OPERATING INSTRUCTIONS
BA 251/501
Rotary Vane Pump
EN
PK 0156 BEN/L (1607)
Table of contents
Table of contents
1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.1 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Setting up the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Connecting the vacuum side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 Connecting the exhaust side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.4 Connecting the cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.5 Connecting to the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Filling up the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.7 Setting up ventilation or measurement connection. . . . . . . . . . . . . . . . . . 18
5.8 Operating fluid level monitoring (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9 Operating fluid temperature monitoring (option) . . . . . . . . . . . . . . . . . . . . 21
6.1 Before switching on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Switching on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 Pumping condensable vapours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Topping up the operating fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.5 Switching off and venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Changing the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Changing the kind of operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4 Clean the cooling water chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.5 Checking the "V" belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6 Cleaning the gas ballast valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.7 Set/adjust the silencer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Shutting down for longer periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 Re-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.1 Rectifying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.1 Spare parts packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2
Table of contents
11.2 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
13 Technical data and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
13.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3
About this manual
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 refers 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.com.
1.2 Conventions
Safety instructions The safety instructions in Pfeiffer Vacuum operating instructions 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
Imminent danger
Indicates an imminent hazardous situation that will result in death or serious injury.
WARNING
Possibly imminent danger
Indicates an imminent hazardous situation that can result in death or serious injury.
CAUTION
Possibly imminent danger
Indicates an imminent hazardous situation that can result in minor or moderate injury.
NOTICE
Command or note
Command to perform an action or information about properties, the disregarding of
which may result in damage to the product.
4
About this manual
V
Pictographs
Instructions in the
Work instruction: here you have to do something.
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 danger, the disregarding of which may result in serious accidents
Important information about the product or this document
text
Symbols used The following symbols are used consistently throughout in all illustrations:
Vacuum flange
Exhaust flange
G
Gas ballast valve
Power connection
5
Safety
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.
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 order numbers of components, see "Accessories".
Use original accessory parts only.
● 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.
2.2 Protective equipment
Determined situations concerning the handling of vacuum pumps require wearing of personal protective equipment. The owner, respectively the employer are obligated to provide an adequate equipment to any operating persons.
Danger to health by hazardous substances during maintenance or installation
Depending on the process vacuum pumps, components or operating fluids can be contaminated by toxic, reactive or radioactive substances.
Wear adequate protective equipment during maintenance and repairs or in case of
reinstallation.
Risk of injury through hot surfaces
Vacuum pumps can become hot during operation.
Allow the pump to cool before maintenance and repairs.
If necessary wear protective gloves according to EN 420.
Increased noise emission!
Increased noise emission can occur within a limited area surrounding the vacuum
pump.
Provide noise protection or
wear hearing protection.
DANGER
CAUTION
WARNING
6
2.3 Proper use
2.4 Improper use
Safety
NOTICE
EC 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.
● Only use the vacuum pump for applications with oxygen concentration ≤ 21%.
● 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 warranties to be forfeited. Improper use
is defined as usage for purposes deviating from those mentioned above, especially:
● pumping of corrosive gases
● pumping of explosive media
● operation 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
● operation of the devices in areas with ionizing radiation
7
Transport and storage
3 Transport and storage
3.1 Transport
Remove the locking cap from the vacuum and exhaust flange immediately before con-
necting!
– Check the cone strainer, paying attention to the O-ring.
Use only the eye bolt on the top side of the pump to lift the pump.
V
3.2 Storage
Fig. 1: Transporting the pump
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 dry and dust-free indoors within the specified environmental con-
ditions.
– 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 longer than two years, it is recommended to carry out main-
tenance and change the operating fluid before using the pump.
8
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.
● Pump model and model number
● Serial number
● Type and amount of operating fluid
● Date of manufacture
For motor-specific data, please see the separately installed motor rating plate.
Scope of delivery ● Pump with/without motor
● Operating fluid P3 (for standard pump)
● Centering ring with O-ring
● Flange cover for vacuum and exhaust flange
● Operating instructions
Pump types
Pump type Pump designs
BA 251 Pump on/without base frame
BA 501 Pump on/without base frame
Product description
9
Product description
50 98 100 40 34 91 99 1
53
5
62
41
43
39
90
17
4.2 Function
The water cooled rotary vane pumps of the UnoLine Plus series are fitted with an operating fluid collecting vessel with return line which ensures constant and slow circulation
of the operating fluid. Condensates, dirt and other particles are separated from the operating fluid and deposited in the sump of the vessel. This system provides the pumps with
a very large supply of operating fluid (BA 251 approx. 17 l, BA 501 approx. 45 l).
The spring loaded pump valves are of wear-resistant stainless steel. The pump is "V" belt
driven. Pump and motor are mounted together in a base frame.
A cooling water controller regulates, contingent on the pump temperature, the cooling
water flow level so that the pump operating temperature is maintained.
1 Operating fluid collecting vessel
with return line
5 Gas ballast valve
17 Connection (G1/2") for external
oil filter (optional)
34 Level switch connection
39 Oiler
40 Sight glass
41 Cooling water controller
43 Motor
50 Venting or measuring
connection
53 Temperature sensor
62 Cooling water drain
90 Operating fluid and
condensate drain valve
91 Operating fluid filler screw (G 1")
98 Vacuum connection
99 Exhaust connection
100 Needle valve
Fig. 2: Rotary Vane Pump BA 251 / BA 501
Range of application Being of a robust design, the pumps are especially suitable for vacuum generation in in-
dustrial applications. The pumps can be used as stand-alone units or as the pre-stage to
roots pumps.
10
5 Installation
5.1 Setting up the pump
Installation location Observe the following requirements when setting up the pump:
● Consider the load-bearing capacity of the installation site.
● Maximum installation altitude 2000 m (above mean sea level)
● Permissible ambient temperature: +12 ... 40°C
● Maximum relative humidity 85%
Fill up with operating fluid before operating the first time (see p. 18, chap. 5.6).
– Amount and type according to rating plate
Set up the pump on an even, horizontal surface.
– The base frame has four holes for anchoring onto the base.
