Betriebsanleitung • Operating Instructions
Translation of the Original Operating Instructions
PK 0152 BE/M (0905)
Rotary Vane Pump
UNO/DUO 2.5, DUO 2.5 C
UNO 5
Table of contents
Table of contents
1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Setting up the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Filling up the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Connecting the vacuum side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Connecting the exhaust side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.5 Connecting to the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Before switching on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Pumping conden sa ble vapours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4 Switching off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Changing the operating fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.1 Shutting down for longer periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.2 Restarting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.1 Rectifying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.1 Spare parts packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Declaration of conformity 30
2
1 About this manual
1.1 Validity
This operating manual is for customers of Pfeiffer Vacuum. It describes the functioning of the designated product and provides the most important information for
safe use of the unit. The description follows applicable EU guidelines. All information provided in this operating manual refer to the current state of the product's development. The documentation remains valid as long as the customer does not
make any changes to the product.
Up-to-date operating instructions can also be downloaded from
www.pfeiffer-vacuum.net.
Applicable documents
UNO/DUO 2.5, UNO 5, DUO 2.5 C Operating instructions
Safety information for vacuum pumps "Safety Guide" PT 0300 BN*
Declaration of Conformity Part of this document
Operating instructions for accessories (order-specifically) see section "accessories"*
*also available via www.pfeiffer-vacuum.net
For information about other certifications, if applicable, please see the signet on
the product or:
About this manual
1.2 Conventions
Safety instructions
• www.tuvdotcom.com
• TUVdotCOM-ID 0000021320
The safety instructions in Pfeiffer Vacuum operating manuals are the result of risk
evaluations and hazard analyses and are oriented on international certification
standards as specified by UL, CSA, ANSI Z-535, SEMI S1, ISO 3864 and DIN 4844.
In this document, the following hazard levels and information are considered:
DANGER
Immediate danger
Death or very severe injuries can occur.
WARNING
Possible danger
Injuries or severe property damages can occur.
CAUTION
Possible danger
Injuries or prperty damages can occur.
NOTE
Command or note
Command to perform an action or information about properties, the disregarding of
which may result in damage to the product.
3
About this manual
G
Pictograph
definitions
Instructions in the
text
Abbreviations used
Symbols used
Prohibition of an action or activity in connection with a
source of danger, the disregarding of which may result in
serious accidents.
Warning of a displayed source of danger in connection
with operation of the unit or equipment.
Command to perform an action or task associated with a
source of danger, the disregarding of which may result in
serious accidents.
Work instruction: here you have to do something.
C version: Corrosive gas version
The following symbols are used consistently throughout in all illustrations:
V
Vacuum flange
Exhaust flange
Gas ballast valve
Power connection
4
2Safety
2.1 Safety precautions
Duty to inform
Each person involved in the installation, operation or maintenance of the vacuum
pump must read and observe the safety-related parts of these operating instructions.
Absolute observe the safety information for vacuum pumps (PT 0300 BN) !
The operator is obligated to make operating personnel aware of dangers originating
from the vacuum pump, the pumped medium and the entire system.
• 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.
Safety
NOTE
2.2 Proper use
2.3 Improper use
NOTE
CE conformity
The manufacturer's declaration of conformity becomes invalid if the operator modifies
the original product or installs additional components.
Following installation into a plant and before commissioning, the operator must
check the entire system for compliance with the valid EU directives and reassess it
accordingly.
• The vacuum pump may only be used to generate a vacuum.
• Installation, operating and maintenance regulations must be complied with.
• Other accessories than those described in this manual must not be used without
the agreement of Pfeiffer Vacuum.
Improper use will cause all claims for liability and guarantees to be forfeited. Improper use is deemed to be all use for purposes deviating from those mentioned
above, especially:
• Pumping of corrosive gases (exception: pumps in C version).
• Pumping of explosive media.
• Operation of the pump in potentially explosive areas.
• Pumping of gases containing impurities such as particles, dusts and condensate;
note the vapour compatibility levels of the pump.
• Pumping of substances that tend to sublime.
• Use of the vacuum pump to generate pressure.
• Pumping of liquids.
• The use of operating fluids not specified by Pfeiffer Vacuum.
• Connection to pumps or units which are not suitable for this purpose according
to their operating instructions.
• Connection to units which have exposed voltage-carrying parts.
5
Transport and storage
1
0
3 Transport and storage
3.1 Transport
Transport instructions
Remove the locking cap from the vacuum and exhaust flange immediately be-
fore connecting!
– Check the cone strainer, paying attention to the o-ring.
