Betriebsanleitung • Operating Instructions
Translation of the Original Operating Instructions
PK 0197 B%/I (0901)
Rotary Vane Pump
DUO 5 M
DUO 5 MC
Table of contents
Table of contents
1 About this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0
5.1 Setting up the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Connecting the vacuum side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Connecting the exhaust side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.4 Connecting to the mains power supply . . . . . . . . . . . . . . . . . . . . . . 1 1
5.5 Filling up the operating f luid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4
5.6 Operation s M o n itorin g (Optio n ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6
6.1 Before switching on the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6
6.2 Switching on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6
6.3 Pumping conden sa ble vapours. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6
6.4 Swit ching off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9
7.2 Changing the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.3 Cleaning or changing the silencer. . . . . . . . . . . . . . . . . . . . . . . . . . 2 3
8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1 Shutting down for longer periods. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4
8.2 Restarting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5
9.1 Rectifying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.1 Spare parts packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3
2
1 About this manual
1.1 Validity
This operating manual is for customers of Pfeiffer Vacuum. It describes the functioning of the designated product and provides the most important information for
safe use of the unit. The description follows applicable EU guidelines. All information provided in this operating manual refer to the current state of the product's development. The documentation remains valid as long as the customer does not
make any changes to the product.
Up-to-date operating instructions can also be downloaded from
www.pfeiffer-vacuum.net.
Applicable documents
DUO 5 M/MC Operating instructions
Safety information for vacuum pumps "Safety Guide" PT 0300 BN*
Declaration of Conformity Part of this document
Operating instructions for accessories (order-specifically) see section "accessories"*
*also available via www.pfeiffer-vacuum.net
About this manual
1.2 Conventions
Safety instructions
The safety instructions in Pfeiffer Vacuum operating manuals are the result of risk
evaluations and hazard analyses and are oriented on international certification
standards 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:
DANGER
Immediate danger
Death or very severe injuries occur.
WARNING
Possible danger
Death or injuries may occur.
CAUTION
Possible danger
Medium to slight injuries may occur.
NOTE
Command or note
Command to perform an action or information about properties, the disregarding of
which may result in damage to the product.
3
About this manual
G
Pictograph
definitions
Instructions in the
text
Abbreviations used
Symbols used
Prohibition of an action or activity in connection with a
source of danger, 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 danger, the disregarding of which may result in
serious accidents.
Work instruction: here you have to do something.
C version: Corrosive gas version
The following symbols are used consistently throughout in all illustrations:
V
Vacuum flange
Exhaust flange
Gas ballast valve
Power connection
4
2Safety
2.1 Safety precautions
Duty to inform
Each person involved in the installation, operation or maintenance of the vacuum
pump must read and observe the safety-related parts of these operating instructions.
Absolute observe the safety information for vacuum pumps (PT 0300 BN) !
The operator is obligated to make operating personnel aware of dangers originating
from the vacuum pump, the pumped medium and the entire system.
Installation and operation of accessories
Pfeiffer Vacuum pumps can be equipped with a series of adapted accessories. The
installation, operation and maintenance of connected devices are described in detail in
the operating instructions of the individual components.
For information on the operating instructions of components, see "Accessories".
Use original accessory parts only.
Safety
NOTE
NOTE
• Do not expose any body parts to the vacuum.
• Observe the safety and accident prevention regulations.
• Check regularly that all safety precautions are being complied with.
• Do not carry out any unauthorised modifications or conversions to the pumps.
• Depending on the operating and ambient conditions, the surface temperature of
the pumps may rise above 70 °C. Use suitable finger guards if necessary.
• When returning the pumps to us please note the instructions in the Service section.
The following safety instructions are only valid for the disassembly of the drive
system for a vacuum pump with a magnetic coupling:
• When disassembling the drive system from the pump housing, the strong magnetic field may influence the function and operational reliability of electrical and
electronic devices.
• Persons with cardiac pacemakers must keep away from the magnetic coupling.
Danger to life!
• Disassembled magnetic couplings must be kept away from computers, data storage media and other electronic components.
• Keep the disassembled components of the magnetic coupling separate at all times. Danger of crushing!
• Do not allow any magnetised parts into the vicinity of the magnetic coupling.
Danger of injury!
5
Safety
2.2 Proper use
2.3 Improper use
NOTE
CE conformity
The manufacturer's declaration of conformity becomes invalid if the operator modifies
the original product or installs additional components.
Following installation into a plant and before commissioning, the operator must
check the entire system for compliance with the valid EU directives and reassess it
accordingly.
• The vacuum pump may only be used to generate a vacuum.
• Installation, operating and maintenance regulations must be complied with.
• Other accessories than those described in this manual must not be used without
the agreement of Pfeiffer Vacuum.
Improper use will cause all claims for liability and guarantees to be forfeited. Improper use is deemed to be all use for purposes deviating from those mentioned
above, especially:
• Pumping of corrosive gases (exception: pumps in C version).
• Pumping of explosive media.