– As an alternative, the base frame can be mounted flexibly on 4 vibration isola-
tors(see p. 43, chap. 12).
When installing the pump in a closed housing, ensure there 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.
Installation
5.2 Connecting the vacuum side
The vacuum connection can be carried out on the vertical port 98 or at the lateral venting
connection 50 (after removing the blank flange).
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 scales, loose parts etc. before installation.
The connection between the pump and the vacuum chamber should be kept as short
as possible.
– Depending on the pump type, use metallic hoses or PVC hoses with flange con-
nections.
– Separators, filters etc. may be installed upstream to protect the pump (see acces-
sories). However, please observe the loss of pumping capacity due to the conductivity of the accessories.
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 hPa abs.) in the lines, ob-
serve all official accident prevention safety regulations.
CAUTION
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.
11
Installation
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 the cooling water
BA series pumps are fitted with a cooling water regulator 41 as standard equipment. The
regulator's job is to keep the pump at its optimum operating temperature.
Requirements for the cooling water
The cooling water must be filtered in all cases. This keeps dirt deposits and organic suspended particles that could accelerate pitting out of the cooling circuit. Complying with
the following requirements for cooling water will prevent corrosion damage:
Requirements for the cooling water
Water filtered, mechanically pure, optically clear, no turbidity, no sediments, chemically neutral
Min. oxygen content 4 mg/kg
Max. chloride content 100 mg/kg
Max. carbonate hardness for the water temperatures
15 ... 25 °C
30 ... 40 °C
Max. potassium permanganate usage
pH value
Aggressive carbon dioxide and ammonia must not be detectable
Max. electrical conductivity 500 μS/cm
Max. impurity particle size 25 μm
Permitted inlet overpressure range; if the pressure is higher a pressure reducer
valve must be integrated
Permitted cooling water temperature range 10 ... 30°C
WARNING
10 ° dH
6° dH
10 mg/kg
7 ... 9
2000 ... 10000 hPa
Connecting cooling
water
Mounting the cooling
water unit (optional)
Installing pressure
monitor (option)
12
The connection must be made so that the flow can be visually checked. The best method
is the free outflow of cooling water via a funnel. If this is not possible because there is no
height difference, a flow indicator must be integrated into the line. Standard flow monitors
or flow indicators may be used.
Screw in cooling water drain screw 62; pay attention to the O-ring.
– Locking screw included in the scope of delivery.
Connecting the cooling water pipe at the inlet (cooling water controller 41)
(G 1/2").
Connecting the cooling water pipe at cooling water outlet 41.1 (G 1/2").
The cooling water connection unit includes the following components and is mounted as
shown in Fig. 3:
– Shut-off valve
– Dirt trap
– Pressure monitor and
– Fastening clip
The pressure monitor can be used as an effective means of monitoring the pump against
cooling water failure.
PK 133 100-T
Fig. 3: Cooling water pressure monitor connection
Assembly
G 1/2”
41.1
Installation
2 Shut-off valve
3 Pressure monitor
3.1 Reducing nipple G 3/8 ... 1/2"
3.2 Dirt trap G 1/2"
3.3 Nipple G 1/2"
3.4 Tee G 1/2"
41 Cooling water controller, (inlet)
41.1 Cooling water connection, outlet
62 Cooling water drain
62
Set pressure monitor 3 in the permissible pressure range of 2 ... 10 bar.
– Liquid pressure hammers must not impact the unit.
Always assemble pressure monitor 3 upright with the pressure connection to the bot-
tom;
– pay attention to inflexible and vibration-free pressure lines. If vibrations are to be
expected (not pump induced), then the unit is to be fastened to a wall or to something similar.
Setting
Set pressure as overpressure based on atmospheric pressure:
– Contact rating at 230 V/AC 1 : 16 A (resistive load)
– Contact rating at 230 V/AC 15 : 6 A (inductive load)
– Contact rating at 230 V/DC 13 : 0.1 A (inductive load)
42
8
6
4
2
p
l
p >
1
p
h
Fig. 4: Set pressure monitor 3
Set switch-point ph at 2 bar;
– contact 1-4 closes at cooling water pressure of > 2 bar.
Set switch-point p
at 1 bar;
l
– if the pressure drops to < 1 bar, contact 1-2 closes and contact 1-4 opens.
13
Installation
W2
U1
L1
V2
V1
W1
U2
L3
L2
W2
U2
V2
U1
V1
W1
L1
L2 L3
5.5 Connecting to the mains power supply
The pumps are supplied with three phase motors for different voltages and frequencies.
The applicable motor type is shown on its rating plate. The drive motor belt pulley has
different diameters for 50 Hz and 60 Hz.
If the pumps are delivered without a motor, permissible pumping rotation speeds are to
be taken into account when selecting the motor (see Technical Data).
Voltage-bearing elements
Danger to life from electric shock.
The electrical connection can be carried out only by trained and authorised electri-
cians.
Disconnect the power supply and secure it against being switched back on.
Ensure the system is adequately earthed.
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. Recommended: Type K slow blow circuit breaker.
DANGER
NOTICE
Three-phase motor The three phase current motor circuit
Delta Connection
The three coils are connected in series with the connection point connected to the mains.
The voltage of each coil is the same as the mains voltage whereas the mains current is
the cube root of the coil current. Delta connections are denoted by the symbol ∆. The
voltage between the mains supply lines is called mains voltage. The mains current is the
current which flows in the supply lines.
Fig. 5: Motor coil and connecting plate of Delta Connection (for low voltage)
Star Connection
The ends of the three coils are connected at the star center. The terminal voltage is the
cube root of the coil voltage; the mains and the coil current are the same. Star connections are denoted by the symbol Y.
14
Installation
W2
U1
L1
V2
V1
W1
U2
L3
L2
W2
U2
V2
U1
V1
W1
L1
L2 L3
Fig. 6: Motor coil and connecting plate of Star Connection (for high voltage)
NOTICE
Do not start with star/delta connection.
Always start motor directly.
Checking the direction of rotation
The direction of rotation must be checked on pumps with three-phase motors! The direction of rotation is marked on the pump housing by an arrow.
CAUTION
Destruction of or damage to the pump!