Use only the handle on the top side of the pump to lift the pump.
3.2 Storage
Fig. 1: Transporting the pump
Check that all the openings on the pump are securely closed.
Store the pump in a cool, dry place; preferably at room temperature (approx.
20°C).
– For a longer period of storage, seal the pump in a PE bag with drying agents
enclosed.
– For a period of storage longer than one year, it is recommended to carry out
maintenance and change the operating fluid.
6
4 Product description
D-35641 Asslar
Mod.: DUO 2.5
Mod.-Nr.: PK D31 XXX D
Ser.- Nr.: 3454440
S : max. XX m /h
Oil : P3 X.X l
Mass : XX kg
n : XXXX 1/min
(N )
2
3
max.
Made in Germany 2005/01
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
• 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.
Product description
Scope of delivery
Differences between
the pump types
Fig. 2: Product identification on the rating plate
• Pump with motor and power cord
• Operating fluid P3 (for standard pump)
• Cone strainer and centering ring/centering ring with nozzle with O-rings
• Locking cap for vacuum and exhaust flange
• Operating instructions
Pump type Pump versions
UNO 5, UNO 2.5
DUO 2.5
DUO 2.5 C
Standard version of pump
• Centering ring at the exhaust flange
Standard version of pump
• Centering ring with nozzle at the exhaust flange
C version of pump; differences from the standard version:
• Operating fluid F4
• Gas ballast valve with dosable flushing gas connection
• Vane material differen t
•Leak rate ≤ 1*10
-5
mbar * l/s
7
Installation
1 2 6.13/48
4/49 5 9 7 6
1
0
4.2 Function
Vacuum pumps of the UNO/DUO series are oil-sealed, single-/two-stage rotary
vane vacuum pumps. The vacuum pumps are equipped with a high vacuum safety
valve that vacuum seals the vacuum chamber and vents the pump at the same time
when the pump is at standstill.
The pumps are suitable for use in laboratories to generate coarse and medium vacuums and can also be used as backing pumps on diffusion or turbomolecular
pumps.
1 Vacuum flange
2 Exhaust flange
3 Operating fluid filler screw
4 Operating fluid drain screw
5 Sightglass
6Motor
6.1 Power switch
7 Gas ballast valve
9Casing
48 O-ring
49 O-ring
Fig. 3: UNO/DUO 2.5 Rotary vane vacuum pump
5 Installation
5.1 Setting up the pump
Installation location
Observe the following requirements when setting up the pump:
• Note the load-bearing capacity of the mounting surface
• Maximum angle of inclination 10° to each side
• Maximum erection height 2000 m N.N.
• Permissible ambient temperature: +12 ... +40°C
• Maximum relative humidity 85%
DN 16 ISO-KF
8
Fig. 4: Setting up
max. 10˚
Fill up with operating fluid before operating the first time (see p. 9, chap. 5.2).
max.
min.
1
0
5
3
– Amount and type according to rating plate
Always place the pump on a firm, even surface.
Where stationary installation is involved, anchor the pump on site; if necessary,
exchange the base for one with mounting holes (on request).
When installing the pump in a closed housing, ensure there is sufficient air cir-
culation.
– Sightglass and gas ballast valve must be visible and readily accessible.
– Voltage and frequency information given on the motor rating plate must be
visible.
5.2 Filling up the operating fluid
The type and amount of operating fluid should be visible on the pump's rating
plate for every rotary vane pump.
The delivery consignment for the standard pump contains suffient operating fluid for one filling. Pumps for special applications (e.g. for pumping corrosive gases)
can be operated with other operating fluids. These must be defined in accordance
with Pfeiffer Vacuum specifications before initial assembly and ordered separately.
Permissible operating fluids
Installation
Filling up the operating fluid
• P3 (Standard operating fluid)
• F4 (Operating fluid for corrosive gas versions)
• D1 (for special applications and higher operating temperature)
– Final pressure of measurement, depending on the type of gas: < 5·10
-2
mbar
NOTE
Only permissible operating fluid ensure the safe function of the pump!
Performance data of the pump are determined with the standard operating fluid.
These can deviate from the default values when using other certified operating fluids.
Use application-specific operating fluid only after consultation with Pfeiffer Vacuum.
Unscrew operating fluid filler screw 3.
Fill up operating fluid;
– correct filling level during operations: Within the markings at the sightglass
frame.
Fig. 5: Filling up the operating fluid
Screw in operating fluid filler screw 3.
Check operating fluid level only when the pump is warm and running; close
– vacuum flange and gas ballast valve to do so,
9
Installation
105
5
32
107
– 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.
