Pfeiffer Vacuum DUO 255 Operating Instructions Manual Download

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We are the only supplier of vacuum technology that provides a complete product portfolio.

COMPETENCE IN THEORY AND PRACTICE

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We support you with your plant layout and provide first-class on-site service worldwide.

Are you looking for a
perfect vacuum solution?
Please contact us:

Pfeiffer Vacuum GmbH

Headquarters • Germany
T +49 6441 802-0
[email protected]

www.pfeiffer-vacuum.com

Summary of Contents for DUO 255

Page 1: ...PD 0065 BEN A 1604 OPERATING INSTRUCTIONS EN Translation of the original instructions DUO 255 DUO 255 M Rotary Vane Pump ...

Page 2: ...perations monitoring Option 15 6 Operation 16 6 1 Before switching on the pump 16 6 2 Switching on the pump 16 6 3 Pumping condensable vapours 17 6 4 Switching off the pump 19 7 Maintenance 20 7 1 Precautions 20 7 2 Changing the operating fluid 21 7 3 Cleaning and re setting the silencer 23 7 4 Changing the gas ballast filter 25 7 5 Assembling the motor and coupling 26 8 Decommissioning 28 8 1 Shu...

Page 3: ...ating instructions are the result of risk evaluations and hazard analyses and are oriented on international certification stan dards as specified by UL CSA ANSI Z 535 SEMI S1 ISO 3864 and DIN 4844 In this document the following hazard levels and information are considered DUO 255 Operating instructions Declaration of Conformity Part of this document Operating instructions for accessories order spe...

Page 4: ...ballast valve Power connection Prohibition of an action to avoid any risk of accidents the disregarding of which may result in serious accidents Warning of a displayed source of danger in connection with operation of the unit or equipment Command to perform an action or task associated with a source of dan ger the disregarding of which may result in serious accidents Important information about th...

Page 5: ...shing Do not allow any magnetised parts into the vicinity of the magnetic coupling Danger of injury 2 2 Protective equipment Determined situations concerning the handling of vacuum pumps require wearing of per sonal protective equipment The owner respectively the employer are obligated to pro vide an adequate equipment to any operating persons Duty to inform Each person involved in the installatio...

Page 6: ...pressure pumping of liquids the use of operating fluids not specified by Pfeiffer Vacuum connection to pumps or units which are not suitable for this purpose according to their operating instructions connection to units which have exposed voltage carrying parts operation of the devices in areas with ionizing radiation CAUTION Risk of injury through hot surfaces Vacuum pumps can become hot during o...

Page 7: ...ting the pump 3 2 Storage Check that all the openings on the pump are securely closed Fill up the pump with new operating fluid to the top edge of the sight glass Store the pump only indoors preferably at temperatures between 10 C and 40 C In rooms with moist or aggressive atmospheres the pump must be airproof shrink wrapped in a plastic bag together with a bag of desiccant After storage periods l...

Page 8: ...lated data on the separately attached motor rating plate Fig 2 Product identification on the rating plate Scope of delivery Pump with motor without motor Operating fluid except F4 and F5 Cone strainer and centering ring with O ring Locking cap for vacuum and exhaust flange Operating instructions Pump types D 35641 Asslar Mod DUO 125 255 Mod Nr PK D6x xxx Ser Nr 3454440 S max 300 m h Oil P3 23 0 l ...

Page 9: ...he version with magnetic coupling has as an alternative to conventional shaft feedthrough a static seal towards the outside Fig 3 DUO 255 1 Vacuum flange 2 Exhaust flange 11 Support 12 Casing 17 Manometer 18 Oil passage for connecting accessories opera tions monitoring mechanical oil filter 115 Gas ballast valve 148 Sight glass 321 Connection temperature sensor 326 Connection operating fluid level...

Page 10: ...e is sufficient air circulation Sight glass and gas ballast valve must be visible and readily accessible Voltage and frequency information given on the motor rating plate must be visible Fig 4 Setting up the pump 5 2 Connecting the vacuum side Remove locking cap from the vacuum flange pay attention to the cone strainer and the respective O ring in the intake port Clear welded lines of any welding ...

Page 11: ...fficial accident prevention safety regulations If the exhaust gases are being extracted the exhaust pressure must be at least 250 hPa greater than the pressure at the intake side WARNING Emission of toxic substances from the exhaust Danger of poisoning from emitted gases or vapours which can be detrimental to health and or can pollute the environment depending on the particular application Comply ...