• Operation of the pump in potentially explosive areas.
• Pumping of gases containing impurities such as particles, dusts and condensate;
note the vapour compatibility levels of the pump.
• Pumping of substances that tend to sublime.
• Use of the vacuum pump to generate 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.
6
3 Transport and storage
3.1 Transport
Transport instructions
Remove the locking cap from the vacuum and exhaust flange immediately be-
fore connecting!
– Check the protective strainer, paying attention to the o-ring.
Use only the handle or the crane eye on the top side of the pump to lift the pump.
– Is the pumps weight > 25 kg lift the pump by a crane.
Transport and storage
3.2 Storage
Fig. 1: Transporting the pump
Check that all the openings on the pump are securely closed.
Store the pump in a cool, dry place; preferably at room temperature (approx.
20°C).
– For a longer period of storage, seal the pump in a PE bag with drying agents
enclosed.
– For a period of storage longer than one year, it is recommended to carry out
maintenance and change the operating fluid.
7
Product description
D-35641 Asslar
Mod.: DUO 10
Mod.-Nr.: PK D62 105 D
Ser.- Nr.: 3454440
S : max. 10 m /h
Oil : P3 1.0 l
Mass : 24 kg
n : 1800 1/min
(N )
2
3
max.
Made in Germany 2005/01
4 Product description
4.1 Product identification
To correctly identify the product when communicating with Pfeiffer Vacuum, always have the information from the rating plate available and use it:
• Pump model and model number
• Serial number
• Type and amount of operating fluid
• Date of manufacture
Please find the voltage range and motor-related data on the separately attached
motor rating plate.
Scope of delivery
Differences between
the pump type
Fig. 2: Product identification on the rating plate
• Pump with motor (power cord/power switch --> dependent on the motor type)
• Operating fluid P3 (for standard pump)
• Cone strainer and centering ring with O-ring
• Locking cap for vacuum and exhaust flange
• Operating instructions
Pump type Pump versions
DUO 5 M Standard version of pump
C version of pump; differences from the standard version:
DUO 5 MC
• Operating fluid F4
• Encapsulated can of the magnetic coupling at the pump system
• Vane material changed
• Gas ballast valve with dosable flushing gas connection
8
4.2 Function
Product description
The vacuum pumps of the DuoLine® are dual stage rotary vane pumps and are
used primarily for rough and medium vacuum applications. The pumps are fitted
with a hydraulically controlled vacuum safety valve which, when the pump is at a
stillstand, closes the vacuum chamber vacuum tight and at the same time vents the
pump. The integrated magnetic coupling functions free of contact and friction.
Therefore it is not subjected to any mechanical wear and is completely maintenance free compared to a conventional shaft feedthrough.
1198 2 1542
11 0 8 028198 a
Fig. 3: Rotary Vane Pump DUO 5 M
1 Vacuum flange
2 Exhaust flange
15 Main switch
28 Casing
42 Gas ballast valve
80 Base plate
110 Sight glass
198 Operating fluid filler screw
198a Operating fluid drain screw
9
Installation
max. 10
°
> 35 mm
5 Installation
5.1 Setting up the pump
Installation location
When installing the pump, observe the following conditions:
• Note the load-bearing capacity of the mounting surface.
• Maximum installation altitude 2000 m (above mean sea level)
• Permissible ambient temperature: +12 ... 40°C
• Maximum relative humidity 85%
Fig. 4: Setting up
Fill up with operating fluid before operating the first time (see p. 14, chap. ).
– Amount and type according to rating plate
Always place the pump on a firm, even surface.
– Where stationary installation is involved, anchor the pump on site.
When installing the pump in a closed housing, ensure there is sufficient air cir-
culation.
– Sightglass and gas ballast valve must be visible and readily accessible.
– Voltage and frequency information given on the motor rating plate must be
visible.
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.
The connection between the pump and the recipient should be kept as short as
possible.
– Depending on the pump type, use metallic hoses or PVC hoses with flange
connections.
– Separators, filters etc. may be installed upstream to protect the pump (see ac-
cessories). However, please observe the loss of pumping capacity due to the
conductivity of the accessories.
10
5.3 Connecting the exhaust side
High pressure in the exhaust line!
Danger of damage to the seals and danger of the pump bursting.
Install the line without shut-off valves on the exhaust side.
If there is danger of a build-up of excess pressure (> 1500 mbar abs.) in the lines,
observe all official accident prevention safety regulations.
If the exhaust gases are being extracted, the exhaust pressure must be at least
250 mbar greater than the pressure at the intake side.
Choose the cross-section of the exhaust line to be at least the size of the nominal
connection diameter of the vacuum pump's exhaust connection.
Piping to the pump must be suspended or supported.
– Physical forces from the piping system must not be allowed to act on vacuum
pumps.
Lay piping from the pump sloping downward so that no condensate can flow
back into the pump; otherwise fit a condensate separator.
– If an air trap is created in the system, then a device for draining condensation
water must be provided at the lowest point.