The pump can be destroyed if the direction of the motor rotation is incorrect.
Remove V-belts and check direction of rotation prior to commissioning the pump.
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.
Slacken V-belt.
Switch on the motor briefly (2 to 3 sec.).
– Motor belt pulley turn in a clockwise direction (see the arrow on the pump housing).
If the direction of rotation is incorrect: Swap two phase contacts at the connecting ca-
ble.
Fill up the operating fluid.
Refit belts and guards (see p. 32, chap. 7.5).
Motor protection With PTC temperature sensors (3PTC)
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. Other approved motor temperature monitoring can be used also by the operator.
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.
Set up the connections so that the directional rotation indicated on the pump is main-
tained, regardless of the representations in the current flow diagram.
15
Installation
BA 251
BA 501
L1
L2
L3
F1 - F3
N
K1
A1 A2 T1 T2 Y2Y1 24 21 22 14 1211
Us
3)
M
W
AC 220 ... 240 V
11
V
U
3
10
T1...T3
2)
2)
2)
S3
1)
1)
1)
F4
S1
k1
S2
K1
US Control voltage
S
OFF button
1
S
ON button
2
S
RESET button, external
3
K1 Contactor
F1 ... F4 Fuses
T1... T3 PTC resistor sensor
H1 Tripping indicator
M Motor, 3-phase
1)
H1
Only for devices with two
relay outputs
2)
Only for MSR type
3)
Only for order no.:
P 4768 051 FQ
Fig. 7: Connection example for a three-phase AC motor with PTC resistor tripping device
With motor protection switch
Suitable are protection switches with slow triggering characteristics. The drive motor can
have a power consumption that is higher than the rated current I
60034-1 it is permissible to exceed the rated current I
1.5 times for a period of 2 min-
N
. According to DIN EN
N
utes. The setting must permit the overload ability of the motor and can be found in the
following table.
Voltage [V] Frequency
[Hz]
230 50 11 34.3 322
400 50 11 19.8 186
265 60 13 34.5 331
460 60 13 19.9 191
Voltage [V] Frequency
[Hz]
400 50 15 27.5 261
690 50 15 15.9 151
460 60 18 28.1 267
Motor rating [kW] IN [A] I
Motor rating [kW] IN [A] I
max
max
[A]
[A]
Electrical connection
with cooling water
pressure monitor
16
Frequency converter (valid for three phase motors)
Operation of rotary vane pumps with variable rotation speeds is possible in the mains frequency range between 35 and 60 Hz. The start-up can use a ramp (run-up time: max.
30 s); the shutdown can occur directly.
Prepare the circuitry of the motor with cooling water pressure monitor 3 according to the
circuit diagram. A combination with a PTC resistor temperature sensor (3TF) is also possible.
3 Pressure monitor
L1
L2
L3
N
PE
3
PE
Fig. 8: Connection with cooling water pressure monitor
F3 Motor protection switch
Installation
17
Installation
.
5.6 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 sufficient operating fluid for
one filling. The use of other operating fluids requires prior authorisation from Pfeiffer Vacuum.
Permissible operating fluid
● P3 (standard operating fluid)
● Operating fluid for special applications on request
Use approved operating fluids only!
The use of operating fluids that have not been approved by Pfeiffer Vacuum shall result
in a limited warranty. In such cases, it is not possible to guarantee that product-specific
performance data will be achieved.
Prior consultation is required before using other application-specific operating fluids.
NOTICE
Filling up the operating fluid
Unscrew operating fluid filler screw 91.
Fill up the operating fluid.
– First fill when the pump is cold: Maximum 3/4 of the min./max. range.
Screw in operating fluid filler screw 91.
91
max
min
Fig. 9: Filling up the operating fluid
Check oiler The bearing oil chambers are factory-filled with P3 lubricant.
Prior to commissioning, check fill level of both oiler 39;
– The oiler should always be filled to a max. of one-third (when the pump is cold); top
up as required.
5.7 Setting up ventilation or measurement connection
18
The ventilation or measurement connection complies with DN 10 ISO-KF and for serialproduction pumps is sealed vacuum-tight with a blank flange.
Other connection possibilities:
● manually or electrically activated valve for ventilating the pump at standstill
● Vacuum gauge for pressure measurement
● Operating fluid feedback for returning operating fluid from the oil mist filter and oil
50
83
83.1
83.2
6
feedback unit
5.8 Operating fluid level monitoring (option)
A level switch 83.2, which is installed at the pump dome 6 (oil sump) is used for monitoring the operating fluid level.
Electrical connection of the level switch 83.2 must be carried out, so that an alarm is released and the pump is switched off, if the operating fluid level falls below the permissible
level. The level switch is preset ex works.
Installation
6 Pump dom
83 Locking screw
83.1 Extension
83.2 Level switch
Fig. 10: Operating fluid level monitoring
Parameter Operating fluid level monitoring
Protection category IP 67
Current max. 35 mA
Contact Closing contact, normally open at min. filling level
Contact rating PNP output, max. 20 mA
Supply: Voltage 12-30 V DC
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
Drain off operating fluid partially.
Loosen locking screw 83 and screw it out.
Install extension 83.1 between the pump dome and the level switch 83.2 as a protec-
tion against excessively high temperatures.
19
Installation
Make sure the operating fluid level monitoring is functioning properly!
Varying operating conditions such as change in temperature impact the proper functioning of the operating fluid level monitoring.
The pump has to be running.
Create reproducible operating conditions; e.g. measure ultimate pressure or intake
pressure 500 hPa;
– if the intake pressure cannot be measured, then, for example, allow for a time de-
lay of 10 min between the reaction and the alarm
Disable the alarm signal during the warm-up phase or in the case of high process-
dependant gas throughput, if necessary.
20
5.9 Operating fluid temperature monitoring (option)
A resistance thermometer 34.1, which is installed at the pump dome (oil sump) is used
for monitoring the operating fluid temperatur.
6
Installation
34.1
34
Fig. 11: Install the temperature sensor
Parameter Resistance thermometer
Protection category IP 65
Method of measurement PT 100
Temperature range -50-+400 °C
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
Drain off operating fluid partially.
Unscrew locking screw 34 (G 1/2").
