Operation Manual
(EN)
Translation of the german original manual
Diaphragm pumps
Models:
► MP / MPC / MPC-X2
601 E
301 Z
412721
2017-02-01
2 - headed
We are constantly working on the further
development of all our product types.
Reprinting or reproduction of this manual,
including extracts, is not allowed without the
prior written permission of Co. Gardner
Denver Thomas GmbH.
All rights under the copyright laws are
expressly reserved by Co. Gardner Denver
Thomas GmbH.
We reserve the right to make changes and
amendments.
Gardner Denver Thomas GmbH
Am Vogelherd 20
98693 Ilmenau
Germany
T +49 3677 604 0
F +49 3677 604 131
welch.emea@gardnerdenver.com
www.welchvacuum.com
Customer Support +49 3677 604 0
Contents
412721 3
Contents
1 Important Information .................................................................................................................... 4
1.1 General Information ......................................................................................................................... 4
1.2 Target Groups .................................................................................................................................. 4
1.3 Intended Use .................................................................................................................................... 4
1.4 Use for an Unauthorized Purpose .................................................................................................... 4
1.5 Safety Devices ................................................................................................................................. 5
1.6 Meaning of the Warning notes ......................................................................................................... 5
1.7 Product Standards, Safety Regulations ........................................................................................... 5
2 Basic Safety Instructions .............................................................................................................. 6
2.1 General Information ......................................................................................................................... 6
2.2 Electricity .......................................................................................................................................... 6
2.3 Mechanical Systems ........................................................................................................................ 6
2.4 Hazardous Substances .................................................................................................................... 7
2.5 High Temperatures .......................................................................................................................... 7
3 Description ..................................................................................................................................... 8
3.1 Design .............................................................................................................................................. 8
3.2 Principle of Operation ....................................................................................................................... 8
3.3 Gas ballast ....................................................................................................................................... 8
3.4 Areas of Application ......................................................................................................................... 8
3.5 Pump head circuitry ......................................................................................................................... 9
3.6 Materials of the medium-affecting pump parts ................................................................................. 9
3.7 Scope of Delivery ............................................................................................................................. 9
3.8 Accessories ...................................................................................................................................... 9
3.8.1 Connection variants A – K .............................................................................................................. 10
4 Technical Data .............................................................................................................................. 11
4.1 Dimensions .................................................................................................................................... 11
4.2 Intake Pressure / Pumping Speed – Diagram ................................................................................ 11
4.3 Device Data .................................................................................................................................... 12
5 Installation and Operation ........................................................................................................... 13
5.1 Unpacking ...................................................................................................................................... 13
5.2 Installation and Connection ............................................................................................................ 13
5.3 Operation ....................................................................................................................................... 13
5.4 Storage ........................................................................................................................................... 13
5.5 Scrap Disposal ............................................................................................................................... 13
6 Maintenance and Servicing ......................................................................................................... 14
6.1 General Requirements ................................................................................................................... 14
6.2 Maintenance Performed by the User ............................................................................................. 14
6.2.1 Disassembly ................................................................................................................................... 15
6.2.2 Assembly ........................................................................................................................................ 15
6.2.3 Test ................................................................................................................................................ 16
6.3 Maintenance by the Manufacturer.................................................................................................. 16
6.4 Damage Report .............................................................................................................................. 16
7 Troubleshooting ........................................................................................................................... 17
8 Spare Parts Overview .................................................................................................................. 18
8.1 Service kit ....................................................................................................................................... 18
8.2 Spare parts view ............................................................................................................................ 19
8.2.1 Spare parts list diaphragm pumps MP 601 E ................................................................................. 20
8.2.2 Spare parts list diaphragm pumps MP 301 Z ................................................................................. 21
8.2.3 Spare parts list diaphragm pumps MPC 601 E .............................................................................. 22
8.2.4 Spare parts list diaphragm pumps MPC 301 Z .............................................................................. 23
8.2.5 Spare parts list diaphragm pumps MPC 601 E-X2, MPC 301 Z-X2............................................... 24
- Instructions for certification - Diaphragm Pumps MPC -
for use in Zone 2 in accordance with device category 3 per ATEX Directive 2014/34/EU
(Page 1 - 3)
- EC Declaration of Conformity
Important Information
4 412721
1 Important Information
1.1 General Information
The Diaphragm Pumps conform to the following directives:
2006 / 42 / EC
Machinery Directive
2014 / 30 / EU
Electromagnetic Compatibility Directive
2014 / 34 / EU
ATEX Guideline for use in potentially explosive atmospheres,
Appendix III (at types MPC only)
The CE sign is located on the rating plate. Observe the binding national and local regulations
when fitting the pump into installations!