Installation
CAUTION
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 with the applicable regulations when working with toxic substances.
Only officially approved filter systems may be used to separate and remove these
substances.
5.4 Connecting to the mains power supply
Depending on the pump type, different motor versions are possible:
• Single phase motor for fixed voltage with a built-in thermal protection switch,
mains switch and connecting cable.
• Three phase motor (without switch and mains cable).
Voltage-bearing elements
Danger to life from electric shock.
The electrical connection can be carried out only by trained and authorised electrici-
ans.
Ensure the system is adequately earthed.
WARNING
DANGER
CAUTION
Excess voltage!
Danger of destroying the motor.
Power connections must comply with local regulations. Voltage and frequency infor-
mation given on the motor rating plate must correspond to the mains voltage and
frequency values.
To protect the motor and supply cable in case of malfunction, mains fuse protection
must be implemented.
11
Installation
WARNING
Danger of injury from moving parts!
After power failure or motor shutdown due to overheating, the motor may restart automatically.
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.
NOTE
The transmission power of the pump’s magnetic coupling is so great that there
is no overload protection for the motor.
Single phase motors
The vacuum pumps are fitted with a built-in thermal protection switch. Depending
on the type of pump, different motor versions with a power cord are possible:
Fig. 5: Motor circuit diagram with switch
Fuse protection
To protect the motor in case of malfunction, carry out fuse protection in accor-
dance with the regional regulations.
– Select a fuse with slow characteristics.
Three-phase motor
12
Inspection of the direction of rotation
With pumps with three-phase motors is it necessary to check the direction of rotation!
CAUTION
Operating fluids may leak out!
If the direction of rotation is incorrect, there is a danger that operating fluids may leak
at the vacuum flange.
Always check the direction of rotation before filling in operating fluid.
Remove the locking cap from the exhaust flange (if existing).
Switch the pump on briefly (from 2 to 3 sec.).
– The motor and motor fan must turn in a clockwise direction (see the arrow on
the support stand).
If the direction of rotation is incorrect: Swap two phase contacts at the connec-
ting cable.
Fill up the operating fluid.
Installation
N
L1
M
3
L2
L3
F1 - F3
K1
10
11
AC 220 ... 240 V
Us
F4
U
V
W
S1
S2
k1
K1
H1
S3
2)
A1 A2 T1 T2 Y2Y1 24 21 22 14 1211
2)
2)
1)
1)
1)
T1...T3
3)
Motor protection
Pump motors equipped with PTC temperature sensors (3PTC) in the stator windings can be connected to a PTC resistor tripping device for protection against overload.
Tripping devices store the shutdown event and need to be manually switched back
on again via the integrated RESET button or via the external RESET S3. Mains-ON
is detected as an automatic RESET. Other approved motor temperature monitoring
can be used also by the operator.
Set up the connections so that the directional rotation indicated on the pump is
maintained, regardless of the representations in the current flow diagram.
Control voltage
U
S
OFF button
S
1
S
ON button
2
RESET button, external
S
3
K1 Contactor
F1 ... F4 Fuses
T1... T3 PTC resistor sensor
H1 Tripping indicator
M Motor, 3-phase
1)
Only for devices with two
relay outputs
2)
Only for MSR type
3)
Only for order no.:
P 4768 051 FQ
Fig. 6: Connection example for a three-phase AC motor with PTC resistor tripping device
13
Installation
max.
min.
198
5.5 Filling up the operating fluid
The type and amount of operating fluid should be visible on the pump's rating
plate for every rotary vane pump.
The delivery consignment for the standard pump contains suffient operating fluid for one filling. Pumps for special applications (e.g. for pumping corrosive gases)
can be operated with other operating fluids. These must be defined in accordance
with Pfeiffer Vacuum specifications before initial assembly and ordered separately.
Permissible operating fluids
• P3 (Standard operating fluid)
• F4 (Operating fluid for corrosive gas versions)
• D1 (for special applications and higher operating temperature)
– Final pressure of measurement, depending on the type of gas: < 5·10
Guarantees relating to attainment of final pressures and trouble free functioning
of the pump apply only providing a permissible operating fluid is used.
NOTE
-2
mbar
Filling up the
operating fluid
Unscrew operating fluid filler screw 198.
Fill up operating fluid.
– Correct filling level during operations: Within the markings at the sightglass
frame.
Fig. 7: Filling up the operating fluid
Screw in operating fluid filler screw 198.
Check operating fluid level only when the pump is warm and running; close
– vacuum flange and gas ballast valve to do so.
– 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.
14
WARNING
Toxic vapours!
Danger of poisoning when igniting and heating synthetic operating fluids (e.g. F4/F5)
above 300°C.
Observe the application instructions of the operating fluid manufacturer.
Do not allow operating fluid to make contact with tobacco products; observe safety
precautions when handling chemicals.