Toxic vapours!
Danger of poisoning when igniting and heating synthetic operating fluids (e.g. F4/F5)
above 300°C.
Observe the application instructions of the operating fluid manufacturer.
Do not allow operating fluid to make contact with tobacco products; observe safety
precautions when handling chemicals.
5.3 Connecting the vacuum side
Remove locking cap from the vacuum flange;
– pay attention to the cone strainer and the respective O-ring in the intake port.
The connection between the pump and the recipient should be kept as short as
possible.
– Depending on the pump type, use metallic hoses or PVC hoses with flange
connections.
– Separators, filters etc. may be installed upstream to protect the pump (see ac-
cessories). However, please observe the loss of pumping capacity due to the
conductivity of the accessories.
WARNING
5.4 Connecting the exhaust side
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 mbar abs.) in the lines,
observe all official accident prevention safety regulations.
If the exhaust gases are being extracted, the exhaust pressure must be at least
250 mbar greater than the pressure at the intake side.
5Cone strainer
32 Centering ring/Centering ring with nozzle
105 O -rin g
107 O -rin g
10
Before attaching the piping at the exhaust flange remove locking cap and insert
centering ring/centering ring with nozzle with the respective O-rings.
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.
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.
5.5 Connecting to the mains power supply
Installation
WARNING
Single phase motors
CAUTION
Excess voltage!
Danger of destroying the motor.
Power connections must comply with local regulations. Voltage and frequency infor-
mation given on the motor rating plate must correspond to the mains voltage and
frequency values.
To protect the motor and supply cable in case of malfunction, mains fuse protection
must be implemented.
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.
The vacuum pumps are fitted with a built-in thermal protection switch. Depending
on the type of pump, different motor versions with a power cord are possible:
11
Installation
0
1
115
230
115
230
Fig. 6: Motor circuit diagram with switch
Changing the voltage range
Only valid for pumps with reversible motor:
The mains voltage must be determined on-site each time before the pump is in-
stalled or moved to a different location.
Disconnect the pump from the power supply.
Set the desired voltage range on the voltage selector switch using a suitable
screwdriver.
Switch position: "115" "230"
Voltage ranges: 115 V ±10%, 50/60 Hz, 230 V ±10%, 50/60 Hz
Overvoltage!
An incorrect voltage range setting can damage the motor.
Disconnect the pump from the power supply.
Only change the voltage range when the pump is disconnected from the power
mains.
Fuse protection
To protect the motor in case of malfunction, carry out fuse protection in accor-
dance with the regional regulations.
– Select a fuse with slow characteristics.
Motor volt-
age [V]
95 ... 105 100 ...
11 5
100 ... 105 110 ...
130
190 ... 210 200
... 220
220 ... 240 220
... 240
115/230 115/230 50 60 2.8/1.4 3.6/1.8/
Frequency
[Hz]
50 60 3.2 3.8
50 60 3.2 3.6 6 6 mit 2 m cable, USA plug and UL certificate (for motor)
50 60 1.6 2
50 60 1.4 1.8
Nominal cur-
rent [A]
Recommended
fuse, slow [A]
6
6
4
4
4
4
6/4
6/4
NOTE
Cable/plug version
with 2 m cable, Japanese plug und UL certificate (only for
winding insulation)
mit 2 m cable, without plug and UL certificate (for motor)
with 2 m cable and three-pin plug
with 2 m cable, without plug with UL certificate for motor
(motor switchable)
12
6 Operation
6.1 Before switching on the pump
Check the operating fluid level in the sightglass.
Compare the voltage and frequency information on the rating plate with the
mains voltage and frequency values.
Check that the exhaust connection allows free flow (max. permissible pressure
1.5 bar absolute).
– Activate the shut-off valves in such a way that they open before or at the same
time as the pump is started.
Protect the pump sufficiently from taking in contaminants by means of suitable
precautions (e.g. dust filters); if necessary, check operating fluid regularly or replace at shorter intervals.
6.2 Switching on
The pump 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 final pressures, the gas ballast valve should be closed.
Operation
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.
6.3 Pumping condensable vapours
Should the process gases contain condensable gases present at high percentages,
the rotary vane pump must be operated with a gas ballast (i.e. with an open gas
ballast valve).
Bad final vacuum and damage to the pump!
Danger of condensation and corrosion due to exceeding the water vapour compatibility (see Technical data) during operation without a gas ballast or in case of insufficient
supply of flushing gas.
Only pump vapours when the pump is warm and the gas ballast valve is open.
