PD 0065 BEN/A (1604)
OPERATING INSTRUCTIONS
EN
Translation of the original instructions
DUO 255, DUO 255 M
Rotary Vane Pump
Table of contents
2
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 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.5 Filling up the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Operations monitoring (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Before switching on the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Switching on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Pumping condensable vapours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Switching off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2 Changing the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.3 Cleaning and re-setting the silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Changing the gas ballast filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.5 Assembling the motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1 Shutting down for longer periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2 Re-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.1 Rectifying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.1 Spare parts packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13 Technical data and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
13.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
About this manual
3
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.
Applicable documents
*also available via 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:
DUO 255 Operating instructions
Declaration of Conformity Part of this document
Operating instructions for accessories (order-specifically) see section "accessories"*
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
Pictographs
Instructions in the
text
Work instruction: here you have to do something.
Symbols used The following symbols are used consistently throughout in all illustrations:
Vacuum flange
Exhaust flange
Gas ballast valve
Power connection
Prohibition of an action to avoid any risk of accidents, the disregarding
of which may result in serious accidents
Warning of a displayed source of danger in connection with operation of
the unit or equipment
Command to perform an action or task associated with a source of danger, the disregarding of which may result in serious accidents
Important information about the product or this document
G
Safety
5
2Safety
2.1 Safety precautions
● 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!
– Minimum distance: 2 m!
● 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!
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.
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.
DANGER
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.
6
Safety
2.3 Proper use
● 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.
2.4 Improper use
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
CAUTION
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.
WARNING
Increased noise emission!
Increased noise emission can occur within a limited area surrounding the vacuum
pump.
Provide noise protection or
wear hearing protection.
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.
Transport and storage
7
3 Transport and storage
3.1 Transport
Transport instructions
Remove the locking cap from the vacuum and exhaust flange immediately before con-
necting!
– Check the protective stainer, paying attention to the O-ring.
Use only the crane eye on the top side of the pump to lift the pump.
Fig. 1: Transporting the pump
3.2 Storage
Check that all the openings on the pump are securely closed.
Fill up the pump with new operating fluid to the top edge of the sight glass.
Store the pump only indoors, preferably at temperatures between -10 °C and +40 °C.
– In rooms with moist or aggressive atmospheres, the pump must be airproof shrink-
wrapped in a plastic bag together with a bag of desiccant.
– After storage periods longer than two years, it is recommended to carry out main-
tenance and change the operating fluid before using the pump.
8
Product description
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.
Fig. 2: Product identification on the rating plate
Scope of delivery ● Pump with motor/without motor
● Operating fluid (except F4 and F5)
● Cone strainer and centering ring with O-ring
● Locking cap for vacuum and exhaust flange
● Operating instructions
Pump types
D-35641 Asslar
Mod.: DUO 125/255
Mod.-Nr.: PK D6x xxx
Ser.- Nr.: 3454440
S : max. 300 m /h
Oil : P3 23.0 l
Mass : 410 kg
n : 1175 1/min
(N )
2
3
max.
Made in Germany 2005/01
Pump type Pump versions
DUO 255 Standard version of pump
DUO 255 M Version with magnetic coupling
Product description
9
4.2 Function
The vacuum pumps of the DUO-Line 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 version with magnetic coupling has as an alternative to conventional shaft
feedthrough a static seal towards the outside.
Fig. 3: DUO 255
1 Vacuum flange
2 Exhaust flange
11 Support
12 Casing
17 Manometer
18 Oil passage for connecting accessories (opera-
tions monitoring, mechanical oil filter)
115 Gas ballast valve
148 Sight glass
321 Connection temperature sensor
326 Connection operating fluid level switch
328 Operating fluid drain screw
327 Operating fluid filler screw
245 O-ring
248 O-ring
350 Motor
12 327 1 2 18 17 115 350
148
328
326/248
321/245
11
10
Installation
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. 14, chap. 5.5).
– Amount and type according to rating plate
Always place the pump on a firm, even surface.
– The base frame has four holes for anchoring onto the base.
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.
Fig. 4: Setting up the pump
5.2 Connecting the vacuum side
Remove locking cap from the vacuum flange;
– pay attention to the cone strainer and the respective O-ring in the intake port.
Clear welded lines of any welding 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.
> 35 mm
Installation
11
5.3 Connecting the exhaust 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.
5.4 Connecting to the mains power supply
Depending on the pump type, different motor versions or mains voltages are possible:
● Three phase motor (without switch and mains cable).
CAUTION
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.
If the exhaust gases are being extracted, the exhaust pressure must be at least
250 hPa greater than the pressure at the intake side.
WARNING
Emission of toxic substances from the exhaust!
Danger of poisoning from emitted gases or vapours, which can be detrimental to health
and/or can pollute the environment, depending on the particular application.
Comply with the applicable regulations when working with toxic substances.
Only officially approved filter systems may be used to separate and remove these
substances.
DANGER
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.
NOTICE
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.
12
Installation
Three-phase motor The three-phase current motor circuit
The connections U1 - L2, V1 - L1 and W1 - L3 result in a clockwise rotation of the motor
shaft as seen looking towards the motor fan.
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.
