VACUUBRAND PC 2004 User Manual
page 1 of 25
Instructions for use
Technology for vacuum systems
PC 2002 VARIO / PC 2004 VARIO
(without controller)
Chemistry pump unit
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
page 2 of 25
Dear customer,
Your VACUUBRAND diaphragm pump shall support you at your work for a long time without any trouble and
with full load output. Thanks to our large practical experience we attained much information how you could
add to an efficient application and to personal safety. Please read these instructions for use prior to the
initial start-up of your pump.
VACUUBRAND diaphragm pumps are the result of many years of experience in construction and practical
operation of these pumps combined with the latest results in material and manufacturing technology.
Our quality maxim is the ”zero fault principle”:
Every delivered diaphragm pump is tested extensively including an endurance run of 18 hours. Due to this
endurance run, also faults, which occur rarely, are reported an can be corrected. Every single diaphragm
pump is tested on achievement of the specification after the endurance run.
Every VACUUBRAND pump leaving our factory achieves the specification. We feel obliged to this
high quality standard.
We are aware that the vacuum pump should not draw a part of the real work and we hope to contribute with
our products to an effective and trouble-free realisation of your work.
Yours
VACUUBRAND GMBH + CO KG
After sales service: Contact your local dealer or call +49 9342 808-193.
Attention! Important notes!
Not permitted! Misuse may cause damage.
Caution! Hot surface!
Isolate equipment from mains.
Note.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
page 3 of 25
Contents
Safety information! ....................................................................................................4
Technical data ............................................................................................................8
Notes on operation.................................................................................................. 12
Troubleshooting ......................................................................................................15
Replacing diaphragms and valves ........................................................................16
Cleaning and assembling components................................................................. 22
Notes on return to the factory ................................................................................ 23
Health and safety clearance form ..........................................................................24
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
Safety information!
Remove all packing material, remove the product from its packing-box, remove the
protective covers from the inlet and outlet ports and keep, inspect the equipment.
If the equipment is damaged, notify the supplier and the carrier in writing within three
days; state the item number of the product together with the order number and the
supplier’s invoice number. Retain all packing material for inspection.
Do not use the equipment if it is damaged.
If the equipment is not used immediately, replace the protective covers. Store the
equipment in suitable conditions.
☞ Read and comply with this manual before installing or operating the equip-
ment.
☞ To operate the VARIO pump a vacuum controller CVC 2000 is necessary!
☞ Transport the pump at the provided handles.
Use the equipment for the intended use only (for generation and measurement of
vacuum).
☞☞
☞ Prevent any part of the human body from coming in contact with the vacuum.
☞☞
☞ Comply with notes on correct vacuum and electrical connections, see section ”Use
and operation”.
☞ Make sure that the individual components are only connected, combined and oper-
ated according to their design and as indicated in the instructions for use.
page 4 of 25
Comply with national safety regulations and safety requirements concerning the
use of vacuum and electrical equipment.
☞ The mains switch for the controller and the pump is at the rear side of the controller.
☞ After switching off the pump, wait 60 sec. minimum until next switching on.
☞ Due to the high leakage current (up to 3.5 mA), a too low rated fault-current circuit
breaker may be activated, especially if several pumps are operated parallelly.
Attention: Make sure that a protective conductor connection is established before the equipment is connected to mains supply!
➨ The pumping units PC 2002 VARIO and PC 2004 VARIO are devices with double-
pole cutoff and a symmetric capacitive circuit.
☞ If the leakage current is obtained by measuring the equivalent leakage current (ac-
cording to VDE 0701, September 2000, section 5.7), the measured value may be
divided by a factor of 2 in case the device is equipped with a double-pole cutoff and
a symmetric capacitive circuit.
☞ The shock currents according to EN 61010 are below the limit of 3,5 mA.
☞ Equipment must be connected only to a suitable fused and protected electrical
supply and a suitable earth point. Failure to connect the motor to ground may result
in deadly electrical shock.
☞ The supply cable may be fitted with a moulded European IEC plug or a plug suitable
for your local electrical supply. If the plug has been removed or has to be removed,
the cable will contain wires colour coded as follows: green or green and yellow:
earth; blue or white: neutral; brown or black: live.
☞ Check that mains voltage and current conform with the equipment (see rating plate).
☞ If the equipment is brought from cold environment into a room for operation, allow
the equipment to warm up (pay attention to water condensation on cold surfaces).
☞ Make sure ventilation is adequate if pump is installed in a housing or if ambient
temperature is elevated.
Comply with all relevant safety requirements (regulations and guidelines) and adopt
suitable safety measures.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
page 5 of 25
☞ Provide a firm level platform for the equipment and check that the system to be
evacuated is mechanically stable and that all fittings are secure.
Attention: Flexible elements tend to shrink when evacuated.
Due to the high compression ratio of the pumps, pressure at the outlet port might be
generated being higher than the max. permitted pressure compatible with the mechanical stability of the system.
☞ Comply with maximum permitted pressures and pressure differences, see sec-
tion ”Technical data”. Do not operate the pump with overpressure at the inlet.
Do not permit any uncontrolled pressurizing (e. g. make sure that the exhaust pipeline cannot become blocked). If you have an exhaust-isolation valve, make sure that
you cannot operate the equipment with the valve closed. Risk of bursting!
☞ Ensure that the system design does not allow the exhaust pipeline to become
blocked.
☞ Max. permitted pressure at the pressure transducer: 2 bar (absolute).
☞ Ensure that the system design does not allow the coolant outlet pipeline to become
blocked.
☞ Secure coolant hoses at the hose nozzles (e.g. with hose clip) to prevent their
accidental slipping.
☞ Check liquid level in both catchpots regularly and drain condensate in time.