When the process has been completed, allow the pump to continue running for
about 30 minutes with the vacuum flange closed and the gas ballast open for operating fluid regeneration purposes.
CAUTION
CAUTION
Gas ballast valve,
standard version
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 7.
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.
13
Operation
7. 1
7. 3
7. 4
7. 2
Gas ballast valve, corrosive gas version
geschlossen
closed
1
1
0
Fig. 7: Standard version of gas ballast valve
geöffnet
open
1
0
1
0
0
If the pumping process requires the connection of flushing gas, the C version of the
gas ballast with the flushing gas connection must be used.
7. 1 O - r i n g
7. 2 O - r i n g
7.3 Proportioning screw
7.4 Flushing gas connection (for DN 6
mm hose)
Gas ballast valve with
solenoid valve
Fig. 8: Corrosive gas version of gas ballast valve
Connect flushing gas at the flushing gas connection 7.4.
Set flushing gas pressure; maximum pressure 1.2 bar (absolute).
– Select the type and amount of flushing gas depending on the process; consult
Pfeiffer Vacuum if necessary.
Use the proportioning screw 7.3 to set the desired amount of gas.
– Closed when fully turned to the right; open when fully turned to the left.
To control the flow of the flushing gas externally, an electromagnetic valve can also
be used as an alternative to the versions described above. The valve makes it easier to operate the gas ballast and allows clean air or other gas to be let in in a process-controlled manner.
CAUTION
Flushing gas pressure higher than allowed endangers the operational reliability
of the pump.
The power input of the pump, the temperature and the ejection of operating fluid will
increase.
Observe the maximum permissible flushing gas pressure.
Set the amount of flushing gas on site; dosing is not possible when using a solenoid
valve!
14
Fig. 9: Solenoid valve for controlling the gas ballast inlet
Performance data of the solenoid valve
2/2 way valve closed when disconnected
Supply voltage 24 VDC, +/- 10 %
Power input 4 W
Socket Type 2506
Threaded connection of flushing gas
Flushing gas pressure max. 1.2 bar (absolute)
Amount of flushing gas max. 250 l/h
1/8" inside
Operation
15
Maintenance
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 mbar, then
the valve closes automatically and vents the pump when the pump is switched off.
Switch the pump off at the mains switch or disconnect from the mains in a secu-
re manner.
Venting the vacuum
chamber
Danger of backflow of operating fluid into the intake line!
Contamination of the connected vacuum system!
Vent the vacuum chamber within 30 s, regardless of the chamber size.
For a longer venting process, use an additional shut-off valve and shut off the intake
line after switching off the pump.
CAUTION
Maintaining the vacuum in the chamber
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
Shut off the intake line immediately after switching off the pump.
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.
CAUTION
an additional shut-off valve in the intake line.
WARNING
on the pump.
16
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.
Maintenance
Switch off the pump, vent it to atmospheric pressure and let it cool down.
Disconnect the drive motor from the mains and secure it so that it cannot be
switched on.
Only dismantle the pump as far as necessary in order to repair defects.
Dispose of used operating fluid in compliance with local regulations.
When using synthetic operating fluids or working with toxic substances or sub-
stances contaminated with corrosive gases, the relevant instructions governing
their use must be observed.
Use only alcohol or similar agents for cleaning pump parts.
Checklist for inspection, maintenance
and overhaul
Certain repair and overhaul work should only be performed by Pfeiffer Vacuum
Service (PV). Pfeiffer Vacuum will be released from all warranty and liability claims
if the required intervals for inspection, maintenance, or overhaul are exceeded or
inspection, maintenance, repair or overhaul procedures are not performed properly. This also applies if replacement parts other than Pfeiffer Vacuum OEM replacement parts are used.
Activity daily as required;
at least
annually
Check operating fluid level X
Visual inspection (leak-tightness/oil
leaks)
Check filter insert of external oil mist filter (if existent)
Change filter insert of external oil mist filter (if existent)
Change operating fluid X
Change oil filter (if existent) X
Cleaning the pump and renew the seals X
Clean gas ballast valve and silencer X
Clean the motor fan cap X
Replace radial shaft seal X (PV)
Clean or change vacuum safety valve X (PV)
Clean or change exhaust valves X (PV)
Change vanes X (PV)
Check or change coupling X (PV)
Depending on the process, the required replacement intervals for lubricants and the intervals
for inspection, maintenance and overhaul may be shorter than the guide values specified in the
table.Consult with Pfeiffer Vacuum Service if necessary.