Fig. 6: Motor coil and connecting plate of Star Connection (for high voltage)
Inspection of the direction of rotation
For pumps with three-phase motors, it is necessary to check the direction of rotation!
Remove the locking cap from the exhaust flange (if existing).
Switch the 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 connecting ca-
ble.
Fill up the operating fluid.
W2
U1
L1
V2
V1
W1
U2
L3
L2
W2
U2
V2
U1
V1
W1
L1
L2
L3
W2
U1
L1
V2
V1
W1
U2
L3
L2
W2
U2
V2
U1
V1
W1
L1
L2
L3
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.
Installation
13
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.
Fig. 7: Connection example for a three-phase AC motor with PTC resistor tripping device
U
S
Control voltage
S
1
OFF button
S
2
ON button
S
3
RESET button, external
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
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)
NOTICE
Do not start with star/delta connection.
Always start motor directly.
14
Installation
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 sufficient operating fluid for
one filling. The use of other operating fluids requires prior authorisation from Pfeiffer Vacuum.
Permissible operating fluids
● P3 (Standard operating fluid)
● D1 for special applications (e.g. higher operating temperatures)
– Ultimate pressure measured with gas type dependent gauge: < 5·10
-2
hPa
Filling up the operating fluid
Unscrew operating fluid filler screw 327.
Fill up operating fluid;
– correct filling level during operations: within the markings at the sight glass frame.
Fig. 8: Filling up the operating fluid
Screw in operating fluid filler screw 327.
Check operating fluid level only when the pump is warm and running; therefore
– close vacuum flange and gas ballast valve,
– correct filling level during operations: within the markings at the sight glass frame,
– check operating fluid daily in non-stop operation, otherwise whenever the pump is
switched on. Refilling is possible when the pump is in final vacuum operation.
NOTICE
Use approved operating 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.
max.
min.
WARNING
Toxic vapours!
Danger of poisoning when igniting and heating synthetic operating fluids (e.g. F4/F5)
above 300 °C.
Observe the application instructions.
Do not allow operating fluid to make contact with tobacco products; observe safety
precautions when handling chemicals.
Installation
15
5.6 Operations monitoring (Option)
For operations monitoring a pressure switch can be installed on the side of the support.
In case of a malfunction, e. g. pressure drop or when the pump is at rest, the contact of
the pressure switch opens. The signal can be used to control external valves.
Fig. 9: Installation location and circuit diagram of pressure switch
Switch off the pump.
Unscrew screw 326 from the oil passage 18.
Screw pressure switch with O-ring into oil passage 18.
Remove protective cover and make electrical connections at the pressure switch.
Reassemble the protective cover.
Parameter Oil pressure switch
Protection category IP 55
Contact Closing contact, normally open
Set point 1000 hPa
Switching voltage 250 V
Switching current V AC2A
1 + 2 closers = pressureless open
1
2
18
326
248
16
Operation
6Operation
6.1 Before switching on the pump
Check the operating fluid level in the sight glass.
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 150
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.
6.2 Switching on the pump
The pump can be switched on in any pressure range between atmospheric and
ultimate pressure.
No special precautions are necessary when pumping dry gases. In order to attain the
lowest possible ultimate pressures, the gas ballast valve should be closed.
Switch on the pump with the vacuum flange closed and allow to warm up for 30 min-
utes.
Monitoring the operating fluid pressure
The pressure values on pressure gauge 17 differ depending on the operating temperature.
During continuous pump operation, check operating fluid level at sight glass 148 and
operating fluid pressure on pressure gauge on a daily basis.
CAUTION
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.
Operating fluid Pump temperature Operating fluid pressure
P3/D1 Cold start (ca. 12°C) max. 10000 hPa
Operating temperature 1500 ... 2500 hPa
Operation
17
6.3 Pumping condensable vapours
Should the process gases contain condensable gases, the rotary vane pump must be
operated with gas ballast (i.e. with an open gas ballast valve).
Gas ballast valve,
standard version
To avoid condensation in the pump when pumping condensable vapours, air is periodically fed into the working chamber at the beginning of the compression phase via the gas
ballast valve 115.
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.
The gas ballast filter is used to keep the air free of particles before entering the suction
chamber.
Fig. 10: Standard version of gas ballast valve 115
Gas ballast valve with
flushing gas connection (option)
If the pumping process requires the use of flushing gas, a supply hose can be connected
at the gas ballast valve.
Unscrew gas ballast filter 122 at ball valve 120.
On the inside thread G 1/ 2 " of ball valve 120, connect the supply line and seal up
thread side.
Set flushing gas pressure on site; maximum pressure 1500 hPa (absolute).
– Select the type and amount of flushing gas depending on the process; consult Pfei-
ffer Vacuum if necessary.
Dose flushing gas with the knob on the ball valve 120 or with a flow meter on site.
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.
115 Gas ballast valve (ball valve) 122 Gas ballast filter
"I"
"0"
122
115
120
18
Operation
Gas ballast valve with
solenoid valve
The inlet of gas ballast or flushing gas can be controlled by a solenoid valve if a conversion kit is used.
If the process does not require flushing, ambient air can also be admitted via the solenoid
valve. For this, remove the hose connection and attach the gas ballast filter 122 to the
solenoid valve.
