WELCH-ILMVAC
OWNER’S MANUAL
FOR
SELF-CLEANING DRY VACUUM SYSTEM™
MODELS: 2025, 2026, 2027 & 2028
2025 |
2027 |
2028 |
(9 Torr, 12 mbar) |
(2 Torr, 2.7 mbar) |
(2 Torr, 2.7 mbar) |
2026 |
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|
(2 Torr, 2.7 mbar) |
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Improved to better meet your laboratory needs.
-New electronics with an enhanced self-cleaning feature to help extend diaphragm life
-Superior vacuum level regulator for setting vacuum pressures
-Improved corrosion resistant housing and front panel
-Protective jar cover to help protect inlet and outlet jars
WARNING
Be sure to properly identify intake and discharge before using pump. See Section 2.14
CAUTION
Do not pump liquids with the pump.
Pumping liquids will cause the pump to stop working.
Welch-Ilmvac |
|
5621 W. Howard Street |
|
Niles, IL 60714 |
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Phone: (847) 676-8800 (Technical Support) |
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Fax: (847) 677-8606 |
Part No. 642835 |
E-Mail: gdwelchvacuum@gardnerdenver.com |
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Web-Page: www.welchvacuum.com |
Printed in USA |
INSTRUCTION
WARNING AND CAUTION
PLEASE READ BEFORE OPERATION
While reading your manual, please pay close attention to areas labeled:
WARNING AND CAUTION.
The description of each is found below.
WARNING
Warnings are given where failure to observe instruction could result in injury or death to people.
CAUTION
Cautions are found where failure to observe
the instruction could result in damage to the equipment, associated equipment and process.
These units confirm to the SI International system of units of measurement.
The following symbols (with recommendation of IEC1010 ) of warning will be found on the pump.
Caution - refer to accompanying documents
Caution - risk of electrical shock
Caution - hot surface
WARNING
Motor includes a self resetting thermal cutout and the pump could restart without actuation under fault condition.
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TABLE OF CONTENTS
SECTIONS |
PAGE |
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Section 01 - Safety Information |
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1.10 |
To Prevent Injury |
04 |
1.20 |
To Reduce Risk of Electrical Shock |
04 |
1.30 |
To Reduce Risk of Electrocution |
04 |
1.40 |
To Reduce Risk of Explosion or Fire |
04 |
Section 02 - Installation |
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2.10 |
Introduction |
05 |
2.20 |
Electrical Power |
06 |
2.30 |
Traps |
07 |
Section 03 - Component, System and Unit Operations |
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3.10 |
Component Description |
09 |
3.20 |
Control Locations |
09 |
3.30 |
Vacuum Gauge / System Control Function |
10 |
3.40 |
Vacuum Level Regulation |
16 |
3.50 |
Gas Ballast Valve |
16 |
3.60 |
Rapid Response Vacuum Adjustment |
16 |
3.70 |
Inlet and Exhaust Separators |
17 |
3.80 |
Unit Start Procedure and Operation |
17 |
Section 04 - Maintenance |
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4.10 |
General Maintenance |
18 |
Section 05 - Calibration |
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5.10 |
Calibration for Model 2027 only |
18 |
Section 06 - Troubleshooting |
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6.10 |
Vacuum Problems |
20 |
Section 07 - Specification |
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7.10 |
Pump Specification Table |
23 |
Section 08 - Drawings, Parts List and Exploded View |
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8.10 |
Dimensional Drawing |
24 |
8.11 |
Schematic Wiring Diagram for Models 2025 and 2026 |
24 |
8.12 |
Schematic Wiring Diagram for Model 2027 |
25 |
8.13 |
Schematic Wiring Diagram for Model 2028 |
25 |
8.14 |
Parts List and Exploded View for Dry Vacuum System |
27 |
8.15 |
Parts List and Exploded View for Repair Kits |
28 |
Section 09 - Warranty |
29 |
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Section 1: SAFETY INFORMATION
1.10To prevent injury....
1.11Never operate this product if it has a damaged cord or plug. If it is not working properly, has been dropped, damaged or has fallen into water, please return the product to a Gardner Denver Welch Vacuum Technology service center for examination and repair.
