Pfeiffer Vacuum DUO 5 MC Operating Instructions Manual Download

Page: 4 / 60

Maintenance

7.1

Maintenance instructions

7.2

Maintenance instructions for magnetic coupling

7.3

Checklist for inspection and maintenance

7.4

Change the operating fluid

7.4.1 Determine degree of aging of P3 operating fluid

7.4.2 Change the operating fluid

7.4.3 Rinse and clean rotary vane vacuum pump

7.5

Remove and clean gas ballast filter

7.5.1 Remove gas ballast valve

7.5.2 Strip and clean gas ballast valve

7.5.3 Remove and clean silencer nozzle

7.5.4 Install gas ballast valve

7.6

Changing the operating fluid type

Decommissioning

8.1

Shutting down for longer periods

8.2

Recommissioning

Recycling and disposal

9.1

General disposal information

9.2

Dispose of rotary vane pump

Malfunctions

Service solutions by Pfeiffer Vacuum

Spare parts

12.1 Spare part packages

12.2 Maintenance kit 1 – maintenance level 1

12.3 Overhaul kit – Maintenance level 3

12.4 Coupling set for versions with magnetic coupling

12.5 Set of vanes

Accessories

13.1 Accessory information

13.2 Order accessories

Technical data and dimensions

14.1 General

14.2 Technical data

14.3 Dimensions

Declaration of conformity

Table of contents

4/60

Summary of Contents for DUO 5 MC

Page 1: ...OPERATING INSTRUCTIONS EN Translation of the Original DUO 5 M DUO 5 MC Rotary vane pump ...

Page 2: ...feiffer vacuum de Further operating instructions from Pfeiffer Vacuum can be found in the Download Center on our website Disclaimer of liability These operating instructions describe all models and variants of your product Note that your product may not be equipped with all features described in this document Pfeiffer Vacuum constantly adapts its products to the latest state of the art without pri...

Page 3: ...4 Identifying the product 18 3 5 Scope of delivery 18 4 Transportation and Storage 19 4 1 Transporting the vacuum pump 19 4 2 Storing the vacuum pump 19 5 Installation 21 5 1 Set up the vacuum pump 21 5 2 Connect the vacuum side 21 5 3 Connect the exhaust side 22 5 4 Fill operating fluid 23 5 5 Connect to mains power supply 24 5 5 1 Connecting single phase motors 25 5 5 2 Connect three phase motor...

Page 4: ...e 42 7 6 Changing the operating fluid type 42 8 Decommissioning 43 8 1 Shutting down for longer periods 43 8 2 Recommissioning 43 9 Recycling and disposal 44 9 1 General disposal information 44 9 2 Dispose of rotary vane pump 44 10 Malfunctions 45 11 Service solutions by Pfeiffer Vacuum 47 12 Spare parts 49 12 1 Spare part packages 49 12 2 Maintenance kit 1 maintenance level 1 49 12 3 Overhaul kit...

Page 5: ...otection switch settings 28 Tbl 7 Maintenance intervals 36 Tbl 8 Troubleshooting for rotary vane pumps 46 Tbl 9 Spare part packages 49 Tbl 10 Content of maintenance kit 1 50 Tbl 11 Accessories for Duo 5 M 52 Tbl 12 Accessories for Duo 5 MC 52 Tbl 13 Consumables 52 Tbl 14 Conversion table Pressure units 53 Tbl 15 Conversion table Units for gas throughput 53 Tbl 16 Technical data Duo 5 M 54 Tbl 17 T...

Page 6: ...26 Fig 12 Connection example with PTC thermistor tripping unit 27 Fig 13 Gas ballast valve standard version 31 Fig 14 Gas ballast valve with flushing gas connection 31 Fig 15 Fill operating fluid 32 Fig 16 Draining the operating fluid 38 Fig 17 Remove rotary vane pump cap 39 Fig 18 Individual parts of the gas ballast valve 40 Fig 19 Remove gas ballast valve 40 Fig 20 Remove silencer nozzle 41 Fig ...