X
X
X
as required;
at least
every 2
years
as required;
at least
every 4
years
7.2 Changing the operating fluid
The changing interval for the operating fluid depends on the pump applications,
but should be carried out once a year.
Depending on the applications, Pfeiffer Vacuum recommends determining the
exact service life of the operating fluid during the first year of operation.
The replacement interval may vary from the guide value specified by Pfeiffer Vacuum
depending on the thermal and chemical loads, and the accumulation of suspended particles and condensation in the operating fluid.
Switch off pump.
Unscrew operating fluid drain screw 4 and drain operating fluid.
NOTE
17
Maintenance
Fill the specimen in a test tube or some similar vessel and test by holding
against the light.
The level of deterioration of operating fluid P3 can be read off the colour scale
in accordance with DIN 51578; request the supplementary sheet PK 0219 BN or
download it from the Internet.
Where discolouration is dark yellow to red brown (equivalent to 4 ... 5 on the sca-
le) change operating fluid.
4
Fig. 10: 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.
WARNING
Operating fluid may contain toxic substances from the pumped media!
Danger of poisoning from the emission of harmful substances from the operating fluid.
Wear suitable protective clothing and respirators.
Dispose of operating fluid according to the local regulations
Screw in operating fluid drain screw 4; pay attention to o-ring.
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
several times (flushing):
Flushing
18
Fill up with operating fluid to the middle of the sight glass.
Operate the pump with the gas ballast open until the pump has warmed up.
Drain the operating fluid again and check for contamination, flush again if neces-
sary.
Screw the operating fluid drain screw back in.
Fill up with operating fluid and check the filling level (siehe S. 9, Kap. 5.2).
Request safety data sheets for operating fluids and lubricants
from Pfeiffer Vacuum or download them from the Internet.
Dispose of operating fluid according to the local regulations.
8 Decommissioning
8.1 Shutting down for longer periods
Before shutting down the pump, observe the following procedure and adequately
protect the pump system against corrosion:
Switch off pump.
Change operating fluid(see p. 17, chap. 7.2).
Start the pump and allow the pump to warm up.
Fill up the pump with new operating fluid to the top edge of the sightglass.
Close vacuum flange and exhaust flange with locking caps.
Decommissioning
NOTE
8.2 Restarting the pump
Visually inspect the inner of the pump before taking it into operation. If there is evidence of rust on the parts of the pump which form the housing, then do not take
it into operation and contact Pfeiffer Vacuum Service.
Depending on how long the pump is taken out of operation, it may be necessary
to replace the radial shaft sealing ring. With reference to DIN 7716 and the manufacturer's specifications we recommend replacing the installed elastomer parts after 2 years.
If drying pearls were inserted then they should be removed now. Improper
handling can cause failure of the pump.
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.
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.
CAUTION
19
Malfunctions
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
CAUTION
NOTE
Problem Possible causes Remedy
Pump will not start
up
Pump switches off
after a while after
being started
Pump does not
attain final pressure
Pumping speed of
pump too low
No mains voltage or voltage
does not correspond to the
motor data
Pump temperature too low Warm up pump to > 12°C
Thermal protection switch has
responded
Pump system dirty
Pump system damaged
Motor defective Replace motor
Thermal protection switch of
the motor has responded
Mains fuse protection triggered
due to overload (e.g. cold start)
Exhaust pressure too high
Measurement reading is false
Pump or connected accessories
are dirty
Operating fluid dirty
Leak in system Repair leak
Operating fluid filling level too
low
Pump damaged Contact Pfeiffer Vacuum Service.
Intake line not well-dimensioned
Exhaust pressure too high
Check mains voltage and mains fuse
protection; check motor switch
Detect and fix cause of overheating;
allow pump to cool off if necessary.
Clean pump; contact Pfeiffer Vacuum
Service if necessary.
Clean and overhaul pump; contact Pfeiffer Vacuum Service if necessary.
Detect and fix cause of overheating;
allow motor to cool off if necessary.
Warm up pump
Check opening of exhaust line and
exhaust accessories
Check gauge, check final pressure without installation connected.
Clean pump and check components for
contamination.
Operate pump for a longer period with
gas ballast valve open or change operating fluid
Top off operating fluid
Keep connections as short as possible
and see that cross-sections are sufficiently dimensioned
Check opening of exhaust line and
exhaust accessories
20
Malfunctions
Problem Possible causes Remedy
Check tightness; replace gasket if necessary
If necessary, install oil mist filter and oil
return unit
Clean and overhaul pump; contact Pfeiffer Vacuum Service if necessary.