Screw in resistance thermometer 34.1; take care with O-ring.
21
Operation
°F °C
Q
123
41
6Operation
6.1 Before switching on
Compare the voltage and frequency information on the rating plate with the mains volt-
age and frequency values.
Check that the exhaust connection allows free flow (max. permissible pressure 1500
hPa 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 precau-
tions (e.g. dust filters); if necessary, check operating fluid regularly or replace at shorter intervals.
Open cooling water supply;
– lever down screw 123 at the cooling water controller 41 by using a screw-
driver and vent the cooling chambers.
Switch on pump only with vented suction chamber, because the normal power of the
motor is insufficient for starting up under vacuum.
22
6.2 Switching on the pump
The pump can be switched on in any pressure range between atmospheric and
ultimate pressure.
The ideal operating condition of the pump is achieved during continuous operation. Cyclic operation is possible, but 10 cycles per hour should not be exceeded and the operating phase should always be longer than the downtime (non-operation time).
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.
V-belts are used as an overload protection
Upon activation of the motor, brief slippage can occur; this is perceived as a whistling
sound.
This is not a sign of insufficient belt tension!
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.
Operation
NOTICE
CAUTION
NOTICE
Increased motor current draw (> rated current) !
With an intake pressure of about 300 h/Pa, the pump has the highest power requirement, which can increase even further under unfavorable operating conditions (e.g.
counter-pressure on exhaust side.
Limit the max. power consumption for 1.5 times the rated current for 2 minutes max.
(according to DIN EN 60034-1.
NOTICE
Pump damage caused by overheating!
Inadequate cooling may cause pump damage.
Vent the cooling chambers and ensure a water flow prior to commissioning or subse-
quently switching on the pump!
Switch on the pump with the vacuum flange closed and allow to warm up for 15 min-
utes.
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.
Setting cooling water The cooling water controller 41 is a continuously operating control valve that is controlled
by the temperature-dependent cooling agent. The thermal sensor is submerged in the
operating fluid and connected via a capillary tube to the bellows in the valve head. The
cooling water controller 41 is factory-set. If other temperatures are required, the pump
temperature can be changed by turning setting disk 1. The respective settings, as well
as the maximum temperature, must only be made after consulting with Pfeiffer Vacuum.
23
Operation
1 Setting disk
2 Setting scale
3 Arrow for temperature setting
41 cooling water controller
123 Vent screw
41
3
°F °C
Q
2
1
123
Fig. 12: Cooling water controller 41
With a screw driver set setting disk 1 of the cooling water controller to the desired op-
erating temperature.
– Factory setting is 50 °C, i.e. bearing oil temperature < 85 °C.
– Replacement controllers are not preset, set temperature is 50 °C measured outside
on the immersion tube of temperature sensor 53.
6.3 Pumping condensable vapours
To increase water vapour compatibility, the pump is fitted with a gas ballast valve 5.
To avoid condensation in the pump when pumping condensable vapours, air or inert gas
(option) is fed into the working chamber at the beginning of the compression phase via
the gas ballast valve 5.
NOTICE
Bad final vacuum and damage to the pump!
Danger of condensation and corrosion due to exceeding the water vapour compatibility
during operation without 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.
24
Operation
103
10 0
5
A
121
5
111
B
Gas ballast valve
standard version
If valve nut 103 of gas ballast valve 5 is turned counterclockwise until it stops, the valve
is opened. If the lock nut is turned clockwise until it stops, the valve closes. An intermediate position is not possible.
The silencer constantly supplies small amounts of ambient air for the pump and thus aids
the quiet running of the pump at ultimate pressure when the gas ballast valve is closed.
100 Needle valve (silencer)
103 Valve nut
Fig. 13: Gas ballast valve 5 in standard version
The silencer is factory-set and should not be changed, otherwise the pump's final
vacuum without gas ballast valve and also noise development are impacted adversely.
Conversion kit for
gas ballast valve (option)
Conversion set 121 is available for the gas ballast valve for connecting flushing gas, a
dust separator and/or a solenoid valve to small flange connection KF 10.
5 Gas ballast valve
111 Needle valve
121 Conversion set DN 10 KF (complete)
A Solenoid valve (option)
B Dust separator SAS 016 (option)
Fig. 14: Conversion set for gas ballast valve with solenoid valve and/or dust separator
● Dust separator:
– A dust separator should be used if dust laden air is sucked in. It should be noted
that when the dust separator becomes fouled the amount of gas ballast fed decreases and the risk of condensation from process media increases.
● Solenoid valve:
– Controlled inlet of ambient air or connecting inert gas possible.
25
Operation
Checking the adjustments
NOTICE
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 of 1500 hPa (absolute).
Set the amount of flushing gas on site; dosing is not possible when using a solenoid
valve!
Reset the silencer using needle valve 111 after converting the gas ballast valve.
In case of intake air exposed to dust install dust separator on the gas ballast valve.
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.
26
6.4 Topping up the operating fluid
.
If the operating fluid has reached its minimum filling level, the operating fluid must be
topped up. The fluid can be topped up during operation in the final vacuum.
Operation
Filling up the operating fluid
Unscrew operating fluid filler screw 91.
When the pump is at operation temperature, top up the operating fluid up to the "max."
marking.
91
max
min
Fig. 15: Filling up the operating fluid
Screw in operating fluid filler screw 91.
6.5 Switching off and venting
The pump can be switched off in any pressure range.
Danger of backflow of operating fluid into the intake line!
Contamination of the connected vacuum system!
Because the pump has no internal safety valve, install an additional shut-off valve in
the intake line.
Shut off the intake line and vent the pump immediately after switching off the pump.
Damage to drive and pump because of oil stroke when switching on!
If the pump is not vented sufficiently after switching off, the rotor can rotate backwards
and suck operating fluid into the suction chamber.
Always vent the pump sufficiently to avoid rising operating fluid.
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
Disconnect intake line after switching off the pump so that operating fluid does not flow
back into the vacuum line.
– An electro-pneumatic activated shut-off valve (see Accessories) can be used for
this purpose; the valve's control can be coupled with the motor voltage.