5.6 Operations Monitoring (Option)
1
2
A pressure switch can be installed on the side of the support to monitor the oil
pressure of the rotary vane pump during operations. By pressure drop and when
the pump is at rest, the contact of the pressure switch opens. The signal can be
used to control external valves.
Switching voltage: 5 ... 250 Volt (potential free)
Maximum current: 2 Amp.
Protection type: IP 55
Installation
1 + 2 closers = pressureless open
Fig. 8: Installation location and circuit diagram of pressure switch
15
Operation
6 Operation
6.1 Before switching on the pump
Check the operating fluid level in the sightglass.
Compare the voltage and frequency information on the rating plate with the
mains voltage and frequency values.
Check that the exhaust connection allows free flow (max. permissible pressure
1.5 bar absolute).
– Activate the shut-off valves in such a way that they open before or at the same
time as the pump is started.
Protect the pump sufficiently from taking in contaminants by means of suitable
precautions (e.g. dust filters); if necessary, check operating fluid regularly or replace at shorter intervals.
6.2 Switching on the pump
The pump can be switched on in any pressure range.
No special precautions are necessary when pumping dry gases. In order to attain
the lowest possible final pressures, the gas ballast valve should be closed.
Hot surface!
Danger of burns if hot parts are touched. Depending on the operating and ambient
conditions, the surface temperature of the pump may rise above 70 °C.
In this case, use suitable finger guards.
Switch on pump at main switch 15.
6.3 Pumping condensable vapours
Should the process gases contain condensable gases present at high percentages,
the rotary vane pump must be operated with a gas ballast (i.e. with an open gas
ballast valve).
Bad final vacuum and damage to the pump!
Danger of condensation and corrosion due to exceeding the water vapour compatibility (see Technical data) during operation without a gas ballast or in case of insufficient
supply of flushing gas.
Only pump vapours when the pump is warm and the gas ballast valve is open.
When the process has been completed, allow the pump to continue running for
about 30 minutes with the vacuum flange closed and the gas ballast open for operating fluid regeneration purposes.
CAUTION
CAUTION
Gas ballast valve,
standard version
16
To avoid condensation in the pump when pumping condensable vapours, ambient
air or alternatively inertgas is periodically fed into the working chamber at the beginning of the compression phase via the gas ballast valve 42.
The gas ballast valve is closed when turning to the right to position 0 and open
when turning to the left to position 1. Intermediate settings are not possible.
Fig. 9: Standard version 42 of gas ballast valve
0
0
1
1
0
1
0
1
C-Version
Operation
Gas ballast valve,
corrosive gas version
If the pumping process requires the connection of flushing gas, the C version of the
gas ballast with the flushing gas connection must be used.
Fig. 10: Corrosive gas version of gas ballast valve
CAUTION
Flushing gas pressure higher than allowed endangers the operational reliability
of the pump.
The power input of the pump, the temperature and the ejection of operating fluid will
increase.
Observe the maximum permissible flushing gas pressure.
Set the amount of flushing gas on site.
Connect flushing gas at the flushing gas connection.
Set flushing gas pressure; maximum pressure 1.5 bar (absolute).
– Select the type and amount of flushing gas depending on the process; consult
Pfeiffer Vacuum if necessary.
17
Operation
6.4 Switching off the pump
The pump can be switched off in any pressure range.
Rotary vane pumps have an integrated safety valve on the intake side. If the differ-
ential pressure between the exhaust side and the intake side is ≥ 250 mbar, then
the valve closes automatically and vents the pump when the pump is switched off.
Switch the pump off at the mains switch or disconnect from the mains in a secu-
re manner.
Venting the vacuum
chamber
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.
CAUTION
Maintaining the vacuum in the chamber
CAUTION
Danger of backflow of operating fluid into the intake line!
Contamination of the connected vacuum system!
Because the safety valve of the pump is not suitable for longer-term sealing, install
an additional shut-off valve in the intake line.
Shut off the intake line immediately after switching off the pump.
18
7 Maintenance
7.1 Precautions
Danger of injury from moving parts!
After power failure or motor shutdown due to overheating, the motor may restart automatically.
Secure the motor so that it cannot be switched on while any work is being performed
If necessary, dismantle the pump from the installation for inspection.
Pump parts may be contaminated from pumped media!
Danger of poisoning due to contact with harmful substances.
Decontaminate the pump before carrying out any maintenance work.
In the event of contamination, take suitable safety precautions to prevent your health
Maintenance
WARNING
on the pump.
WARNING
from being harmed by any dangerous substances.
Switch off the pump, vent it to atmospheric pressure and let it cool down.
Disconnect the drive motor from the mains and secure it so that it cannot be
switched on.
Only dismantle the pump as far as necessary in order to repair defects.
Dispose of used operating fluid in compliance with local regulations.
When using synthetic operating fluids or working with toxic substances or sub-
stances contaminated with corrosive gases, the relevant instructions governing
their use must be observed.
Use only alcohol or similar agents for cleaning pump parts.