Replace motor; contact Pfeiffer Vacuum
Service if necessary
Loss of operating
fluid
Unusual operating
noises
Swivel gasket leaky
Radial shaft seal ring leaky Replace seal ring and check bushing
Operational loss of operating
fluid
Silencer dirty Clean or replace the silencer.
Damage to the pump system
Motor bearing defective
NOTE
Service work should be carried out by qualified personal only!
Pfeiffer Vacuum is not liable for any damage to the pump resulting from work carried
out improperly.
Take advantage of our service training programs; additional information at
www.pfeiffer-vacuum.net.
Please state all the information on the pump rating plate when ordering spare parts.
21
Service
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.net (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
shipment.
Fill in the contamination declaration and enclose it in the shipment (required!).
Dismantle all accessories.
Drain operating fluid/lubricant.
Drain cooling medium, if used.
Send the pump or unit in its original packaging if possible.
1)
Sending of contaminated pumps or devices
No units will be accepted if they are contaminated with micro-biological, explosive
or radioactive substances. “Hazardous substances” are substances and compounds in accordance with the hazardous goods directive (current version). If
pumps are contaminated or the declaration on contamination is missing, Pfeiffer
Vacuum performs decontamination at the shipper's expense.
Neutralise the pump by flushing it with nitrogen or dry air.
Close all openings airtight.
Seal the pump or unit in suitable protective film.
Return the pump/unit only in a suitable and sturdy transport container and send
it in while following applicable transport conditions.
Service orders
All service orders are carried out exclusively according to our repair conditions for
vacuum units and components.
22
1)
Forms under www.pfeiffer-vacuum.net
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.
Set of seals
The set of seals contains all seals including all o-rings of the assembly groups and
the subassemblies.
Maintenance kit
The pack contains the o-rings of the operating fluid filler and drain screw for changing the operating fluid. Also the radial shaft seal ring(s) and the o-ring for the casing after cleaning the operating fluid sump is included.
Set of vanes
The pack contains the vanes of the pump stages and the vane springs.
Spare parts
Standard
pump type
PK D31 707 ...
PK D31 712
PK D41 707 ...
PK D41 712
PK D31 807 ...
PK D31 812
Overhaul kit
The pack contains all wearing parts of the pump to replace the following parts after
dismantling the whole pump:
• Set of seals
• Wearing parts of the pumping system
• Wearing parts of the vacuum safety valve
• Wearing parts of the gas ballast valve.
Set of vacuum safety valve
The pack contains the wearing parts of the vacuum safety valve. Also the o-rings
between the valve housing and the pumping system and the o-ring of the casing
are included.
Set of discharge valves
The pack contains the wearing parts of the discharge valves. Also the wearing parts
of the exhaust valve and the o-ring of the casing are included.
Coupling kit
The pack contains the coupling halfs, the can and the radial shaft seal rings.
Set of
Pump
type
UNO 2.5 PK E00 002 -T PK E08 003 -T PK E01 004 -T PK E02 005 -T PK E04 001 -T PK E05 001 -T PK E06 001 -T
DUO 2.5 PK E00 002 -T PK E08 014 -T PK E01 004 -T PK E02 008 -T PK E04 001 -T PK E05 001 -T PK E06 001 -T
UNO 5 PK E00 002 -T PK E08 004 -T PK E01 004 -T PK E02 026 -T PK E04 007 -T PK E05 010 -T PK E06 001 -T
Set of seals Set of vanes
Maintenance
kit
Overhaul kit
vacuum
safety
valves
Discharge
valves
Coupling
kit
23
Spare parts
Spare parts
package
Set of seals PK E00 002 -T 13.1, 14 , 100, 101, 102, 103, 104, 105, 106, 107, 108, 109*, 110.
Set of vanes PK E08 003 -T 12.4, 12.10, 12.15
Maintenance kit PK E01 004 -T 14, 101, 102, 107, 110.
Overhaul kit PK E02 005 -T PK E00 0 02 -T, 3, 4, 7.7, 13, 16, 17, 19, 22, 24, 12.4, 12.10, 12.15
Set of vacuum
safety valves
Discharge valves PK E05 001 -T 14, 24, 25, 102, 104, 106.
Coupling kit PK E06 001 -T 3, 19, 110.
*
only for UNO 5
No.
PK E08 004 -T
PK E08 014 -T
PK E02 008 -T PK E00 002 -T, 3, 4, 7.7, 13, 16, 17, 19, 22, 24, 12.4, 12.10, 12.15
PK E02 026-T PK E00 002 -T, 3, 4, 13, 7.1, 7.2, 7.7, 12.4, 12.10, 12.15, 13.3, 16,
PK E04 001 -T 4, 14, 16, 17, 22, 102, 104, 106.