Fig. 11: Assembling the solenoid valve at the gas ballast inlet
Remove gas ballast filter 122.
Unscrew connection 154, take care to ensure the flat gasket is secure.
Seal the external thread G 1/2" of screw connection part I and attach to ball valve 120.
Mount the screw connection part II so that the solenoid valve is facing up; take care
to ensure the flat gasket is secure.
Make electrical connections 24 V DC.
Attach flushing gas to hose connection (NW 12… 14 mm) or after removing the hose
nozzle attach to the internal thread G 1/2".
Set flushing gas pressure; maximum pressure 1500 hPa (absolute).
– Select the type and amount of flushing gas depending on the process; consult Pfei-
ffer Vacuum if necessary.
Dose flushing gas with the knob on the ball valve 120 or with a flow meter on site.
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.
Set the amount of flushing gas on site.
Supply voltage: 24 V AC/DC
Starting power: 80 W
Stopping power: 6 W
Valve closed without current
122
120
154
“I“
“II“
Operation
19
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 differential
pressure between the exhaust side and the intake side is 250 hPa, 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 secure man-
ner.
Venting the vacuum
chamber
Maintaining the vacuum in the chamber
NOTICE
Danger of backflow of operating fluid into the intake line!
Contamination of the connected vacuum system!
Vent the vacuum chamber within 30 s, regardless of the chamber size.
For a longer venting process, use an additional shut-off valve and shut off the intake
line after switching off the pump.
NOTICE
Danger of backflow of operating fluid into the intake 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.
20
Maintenance
7 Maintenance
7.1 Precautions
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.
Magnetic coupling The following safety instructions are only valid for the disassembly of the drive system
for vacuum pumps with magnetic coupling!
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.
WARNING
Pump parts may be contaminated from pumped media!
Danger of poisoning due to contact with harmful substances.
Decontaminate the pump before carrying out any maintenance work.
In the event of contamination, take suitable safety precautions to prevent your health
from being harmed by any dangerous substances.
DANGER
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 (≤ 2m) of the magnetic
field.
Rooms in which open couplings are accessible must be identified: ’’ No trespassing
for persons with heart pacemaker’’!
Disassembled magnetic couplings must be kept away from computers, data storage
media and other electronic components.
Maintenance
21
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.
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.
The level of deterioration of operating fluid P3 can be determined for clean processes
with the colour scale (in accordance with DIN 51578); supplementary sheet PK 0219
BN on request or at www.pfeiffer-vacuum.com.
Suck off operating fluid from the pump through the operating fluid filler opening.
Fill the specimen in a test tube or some similar vessel and test by holding against the
light.
Where discolouration is red brown (equivalent to 5 on the scale) change operating flu-
id at the latest.
Switch off the pump.
Unscrew operating fluid filler screw 327.
Unscrew operating fluid drain screw 328.
Activity K/I/
W/R
1
1. K: Checking, I: Inspection, W: Maintenance, R: Overhaul
daily as required;
at least
annually
as required;
at least every
2 years
as required;
at least every
4 years
Check operating fluid level K X
Visual inspection (leak-tightness/oil leaks) K X
Check filter insert of external oil mist filter (if
existent)
KX
Change operating fluid I X
Disassemble casing, sight glass and pump-
ing system and clean casing outside (without cleaning agent)
IX
Clean gas ballast valve and silencer I X
Clean the motor fan cap I X
Disassemble the pump, clean and exchange
seals and wearing parts:
Radial shaft seal ring
Coupling half at motor side
Hydraulic valve
Exhaust valve tongue
Valve flap of the gas ballast valve
Vane springs
W X (PV)
Carry out work in accordance the maintenance and additionally:
Change vanes
Change valves, springs and sight glass
Change silencer nozzle
Check coupling and exchange if neces-
sary
R X (PV)
Depending on the process, the required replacement intervals for the operating fluid and the intervals for
inspection, maintenance and overhaul may be shorter than the guide values specified in the table. Consult
Pfeiffer Vacuum Service, if necessary.
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.
22
Maintenance
Fig. 12: Draining the operating fluid
Screw in operating fluid drain screw 328; pay attention to O-ring.
Screw in operating fluid filler screw 327.
Allow pump to run for a maximum of 5 seconds with the vacuum flange open.
Drain off remaining operating fluid.
– In case of serious contamination, the operating fluid will have to be changed sev-
eral times (flushing):
Fill up with operating fluid and check the filling level (see p. 14, chap. 5.5).
Flushing and cleaning
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 back in.
Fill up with operating fluid and check the filling level (see p. 14, chap. 5.5).
328
327
WARNING
Hot operating fluid!
Danger of burns when draining due to contact with skin.
Wear suitable protective clothing.
Use a suitable collecting vessel.
WARNING
Operating fluid may contain toxic 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
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.
Maintenance
23
Checking the oil filter The oil filter described here is integrated into the pump‘s oil circulation. Alternative, an
additional external oil filter can be used.
Fig. 13: Dismantle and clean oil filter
Unscrew screws 293 and remove cover 14, use tapped holes if necessary; observe
O-ring 264.