Our products are sold worldwide and can therefore be equipped with the typical national
plugs and for the various voltages. You will find more information about the available pump
designs on our web page in the internet.
1.2 Target Groups
This Operating Manual is intended for the personnel planning, operating and maintaining
Diaphragm Pumps.
This group of people includes:
Designers and fitters of vacuum apparatus
Employees working on commercial laboratory and industrial vacuum technology applica-
tions
Service personnel for diaphragm pumps
The personnel operating and maintaining the diaphragm pumps must have the technical
competence required to perform the work that has to be done. The user must authorize the
operating personnel to do the work that has to be done. The personnel must have read and
understood the complete Operating Manual before using the diaphragm pumps.
The Operating Manual must be kept at the place of use and be available to the personnel
when required.
1.3 Intended Use
The layout of the diaphragm pump must be appropriate for the conditions of use. The
user bears the sole responsibility for this.
The diaphragm pump may only be operated under the conditions stated
– in the "Technical Data" section,
– on the type plate, and
– in the technical specification for the order concerned.
Diaphragm pumps are approved for extracting, pumping and compressing gases and vapours. If these gases and vapours are toxic or explosive, then the user must observe the
currently valid safety regulations for this application. Special types of diaphragm pumps
are available for aggressive and explosive gas mixtures.
1.4 Use for an Unauthorized Purpose
It is forbidden to use the pump for applications deviating from the technical data stated on
the type plate or the conditions stated in the supply contract, or to operate it with missing or
defective protective devices.
Important Information
412721 5
1.5 Safety Devices
Measures such as the following are for the safety of the operating personnel:
electrical connection with a protective conductor (operating mode S1) and an earthing
plug
Motor protection device (thermal)
“Hot Surface" label on the pump body - warning notice
The diaphragm pump must not be operated without these elements.
1.6 Meaning of the Warning notes
Take note of the warning notices. They are in the following box:
CAUTION ! / WARNING !
Hazard which may lead to serious injuries or material damage.
1.7 Product Standards, Safety Regulations
Diaphragm Pumps meet the following product standards:
DIN EN ISO 12100:2011-03
Safety of machinery General principles for design - Risk assessment and risk reduction
DIN EN ISO 13857:2008-06
Safety of machinery - Safety distances to prevent hazard zones being reached
by upper and lower limbs
DIN EN 1012-2:2011-12
Compressors and vacuum pumps - Safety requirements Part 2: Vacuum pumps
DIN EN ISO 2151:2009-01
Acoustics - Noise test code for compressors and vacuum pumps - Engineering
method (grade 2)
DIN EN ISO 2151:2009-01
Safety of machinery - Electrical equipment of machines Part 1: General requirements
DIN EN 61000-6-2:2011-06
DIN EN 61000-6-4:2011-09
Electromagnetic compatibility (EMC) Part 6-2: Generic standards - Immunity for industrial environments
Part 6-4: Generic standards - Emission standard for industrial environments
DIN EN 61010-1/A1:2015-04
Safety requirements for electrical equipment for measurement, control and
laboratory use - Part 1: General requirements
DIN EN 50110-1:2014-02
Operation of electrical installations
DIN EN 1127-1:2011-10
Explosive atmospheres - Explosion prevention and protection Part 1: Basic concepts and methodology
DIN EN 13463-1:2009-07
DIN EN 13463-5:2011-10
Non-electrical equipment for use in potentially explosive atmospheres Part 1: Basic method and requirements
Part 5: Protection by constructional safety 'c'
Directive 2012/19/EU
Electrical and electronics - old devices (WEEE)
Directive 2011/65/EU
Dangerous materials in electrical and electronics devices (RoHS II)
China - RoHS II
Environment protection law - China 2016-01
The following additional safety regulations apply in the FR Germany:
BGV A3
Electrical equipment and operating materials
VBG 5
Power-driven machines
BGR 120
Guidelines for laboratories
BGI 798
Hazard assessment in the laboratory
BGG 919 (VBG 16)
Accident prevention regulations for "compressors"
BGR 189 (BGR 195;192;197)
Use of protective working clothes
Observe the standards and regulations applying in your country when you use the diaphragm pumps.