Page 7: ...group These operating instructions are aimed at all persons performing the following activities on the product Transportation Setup Installation Usage and operation Decommissioning Maintenance and cleaning Storage or disposal The work described in this document is only permitted to be performed by persons with the appropriate technical qualifications expert personnel or who have received the relev...

Page 8: ...efore filling in the oil check direction of rotation of the pump ATTENTION Avant remplir l huile vérifier le sense de rotation de la pompe Sticker yellow three phase motor only Attention Check the direction of rotation of the rotary vane pump be fore filling with operating fluid Achtung nur mit F4 befüllen Attention only F4 to be used Sticker orange special operating fluid only Attention Fill rota...

Page 9: ...diameter Diamètre nominal FCR Fluorinated rubber IN Rated nominal current Imax Maximum current ISO Flange Connector in accordance with ISO 1609 and ISO 2861 M version Version with magnetic coupling PE Protective ground protective earth ODK Operating fluid return line oil drain kit PTC Temperature dependent resistor positive temperature coefficient M version Version with magnetic coupling MC versio...

Page 10: ...damage to property Is used to highlight actions that are not associated with personal injury Instructions to avoid damage to property Notes tips or examples indicate important information about the product or about this docu ment 2 2 Safety instructions All safety instructions in this document are based on the results of the risk assessment carried out in accordance with Machinery Directive 2006 4...

Page 11: ... persons Allow the vacuum pump to cool down before carrying out any work Contact Pfeiffer Vacuum for suitable touch protection in system solutions Risks during operation WARNING Danger of poisoning due to toxic process media escaping from the exhaust pipe During operation with no exhaust line the vacuum pump allows exhaust gases and vapors to escape freely into the air There is a risk of injury an...

Page 12: ... poisonous substances Illegal disposal of toxic sub stances causes environmental damage Take suitable safety precautions and prevent health hazards or environmental pollution by toxic process media Decontaminate affected parts before carrying out maintenance work Wear protective equipment WARNING Danger of injury from strong magnetic field There is a risk of injury for people with pacemakers and m...

Page 13: ...vent of a fault the surface temperature of the vacuum pump can increase to above 105 C Allow the vacuum pump to cool down before carrying out any work Wear personal protective equipment if necessary CAUTION Danger of injury from moving parts After a power failure or a standstill as a result of overheating the motor restarts automatically There is a risk of injury to fingers and hands if they enter...

Page 14: ...g agents or cleaning agent residues Do not carry out your own conversions or modifications on the unit Observe the unit protection class prior to installation or operation in other environments Provide suitable touch protection if the surface temperature exceeds 70 C 2 4 Safety precautions for vacuum pumps with magnetic coupling The following safety instructions are only valid for the working with...

Page 15: ...cuum pump outside the specified area of application Use for pressure generation Use in strong electrical magnetic or electromagnetic fields Connection to vacuum pumps or equipment which are not suitable for this purpose according to their operating instructions Connection to devices with exposed live parts Use of accessories or spare parts not listed in these instructions Use of operating fluids o...

Page 16: ... guidelines and laws referred to in this documentation The above individuals must have an explicitly granted operational authorization to commission program configure mark and earth devices systems and circuits in accordance with safety technology standards Trained individuals Only adequately trained individuals may carry out all works in other transport storage operation and disposal fields Such ...

Page 17: ...uum connection 8 Base plate 2 Protective cap 9 Stand 3 Handle 10 Drain screw 4 Exhaust connection 11 Sight glass 5 Mains switch single phase motor only 12 Filler screw 6 Motor 13 Gas ballast valve 7 Locking screw oil pressure switch 3 2 Operating principle 1 3 4 5 6 2 Fig 3 Rotary vane vacuum pump functional principle 1 Housing 4 Vane 2 Vacuum flange inlet 5 Suction chamber 3 Rotor 6 Exhaust outle...

Page 18: ... causing condensation in the suction chamber Operating fluid oil The pump oil also known as operating fluid fulfills various tasks in a rotary vane pump lubrication of all moving parts filling part of the dead volume under the exhaust valve sealing the gap between the intake and exhaust channel and between the vanes and the working chamber ensuring an optimal temperature balance through heat trans...