Unscrew screws 292 from flange 77 and lift flange with oil filter 59 out of the pump;
pay attention to dripping operating fluid.
Dismantle filter unit in accordance with figure and clean oil filter 59 in petrol or similar
cleaning agent.
Blow out filter with air and dry.
Assembling is carried out in reverse order.
Fill up with operating fluid to the middle of the sight glass.
– Filling quantity approx. 25 l of operating fluid.
7.3 Cleaning and re-setting the silencer
If the silencer is not functioning, a knocking noise becomes audible at final vacuum. This
does not damage the pump, although can have a negative affect at the installation location.
NOTICE
Also check and clean if necessary the oil filter every time you change the operating fluid.
In case of maintenance, always change the oil filter
14 Cover
59 Oil filter
77 Flange
92 Spacer sleeve
94 Washer
95 Screw
264 O-ring
292 Screws
293 Screws
293
292
77
59
92
94
95
264
14
24
Maintenance
Dismantling
Fig. 14: Dismantle silencer
Drain off operating fluid.
Unscrew screws 293 and remove cover 14, use tapped holes if necessary; observe
O-ring 264.
Unscrew screws 292 from flange 77 and lift flange with oil filter 59 out of the pump;
pay attention to dripping operating fluid.
Unscrew screws 332 and remove baffle plate 16.
Lift casing 12 with a chain hoist at eye bolt R or a jack lift. Caution! Casing weighs
approx. 46 kg.
Unscrew nuts 334 and remove washers 346.
Carefully back casing 12 away from support stand 11 in axial direction; pay attention
to O-ring 269.
Dismantle valve housing 71 in axial direction, clean and check radial borehole for free
flow.
Unscrew valve spindle 72.
Examine O-rings 242, valve spindle 72 and valve seat for wear and replace if neces-
sary.
Reassemble in the reverse sequence. Carefully push O-ring 242 into the nut in valve
spindle 72 and oil lightly with operating fluid.
Setting the silencer The silencer is set using a standard screwdriver when the pump is running at operating
temperature and vacuum flange and gas ballast valve are closed:
Bring pump up to operating temperature.
Unscrew operating fluid filler screw 327.
Turn valve spindle 72 approx. 3 rotations using screwdriver (flush), wait a few seconds
and then reclose far as it will go (clockwise).
11 Support stand
12 Casing
14 Cover
16 Baffle plate
59 Oil filter
71 Valve housing
72 Valve spindle
77 Flange
242 O-ring
264 O-ring
292 Screws
293 Screws
327 Operating fluid filler screw
332 Screws
334 Hexagon nut
346 Washer
242
71
242
72
327
293
14
264
292
59
12
16
11
77
R
332
334/
346
Maintenance
25
Slowly open valve spindle 72 (1/2 to 1 rotation) until the oil hammer noise disappears.
Screw in operating fluid filler screw 327.
7.4 Changing the gas ballast filter
The greater the contamination, the lower the filter air throughput and the greater the risk
of condensation and corrosion within the pump.
Standard version
Fig. 15: Gas ballast valve (standard version)
Turn the cover and open the filter housing 122.
Clean filter insert 123 or replace as necessary.
120 Gas ballast valve (ball valve)
122 Filter housing
123 Filter insert
120
122
123
26
Maintenance
7.5 Assembling the motor and coupling
Crown gear coupling When performing installation work on the coupling, it is important to observe the instal-
lation instructions of the coupling manufacturer:
www.ktr.com/de/index/service/montageanleitung.htm
The shaft of the drive motor must be aligned with the pump shaft:
– Observe the permissible angular and radial displacements.
– Maintain clearance E so that the crown gear can still move axially.
Tighten the screws in the coupling half with the prescribed torque and secure the stud
bolt with Loctite 243.
Fig. 16: Assembling the crown gear coupling at pump with standard coupling
Magnetic coupling The following safety instructions are only valid for the disassembly of the drive system
for vacuum pumps with magnetic coupling!
NOTICE
Damage to motor bearings
Blows or pressure when mounting the coupling half can damage the motor bearings.
Clean and lightly oil the shaft journals.
Push the coupling half onto the shaft. If necessary, warm the coupling half, or use the
internal thread in the shaft journal and suitable tools and push the coupling half in
place.
E: 116
+0,5
mm mm
T
A
: 17 Nm
T
E
A
DANGER
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 (≤ 2m) of the magnetic
field.
Rooms in which open couplings are accessible must be identified: ’’ No trespassing
for persons with heart pacemaker’’!
Disassembled magnetic couplings must be kept away from computers, data storage
media and other electronic components.
Maintenance
27
Fig. 17: Dismantling/assembling the drive motor at pumps with magnetic coupling
Secure motor with chain hoist.
Remove gas ballast valve 115 from the pump and absorb the operating fluid under-
neath.
Pull off taper pins 344 with a pin puller (tool kit).
Unscrew screws 302.2.
Screw in two guide pins F in place of the two screws 302.2.
Pull off taper pins 344 with a pin puller (tool kit).
Then unscrew the remaining screws 302.5 (5x).
Press cover 10 and motor off evenly with two jack screws W62 and pull off horizontal-
ly;
– loosen the screws 290 at the oil cooler 208 during the releasing process and gently
tilt the oil cooler 208 when passing the fan 195.