Page 12: ...e is the cube root of the coil voltage the mains and the coil current are the same Star connec tions are denoted by the symbol Y Fig 6 Motor coil and connecting plate of Star Connection for high voltage Inspection of the direction of rotation For pumps with three phase motors it is necessary to check the direction of rotation Remove the locking cap from the exhaust flange if existing Switch the pu...

Page 13: ...he connections so that the directional rotation indicated on the pump is main tained regardless of the representations in the current flow diagram Fig 7 Connection example for a three phase AC motor with PTC resistor tripping device US Control voltage S1 OFF button S2 ON button S3 RESET button external K1 Contactor F1 F4 Fuses T1 T3 PTC resistor sensor H1 Tripping indicator M Motor 3 phase 1 Only ...

Page 14: ...w 327 Check operating fluid level only when the pump is warm and running therefore close vacuum flange and gas ballast valve correct filling level during operations within the markings at the sight glass frame check operating fluid daily in non stop operation otherwise whenever the pump is switched on Refilling is possible when the pump is in final vacuum operation NOTICE Use approved operating fl...

Page 15: ...ig 9 Installation location and circuit diagram of pressure switch Switch off the pump Unscrew screw 326 from the oil passage 18 Screw pressure switch with O ring into oil passage 18 Remove protective cover and make electrical connections at the pressure switch Reassemble the protective cover Parameter Oil pressure switch Protection category IP 55 Contact Closing contact normally open Set point 100...

Page 16: ...n atmospheric and ultimate pressure No special precautions are necessary when pumping dry gases In order to attain the lowest possible ultimate pressures the gas ballast valve should be closed Switch on the pump with the vacuum flange closed and allow to warm up for 30 min utes Monitoring the oper ating fluid pressure The pressure values on pressure gauge 17 differ depending on the operating tempe...

Page 17: ...ushing gas a supply hose can be connected at the gas ballast valve Unscrew gas ballast filter 122 at ball valve 120 On the inside thread G 1 2 of ball valve 120 connect the supply line and seal up thread side Set flushing gas pressure on site maximum pressure 1500 hPa absolute Select the type and amount of flushing gas depending on the process consult Pfei ffer Vacuum if necessary Dose flushing ga...

Page 18: ...is facing up take care to ensure the flat gasket is secure Make electrical connections 24 V DC Attach flushing gas to hose connection NW 12 14 mm or after removing the hose nozzle attach to the internal thread G 1 2 Set flushing gas pressure maximum pressure 1500 hPa absolute Select the type and amount of flushing gas depending on the process consult Pfei ffer Vacuum if necessary Dose flushing gas...

Page 19: ... Maintaining the vac uum in the chamber NOTICE Danger of backflow of operating fluid into the intake line Contamination of the connected vacuum system Vent the vacuum chamber within 30 s regardless of the chamber size For a longer venting process use an additional shut off valve and shut off the intake line after switching off the pump NOTICE Danger of backflow of operating fluid into the intake l...

Page 20: ...shutdown due to overheating the motor may restart auto matically Secure the motor so that it cannot be switched on while any work is being performed on the pump If necessary dismantle the pump from the installation for inspection WARNING Pump parts may be contaminated from pumped media Danger of poisoning due to contact with harmful substances Decontaminate the pump before carrying out any mainten...

Page 21: ... daily as required at least annually as required at least every 2 years as required at least every 4 years Check operating fluid level K X Visual inspection leak tightness oil leaks K X Check filter insert of external oil mist filter if existent K X Change operating fluid I X Disassemble casing sight glass and pump ing system and clean casing outside with out cleaning agent I X Clean gas ballast v...

Page 22: ... operating fluid again and check for contamination flush again if necessary Screw the operating fluid drain screw back in Fill up with operating fluid and check the filling level see p 14 chap 5 5 328 327 WARNING Hot operating fluid Danger of burns when draining due to contact with skin Wear suitable protective clothing Use a suitable collecting vessel WARNING Operating fluid may contain toxic sub...

Page 23: ...similar cleaning agent Blow out filter with air and dry Assembling is carried out in reverse order Fill up with operating fluid to the middle of the sight glass Filling quantity approx 25 l of operating fluid 7 3 Cleaning and re setting the silencer If the silencer is not functioning a knocking noise becomes audible at final vacuum This does not damage the pump although can have a negative affect ...

Page 24: ...le 72 Examine O rings 242 valve spindle 72 and valve seat for wear and replace if neces sary Reassemble in the reverse sequence Carefully push O ring 242 into the nut in valve spindle 72 and oil lightly with operating fluid Setting the silencer The silencer is set using a standard screwdriver when the pump is running at operating temperature and vacuum flange and gas ballast valve are closed Bring...