19
Maintenance
Checklist for inspection, maintenance
and overhaul
Certain repair and overhaul work should only be performed by Pfeiffer Vacuum
Service (PV). Pfeiffer Vacuum will be released from all warranty and liability claims
if the required intervals for inspection, maintenance, or overhaul are exceeded or
inspection, maintenance, repair or overhaul procedures are not performed properly. This also applies if replacement parts other than Pfeiffer Vacuum OEM replacement parts are used.
Activity daily as required;
at least
annually
as required;
at least
every 2
years
Check operating fluid level X
Visual inspection (leak-tightness/oil
leaks)
Check filter insert of external oil mist filter (if existent)
Change filter insert of external oil mist filter (if existent)
Change operating fluid X
Cleaning the pump and renew the seals X
Clean gas ballast valve and silencer
nozzle
Clean the motor fan cap X
Clean or change vacuum safety valve X (PV)
Clean or change exhaust valves X (PV)
Change vanes and hydraulic vane X (PV)
Check or change coupling X (PV)
Depending on the process, the required replacement intervals for lubricants and the intervals for
inspection, maintenance and overhaul may be shorter than the guide values specified in the
table. Consult with Pfeiffer Vacuum Service if necessary.
X
X
X
X
as required;
at least
every 4
years
20
7.2 Changing the operating fluid
The changing interval for the operating fluid depends on the pump applications,
but should be carried out once a year.
Depending on the applications, Pfeiffer Vacuum recommends determining the
exact service life of the operating fluid during the first year of operation.
The replacement interval may vary from the guide value specified by Pfeiffer Vacuum
depending on the thermal and chemical loads, and the accumulation of suspended particles and condensation in the operating fluid.
Hot operating fluid!
Danger of burns when draining due to contact with skin.
Wear suitable protective clothing.
Use a suitable collecting vessel.
Switch off pump.
Unscrew operating fluid drain screw 198a and drain operating fluid.
Fill the specimen in a test tube or some similar vessel and test by holding
against the light.
The level of deterioration of operating fluid P3 can be read off the colour scale
in accordance with DIN 51578; request the supplementary sheet PK 0219 BN or
download it from the Internet.
Where discolouration is dark yellow to red brown (equivalent to 4 ... 5 on the sca-
le) change operating fluid.
Maintenance
NOTE
WARNING
198a
Fig. 11: Draining the operating fluid
WARNING
Operating fluid may contain toxic substances from the pumped media!
Danger of poisoning from the emission of harmful substances from the operating fluid.
Wear suitable protective clothing and respirators.
Dispose of operating fluid according to the local regulations
Screw in operating fluid drain screw 198a; pay attention to o-ring.
Allow pump to run for a maximum of 5 seconds with the vacuum flange open.
21
Maintenance
Drain off remaining operating fluid.
– In case of serious contamination, the operating fluid will have to be changed
several times (flushing):
Flushing
Fill up with operating fluid to the middle of the sight glass.
Operate the pump with the gas ballast open until the pump has warmed up.
Drain the operating fluid again and check for contamination, flush again if neces-
sary.
Screw the operating fluid drain screw back in.
Fill up with operating fluid and check the filling level (see p. 14, chap. ).
NOTE
Request safety data sheets for operating fluids and lubricants
from Pfeiffer Vacuum or download them from the Internet.
Dispose of operating fluid according to the local regulations.
22
7.3 Cleaning or changing the silencer
148
42
182
44
138
138
141
The silencer 44 is a nozzle inside the pump housing and cannot be altered; when
dirty it should either be cleaned or replaced.
Dismantling
Unscrew 2 cheesehead screws 182 from the gas ballast valve housing.
Remove the gas ballast valve housing 42 from the casing 28; taking care with o-
ring 148.
Unscrew silencer nozzle 44 and o-ring 138; clean it and replace o-ring 138 if ne-
cessary.
Maintenance
42 Gas ballast valve housing
44 Silencer nozzle
138 O-ring
141 O-ring
148 O-ring
Fig. 12: Gas ballast valve with silencer nozzle 44
23
Decommissioning
8 Decommissioning
8.1 Shutting down for longer periods
Before shutting down the pump, observe the following procedure and adequately
protect the pump system against corrosion:
Switch off pump.
Change operating fluid(see p. 21, chap. 7.2).
Start the pump and allow the pump to warm up.
Fill up the pump with new operating fluid to the top edge of the sightglass.
Close vacuum flange and exhaust flange with locking caps.
8.2 Restarting the pump
Visually inspect the inner of the pump before taking it into operation. If there is evidence of rust on the parts of the pump which form the housing then do not take it
into operation and contact Pfeiffer Vacuum Service.
With reference to DIN 7716 and the manufacturer's specifications we recommend
replacing the installed elastomer parts after 2 years.
If drying pearls were inserted then they should be removed now. Improper
handling can cause failure of the pump.
8.3 Disposal
CAUTION
Emission of operating fluid!
Danger of the operating fluid being emitted at the exhaust flange if overfilled.