NOTICE
Danger of bursting when the motor is removed!
The separating can of the magnetic coupling is made of plastic or ceramics, and can be
destroyed when the motor is pulled off.
Suspend the motor at the eyebolt to the lifting device and pull it off horizontally.
Use jack screws and guide pins.
302.2
10
195
208*
W50
W50
W62
W62
290*
321
176
301
195
302.5
344
191
302.5
115
* parts 208/290
only valid for DUO 255 M
* Teile 208/290
nur für DUO 255 M gültig
28
Decommissioning
Detach motor in an axial direction from motor intermediate flange 194.
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.
Start the pump and allow the pump to warm up.
Switch off the pump.
Fill up the pump with new operating fluid to the top edge of the sight glass.
Close vacuum flange and exhaust flange with locking caps.
Store the pump only indoors, preferably at temperatures between -10 °C and +40 °C.
– In rooms with moist or aggressive atmospheres, the pump must be airproof shrink-
wrapped in a plastic bag together with a bag of desiccant.
– After storage periods 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
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.
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.
NOTICE
Re-starting
The serviceability of the operating fluid without operation is a maximum of 2 years. Before restarting after a shut-down of 2 years or longer, carry out the following work.
Replace the operating fluid.
Replace the radial shaft sealing rings and further elastomer parts.
Replace bearings at pumps with anti-friction bearings.
Follow the maintenance instructions and inform Pfeiffer Vacuum.
Malfunctions
29
9 Malfunctions
Please note the following instructions should the pump malfunction:
9.1 Rectifying malfunctions
CAUTION
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.
NOTICE
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.
Problem Possible causes Remedy
Pump will not start up No mains voltage or voltage does
not correspond to the motor data
Check mains voltage and mains fuse protec-
tion; check motor switch
Pump temperature too low Warm up pump to > 12 °C
Thermal protection switch has re-
sponded
Detect and fix cause of overheating; allow
pump to cool off if necessary.
Pump system dirty Clean pump; contact Pfeiffer Vacuum Ser-
vice if necessary.
Pump system damaged Clean and overhaul pump; contact Pfeiffer
Vacuum Service if necessary.
Motor defective Replace motor
Pump switches off after a while after being
started
Thermal protection switch of the
motor has responded
Detect and fix cause of overheating; allow
motor to cool off if necessary.
Mains fuse protection triggered
due to overload (e.g. cold start)
Warm up pump
Exhaust pressure too high Check opening of exhaust line and exhaust
accessories
Pump does not attain
ultimate pressure
Measurement reading is false Check gauge, check ultimate pressure with-
out installation connected.
Pump or connected accessories
are dirty
Clean pump and check components for con-
tamination.
Operating fluid dirty Operate pump for a longer period with gas
ballast valve open or change operating fluid
Leak in system Repair leak
Operating fluid filling level too low Top off operating fluid
Pump damaged Contact Pfeiffer Vacuum Service.
Pumping speed of
pump too low
Intake line not well-dimensioned Keep connections as short as possible and
ensure that cross-sections are sufficiently
dimensioned
Exhaust pressure too high Check opening of exhaust line and exhaust
accessories
Loss of operating fluid Swivel gasket leaky Check tightness; replace gasket if neces-
sary
Radial shaft seal ring leaky Replace seal ring and check bushing
Operational loss of operating fluid,
without ONF/OME
Install oil mist filter and oil return unit
Operational loss of operating fluid,
with ONF/OME
Clean oil mist filter and oil return unit,
change filter respectively
30
Malfunctions
Unusual operating
noises
Silencer dirty Clean or replace the silencer.
Damage to the pump system Clean and overhaul pump; contact Pfeiffer
Vacuum Service if necessary.
Motor bearing defective Replace motor; contact Pfeiffer Vacuum
Service if necessary
Problem Possible causes Remedy
Unusual operating
noises
Motor runs - pump doesn’t (only
valid for pumps with magnetic
coupling system)
Magnetic coupling system defective or magnetic
field "broken away", contact Pfeiffer Vacuum
Service if necessary.
Attention! Magnetic field:
If the magnetic field has "broken away", the ori-
entation of the magnets with respect to each other can only be re-established at standstill. If the
pump is left to operate with a "broken away"
magnetic field, demagnetisation will take place
and the coupling is destroyed.
Problem Possible causes Remedy
NOTICE
Service work should be carried out by a qualified 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.
Service
31
10 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".
1)
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.