Page 19: ...t aid if necessary trolley lift truck 3 Transport the product in its original packaging 4 Always place the product on an adequately sized level surface 3 1 2 Fig 4 Transporting the vacuum pump 1 Handle 3 Base plate 2 Protective caps Transporting the vacuum pump without its packaging 1 Unpack the vacuum pump 2 To protect the inside of the pump leave both protective caps on the connection flanges du...

Page 20: ... sure that the gas ballast valve is closed 4 Store the vacuum pump only in dry dust free rooms within the specified ambient conditions 5 In rooms with humid or aggressive atmospheres Hermetically seal the vacuum pump together with a drying agent in a plastic bag 6 Change the operating fluid if the storage period is longer than 2 years Transportation and Storage 20 60 ...

Page 21: ...nrestricted access for untrained persons Touch protection required Pfeiffer Vacuum supports you in implementing the touch protection 1 Place the vacuum pump on a flat horizontal surface to safeguard the operating fluid supply 2 Observe the max permissible angle of inclination of 10 3 Screw the base plate of the vacuum pump to the mounting surface if necessary 4 When installing the pump in a closed...

Page 22: ...onnect the exhaust side CAUTION Danger of injury from bursting as a result of high pressure in the exhaust line Faulty or inadequate exhaust pipes lead to dangerous situations e g increased exhaust pressure There is a danger of bursting Injuries caused by flying fragments the escaping of high pressure and damage to the unit cannot be excluded Open shut off units immediately before or at the same t...

Page 23: ... from condensate 1 Install a condensate separator in the exhaust line if necessary 2 Use the lowest exhaust line point for the condensate drain 5 4 Fill operating fluid WARNING Danger of poisoning from toxic vapors Igniting and heating synthetic operating fluid generates toxic vapors Danger of poisoning if inhaled Observe the application instructions and precautions Do not allow tobacco products t...

Page 24: ...lectric shock Touching exposed and voltage bearing elements causes an electric shock Improper connection of the mains supply leads to the risk of touchable live housing parts There is a risk to life Before the installation check that the connection leads are voltage free Make sure that electrical installations are only carried out by qualified electricians Provide adequate grounding for the device...

Page 25: ...ction switch In event of excess temperature the protection switch interrupts the motor current but does not offer a per manent shut down of the motor Once the engine has cooled the vacuum pump restarts automatically U1 U2 L1 L2 N M Z1 Z2 21 1 20 Fig 9 Motor circuit diagram single phase motor with switch On site protection The magnetic coupling does not offer an overload protection The magnetic cou...

Page 26: ...upply lines is called mains voltage The mains current is the current flowing in the incoming supply lines W2 U1 L1 V2 V1 W1 U2 L3 L2 W2 U2 V2 U1 V1 W1 L1 L2 L3 Fig 11 Star circuit for high voltage The ends of the 3 phases are connected in the star point The terminal voltage is 3 times the phase voltage the mains current is equal to the phase current The star circuit is marked with the Y symbol 5 5...

Page 27: ... button H1 Tripping indicator S2 ON button M Motor 3 phase S3 RESET button 1 For devices with two relay outputs only K1 Contactor 2 For MSR type model only F1 F4 Fuses 3 Only for order no P 4768 052 FQ and P 4768 052 FE Procedure After shut down switch the tripping unit back on manually via the installed RESET button or via the external RESET S3 Switching on mains detected as automatic RESET 5 5 6...

Page 28: ...the settings for the motor protection switch from the following table Set the desired value on the contactor Voltage V Frequency Hz Motor rating kW IN A Imax A 190 210 330 365 200 230 346 400 50 0 25 1 55 6 50 0 25 0 9 3 60 0 25 1 35 5 60 0 25 0 78 3 218 242 380 420 250 277 440 480 50 0 25 1 7 8 50 0 25 1 0 5 60 0 3 1 7 8 60 0 3 1 0 5 Tbl 6 Motor protection switch settings Installation 28 60 ...

Page 29: ...ecifications on the motor rating plate with the available mains voltage and frequency 3 Protect the vacuum pump from sucking in contaminates using suitable measures 4 Check the operating fluid at regular intervals 5 Check the exhaust connection for free passage max permissible pressure 1500 hPa absolute 6 Actuate the shut off units so that the shut off units open before or at the same time as the ...