PK E04 007 -T 4, 14, 16, 17, 22, 104, 106, 109.
PK E05 010 -T 14, 24, 25, 104, 106, 109.
Parts according to the exploded view on the following page
17, 19, 22, 24, 28, 31.
24
1/108
2/108
8
7. 7
101
61
32
105
5
106
16
17
101
40
104
4
22
106
20
12 (12.4, 12.10,
12.15)
107
102/
109
87
102
9
14
25
100
103
24
11
10
86 107
13/
13.1/
13.2/
13.4
28
11 0
3
6
19
Spare parts
Exploded view
1 Intake connection
2 Exhaust connection
3 Coupling half
4 Valve plate
5Cone strainer
6Motor
7 Gas ballast valve
7.1 O-ring (Fig. see Chap.
6.3)
7.2 O-ring (Fig. see Chap.
6.3)
7.7 Valve flap/gas ballast valve
8 Support stand
9Casing
10 Handle
11 Pump system (UNO)
12 Pump system (DUO)
12.4 Vane
12.10 Hydraulic vane
12.15 Vane spring
13 Sightglass
13.1 Sightglass seal (round)
13.2 Sightglass seal (oval)
13.4 Sightglass seal (oval)
14 Seal of casing
16 Compression spring
17 Hydraulic valve
19 Coupling disk
20 Vacuum safety valve
housing
22 Compression spring
24 Valve flap
25 Valve trap
28 Rubber foot
32 Centering ring/Cente-
ring ring with nozzle
40 Silencer
86 Operating fluiddrain
screw
87 Operating fluidfiller
screw
100 O-ring
101 O-ring
102 O-ring
103 O-ring
104 O-ring
105 O-ring
106 O-ring
107 O-ring
108 O-ring
109 O-ring
110 Radial shaft seal ring
25
Accessories
12 Accessories
Description UNO 2.5 DUO 2.5
KAS 16, Condensate separator for pumping speeds of up to 2.5-5
3
m
/h
ONF 16, oil mist filter for pumping speeds of up to 2.5-5 m
Oil return unit from ONF 16 to DUO 2.5 PK 194 315-T PK 194 315-T
STP 016, dust separator, single-stage for minor contamination PK Z60 203 PK Z60 203
ZFO 016, zeolite trap PK Z70 003 PK Z70 003
PK Z10 003 PK Z10 003
3
/h PK Z40 0 03 PK Z40 0 03
Description UNO 5
KAS 16, Condensate separator for pumping speeds of up to 2.5-5
3
m
/h
ONF 16, oil mist filter for pumping speeds of up to 2.5-5 m
Oil return unit from ONF 16 to DUO 2.5 PK 194 315-T
STP 016, dust separator, single-stage for minor contamination PK Z60 203
ZFO 016, zeolite trap PK Z70 003
PK Z10 003
3
/h PK Z40 003
Description Size Number
Operating fluid P3 1 litre PK 001 106 -T
Operating fluid P3 5 litre PK 001 107 -T
Operating fluid P3 20 litre PK 001 108 -T
Operating fluid F4 1 litre PK 005 887 -T
Operating fluid F4 0,5 litre PK 005 886 -T
Operating fluid F4 0,25 litre PK 005 885 -T
Operating fluid D1 1 litre PK 0 05 875 -T
Operating fluid D1 5 litre PK 0 05 876 -T
Operating fluid D1 20 litre PK 005 877 -T
26
13 Technical data
Parameter UNO 2.5 DUO 2.5
Flange (in) DN 16 ISO-KF DN 16 ISO-KF
Flange (out) DN 16 ISO-KF DN 16 ISO-KF
Pumping speed at 50 Hz 2.5 m
Pumping speed at 60 Hz 2.9 m
Ultimate pressure with gas ballast ≤ 1 mbar ≤ 6·10
Ultimate pressure without gas ballast ≤ 5·10
Leakage rate safety valve ≤ 1·10
Water vapor tolerance at 50 Hz 15 mbar 15 mbar
Water vapor tolerance at 60 Hz 15 mbar 15 mbar
Water vapor capacity 50 Hz 26 g/h 30 g/h
Water vapor capacity 60 Hz 30 g/h 34 g/h
Emission sound pressure level without gas
ballast
Pump fluid filling 0.45 l 0.4 l
Rated power 50 Hz 0.15 kW 0.15 kW
Rated power 60 Hz 0.18 kW 0.18 kW