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
32
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 pack/
spare parts
Revision index /
Versi on
No. consisting of the parts correspondent
to exploded views on the following
pages
Sets of seals "A" PK E00 023 -T 48, 106, 144, 240, 242, 244, 246, 248, 250,
251, 254, 256, 258, 260, 262, 264, 266,
269, 270
"C" PK E00 025 -T 48, 102, 144, 147, 240, 242, 244, 245, 246,
247, 248, 250, 251, 255, 256, 258, 260,
262, 264, 266, 269, 270
"C"/DUO 255 M PK E00 027 -T 48, 102, 144, 147, 240, 242, 244, 245, 246,
247, 248, 250, 251, 254, 255, 256, 258,
260, 262, 264, 266, 267, 269, 270
Maintenance kit "A" PK E01 033 -T 29, 59, 60, 142, 144, 145, 173, 250, 254,
260, 264, 266, 269
"A"/DUO 255 M PK E01 035 -T 59, 60, 228, 247, 250, 256, 264, 269
Overhaul kit "A" PK E02 036 -T PK E00 023 -T, 15, 17, 24, 29, 30, 31, 38,
52, 53, 56, 59, 60, 65, 70, 81, 85, 88, 98,
99, 142, 145, 173, 206
"C" PK E02 038 -T PK E00 025 -T, 17, 24, 29, 30, 31, 38, 52,
53, 56, 59, 60, 65, 70, 81, 85, 88, 98, 99,
142, 145, 148, 173, 230
"C"/DUO 255 M PK E02 051 -T PK E00 027 -T, 17, 24, 29, 30, 31, 38, 52,
53, 56, 59, 60, 65, 70, 81, 85, 88, 98, 99,
142, 145, 148, 173, 230
Pumping system, P3 DUO 255 PK E03 013 -T 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 36, 37, 38, 39, 41, 42, 43, 44, 48,
52, 53, 54, 56, 57, 58, 59, 60, 254, 256,
258, 260, 280, 282, 287, 288, 294, 296,
312, 338
Pumping system, P3 DUO 255 M PK E03 050 -U 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 36, 37, 38, 39, 41, 42, 43, 44, 48,
52, 53, 54, 56, 57, 58, 59, 60, 254, 260,
280, 282, 287, 294, 296, 338
Pumping system, D1 DUO 255 PK E03 014 -T 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 36, 37, 38, 39, 41, 42, 43, 44, 48,
52, 53, 54, 56, 57, 58, 59, 60, 254, 260,
280, 282, 287, 294, 296, 338
Pumping system, D1 DUO 255 M PK E03 051 -U 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 36, 37, 38, 39, 41, 42, 43, 44, 48,
52, 53, 54, 56, 57, 58, 59, 60, 254, 260,
280, 282, 287, 294, 296, 338
Fore-vacuum safety
valve set
DUO 255 -/M PK E04 008 -T 59, 79, 80, 81, 82, 83, 84, 85, 88, 98, 99,
262, 264
Exhaust valve set,
stage I
DUO 255 -/M PK E05 011 -T 56, 59, 60
Exhaust valve set,
stage Ii
DUO 255 -/M PK E05 013 -T 48, 52, 53, 54, 258, 294
Coupling set DUO 255 PK E06 006 -T 170, 171, 173, 175
Set of vanes DUO 255 -/M PK E08 028 -T 30, 31, 38
Filter insert for gas
ballast valve
DUO 255 -/M P 0996 094 123
Spare parts
33
Exploded view DUO 255, pump complete
13
221
201
223
224
205
74
204
220
262
228
324
246
320
21
75
298
342
300
19
336
340
273
200
222
272
11
251
289
244
322
326
248
203
310
226
144
145
144
142
266
221
227
224
208
290
140
284
170
171
172
304
173
176
175
10
302
350
300
254
118
120
122
123
18
270
344
220
102/
103
(106)