Open magnetic venting valve at measurement connection 50 and vent the pump.
– To prevent premature venting the venting valve can be coupled with the shut-off
valve's position indicator.
If the ambient temperature is less than 0 °C, the cooling water must be drained at Pos.
62 after the pump is switched off and after prolonged down time (see p. 12, chap. 5.4).
CAUTION
NOTICE
27
Maintenance
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
WARNING
on the pump.
WARNING
from being harmed by any dangerous substances.
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
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 to carry out maintenance.
Dispose of used operating fluid in compliance with local regulations.
When using synthetic operating fluids or working with toxic substances or substances
contaminated with corrosive gases, the relevant instructions governing their use must
be observed.
Use only alcohol or similar agents for cleaning pump parts.
28
Maintenance
Checklist for inspection, maintenance
and overhaul
Certain maintenance 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, below listed, intervals are exceeded or maintenance or overhaul procedures
are not performed properly. This also applies if replacement parts other than Pfeiffer Vacuum OEM replacement parts are used.
Activity
Check operating fluid level X
Visual inspection (leak-tightness/oil leaks) X
Check cooling water flow lines X
Clean cooling water flow lines X
Clean gas ballast valve X
Clean the fan cap of the motor X
Check "V" belt drive X
Change operating fluid X
Change "V" belts X
Replace radial shaft seals X (PV)
Replace exhaust valves X (PV)
Replace vanes X (PV)
Replace bearings X (PV)
Depending on the process, the required replacement intervals for lubricants and the intervals for inspec-
tion, maintenance and overhaul may be shorter than the guide values specified in the table. Consult
with Pfeiffer Vacuum Service if necessary.
daily
as required
as required;
at least annually
as required;
at least every 2 years
as required;
at least every 4 years
7.2 Changing the operating fluid
The service life of the operating fluid is dependent on the application area for the pump.
It must be changed if:
● The specified ultimate pressure is no longer reached
● The operating fluid in the sight glass is visibly contaminated, milky, or cloudy
● The operating fluid is thermally aged, identifiable by its color ID value (applies to min-
eral oils only).
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.
The level of deterioration of organic operating fluids (P3, for example) 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.
Fill the specimen in a test tube or some similar vessel and test by holding against the
light.
Where discolouration is dark yellow to red brown (equivalent to 4 ... 5 on the scale)
change operating fluid.
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
Open operating fluid drain screw 90 and drain operating fluid.
29
Maintenance
90
Fig. 16: Draining the operating fluid
WARNING
Hot operating fluid!
Danger of burns when draining due to contact with skin.
Wear suitable protective clothing.
Use a suitable collecting vessel.
Flushing and cleaning
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
Allow the pump to run for approx. 10 seconds with open gas ballast valve 5 so that the
remaining operating fluid drains from the pump body.
– In case of serious contamination, the operating fluid will have to be changed sev-
eral times (flushing):
Close operating fluid drain valve 90.
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 necessary.
Screw the operating fluid drain screw 90 back in.
Fill up with operating fluid and check the filling level (see p. 18, chap. 5.6).
Request safety data sheets for operating fluids and lubricants
from Pfeiffer Vacuum or download at www.pfeiffer-vacuum.com.
Dispose of operating fluid according to the local regulations.
30
7.3 Changing the kind of operating fluid
When filling up, topping up or changing the operating fluid, always use the type of operating fluid indicated on the pump type plate. If, for example, amended process conditions
require the use of a different operating fluid, the fluid can be changed as follows:
Changing the type of operating fluid.
A change of operating fluid type can be only be made between mineral (P3) and synthetic operating fluid (D1). It is not possible to change from these two types to F4/F5 or
the other way round!
For the two flushing processes and final fill, the pump needs to be filled up three times
with fresh operating fluid, and this is the amount of operating fluid required.
Perform two flushing processes with the new operating fluid.
Clean any accessories present such as the ONF/OME or ORF/ODK and replace their
filter elements; pay attention to whether more operating fluid is required.
Fill the pump for the final time with the third filling.
Note down the current type of operating fluid in an appropriate place on the pump
(preferably on the type plate).
Maintenance
NOTICE
31
Maintenance
3.2
7.4 Clean the cooling water chambers
Contamination and calcium deposits can affect the pump's cooling water circuit and bring
about an elevated operating temperature. This can be avoided, depending on the cooling
water quality, by cleaning the cooling water chambers at regular intervals.
Stop cooling water feed and drain cooling chamber at outlet 62.
Remove flanges 14, 15 and 95; observe seals 22 and 23 (see p. 41, chap. 11.2).
Clean the cooling water chamber with a suitable agent.
Remount flanges with seals and screw outlet screw 62 back in.
Restore cooling water feed (see p. 12, chap. 5.4) and bleed cooling chambers.
Cleaning the dirt trap
Fig. 17: Cleaning the dirt trap
Stop cooling water supply.
Open sealing plug on dirt trap 3.2; pay attention to seal.
Clean sieve insert.
7.5 Checking the "V" belt drive
The correct belt bias is crucial to efficient power transmission and achieving the usual
belt lifespans. The belts will fail prematurely if the bias is too low or too high. Excessive
belt bias frequently results in pump or motor bearing defects.
The V-belt drive must be checked regularly for wear, damage and V-belt bias.
If drive belts are exposed!
Fingers and hands can become crushed while carrying out service activities.
Isolate power before removing belt guard.
Do not expose any body parts to the operating range of the belt drive.
Wear close-fitting clothing.
Remount belt guard on completion of the work.
WARNING
32
Fitting the "V" belts Observe the following instructions carefully:
L
L/2
E
Trum
f
a
A
C
If one or several belts fail, a new set must be mounted.
– Use only measured V-belt sets.
Align shafts and pullies.
– The maximum deviation of the pully alignment must not exceed 1°.
Reduce the motor distance so that the belt can be fitted into the grooves without force.
The use of levers, screwdrivers etc. to force fit is not permitted.
Do not use belt wax or spray.