Basic Safety Instructions
6 412721
2 Basic Safety Instructions
2.1 General Information
Warning notices must be observed. Disregarding them may lead to damage to health and
property.
The diaphragm pumps must be operated by personnel who can detect impending dangers
and take action to prevent them from materialising.
The manufacturer or authorized authorised workshops will only service or maintain the diaphragm pump if it is accompanied by a fully completed damage report. Precise information
about the contamination (also negative information if necessary) and thorough cleaning of
the diaphragm pump are legally binding parts of the contract.
Contaminated diaphragm pumps and their individual parts must be disposed of in accordance with the legal regulations.
The local regulations apply in foreign countries.
2.2 Electricity
The diaphragm pumps of operation mode S1 are supplied. When the location of operation
mode S1 devices is changed, please note that the testing must be repeated in accordance
with DIN EN 0105, DIN EN 0702 and BGV A2.
The local regulations apply in foreign countries.
Please note the following when connecting to the electrical power supply system:
The electrical power supply system must have a protective connector according to DIN
VDE 0100-410 (IEC 60364-4-41).
The protective connector must not have any breaks.
The connecting cable must not be damaged.
2.3 Mechanical Systems
Improper use can lead to injuries or material damage. Observe the following instructions:
Only operate the diaphragm pumps with hoses of the specified dimensions.
The maximum permissible pressure of 1 bar at the suction connection must not be ex-
ceeded.
Hazardous substances must be separated out as far as this is technically possible before
they reach the pump.
External mechanical stresses and vibrations must not be transmitted to the pump. Only
use flexible laboratory hoses for connecting diaphragm pumps.
The overpressure generated at the pressure port must not exceed 1 bar.
The pump must not be used to suck up fluids. Lay the exhaust pipe so that it slopes
downwards, so allowing condensate to flow out of the pump. Collect the condensate and
dispose of it in an environmentally compatible manner.
Prevent dyes exuding.
Maintain a space of least 20 mm between the pump and adjacent parts in order to enable
the pump to cool.
CAUTION !
Solid particles in the pumping medium impair the pumping action and can lead to
damage. Prevent solid particles penetrating into the pump.
Basic Safety Instructions
412721 7
2.4 Hazardous Substances
The operating company bears the responsibility for the use of the diaphragm pump.
Hazardous substances in the gases to be pumped can cause personal injuries and property
damage. Pay attention to the warning notices for handling hazardous substances.
The local regulations apply in foreign countries.
Combustible Gases
Examine before switching on whether that can form gas combustible gas/air mixtures which
can be promoted! Consider the regulations of the guideline 1999/92/EC.
Explosive gases
The diaphragm pumps of the series MPC are certified according to ATEX guidelines
2014/34/EU, device category 3, valid for the gas contacting parts (interior) of the pump.
The diaphragm pumps of the series MP are not certified according to ATEX guidelines
2014/34/EU.
Aggressive gases
The MPC series is designed for extracting contaminated gases!
The use of diaphragm pumps of the series MP cannot be recommended for such cases of
application!
Especially aggressive gases have to be explicitly checked for material resistance as de-
scribed in chapter 3.6 and, if necessary, modified.
Poisonous gases
Use a separator when pumping poisonous or harmful gases. Prevent such substances from
leaking out of the appliance or pump. Treat these substances according to the applicable
environmental protection regulations.
Test the strength and leak-tightness of the connecting lines and the connected apparatus.
Prevent environmental poisons, e.g. mercury, getting into the diaphragm pumps.
Fulfil the requirements, for example:
German Hazardous Substances Regulation (GefStoffV) of 01. December 2010
Regulation 2016/1179/EU
(Classification, Packaging and Labelling of hazardous substances),
Manufacturer's safety data sheets on hazardous substances.