269
230
17
141
332
333
250
255
328
248
245
321
326
284
146
147
148
147
293
14
264
250
327
12
16
34
Spare parts
10 Cover
11 Support stand
12 Casing
13 Sealing, casing
14 Flange
16 Baffle plate
17 Spring manometer
18 Flange, OFM
19 Base
21 Pumping system, complete
74 Vacuum safety valve, complete
75 Flange ring
102 Over pressure valve, complete
103 Housing
106 Valve seat ring (pressure relief valve)
118 Screw fitting, G1 1/4" to G 1/2"
120 Ball valve, G 1/2"
122 Gas ballast filter, complete
123 Filter insert for gas ballast filter
140 Centering flange for rssr.
141 Sealing nipple
142 Compensating washer for rssr.
144 Radial shaft seal ring (rssr)
145 Spacer
146 Sight glass frame
147 Sight glass seal
148 Sight glass
170 Fan
171 Coupling half
172 Washer
173 Coupling set
176 Stud screw for coupling
200 Pipe
201 Oil pipe, 12
203 Oil pipe, 6
204 Oil pipe, 6
205 Oil pipe, 12
208 Oil cooler
220 Straight screwed coupling, G 1/8"
221 Straight screwed coupling, G 3/8"
222 Straight screwed coupling, G 1/2"
223 Elbow union, G 1/8"
224 Elbow union, G 3/8"
226 Screw fitting
227 Hose connection for oil cooler
228 Strainer
230 Sealing ring
244 O-ring
245 O-ring
246 O-ring
248 O-ring
250 O-ring
251 O-ring
254 O-ring
255 O-ring
262 O-ring
264 O-ring
266 O-ring
269 O-ring (for revision index "A")
270 Flat seal
272 Stud screw
273 Stud screw
284 Allen head screw
289 Screws for flange (18)
290 Allen head screw
293 Allen head screw
298 Allen head screw, M 10
300 Hexagon head screw
302 Hexagon head screw
304 Countersunk screw
310 Allen head screw
320 Crane eye
321 Locking screw, M14 x 1.5
322 Locking screw, G 1/8"
324 Locking screw, G 3/8"
326 Locking screw, G 1/2"
327 Locking screw, G 3/4"
328 Operating fluid drain screw
332 Allen head screw
334 Hexagon nut
336 Hexagon nut
340 Lock washer
342 Washer
344 Tapered pin
346 Washer
350 Motor
Spare parts
35
Fig. 18: DUO 255 M with magnetic coupling
286
198
197
196
176
10
302
300
350
191
319
301 (DUO 255
298 (DUO 125
295 (DUO 255 M)
293 (DUO 125 M)
141
266
140
325
267
193
194
284
192
172
304
323
195
145
144
144
142 (DUO 255 M)
143 (DUO 125 M)
10 Cover
140 Centering flange
141 Sealing nipple (for DUO 125 M
in support plate 22)
142 Washer
143 Supporting ring
144 Radial shaft seal ring
145 Spacer
172 Washer
176 Stud screw
191 Motor intermediate flange
192 Magnetic coupling
193 Can
194 Collar flange
195 Fan
196 Magnetic coupling, motor
197 Fan blade
198 Counter ring, fan
266 O-ring
267 O-ring
284 Allen head screw
286 Allen head screw
293 Allen head screw
304 Allen head screw
295 Allen head screw
298 Hexagon head screw
300 Hexagon head screw
302 Hexagon head screw
301 Hexagon head screw
319 Eye bolt
323 Locking screw
325 Locking screw
350 Motor
36
Spare parts
Exploded view DUO 255, pumping system
48
258
30
27
250
63
53
256
312
65
31
31
30
28
284
34
23
43
42
41
38
33
282
31
34
38
26
25
24
296
37
26
25
24
36
39
56
296
296
44
64
288
58
57
59
60
32
294
24
25
26
33
52
22
26
24
25
29
23
31
280
338
23
260
54
294
225
70
242
254
254
254
22 Support plate
23 Set screw
24 Needle bearing
25 Cover ring for needle bearing
26 Circlip for needle bearing
27 Rotor I
28 Key
29 Protective sleeve for radial ssr.
30 Vane, stage I
31 Pressure spring
32 Cylinder
33 Locking screw
34 Nozzle
36 Spacer
37 Rotor II
38 Vane, stage II
39 Bearing cover
41 Key
42 Gear wheel, driven
43 Gear wheel, treibend
44 Cover, oil pump
48 Valve seat, complete
52 Valve stamp, stage I
53 Pressure spring for valve, stage I
54 Valve housing, stage I
56 Pressure valve, stage II
57 Valve housing, stage II
58 Stud bolt of valve, stage II
59 Oil filter
60 Sieve box of valve, stage II
63 Housing of non-return valve
64 Valve insert of non-return valve
65 PLate spring of non-return valve
70 Silencer, complete
225 Elbow union G 1/2"
242 O-ring
250 O-ring
254 O-ring
256 O-ring
258 O-ring
260 O-ring
280 Allen head screw
282 Allen head screw
284 Allen head screw
288 Allen head screw
294 Allen head screw
296 Allen head screw
312 Allen head screw
338 Hexagon nut
Spare parts
37
Exploded view DUO 255, vacuum safety valve
59 Oil filter
75 Flange ring
76 Valve housing
77 Valve cover
78 Valve cover for hydraulic valve
79 Hexagon cap nut
80 Piston
81 Pressure spring
82 Guiding piece
83 Circlip
84 Valve stem
85 Buffer
86 Valve plate
92 Pipe
94 Washer
95 Allen head screw
98 Pressure spring
99 Hydraulic piston
100 Cover
88 Pos. 86 + 262
262 O-ring
264 O-ring
284 Allen head screw
292 Allen head screw
298 Allen head screw
298
77
292
94
98
78
79
80
100
99
92
59
81
82
85
84
88
86
76
262
264
284
83
95
262
84/85/86:
mit Loctite 222 kleben/
apply Loctite 222
75
298
298
264
38
Accessories
12 Accessories
Further detailed accessories are contained in the Pfeiffer Vacuum printed or Online Catalogue.