Page 30: ...cuum con nection closed Inspect operating fluid level 1 Regularly check operating fluid level while vacuum pump is running and at operating temperature 2 Make sure that fill level is within markings on sight glass 3 Check operating fluid fill level daily during continuous operation and every time vacuum pump is switched on 6 3 Operating the rotary vane pump with gas ballast NOTICE Risk of damage f...

Page 31: ...as pressure of 1 500 hPa absolute Dose the flushing gas quantity with the dosing screw on the gas ballast valve or on site Flushing gas valve installation is optional For some processes Pfeiffer Vacuum recommends the addition of flushing gas to dilute the process gas and prevent condensation in the vacuum pump 1 Fig 14 Gas ballast valve with flushing gas connection 1 Flushing gas connection M 5 wi...

Page 32: ...WAF 8 Calibrated torque wrench tightening factor 2 5 Fill operating fluid Operating fluid can be refilled during operation in the final vacuum 1 Unscrew the filler screw 2 Refill with operating fluid up to the max mark before the minimum fill level is reached 3 Screw in the filler screw again Be careful with o ring Tightening torque 3 0 Nm 6 5 Switching off the vacuum pump NOTICE Contamination fro...

Page 33: ... operations Pfeiffer Vacuum rotary vane pumps have an integral vacuum safety valve on the intake side The vac uum safety valve automatically closes from a differential pressure of 250 hPa between the exhaust and intake sides when the vacuum pump is switched off and vents the vacuum pump Procedure 1 If required switch the vacuum pump off in each pressure range 2 Switch the mains switch off or secur...

Page 34: ...still as a result of overheating the motor restarts automatically There is a risk of injury to fingers and hands if they enter the operating range of rotating parts Safely disconnect motor from the mains Secure the motor against reactivation Dismantle the vacuum pump for inspection away from the system if necessary NOTICE Danger of property damage from improper maintenance Unprofessional work on t...

Page 35: ... Reduced maintenance intervals Depending on the operating conditions the required maintenance intervals can be shorter than the ref erence values specified Contact Pfeiffer Vacuum Service Spare parts You can find the corresponding spare parts in the chapter Spare parts packages Action described in document OI or MM Inspec tion OI Mainte nance lev el 1 OI Mainte nance level 2 MM Mainte nance level ...

Page 36: ...operating fluid Danger of burns when draining operating fluid if it comes into contact with the skin Wear protective equipment Use a suitable collection receptacle Pfeiffer Vacuum recommends determining the precise service life of the operating fluid in the first operating year The service life may deviate from the reference value specified depending on thermic and chemical loads and the accumulat...

Page 37: ... Be careful with o ring 2 Use the pipette to extract a sample of the operating fluid from the filling port 3 Pour the sample into a test tube 4 Check the sample in bright light 5 If it is a reddish brown color at the latest corresponding with color identification number 5 change the operating fluid 6 Screw in the filler screw Be careful with o ring Tightening torque 3 Nm 7 4 2 Change the operating...

Page 38: ...er screw Be careful with o ring 2 Place a collection receptacle below the drain hole 3 Unscrew the drain screw Be careful with o ring 4 Allow operating fluid to drain into collection receptacle Agitate remaining operating fluid 1 Screw in the filler screw 2 Screw in the drain screw 3 Switch on the vacuum pump with the vacuum flange open for a maximum of 5 seconds Drain remaining operating fluid 1 ...

Page 39: ...erating fluid changes 3 Check pollution level and repeat process if necessary 4 If accessories are installed replace corresponding filter elements 1 1 2 Fig 17 Remove rotary vane pump cap 1 Stand 4 Allen head screws 2 Pumping system 5 Cap 3 O ring 6 Drain screw Remove and clean cap 1 Drain operating fluid 2 Unscrew 4 Allen head screws from cap 3 Remove cap from rotary vane pump stand Take care wit...