Setting the V-belt bias
Maintenance
Fig. 18: Setting the belt bias
Setting values for correct
V-belt bi as
Impression depth of strand (Ea) 15+2 mm 21+2
Test load for belt bias (f) 50 N 50 N
Branch length of gear, theoretical (L) 488 mm 697 (50 Hz)
BA 251
50/60 Hz
A Load hook
C Scale for test load
BA 501
50/60 Hz
705 (60 Hz)
Place spring balance with load hook A in centre of strand.
Apply required test load f of 50 N according to scale C; pull spring balance at right-
angle to the strand.
If necessary, correct the bias until the setpoint value is reached.
Observe the drive during the first few hours of operation and retension after approx.
0.5 to 4 hours running time under full load.
Check the belt bias again after approx. 24 hours of operation and correct if necessary.
33
Maintenance
112
113
5
114
115
116
117
118
104
105/106
119
120
100
110
109
101
102
107/108
103
7.6 Cleaning the gas ballast valve
Gas ballast valve 5 is only exposed to contamination if dusty air is sucked in.
100 Needle valve
101 Locking nut
102 Self-locking nut
103 Valve nut
104 Valve housing
105 Intermediate piece
106 Clamping block
107 Washer
108 Washer
109 Valve plate
110 Gas ket
112 Retention screw
113 Circlip
114 Valv e i nse rt
115 Valve spring
116 Scr ew
117 Scr ew
118 O-ring
119 Sealing ring
120 Angle piece
Fig. 19: Gas ballast valve
Unscrew gas ballast valve from angle piece 120, observe sealing ring 119.
Loosen retention screw 112 and unscrew valve nut 103.
Loosen locking nut 101 and unscrew needle valve 100.
Loosen self-locking nut 102 and remove plain washers 107 and 108.
Remove valve plate 109.
Unscrew screw 117 and remove parts 105 and 106; observe O-ring 118.
Lever out valve insert 114 and remove circlip 113.
Pull valve insert 114 from valve housing 104.
Undo screws 116 and remove valve springs 115.
Clean all parts and examine for wear. Replace gasket 110 if necessary.
Reassemble in the reverse sequence.
Once the gas ballast valve has been removed and re-assembled, the silencer
must be reset!
34
7.7 Set/adjust 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 at the installation location.
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.
Close needle valve 100/111 and wait until you hear oil hammer.
Untwist needle 100/111 until the oil hammer noise disappears (approx. 1/2 rotation).
Hold needle valve 100/111 in position with the screwdriver and tighten fixing nut 101.
Maintenance
If the silencer is set correctly, the pump vacuum has a total pressure of
< 6.0 10
-2
hPa.
35
Decommissioning
8 Decommissioning
8.1 Shutting down for longer periods
Follow the following procedure before shutting down the pump for a longer period of time:
Switch off the pump.
Change the operating fluid (see p. 29, chap. 7.2).
Switch pump on and bring to operating temperature.
Turn off the vacuum pump, vent to atmospheric pressure and allow to cool.
Close the flange openings by using the original protective covers.
Stop cooling water feed and remove cooling water intake and output lines.
Unscrew cooling water drain screw 62 and empty cooling water chambers to avoid
rust and frost damage.
Fill in additional operating fluid in accordance with table below:
– BA 251: 5 l
– BA 501: 10 l
Store the pump only dry and dust-free indoors within the specified environmental con-
ditions.
– 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 longer than two years, it is recommended to carry 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
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.
Visually inspect the inner of the pump dome 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.
Depending on how long the pump is taken out of operation, it may be necessary to replace the radial shaft sealing rings. With reference to DIN 7716 and the manufacturer's
specifications we recommend replacing the installed elastomer parts after 2 years. After
this time the bearings should also be replaced; contact Pfeiffer Vacuum Service.
If drying pearls were inserted then they should be removed now. Improper handling
can cause failure of 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.
36
9 Malfunctions
Please note the following instructions should the pump malfunction:
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.
9.1 Rectifying malfunctions
Problem Possible causes Remedy
Pump will not start up No mains voltage or voltage does
Pump switches off after a while after being
started
High increase in operating temperature
Pump not achieving
the ultimate pressure
Pumping speed of
pump too low
Malfunctions
CAUTION
NOTICE
Check mains voltage and mains fuse protec-
not correspond to the motor data
Ambient temperature too low Warm up pump to > 12 °C
Suction chamber not flooded Flood on suction side after switching off
Thermal cut-off switch has responded
Defective motor cut-off switch
(building side)
Dirty pump system Clean pump; notify Pfeiffer Vacuum service
Damaged pump system Clean and overhaul pump; notify Pfeiffer
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 Check opening of exhaust line and exhaust
Fault in cooling water circuit Check flow paths for dirt and lime deposits;
Leak in the system Fix leak
Falsified measuring result Check gauge, test ultimate pressure without
Pump or connected accessories
dirty
Dirt in operating fluids Operate pump for a longer period of time
Gas ballast valve is open Close valve.
Silencer is open Set/adjust the silencer
Operating fluids fill level too low Fill up operating fluids
Pump is damaged Contact Pfeiffer Vacuum Service.
Intake line not well-dimensioned Keep connections as short as possible and
Exhaust pressure too high Check opening of exhaust line and exhaust
tion; check motor switch
pump
Detect and fix cause of overheating; allow
pump to cool off if necessary.
Re-set or replace switch.
department, if necessary.
Vacuum service department, if necessary.
Detect and fix cause of overheating; allow
pump to cool off if necessary.
Warm up pump
accessories
clean, if necessary.
connected system.
Clean pump and check components for dirt.
with opened gas ballast valve or replace operating fluids
see that cross-sections are sufficiently dimensioned
accessories
37
Malfunctions
Problem Possible causes Remedy
Loss of operating fluids in pump and oiler
Unusual noises during
operation
Leaking O-ring in pump dome Check for tightness; replace O-ring, if nec-
Leaking radial shaft seal ring Check seal ring and replace, if necessary
Operation-related loss of operating
fluids; operating fluid in exhaust
lines
V-belt tension too low Check V-belt tension
Dirt in silencer Clean or replace the silencer.
Damage in pump system Clean and overhaul pump; notify Pfeiffer
Motor bearing defective Replace motor; notify Pfeiffer Vacuum ser-
essary
Install oil mist filter and oil return unit, if necessary
Vacuum service department, if necessary.
vice department, if necessary
NOTICE
Service work should be carried out by a qualified person 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.pfei-
ffer-vacuum.com.