Drain the operating fluid to the normal level before restarting the pump.
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 regulations.
24
9 Malfunctions
Please note the following instructions should the pump malfunction:
Strong magnetic field in the vicinity of the drive system!
Danger to life for persons with cardiac pacemakers when the drive system is disassembled.
Persons with cardiac pacemakers must not enter the area of the magnetic field.
Disassembled magnetic couplings must be kept away from computers, data storage
Hot surface!
Danger of burns if hot parts are touched. The surface temperature of the pump may
rise above 105 °C in case of malfunction.
Carry out work on the pump only after it has cooled to a safe temperature.
Motor overload!
Depending on the malfunction (e.g. blocking during cold start), the motor may not be
sufficiently protected by the built-in thermal protection switch from damage through
overheating.
Implement an additional network safety device.
Malfunctions
DANGER
media and other electronic components.
CAUTION
NOTE
25
Malfunctions
9.1 Rectifying malfunctions
Problem Mögliche Ursachen Behebung
Pump will not start
up
Pump switches off
after a while after
being started
Pump does not
attain final pressure
Pumping speed of
pump too low
Loss of operating
fluid
Unusual operating
noises
No mains voltage or voltage
does not correspond to the
motor data
Pump temperature too low Warm up pump to > 12°C
Thermal protection switch has
responded
Pump system dirty
Pump system damaged
Motor defective Replace motor
Thermal protection switch of
the motor has responded
Mains fuse protection triggered
due to overload (e.g. cold start)
Exhaust pressure too high
Measurement reading is false
Pump or connected accessories
are dirty
Operating fluid dirty
Leak in system Repair leak
Operating fluid filling level too
low
Pump damaged Contact Pfeiffer Vacuum Service
Intake line not well-dimensioned
Exhaust pressure too high
Swivel gasket leaky
Operational loss of operating
fluid
Silencer dirty
Damage to the pump system
Motor bearing defective
Check mains voltage and mains fuse
protection; check motor switch
Detect and fix cause of overheating;
allow pump to cool off if necessary
Clean pump; contact Pfeiffer Vacuum
Service if necessary
Clean and overhaul pump; contact Pfeiffer Vacuum Service if necessary
Detect and fix cause of overheating;
allow motor to cool off if necessary
Warm up pump
Check opening of exhaust line and
exhaust accessories
Check gauge, check final pressure without installation connected
Clean pump and check components for
contamination
Operate pump for a longer period with
gas ballast valve open or change operating fluid
Top off operating fluid
Keep connections as short as possible
and see that cross-sections are sufficiently dimensioned
Check opening of exhaust line and
exhaust accessories
Check tightness; replace gasket if necessary
If necessary, install oil mist filter and oil
return unit
Clean or replace the silencer; (see p. 23,
chap. 7.3)
Clean and overhaul pump; contact Pfeiffer Vacuum Service if necessary
Replace motor; contact Pfeiffer Vacuum
Service if necessary
26
NOTE
Service work should be carried out by qualified personal only!
Pfeiffer Vacuum is not liable for any damage to the pump resulting from work carried
out improperly.
Take advantage of our service training programs; additional information at
www.pfeiffer-vacuum.net.
Please state all the information on the pump rating plate when ordering spare parts.
10 Service
Service
Pfeiffer Vacuum offers first-class service!
• Maintenance/repairs on site by Pfeiffer Vacuum field service
• Maintenance/repairs in a nearby service center or service point
• Fast replacement with exchange products in mint condition
• Advice on the most cost-efficient and quickest solution
Detailed information and addresses at: www.pfeiffer-vacuum.net (Service).
Maintenance and repairs in the Pfeiffer Vacuum ServiceCenter
The following steps are necessary to ensure a fast, smooth servicing process:
Download the forms "Service Request" and "Declaration on Contamination".
Fill in the "Service Request" form and send it by fax or e-mail to your service
address.
Include the confirmation on the service request from Pfeiffer Vacuum with your
shipment.
Fill in the contamination declaration and enclose 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.
1)
Sending of contaminated pumps or devices
No units will be accepted if they are contaminated with micro-biological, explosive
or radioactive substances. “Hazardous substances” are substances and compounds in accordance with the hazardous goods directive (current version). If
pumps are contaminated or the declaration on contamination is missing, Pfeiffer
Vacuum performs decontamination at the shipper's expense.
Neutralise the pump by flushing it with nitrogen or dry air.
Close all openings airtight.
Seal the pump or unit in suitable protective film.
Return the pump/unit only in a suitable and sturdy transport container and send
it in while following applicable transport conditions.
Service orders
All service orders are carried out exclusively according to our repair conditions for
vacuum units and components.
1)
Forms under www.pfeiffer-vacuum.net
27
Spare parts
11 Spare parts
11.1 Spare parts packages
The spare parts packages listed here are only applicable for standard models.
Please state all information on the rating plate when ordering spare parts. Other
spare parts than those described in this manual must not be used without the
agreement of Pfeiffer Vacuum.
