damage and replace if neces-
sary.

page 20 of 27
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully
the validity of this document with respect to his product. Manual-no.: 999198 / 29/09/2009
➨Bring the diaphragms into a position in which they are in
contact with the housing and centred with respect to the
bore.
☞Make sure that the square head screw of the diaphragm
clamping disc is correctly seated in the guide hole of the
diaphragm support disc.
☞Position washers between diaphragm support disc and
rod.
➨Assemble diaphragm clamping disc, diaphragm and dia-
phragm support disc to connecting rod.
☞For that purpose, put pumping unit in upright position, if
necessary. Afterwards, lay the pumping unit down again.
➨Lift diaphragm carefully.
➨Apply pressure to the adjacent clamping disc to bring con-
necting rod into upper turning point position if necessary.
☞Never use a spiky or sharp-edged tool to lift the dia-
phragm.
➨Use the diaphragm key to grip the diaphragm support disc
below the diaphragm.
➨Apply pressure to the diaphragm clamping disc to bring
the diaphragm into the lower turning point position. Press
diaphragm key against diaphragm clamping disc, unscrew
and remove diaphragm support disc with diaphragm.
☞ If the old diaphragm is difcult to separate from the support
disc, immerse assembly in naphtha or petroleum ether. Do
not inhale!
☞Check for washers under clamping disc. Do not mix the
washers from the different heads. Make sure that the origi-
nal number is reassembled at the individual pump head.
➨Position new diaphragm between diaphragm clamping
disc with square head screw and diaphragm support disc.
☞Attention: Position diaphragm with pale side towards dia-
phragm clamping disc (to pump chamber).
➨Lift diaphragm at the side and position carefully together
with diaphragm clamping disc and diaphragm support disc
in the diaphragm key.
☞Avoid damaging the diaphragm: Do not bend diaphragm
too much.
➨Check for washers. Do not mix the washers from the dif-
ferent heads. Assemble the original number of washers
between support disc and connecting rod at the individual
pump head.
☞ Smaller number of washers: The pump will not attain nal
vacuum. More washers: Clamping disc will hit head cover;
noise or even blockage of the pump.