Page 25: ...ter The greater the contamination the lower the filter air throughput and the greater the risk of condensation and corrosion within the pump Standard version Fig 15 Gas ballast valve standard version Turn the cover and open the filter housing 122 Clean filter insert 123 or replace as necessary 120 Gas ballast valve ball valve 122 Filter housing 123 Filter insert 120 122 123 ...

Page 26: ...r the disassembly of the drive system for vacuum pumps with magnetic coupling NOTICE Damage to motor bearings Blows or pressure when mounting the coupling half can damage the motor bearings Clean and lightly oil the shaft journals Push the coupling half onto the shaft If necessary warm the coupling half or use the internal thread in the shaft journal and suitable tools and push the coupling half i...

Page 27: ...nd motor off evenly with two jack screws W62 and pull off horizontal ly loosen the screws 290 at the oil cooler 208 during the releasing process and gently tilt the oil cooler 208 when passing the fan 195 NOTICE Danger of bursting when the motor is removed The separating can of the magnetic coupling is made of plastic or ceramics and can be destroyed when the motor is pulled off Suspend the motor ...

Page 28: ...out main tenance and change the operating fluid before using the pump Do not store pump in the vicinity of machines lanes etc because strong vibrations can damage the rotor bearings 8 2 Re starting 8 3 Disposal Products or parts thereof mechanical and electrical components operating fluids etc may cause environmental burden Safely dispose of the materials according to the locally applicable regula...

Page 29: ...g started Thermal protection switch of the motor has responded Detect and fix cause of overheating allow motor to cool off if necessary Mains fuse protection triggered due to overload e g cold start Warm up pump Exhaust pressure too high Check opening of exhaust line and exhaust accessories Pump does not attain ultimate pressure Measurement reading is false Check gauge check ultimate pressure with...

Page 30: ...ice if necessary Attention Magnetic field If the magnetic field has broken away the ori entation of the magnets with respect to each oth er can only be re established at standstill If the pump is left to operate with a broken away magnetic field demagnetisation will take place and the coupling is destroyed Problem Possible causes Remedy NOTICE Service work should be carried out by a qualified pers...

Page 31: ...it in the shipment required Dismantle all accessories Drain operating fluid lubricant Drain cooling medium if used Send the pump or unit in its original packaging if possible Sending of contaminated pumps or devices No units will be accepted if they are contaminated with micro biological explosive or ra dioactive substances Hazardous substances are substances and compounds in ac cordance with the ...

Page 32: ... T PK E00 025 T 17 24 29 30 31 38 52 53 56 59 60 65 70 81 85 88 98 99 142 145 148 173 230 C DUO 255 M PK E02 051 T PK E00 027 T 17 24 29 30 31 38 52 53 56 59 60 65 70 81 85 88 98 99 142 145 148 173 230 Pumping system P3 DUO 255 PK E03 013 T 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 38 39 41 42 43 44 48 52 53 54 56 57 58 59 60 254 256 258 260 280 282 287 288 294 296 312 338 Pumping system P3 DUO...

Page 33: ... 298 342 300 19 336 340 273 200 222 272 11 251 289 244 322 326 248 203 310 226 144 145 144 142 266 221 227 224 208 290 140 284 170 171 172 304 173 176 175 10 302 350 300 254 118 120 122 123 18 270 344 220 102 103 106 269 230 17 141 332 333 250 255 328 248 245 321 326 284 146 147 148 147 293 14 264 250 327 12 16 ...

Page 34: ...5 Oil pipe 12 208 Oil cooler 220 Straight screwed coupling G 1 8 221 Straight screwed coupling G 3 8 222 Straight screwed coupling G 1 2 223 Elbow union G 1 8 224 Elbow union G 3 8 226 Screw fitting 227 Hose connection for oil cooler 228 Strainer 230 Sealing ring 244 O ring 245 O ring 246 O ring 248 O ring 250 O ring 251 O ring 254 O ring 255 O ring 262 O ring 264 O ring 266 O ring 269 O ring for ...

Page 35: ...22 142 Washer 143 Supporting ring 144 Radial shaft seal ring 145 Spacer 172 Washer 176 Stud screw 191 Motor intermediate flange 192 Magnetic coupling 193 Can 194 Collar flange 195 Fan 196 Magnetic coupling motor 197 Fan blade 198 Counter ring fan 266 O ring 267 O ring 284 Allen head screw 286 Allen head screw 293 Allen head screw 304 Allen head screw 295 Allen head screw 298 Hexagon head screw 300...