Rotation speed at 50 Hz 3000 1/rpm 3000 1/rpm
Rotation speed at 60 Hz 3600 1/rpm 3600 1/rpm
Switch
Weight 10.2 kg 10.5 kg
3
/h 2.5 m3/h
3
/h 2.9 m3/h
-3
mbar
-2
mbar ≤ 6·10-3 mbar
-4
mbar l/s 1·10-4 mbar l/s
≤ 53 dB (A) ≤ 53 dB (A)
Yes, with 2 m mains
cable with safety plug
Yes, with 2 m mains
cable and safety
plug
Technical data
Parameter UNO 5
Flange (in) DN 16 ISO-KF
Flange (out) DN 16 ISO-KF
3
Pumping speed at 50 Hz 4.6 m
Pumping speed at 60 Hz 5.1 m
Ultimate pressure with gas ballast 1 mbar
Ultimate pressure without gas ballast ≤ 5·10
Leakage rate safety valve ≤ 1·10
Water vapor tolerance at 50 Hz 20 mbar
Water vapor tolerance at 60 Hz 20 mbar
Water vapor capacity 50 Hz 65 g/h
Water vapor capacity 60 Hz 75 g/h
Emission sound pressure level without gas
ballast
Pump fluid filling 0.4 l
Rated power 50 Hz 0.15 kW
Rated power 60 Hz 0.18 kW
Rotation speed at 50 Hz 3000 1/rpm
Rotation speed at 60 Hz 3600 1/rpm
Switch
Weight 10.5 kg
/h
3
/h
-2
mbar
-4
mbar l/s
≤ 55 dB (A)
Yes, with 2 m mains
cable and safety
plug
27
Technical data
202
185.5
173.5
124
32.5
130
156
322
88
95
123
127
175.5
31.5
60
3
( )
8.5
3
62
+2
+2
DN 16 ISO-KF
1
0
310
124
(( ))
8.5
173.5
176.5
130
156
60
88
95
123
175.5
31.5
127
32.5
3
3
36
+2
DN 16 ISO-KF
1
0
13.1 Dimensions
Fig. 11: Dimensions for motor versions: 95 ... 105 V, 50 Hz / 100 ... 115V, 60 Hz
Fig. 12: Dimensions for motor versions: 190 ... 210 V, 50 Hz / 200 ... 220 V, 60 Hz;
220 ... 240 V, 50/60 Hz
28
(8.5)
88
95
123
127
175.5
31.5
60
318
130
156
32.5
124
181.5
194.5
(( ))
8.5
3
3
52
DN 16 ISO-KF
1
0
+2
+2
124
DN 16 ISO-KF
0
1
200
Technical data
31.5
60
175.5
32.5
177
156
3
130
3
13090
310
336
Fig. 13: Dimensions for motor versions: 115/230, 50/60 Hz
88
95
123
127
Fig. 14: Dimensions for motor versions: 100 ... 105 V, 50 Hz / 110 ... 130 V, 60 Hz
29
Declaration of conformity
according to the EC directive:
• Machinery 2006/42/EC (Annex II, no. 1 A)
We hereby declare that the product cited below satisfies all relevant provisions
of EC Machinery Directive 2006/42/EC.
In addition, the product cited below satisfies all relevant provisions of EC Directive "Electromagnetic Compatibility" 2004/108/EC .
The agent responsible for compiling the technical documentation is Mr. Sebastian Oberbeck, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Aßlar.
®
DuoLine
UNO/DUO 2.5, UNO 5, DUO 2.5 C
Guidelines, harmonised standards and national standards and specifications
which have been applied:
/DuoLine™
Signatures:
(M.Bender)
Managing Director
DIN EN ISO 12100-1 : 2004 DIN EN 61010 : 2002 DIN EN 61000-6-3 : 2007
DIN EN ISO 12100-2 : 20 04 DIN EN ISO 13857 : 2008 DIN EN 61000-6-4 : 2007
DIN EN 1012-2 : 1996 DIN EN 61000-6-1 : 2007
DIN EN ISO 14121-1 : 2007 DIN EN 61000-6-2 : 20 06
Pfeiffer Vacuum GmbH
Berliner Straße 43
35614 Asslar
Germany
(Dr. M. Wiemer)
Managing Director
CE/2010
Pfeiffer Vacuum Technology AG · Headquarters/Germany
Tel. +49-(0) 64 41-8 02-0 · Fax +49-(0) 64 41-8 02-2 02 · info@pfeiffer-vacuum.de · www.pfeiffer-vacuum.net
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