Please state all the information on the pump rating plate when ordering spare parts.
38
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.com (Service).
Maintenance and repairs in 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 out the "Service Request" form and send it by fax or e-mail to your Pfeiffer Vacuum
service address.
Include the confirmation on the service request from Pfeiffer Vacuum with your ship-
ment.
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.com
39
Spare parts
11 Spare parts
Set of seals
The set of seals contains all seals of the assembly groups and the subassemblies including the radial shaft seals.
Maintenance kit
The pack contains the following parts:
● Radial shaft seal rings
● The O-rings of the operating fluid filler and drain screw when changing the operating
fluid
● The O-ring for the pump dome, after cleaning the operating fluid sump
Set of vanes
The kit contains the vanes of the pump stage, the vane springs and the guide pins (only
for the BA 501).
Overhaul kit
The kit contains all wearing parts of the pump:
● Set of seals
● Wearing parts of the pumping system
● Wearing parts of the gas ballast valve
● Oiler
● Fan belt (only for pumps with motor)
Set of discharge valves
The kit contains the wearing parts of the discharge valves. Also the O-ring of the pump
dome is included.
Cooling water controller
● Cooling water controller
● Sleeve of the thermal sensor
● Parts of the piping
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.
Article no.: Pump type seals Mainte-
nancekit
PK C42 602 BA 251 / 50 Hz PK E40 001 -T PK E41 001 -T PK E42 002 -T PK E45 002 -T PK E48 001 -T PK 081 950 -T
PK C42 637 BA 251 / 60 Hz PK E40 001 -T PK E41 001 -T PK E42 002 -T PK E45 002 -T PK E48 001 -T PK 081 950 -T
PK C43 602 BA 501 / 50 Hz PK E40 002 -T PK E41 002 -T PK E42 004 -T PK E45 001 -T PK E48 002 -T PK 081 950 -T
PK C43 637 BA 501 / 60 Hz PK E40 002 -T PK E41 002 -T PK E42 004 -T PK E45 001 -T PK E48 002 -T PK 081 950 -T
kit valves Set of vanes Cooling water
controller
40
11.2 Drawings
Spare parts
41
Spare parts
1 Condensate separator with operating fluid re-
turn unit
2 Cover
3 Rotor
4 Intake pipe
5 Gas ballast valve
6 Pump dome
7 Valve crown
8 Pump body
9 Bearing housing/drive side
10 Bearing cover/drive side
11 Bearing housing/non drive side
12 Bearing cover/non drive side
13 Vane
14 Blank flange
15 Blank flange
16 Washer
17 Spacer ring
18 Pipe
19 Valve pipe
20 Exhaust valve
21 Valve seat
22 Seal
23 Seal
24 Seal
25 Setting ring
26 Set screw
27 "V" belt pulley
28 Flange cover
29 Supporting ring
30 Window ring
31 Centering ring
32 Tensioning ring
33 Blank flange
34 Locking screw with sealing ring
35 Vane spring
36 Strainer
37 Guide pin (only for BA 501)
38 Cylinder roller bearing
39 Oiler
40 Sight glass
41 Cooling water controller
42 Double nipple
44 Screwed connection
45 Angle
46 Seal
47 Radial shaft seal
48 Radial shaft seal
49 O-ring
51 O-ring
52 O-ring
54 O-ring
55 O-ring
56 O-ring
57 O-ring
57 O-ring
58 O-ring
59 O-ring
60 O-ring
61 O-ring
63 Screw
64 Screw
65 Spring washer
66 Washer
67 Screw
68 Screw
69 Screw
70 Screw
73 Screw
75 Screw
76 Screw
77 Ring screw
79 Dowel pin
80 Key
81 Screw
83 Locking screw with sealing ring
84 Pressure piece
85 Pressure ring
86 Screw-in sleeve
87 Pipe
88 Flange
90 Operating fluid and condensate drain
valve
91 Operating fluid filler screw
92 Sleeve
93 O-ring
94 Locking screw
95 Flange
96 "V" belt
42
12 Accessories
Designation BA 251
KAS 63, condensate separator PK Z10 010
OME 100 M, oil mist filter for pumping speeds up to 300 m
Oil return unit, ORF 005, standard version PK Z90 065
ZFO 063, zeolite trap PK Z70 010
FAK 063, activated carbon filter PK Z30 010
KLF 063, cold trap PK Z80 010
PTC-resistor tripping device P 4768 051 FQ
Operating fluid level monitoring, 24 V DC for BA 251/501 PK 133 115 -T
Reducing piece, stainless steel, DN 100/63 ISO-K PF 321 210-X
Cooling water connection unit for BA 251/501 PK 133 100 -T
Pressure monitor for cooling water circulation system BA 251/501 P 4747 161 MF
Resistance thermometer PT 100 PK 132 101 -T
EVB 063 PA, Angle valve, electropneumatic, with PI, with PV, 24 V DC PF B18 201
SAS 16, dust separator, DN 16 ISO-KF, polyester filter PK Z60 506
VFS 010, Air venting valve 24 V DC PK V52 024
Vibration isolators for BA 251/501 PK 132 855 -T
Conversion kit for gas ballast valve to KF connection PK 133 863 -T
SAS 63 dust separator, DN 63 ISO-K, polyester filter PK Z60 511
Magnetic gas ballast valve 230 V-50/60 Hz PK V52 001
3
/h PK Z40 012
Accessories
Designation BA 501
KAS 100, condensate separator PK Z10 012
OME 160 M, oil mist filter for pumping speeds of up to 500 m
Oil return unit, ORF 005, standard version PK Z90 065
FAK 100, activated carbon filter PK Z30 012
PTC-resistor tripping device P 4768 051 FQ
Operating fluid level monitoring, 24 V DC for BA 251/501 PK 133 115 -T
Reducing piece, stainless steel, DN 160/100 ISO-K PF 321 221 -X
Cooling water connection unit for BA 251/501 PK 133 100 -T
Pressure monitor for cooling water circulation system BA 251/501 P 4747 161 MF
Resistance thermometer PT 100 PK 132 101 -T
EVB 100 PA, Angle valve, electropneumatic, with PI, with PV, 24 V DC PF B28 201
SAS 16, dust separator, DN 16 ISO-KF, polyester filter PK Z60 506
Supporting frame for OME 160 M with BA 501 PK 133 904 -T
VFS 010, Air venting valve 24 V DC PK V52 024
Vibration isolators for BA 251/501 PK 132 855 -T
Conversion kit for gas ballast valve to KF connection PK 133 863 -T
SAS 100 dust separator, DN 100 ISO-K, polyester filter PK Z60 512
Magnetic gas ballast valve 230 V-50/60 Hz PK V52 001
3
/h PK Z40 014
Further detailed accessories are contained in the Pfeiffer Vacuum printed or Online Catalogue.