Page 36: ...pacer 37 Rotor II 38 Vane stage II 39 Bearing cover 41 Key 42 Gear wheel driven 43 Gear wheel treibend 44 Cover oil pump 48 Valve seat complete 52 Valve stamp stage I 53 Pressure spring for valve stage I 54 Valve housing stage I 56 Pressure valve stage II 57 Valve housing stage II 58 Stud bolt of valve stage II 59 Oil filter 60 Sieve box of valve stage II 63 Housing of non return valve 64 Valve in...

Page 37: ...g 82 Guiding piece 83 Circlip 84 Valve stem 85 Buffer 86 Valve plate 92 Pipe 94 Washer 95 Allen head screw 98 Pressure spring 99 Hydraulic piston 100 Cover 88 Pos 86 262 262 O ring 264 O ring 284 Allen head screw 292 Allen head screw 298 Allen head screw 298 77 292 94 98 78 79 80 100 99 92 59 81 82 85 84 88 86 76 262 264 284 83 95 262 84 85 86 mit Loctite 222 kleben apply Loctite 222 75 298 298 26...

Page 38: ...51 FQ Oil level monitoring 24 V DC for Okta 250 M Okta 500 M Okta 1000 M Okta 2000 M Okta 4000 M Okta 6000 M G 1 1 4 PK 005 639 U Oil level monitoring 20 250 V AC for Okta 250 M Okta 500 M Okta 1000 M Okta 2000 M Okta 4000 M Okta 6000 M G 1 1 4 PK 004 930 U OFM 255 mechanical oil filter PK Z90 341 Oil return unit ORF 005 standard version PK Z90 065 Oil pressure switch for Duo 125 255 PK 223 806 T ...

Page 39: ...1 0 1 0 75 bar 1000 1 1 105 1000 100 750 Pa 0 01 1 10 5 1 0 01 1 10 3 7 5 10 3 hPa 1 1 10 3 100 1 0 1 0 75 kPa 10 0 01 1000 10 1 7 5 Torr mm Hg 1 33 1 33 10 3 133 32 1 33 0 133 1 1 Pa 1 N m2 mbar l s Pa m3 s sccm Torr l s atm cm3 s mbar l s 1 0 1 59 2 0 75 0 987 Pa m3 s 10 1 592 7 5 9 87 sccm 1 69 10 2 1 69 10 3 1 1 27 10 2 1 67 10 2 Torr l s 1 33 0 133 78 9 1 1 32 atm cm3 s 1 01 0 101 59 8 0 76 1...

Page 40: ...d power 50 Hz 7 5 kW Rated power 60 Hz 9 0 kW Switch No Mains cable No Shipping and storage temperature 25 55 C Operating fluid filling 25 l Weight 360 kg Cooling method standard Air Parameter Duo 255 M Flange in DN 100 ISO F Flange out DN 100 ISO F Pumping speed at 50 Hz 250 m3 h Pumping speed at 60 Hz 300 m3 h Ultimate pressure with gas ballast 4 10 3 hPa Ultimate pressure without gas ballast 3 ...

Page 41: ...ata and dimensions 41 13 3 Dimensions Fig 19 DUO 255 DUO 255 M 741 670 460 478 498 310 670 856 145 30 14 G 3 4 2x 100 276 720 390 318 5 G1 2 M14 x 1 5 145 M8 17tief 8x 1494 3 0 1407 3 0 DUO 255 M DN 100 ISO F Ø Ø ...

Page 42: ...cumentation is Mr Sebastian Ober beck Pfeiffer Vacuum GmbH Berliner Straße 43 35614 Aßlar DuoLine DUO 255 Harmonised standards and national standards and specifications which have been ap plied DIN EN ISO 12100 2010 DIN EN 61010 1 2010 DIN EN 61000 6 3 2007 A1 2011 DIN EN 1012 2 2011 12 DIN EN 61000 6 1 2007 DIN EN 61000 6 4 2007 A1 2011 DIN EN ISO 13857 2008 DIN EN 61000 6 2 2006 DIN EN ISO 2151 ...

Page 43: ...e are the only supplier of vacuum technology that provides a complete product portfolio COMPETENCE IN THEORY AND PRACTICE Benefit from our know how and our portfolio of training opportunities We support you with your plant layout and provide first class on site service worldwide Are you looking for a perfect vacuum solution Please contact us Pfeiffer Vacuum GmbH Headquarters Germany T 49 6441 802 ...

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