Page 40: ...5 Remove and clean gas ballast filter The gas ballast valve is soiled if the vacuum pump takes in ambient air containing dust 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 Fig 18 Individual parts of the gas ballast valve 1 Valve housing 9 Cylinder bolt 2 O ring 6 2 2 10 Rotary knob 3 Tappet 11 Countersink screw 4 O ring 8 2 12 O ring 27 2 5 5 Compression spring 13 Plate spring 6 Washer 14 Washer 7 Circlip 1...

Page 41: ... Be careful with o ring 8 Unscrew cylinder screw from valve housing underside 9 Be careful with washer and compression spring Dowel pin remains in valve housing 10 Clean all parts and check parts for wear 11 Replace wear parts according to maintenance kit 7 5 3 Remove and clean silencer nozzle The silencer nozzle is installed below the gas ballast valve The nozzle has a type specific opening If th...

Page 42: ...ad screws Tightening torque 1 0 Nm 15 Position leaf spring on dowel pin curvature facing housing 16 Bias and fixate leaf spring with cylinder screw and washer Tightening torque 2 5 Nm 17 Install complete valve with O ring 18 Tighten cheese head screws Tightening torque 2 5 Nm 7 6 Changing the operating fluid type Possibilities for changing the operating fluid type The operating fluid type can be c...

Page 43: ...ms within the specified ambient conditions 10 Pack the vacuum pump together with a drying agent in a plastic bag and seal the vacuum pump airtight if it is to be stored in rooms with damp or aggressive atmospheres 11 For longer storage periods 2 years Pfeiffer Vacuum recommends changing the operating fluid again prior to recommissioning 8 2 Recommissioning NOTICE Risk of damage to vacuum pump as a...

Page 44: ...mponents must be disposed of in accordance with the applica ble regulations relating to environmental protection and human health with a view to reducing natural resource wastage and preventing pollution 9 1 General disposal information Pfeiffer Vacuum products contain materials that you must recycle Dispose of our products according to the following Iron Aluminium Copper Synthetic Electronic comp...

Page 45: ...onnect motor from the mains Secure the motor against reactivation Dismantle the vacuum pump for inspection away from the system if necessary NOTICE Danger of property damage from improper maintenance Unprofessional work on the vacuum pump will lead to damage for which Pfeiffer Vacuum accepts no liability We recommend taking advantage of our service training offering When ordering spare parts speci...

Page 46: ...uid level too low Top up the operating fluid Leak in system Locate and eliminate the leak Vacuum pump is dam aged Contact Pfeiffer Vacuum Serv ice Pumping speed of vacuum pump too low The intake line is not suit ably dimensioned Make sure that connections are short and cross sections ade quately dimensioned Exhaust pressure too high Check exhaust line outlet open ing and exhaust side accesso ries ...

Page 47: ...lity You can find more detailed information and addresses on our homepage in the Pfeiffer Vacuum Service section You can obtain advice on the optimal solution for you from your Pfeiffer Vacuum representa tive For fast and smooth service process handling we recommend the following 1 Download the up to date form templates Explanations of service requests Service requests Contamination declaration a ...

Page 48: ...oduct in suitable stable transport containers only e Maintain applicable transport conditions ERKLÄRUNG KONTAMINIERUNG 6 Attach the contamination declaration to the outside of the packag ing 7 Now send your product to your local Service Center 8 You will receive an acknowledgment quotation from Pfeiffer Vac uum Our sales and delivery conditions and repair and maintenance conditions for vacuum devi...

Page 49: ...version PK E31 004 AT Overhaul kit maintenance level 3 M version PK E32 008 T MC version PK E32 006 T Set of vanes M version PK E38 008 T MC version PK E38 009 T Coupling set M version PK E36 005 T MC version PK E36 006 T Tbl 9 Spare part packages 12 2 Maintenance kit 1 maintenance level 1 Order no PK E31 004 AT Maintenance kit 1 contains Filler and drain screw seals for one operating fluid change...

Page 50: ...tains all the wear parts of the vacuum pump which must be replaced after the vac uum pump has been dismantled and cleaned Set of seals Wear parts of the pumping system including vane and springs Wear parts of the vacuum safety valve Wear parts of the gas ballast valve 12 4 Coupling set for versions with magnetic coupling The coupling set contains Both coupling halves Containment shell with O ring ...