Spare parts package Pump type Article no. Parts according to the
Set o f seals
Maintenance kit
Set o f vanes
Overhaul kit
Vacuum safety valve
Pumping system, complete and tested with P3
Pumping system, complete and tested with D1
Pumping system, complete and tested with F4
Pumping system, complete and tested with F4
Exhaust valve, stage II
Coupling ki
exploded view on the following page
DUO 5 M
DUO 5 MC
DUO 5 M
DUO 5 MC
DUO 5 M PK E38 008 -T 7, 8, 9, 10.
DUO 5 MC PK E38 009 -T 7, 8, 9, 10.
DUO 5 M PK E32 008 -T
DUO 5 MC PK E32 006 -T
DUO 5 M
DUO 5 MC
DUO 5 M PK E33 001 -T 4.1
DUO 5 M PK E33 004 -T 4.1
DUO 5 M PK E33 002 -T 4.1
DUO 5 MC PK E33 003 -T 4.1
DUO 5 M
DUO 5 MC
DUO 5 M PK E36 005 -T 18, 20, 24, 184, 254.
DUO 5 MC PK E36 006 -T 18, 20, 24, 184, 254.
PK E30 005 -T
PK E31 004 -T 138, 144, 162.
PK E34 004 -T
PK E35 002 -T 100, 102, 184, 204, 208.
76, 112 138, 141, 142, 144, 147, 148,
149, 150, 152, 154, 156, 158, 160,
162, 254.
PK E30 005 -T, 7, 8, 9, 10, 32, 44, 51,
100, 102, 106, 110, 114, 208.
PK E30 005 -T, 7, 8, 9, 10, 32, 44, 51,
100, 102, 106, 110, 114, 208.
30, 32, 34, 70, 100, 106, 108, 147,
152, 154, 160, 188, 204, 208, 220,
250.
28
PD0014_expl_B
96724
162
110/
112
142
51
44
144
7/ 8/ 34 188
10 10
106
220 108
188 30 204/ 152 32 147 250
70/208/
100
102 184 254 158 20
24 184
154/
160
149
150
215/
138/
141/
148
}
80
114
18
Exploded view DUO 5 M
Spare parts
4.1 Pump cylinder, complete
7 Vanes, rough stage
8 Vanes, rough stage
9 Hydraulic vanes
10 Compression spring
18 Magnetic coupling,
drive side
20 Magnetic coupling,
pump side
24 Can
30 Housing, vacuum safety valve
32 Valve plate, vacuum safety valve
34 Valve cover, vacuum safety valve
42 Gas ballast valve housing
(further parts see Section 7.3.)
44 Silencer nozzle
51 Plate spring
70 Valve trap
76 Rapid action coupling
80 Base plate
100 Valve buffer
102 Valve plate
106 Hydraulic piston
108 Compression spring
110 Sight glass
112 Sight glass seal
114 Rubber foot
138 O-ring (GB valve)
141 O-ring (GB valve)
142 O-ring
144 O-ring
147 O-ring
148 O-ring (GB valve)
149 O-ring
150 O-ring
152 O-ring
154 O-ring
158 O-ring
160 O-ring
162 O-ring
184 Allan head screw
188 Allan head screw
204 Circlip
208 Compression spring
215 Compression spring GB valve
220 Screw
250 Compression spring for vacuum
safety valve
254 O-ring
29
Accessories
12 Accessories
Further detailed accessories are contained in the Pfeiffer Vacuum printed or Online
Catalogue.
Description DUO 5 M DUO 5 MC
KAS 16, Condensate separator for pumping speeds of
up to 2.5-5 m
ONF 16, oil mist filter for pumping speeds of up to 2.5-5
3
m
/h
STP 016, dust separator, single-stage for minor contamination
Oil return unit from ONF 16 to DUO 5 M, oil return unit
from ONF 25 to DUO 10 M, oil return unit from ONF 25 L
to DUO 20 M, standard version
Oil pressure switch PK 196 449 PK 196 449
Operational monitoring unit for DUO 5 M, 10 M, 20 M
und DUO 5 MC, 10 MC, 20 MC
Operating fluid level monitoring, 24 V DC for DUO 5 M,
10 M, 20 M and DUO 5 MC, 10 MC, 20 MC
Barretter actuation unit 3 TF P4 768 051 FQ P4 768 051 FQ
3
/h
PK Z10 003 -
PK Z40 003 -
PK Z60 203 -
PK 196 172-T -
PK 196 141-T PK 196 141-T
PK 196 157-T PK 196 157-T
Operating fluid
Description Size Number
Operating fluid P3 1 litre PK 001 106 -T
Operating fluid P3 5 litre PK 001 107 -T
Operating fluid P3 20 litre PK 001 108 -T
Operating fluid F4 1 litre PK 005 887 -T
Operating fluid F4 0,5 litre PK 005 886 -T
Operating fluid F4 0,25 litre PK 005 885 -T