☞ Check the overpressure safety relief device at the exhaust waste vapour condenser
in appropriate intervals.
☞ Avoid overpressure of more than 0.2 bar in case inert gas is connected.
☞ The diameter of the inlet and outlet pipeline should be at the least as large as the
diameter of the pump connection pipelines.
To the best of our knowledge the equipment is in compliance with the requirements of
the applicable EC-directives and harmonized standards (see “Declaration of conformity”) with regard to design, type and model, especially directive IEC 1010. This directive
gives in detail conditions, under which the equipment can be operated safely (see also
IP degree of protection).
☞ Adopt suitable measures in case of differences, e. g. using the equipment outdoors,
installation in altitudes of more than 1000 m above mean sea level, conductive
pollution or dewiness.
Pay attention to symbol ”hot surfaces” on the equipment.
☞ Adopt suitable measures to prevent any danger arising from the formation of hot
surfaces or electric sparks.
The pumps are not suitable to pump dangerous or explosive gases or explosive or
flammable mixtures. Ensure that the materials of the wetted parts are compatible
with the pumped substances, see section “Technical data”.
☞ Adopt suitable measures to prevent the release of dangerous, explosive, corrosive
or polluting fluids.
☞ Use inert gas for gas ballast or venting if necessary.
☞ The user must take suitable precautions to prevent any formation of explosive
mixtures in the expansion chamber. In case of a diaphragm crack, mechanically
generated sparks, hot surfaces or static electricity may ignite these mixtures.
☞ Take adequate precautions to protect people from the effects of dangerous sub-
stances (chemicals, thermal decomposition products of fluoroelastomers), wear
appropriate safety-clothing and safety glasses.
☞ Comply with applicable regulations when disposing of chemicals. Take into consid-
eration that chemicals may be polluted.
The motor is shut down by a thermal cutout in the winding.
☞ Manual reset is necessary. Switch off the pump or isolate the equipment from mains.
Wait approx. five minutes before restarting the pump.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
page 6 of 25
☞ Attention: In case of supply voltage below 100V, the lock of the cutout might be
restricted and the pump might restart on its own after sufficient cooling down. Take
suitable precautions, if an automatic restart of the pump may lead to a critical
dangerous situation.
☞ Avoid high heat supply (e. g. due to hot process gases).
☞ Ensure sufficient air admittance if pump is installed in a housing.
Due to the residual leak rate of the equipment, there may be an exchange of gas,
albeit extremely slight, between the environment and the vacuum system.
☞ Adopt suitable measures to prevent contamination of the pumped substances or
the environment.
Pumping at high inlet pressure may lead to overpressure at the gas ballast valve.
☞ Pumped gases or condensate might be pushed out in case the valve is open.
☞ If an inert gas supply is connected, ensure that the inlet pipeline is not contami-
nated.
☞ Failure of the pump (e. g. by power failure) or connected components, parts of the
supply (e. g. coolant) or change of parameters (e. g. increase of pressure in the
coolant system) must not lead to a critical dangerous situation under any circumstances.
Electronic equipment is never 100% fail-safe. This may lead to an indefinite status of
the equipment. Provide protective measures against misfunction and failure.
☞ Operating the pump with high or low frequency, stand still of the pump or operating
the air admittance valve must not lead to a critical dangerous situation under any
circumstances.
Ensure that in case of failure the pump and the vacuum system always will turn into a
safe status.
☞ In case of diaphragm cracks or leaks in the manifold pumped substances might be
released into the environment or into the pump housing. To reduce the risk of leaks,
ask for a diaphragm pump with additional safety diaphragm.
☞ Comply especially with notes on operation and use and maintenance.
Use only genuine spare parts and accessories.
☞ Otherwise safety and performance of the equipment as well as the electromagnetic
compatibility of the equipment might be reduced.
Possibly the CE mark becomes void if not using genuine spare parts.
Ensure that maintenance is done only by suitable trained and supervised technicians. Ensure that the maintenance technician is familiar with the safety procedures
which relate to the product processed by the vacuum system and that the equipment,
if necessary, is appropriately decontaminated before starting maintenance.
Comply with local and national safety regulations.
Wear parts have to be replaced regularly. In case of normal wear the lifetime of the
diaphragms and valves is > 10000 operating hours. Bearings have a typical durability
of 40000 h.
➨ Isolate equipment from mains and wait two minutes before starting mainte-
nance to allow the capacitors to discharge.
➨ Before starting maintenance, wait two minutes after isolating the equipment from
mains to allow the capacitors to discharge.
☞ Ensure that the pump cannot be operated accidentally. Never operate the pump
if covers or other parts of the pump are disassembled. Never operate a defective or damaged pump.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
page 7 of 25
☞ Attention: The pump might be contaminated with process chemicals which have
been pumped during operation. Ensure that the pump is decontaminated before
maintenance and take adequate precautions to protect people from the effects of
dangerous substances if contamination has occurred.
☞ Before starting maintenance vent the pump, isolate the pump and other compo-
nents from the vacuum system. Allow sufficient cooling of the pump. Drain condensate, if applicable. Separate the pump from the coolant circuit.
In order to comply with law (occupational, health and safety regulations, safety at work
law and regulations for environmental protection) vacuum pumps, components and
measuring instruments returned to the manufacturer can be repaired only when certain
procedures (see section ”Notes on return to the factory”) are followed.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
Technical data
page 8 of 25
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* Technical data according to EN 61010-1 and EN 1012-2 .The pump achieves its ultimate pumping speed and ultimate vacuum only at operating temperature (after approx. 15 min.).
** Pumping speed of diaphragm pump
*** Typical current draw in mode ”Continuous pumping” and frequency ”HI”.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check
carefully the validity of this document with respect to his product. manual-no.: 999080 / 24/04/2008
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