Designation Duo 255
STP 100, dust separator, single-stage for minor contamination PK Z60 212
STR 100, dust separator, dual-stage for medium contamination PK Z60 112
KAS 100, condensate separator for pumping speeds of up to 250 m
3
/h PK Z10 012
OME 100, oil mist filter for pumping speeds up to 300 m
3
/h PK Z40 012
FAK 100, activated carbon filter PK Z30 012
PTC-resistor tripping device P 4768 051 FQ
Oil level monitoring 24 V DC for Okta 250 / M / Okta 500 / M / Okta 1000
/ M / Okta 2000 / M / Okta 4000 / M / Okta 6000 / M, G 1 1/4
PK 005 639 -U
Oil level monitoring 20-250 V AC for Okta 250 / M / Okta 500 / M / Okta
1000 / M / Okta 2000 / M / Okta 4000 / M / Okta 6000 / M, G 1 1/4
PK 004 930 -U
OFM 255, mechanical oil filter PK Z90 341
Oil return unit, ORF 005, standard version PK Z90 065
Oil pressure switch for Duo 125/255 PK 223 806 -T
Gas ballast valve - conversion kit with magnet valve, 24 V DC PK 215 795 -T
P3, mineral oil, 1 l PK 001 106 -T
P3, mineral oil, 5 l PK 001 107 -T
P3, mineral oil, 20 l PK 001 108 -T
D1, synthetic diester based oil, 1 l PK 005 875 -T
D1, synthetic diester based oil, 5 l PK 005 876 -T
D1, synthetic diester based oil, 20 l PK 005 877 -T
Technical data and dimensions
39
13 Technical data and dimensions
13.1 General
Conversion table: pressure units
Conversion table: gas throughput units
mbar bar Pa hPa kPa Torr
mm Hg
mbar 1 1 · 10
-3
100 1 0.1 0.75
bar 1000 1 1 · 10
5
1000 100 750
Pa 0.01 1 · 10
-5
1 0.01 1 · 10
-3
7.5 · 10
-3
hPa 1 1 · 10
-3
100 1 0.1 0.75
kPa 10 0.01 1000 10 1 7.5
Tor r
mm Hg
1.33 1.33 · 10
-3
133.32 1.33 0.133 1
1 Pa = 1 N/m
2
mbar·l/s Pa·m3/s sccm Torr·l/s atm·cm3/s
mbar·l/s 1 0.1 59.2 0.75 0.987
Pa·m
3
/s 10 1 592 7.5 9.87
sccm 1.69 · 10
-2
1.69 · 10
-3
1 1.27 · 10
-2
1.67 · 10
-2
Torr·l/s 1.33 0.133 78.9 1 1.32
atm·cm
3
/s 1.01 0.101 59.8 0.76 1
40
Technical data and dimensions
13.2 Technical data
Table 1: Typical ultimate pressure according to PNEUROP
Table 2: Typical ultimate pressure according to PNEUROP
Parameter Duo 255
Flange (in) DN 100 ISO-F
Flange (out) DN 100 ISO-F
Pumping speed at 50 Hz 250 m
3
/h
Pumping speed at 60 Hz 300 m
3
/h
Ultimate pressure with gas ballast 4 · 10
-3
hPa
Ultimate pressure without gas ballast 3 · 10
-3
hPa
Exhaust pressure, min. 250 hPa
Exhaust pressure, max. 1500 hPa
Rotation speed at 50 Hz 1000 min
-1
Rotation speed at 60 Hz 1200 min
-1
Leak rate safety valve 1 · 10-5Pa m3/s
Emission sound pressure level without gas ballast at 50 Hz 75 dB (A)
Ambient temperature 12-40 °C
Protection category IP 55
Rated power 50 Hz 7.5 kW
Rated power 60 Hz 9.0 kW
Switch No
Mains cable No
Shipping and storage temperature -25-+55 °C
Operating fluid filling 25 l
Weight 360 kg
Cooling method, standard Air
Parameter Duo 255 M
Flange (in) DN 100 ISO-F
Flange (out) DN 100 ISO-F
Pumping speed at 50 Hz 250 m
3
/h
Pumping speed at 60 Hz 300 m
3
/h
Ultimate pressure with gas ballast 4 · 10
-3
hPa
Ultimate pressure without gas ballast 3 · 10
-3
hPa
Exhaust pressure, min. 250 hPa
Exhaust pressure, max. 1500 hPa
Rotation speed at 50 Hz 1000 min
-1
Rotation speed at 60 Hz 1200 min
-1
Leak rate safety valve 1 · 10-5Pa m3/s
Emission sound pressure level without gas ballast at 50 Hz 75 dB (A)
Ambient temperature 12-40 °C
Protection category IP 55
Rated power 50 Hz 7.5 kW
Rated power 60 Hz 9 kW
Switch No
Mains cable No
Shipping and storage temperature -25-+55 °C
Operating fluid filling 25 l
Weight 397 kg
Cooling method, standard Air
Technical data and dimensions
41
13.3 Dimensions
Fig. 19: DUO 255, DUO 255 M
7
4
1
6
7
0
460
478
4
9
8
310
670
856
1
4
5
30
14
G 3/4 (2x)
1
0
0
2
7
6
720
390
318,5
G1/2
M14 x 1,5
145
M8 - 17tief (8x)
(1494 )
+3
- 0
1407
+3
- 0
(...): DUO 255 M
DN 100 ISO-F
Ø
Ø
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.
DuoLine™
DUO 255
Harmonised standards and national standards and specifications which have been applied:
DIN EN ISO 12100 : 2010 DIN EN 61010-1 : 2010 DIN EN 61000-6-3 : 2007 + A1: 2011
DIN EN 1012-2 : 2011-12 DIN EN 61000-6-1 : 2007 DIN EN 61000-6-4 : 2007 + A1: 2011
DIN EN ISO 13857 : 2008 DIN EN 61000-6-2 : 2006 DIN EN ISO 2151 : 2: 2008
ISO 21360-1, 2 : 2012
Signature:
Pfeiffer Vacuum GmbH
Berliner Straße 43
35614 Asslar
Germany
(Dr. Ulrich von Hülsen)
Managing Director
2016-04-11
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