Operating fluid D1 1 litre PK 005 875 -T
Operating fluid D1 5 litre PK 005 876 -T
Operating fluid D1 20 litre PK 005 877 -T
30
13 Technical data
Parameter DUO 5 M, 3-ph Motor, 3 TF
Flange (in) DN 16 ISO-KF
Flange (out) DN 16 ISO-KF
Pumping speed at 50 Hz 5 m
Pumping speed at 60 Hz 6 m
Ultimate pressure with gas ballast ≤ 2·10
Ultimate pressure without gas ballast ≤ 5·10
Leakage rate safety valve ≤ 1·10
Water vapor tolerance at 50 Hz 25 mbar
Water vapor tolerance at 60 Hz 28 mbar
Water vapor capacity 50 Hz 90 g/h
Water vapor capacity 60 Hz 120 g/h
Emission sound pressure level without
gas ballast
Pump fluid filling 0.75 l
Rated power 50 Hz 0.25 kW
Rated power 60 Hz 0.25 kW
Rotation speed at 50 Hz 1500 1/rpm
Rotation speed at 60 Hz 1800 1/rpm
Mains requirement: voltage (range)
Switch No
Weight 19 kg
3
/h
3
/h
-2
mbar
-3
mbar
-4
mbar l/s
≤ 55 dB (A)
218-242/380-420 V (+/- 5 %) 50 Hz ;
254-277/440-480 V (+/- 5 %) 60 Hz
Technical data
Parameter DUO 5 M, 1-ph Motor
Flange (in) DN 16 ISO-KF
Flange (out) DN 16 ISO-KF
3
Pumping speed at 50 Hz 5 m
Pumping speed at 60 Hz 6 m
Ultimate pressure with gas ballast ≤ 2·10
Ultimate pressure without gas ballast ≤ 5·10
Leakage rate safety valve ≤ 1·10
Water vapor tolerance at 50 Hz 25 mbar
Water vapor tolerance at 60 Hz 28 mbar
Water vapor capacity 50 Hz 90 g/h
Water vapor capacity 60 Hz 120 g/h
Emission sound pressure level without
gas ballast
Pump fluid filling 0.75 l
Rated power 50 Hz 0.37 kW
Rated power 60 Hz 0.37 kW
Rotation speed at 50 Hz 1500 1/rpm
Rotation speed at 60 Hz 1800 1/rpm
Mains requirement: voltage (range)
Switch
Weight 22 kg
/h
3
/h
-2
mbar
-3
mbar
-4
mbar l/s
≤ 57 dB (A)
200-240 V (+/- 5 % ) 50 Hz ;
208-240 V (+/- 5 %) 60 Hz
Yes, with 2 m mains cable
and safety plug
31
Technical data
244
58
144
216
248
3
65
47
79
107
135
160
239.5
461.5
215
47
61
100 ... 114
7.5
10.5
223.5
Ø7
DN 16 ISO-KF
18
244
58
144
216
248
3
65
47
79
107
135
160
225.5
461.5
215
47
61
100 ... 114
223.5
Ø7
DN 16 ISO-KF
18
145
58
3
65
79
248
216
432.5±1
215
47
61
18
215
107
100 ...114
160
135
201.5
Ø
7
DN 16 ISO-KF
13.1 Dimensions
Fig. 13: DUO 5 M, 1-phase (115 V)
32
Fig. 14: DUO 5 M, 1-ph Motor (230 V)
Fig. 15: DUO 5 M, 3-phase, 3 TF
Declaration of conformity
according to the EC directive:
• Machinery 2006/42/EC (Annex II, no. 1 A)
We hereby declare that the product cited below satisfies all relevant provisions of
EC directive "Machinery" 2006/42/EC.
In addition, the product cited below satisfies all relevant provisions of EC directive
"Electromagnetic Compatibility" 2004/108/EC .
The agent responsible for compiling the technical documentation is Mr. Sebastian
Oberbeck, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Aßlar.
®
DuoLine
DUO 5 M/MC
Guidelines, harmonised standards and national standards and specifications
which have been applied:
/DuoLine™
Signatures:
(M.Bender)
Managing Director
DIN EN ISO 12100-1 : 2004 DIN EN 61010 : 2002 DIN EN 61000-6-3 : 2007
DIN EN ISO 12100-2 : 2004 DIN EN ISO 13857 : 2008 DIN EN 61000-6-4 : 2007
DIN EN 1012-2 : 1996 DIN EN 61000-6-1 : 2007
DIN EN ISO 14121-1 : 2007 DIN EN 6100 0-6-2 : 2006
Pfeiffer Vacuum GmbH
Berliner Straße 43
35614 Asslar
Germany
(Dr. M. Wiemer)
Managing Director
CE/2010
Technical data
34
Pfeiffer Vacuum Technology AG · Headquarters/Germany
Tel. +49-(0) 64 41-8 02-0 · Fax +49-(0) 64 41-8 02-2 02 · info@pfeiffer-vacuum.de · www.pfeiffer-vacuum.net
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