Page 51: ... For cooling e g with liquid nitrogen Prevents backflow of any operating fluid vapors through condensa tion and protects the vacuum pump and operating fluid against vapors from the process PTC resistor tripping device Monitors the temperature of the motor winding Process monitoring unit Monitors the operating fluid level operating fluid temperature exhaust pressure 13 2 Order accessories Descripti...

Page 52: ...ure Switch PK 196 484 T OME 16 C Oil Mist Separator PK Z40 400 Oil Return Unit from OME 16 S to Duo 5 M Duo 10 M PK 005 987 T Blank Flange Gas Ballast Valve PK 196 391 T Tbl 12 Accessories for Duo 5 MC Selection field Part number P3 mineral oil 1 l PK 001 106 T P3 mineral oil 5 l PK 001 107 T P3 mineral oil 20 l PK 001 108 T D1 synthetic diester based oil 1 l PK 005 875 T D1 synthetic diester base...

Page 53: ...m 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 Tbl 15 Conversion table Units for gas throughput 14 2 Technical data Type designation Duo 5 M Duo 5 M Duo 5 M Duo 5 M Part number PK D61 105 PK D61 707 PK D61 712 PK D61 017 Connection flange in DN 16 ISO KF DN 16 ISO KF DN...

Page 54: ...0 Hz 0 25 kW 0 37 kW 0 37 kW 0 37 kW Rated power 60 Hz 0 3 kW 0 37 kW 0 37 kW 0 37 kW Rotation speed at 50 Hz 1500 rpm 1500 rpm 1500 rpm 1500 rpm Rotation speed at 60 Hz 1800 rpm 1800 rpm 1800 rpm 1800 rpm Magnetic coupling Yes Yes Yes Yes Protection degree IP55 IP55 IP55 IP54 Switch No Yes Yes Yes Mains cable No Yes Yes Yes Mains cable included No Yes Yes Yes Weight 19 kg 25 kg 25 kg 22 kg Tbl 16...

Page 55: ... 0 37 kW Rotation speed at 50 Hz 1500 rpm 1500 rpm Rotation speed at 60 Hz 1800 rpm 1800 rpm Magnetic coupling Yes Yes Corrosive gas version Yes Yes Protection degree IP55 IP55 Switch Yes Yes Mains cable Yes Yes Mains cable included Yes Yes Weight 25 kg 25 kg Tbl 17 Technical data Duo 5 MC 14 3 Dimensions Dimensions in mm 2x Ø7 61 47 18 7 5 4 5 216 1 107 100 114 Ø7 135 160 147 DN 16 ISO KF 65 47 3...

Page 56: ...79 58 Fig 23 Dimension diagram Duo 5 M single phase motor 230 V 3 216 2 n7 248 216 1 47 65 205 137 58 435 1 107 100 114 Ø7 135 237 1 35 47 61 DN 25 ISO KF Ø14 4 5 13 160 Hose connection Fig 24 Dimension diagram Duo 5 M single phase motor 230 V hose connection Technical data and dimensions 56 60 ...

Page 57: ...3 147 58 216 79 2 n7 248 438 1 201 5 1 47 65 107 100 114 Ø7 135 13 216 1 18 4 5 47 61 DN 16 ISO KF 160 Fig 25 Dimension diagram Duo 5 M three phase motor Technical data and dimensions 57 60 ...

Page 58: ...ubstances delegated directive 2015 863 EU Harmonized standards and applied national standards and specifications DIN EN ISO 12100 2011 DIN EN 61010 1 2011 DIN EN 1012 2 2011 12 DIN EN 61000 6 2 2006 DIN EN ISO 13857 2008 DIN EN 61000 6 4 2011 DIN ISO 21360 1 2016 DIN EN ISO 2151 2009 ISO 21360 2 2012 DIN EN IEC 63000 2019 The authorized representative for the compilation of technical documents is ...

Page 59: ...59 60 ...

Page 60: ... PK0197 ed Q Date 2012 P N PK0197BEN ...

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