43
Technical data and dimensions
13 Technical data and dimensions
13.1 General
● Recommendations of PNEUROP committee PN5
● ISO 21360; 2007: "Vacuum technology - Standard methods for measuring vacuum-
pump performance - General description"
Conversion table: pressure units
mbar bar Pa hPa kPa Torr
mbar 1 1 · 10
bar 1000 1 1 · 10
Pa 0.01 1 · 10
hPa 1 1 · 10
kPa 10 0.01 1000 10 1 7.5
Torr
mm Hg
1.33 1.33 · 10
Conversion table: gas throughput units
-3
-5
-3
-3
1 Pa = 1 N/m
mm Hg
100 1 0.1 0.75
5
1 0.01 1 · 10
100 1 0.1 0.75
133.32 1.33 0.133 1
1000 100 750
2
-3
7.5 · 10
-3
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
3
Pa·m
/s 10 1 592 7.5 9.87
sccm 1.69 · 10
Torr·l/s 1.33 0.133 78.9 1 1.32
3
atm·cm
/s 1.01 0.101 59.8 0.76 1
-2
1.69 · 10
-3
1 1.27 · 10
-2
1.67 · 10
-2
44
13.2 Technical data
Technical data and dimensions
Parameter BA 251 BA 501
Flange (in) DN 63 ISO-F DN 100 ISO-F
Flange (out) DN 63 ISO-K DN 100 ISO-K
Pumping speed at 50 Hz 250 m
Pumping speed at 60 Hz 250 m
Ultimate pressure with gas ballast 1 hPa 1 hPa
Ultimate pressure without gas ballast 5 · 10
Exhaust pressure, min. Atmospheric pressure Atmospheric pressure
Exhaust pressure, max. 1500 hPa 1500 hPa
Nominal rotation speed at 50 Hz 1500 min
Nominal rotation speed at 60 Hz 1800 min
Nominal rotation speed pump, 50 Hz 490 min
Nominal rotation speed pump, 60 Hz 490 min
Emission sound pressure level without gas bal-
last at 50 Hz
Emission sound pressure level without gas bal-
last at 60 Hz
Ambient temperature 12-40 °C 12-40 °C
Protection category IP 55 IP 55
Rated power 50 Hz 11 kW 15 kW
Rated power 60 Hz 13 kW 18 kW
Mains requirement: voltage 50 Hz 230/400 (± 5%) V 400/690 (± 5%) V
Mains requirement: voltage 60 Hz 265/460 (± 5%) V 460 (± 5%) V
Switch No No
Mains cable No No
Shipping and storage temperature -25-+55 °C -25-+55 °C
Operating fluid P3 P3
Operating fluid filling 17 l 45 l
Weight: with motor 570 kg 1100 kg
Cooling method, standard Water Water
Cooling water pressure 2000-10000 hPa 2000-10000 hPa
Cooling water temperature 10-30 °C 10-30 °C
Cooling water consumption > 50 l/h > 90 l/h
Temperature: Operating 80 °C 80 °C
Table 1: Typical ultimate pressure according to PNEUROP
3
/h 500 m3/h
3
/h 500 m3/h
-2
hPa 5 · 10-2hPa
-1
-1
-1
-1
1500 min
1800 min
345 min
345 min
-1
-1
63 dB (A) 65 dB (A)
63 dB (A) 65 dB (A)
-1
-1
45
Technical data and dimensions
1030
1528
746
840
884
277
522
220
520
130
734
480
ø18 (6x)
980
DN 63 ISO -F
DN 10 KF
DN 63 ISO-K
467
25
13.3 Dimensions
Fig. 20: BA 251
46
891
Technical data and dimensions
1130
ø18 (6x)
1907
442
160
715310
1260
1204
DN 100 ISO-F
DN 10 KF
672
28
100
1070
990
DN 100 ISO-K
280
645
685
200
Fig. 21: BA 501
47
Technical data and dimensions
Frame with vibration
isolators
1150,5
Ø 22
(4x)
(851,5)
694,5
1113,5
(1374,5)
(1337,5)
A-A 1 : 5
217 (237)
A
(645)
488
A
137
BA 251 (BA 501)
48
Declaration of conformity
We hereby declare that the product cited below satisfies all relevant provisions according to the following EC directives:
● Machinery 2006/42/EC (Annex II, no. 1 A)
● Electromagnetic Compatibility 2014/30/EU
● Restriction of the use of certain Hazardous Substances 2011/65/EU
The agent responsible for compiling the technical documentation is Mr. Sebastian Oberbeck, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Aßlar.
UnoLine™ Plus
BA 251/501
Harmonised standards and national standards and specifications which have been applied:
DIN EN ISO 12100 : 2010 ISO 21360-1, 2 : 2012 DIN EN 61000-6-3 : 2007
DIN EN 1012-2 : 2011-12 DIN EN 61000-6-1 : 2007 DIN EN 61000-6-4 : 2007
DIN EN ISO 13857 : 2008 DIN EN 61000-6-2 : 2006 DIN EN ISO 2151 : 2009
Signature:
Pfeiffer Vacuum GmbH
Berliner Straße 43
35614 Asslar
Germany
(Dr. Ulrich von Hülsen)
Managing Director
2016-07-27
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T +49 6441 802-0
info@pfeiffer-vacuum.de
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