2.5 High Temperatures
The diaphragm pump may heat up as a result of the temperature of the gas being pumped
and through compression heat.
Prevent the following maximum permissible temperatures from being exceeded.
+ 40 °C for the environment, and
+ 60 °C for the gas to be pumped.
The motor for single phase alternating current is protected against overload by an integrated
motor protection switch.
Description
8 412721
3 Description
3.1 Design
The diaphragm pump consists of a pump body
and a drive motor.
The pump casing contains the drive unit and two
pump heads. Each pump head contains a diaphragm and the work valves. Both pump heads
are arranged opposite each other.
The pump heads are driven via an eccentric shaft
with a connecting rod.
1 to 2 stage pumps are supplied, depending upon
the circuitry of the pump heads.
Fig. 1 Diaphragm pump MP 601 E
3.2 Principle of Operation
Motor, eccentric shaft and connecting rod set the diaphragms in stroke movement. This
changes the size of the space between the diaphragms and pump head (pump chamber).
Increasing the size of the pump chamber opens the inlet valve while the outlet valve is
closed (intake process).
Decreasing the size of the pump chamber ejects the gas through the outlet valve.
The valves are actuated by the gas being pumped. A large proportion of fluid in the diaphragm pump minimizes the pumping efficiency.
3.3 Gas ballast
When condensable vapours are pumped, they
may be compressed above the saturated vapour
pressure and condense.
Opening the gas ballast valve (A) in the
suction line allows air to flow into the pump chamber. This prevents condensation and flushes the
pump clear.
Operation leads to increasing the ultimate pressure and the operating temperature.
The gas ballast valve is only provided as standard
for MPC type diaphragm pumps. The fitting into
other pump types is an option or must be specified
in the supply contract.
Fig. 2 Gas ballast valve on the
MPC 301 Z
3.4 Areas of Application
Diaphragm Pumps are intended to:
Pumping and compressing neutral and aggressive gases and vapours.
Generating a vacuum down to an ultimate pressure < 8 mbar.
Use in physical and chemical laboratories in trade and industry.
Use for vacuum filtration, vacuum distillation and vacuum drying, and other vacuum tech-
nology applications.
(A)
Description
412721 9
3.5 Pump head circuitry
One-stage (E):
Both pump heads are connected in parallel.
Ultimate pressure:
< 75 mbar
Models:
MP 601 E, MPC 601 E and MPC 601 E-X2
Two-stage (Z):
Both pump heads are connected in series.
Ultimate pressure:
< 8 mbar
Models:
MP 301 Z, MPC 301 Z and MPC 301 Z-X2
Special designs:
Special diaphragm pumps can be supplied after consultation with the manufacturer or for
a corresponding supply contract.
Explosion protection motors.
Motors for different voltages.
3.6 Materials of the medium-affecting pump parts
Component
Standard design
Chemical model
(resistant to aggressive gases)
MP
MPC
MPC - X2
Seal
EPDM
EPDM
FFKM, PTFE
Screw fitting /
Connecting element
PA, PP
PP, PVDF
PVDF
Valve
PEEK
PEEK
PFA
Diaphragm
Elastomer +
PTFE Layer
Elastomer +
PTFE Layer
PTFE mod.
Vacuum hose
PTFE
PTFE
Connection head / Pump head
Aluminium
PTFE with carbon-fibre reinforcing
*)
*)
electrically conductive (with manufacturer's certificate of electrical conductivity)
Material resistance to aggressive media see: Publisher Hoppenstedt Publishing (18. September 2007)
3.7 Scope of Delivery
The scope of delivery is specified in the supply contract.
3.8 Accessories
Designation
Usage
Order no.
Vacuum Control Box
VCB 521 cv
for measuring and regulation of vacuum
600053
Vacuum Regulator
with dial gauge DBR-A
for intake allows the adjustment of the
ultimate pressure
700458
Gas ballast valve
for diaphragm pumps of type MP…,
manually operated
400599-02
Mains connection cable
IEC with plug type 12 (CH)
for diaphragm pumps of MP/MPC in 230 V
825877
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