1.12Keep the cord away from the heated surfaces.
1.13Never block any air openings or place it on a soft surface where the openings may be blocked. The air openings are for ventilation of the motor inside the housing. Keep all air openings free of lint, dirt and other foreign objects.
1.14The PTFE pump is thermally protected and can automatically restart when the protector resets. Always disconnect power source before servicing.
1.15Wear safety glasses or goggles when operating this product.
1.16Use only in well ventilated areas. The motor is fan cooled enclosed in a shell.
WARNING
Do not operate the pumps in an atmosphere containing flammable or explosive gases/vapors.
WARNING
Never block the exhaust port. If the exhaust is blocked, pressure will build-up in the pump with the potential of the pump head bursting and causing possible injury to personnel in the area.
1.17All electrical products generate heat. To avoid serious burns never touch unit during or immediately after operation.
1.18Be sure to properly identify intake and discharge before using pump. See Section 2.14.
WARNING
Remove plug(s) from Exhaust Port(s). The Self cleaning Dry Vacuum
System has one outlet port and one inlet port. The ports are labeled.
1.20To reduce risk of electrical shock....
1.21Do not disassemble. Disassembly or attempted repairs if accomplished incorrectly can create electrical shock hazard. Refer servicing to qualified service agencies only: Contact your closest Gardner Denver Welch Vacuum Technology sales office. See directory on back cover.
1.22Unit is supplied with a three pronged plug. Be sure to connect pump to a properly grounded outlet only.
1.30To reduce risk of electrocution…
1.31Do not use this product in or near area where it can fall or be pulled into water or other liquids.
1.32Do not reach for this product if it has fallen into liquid. Unplug immediately.
1.33Never operate this product outdoors in the rain or in a wet area.
1.40To reduce risk of explosion or fire…
1.41Do not use this pump near explosive atmospheres or where aerosol (spray) products are being used.
1.41Do not use this product near flames.
WARNING
Failure to observe the above safety precautions could result in severe bodily injury, including death in extreme cases.
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Section 2: INSTALLATION
2.10Introduction
This manual has been compiled not only for the care and maintenance of the Welch Dry Vacuum System now in your possession, but as a helpful reference and guide to prevent many problems which can occur if used improperly.
2.11Unpacking
Carefully remove the Dry Vacuum System from the shipping carton. Preserve all paperwork for future reference. If damage has occurred from shipment a claim must be filed with the carrier immediately; preserve the shipping carton for inspection by the carrier. If you are required to communicate with your dealer or Welch-Ilmvac be sure to include your order numbers for quick identification. Do not return the system to the factory without first calling for a returned goods number. Contact your closest Welch-Ilmvac sales office.
2.12System Mounting
Rubber feet are attached to the pump. Rubber feet are excellent for applications involving a semi-flexible surface such as a bench top; they help to isolate noise and eliminate creeping. The Self-Cleaning Dry Vacuum System must be positioned with the feet on a flat surface.
2.13System Location
The Self-Cleaning Dry Vacuum System should be located preferably in a clean, dry and well ventilated area. Please be sure not to block the ventilation ports located on the metal shell. The pump should be placed where the surrounding temperature remains between 10°C and 40°C (50°F and 104°F). Always check to insure the location chosen is protected from direct or indirect moisture contact. The pump should be located as closely to its system in order to utilize it most efficiently.
WARNING
Don’t operate this pump in an atmosphere containing flammable or explosive gases or vapors.
CAUTION
If operating the unit in a hood, be aware of other hood uses and users – always avoid activities that could compromise unit function. For example, an acid digestion in the hood with the pump system will destroy unit electronics.
WARNING
Do not position the equipment so that it is difficult to operate the disconnecting device. (Removal of the plug or power cord from the socket outlet).
2.14Inlet and Outlet Provisions
An inlet hose barb which accepts ¼” (7mm) I.D. hose makes it easy to connect the system to your concentrator, rotary evaporator or gel dryer. Since the vacuum system operates in the viscous flow range, the small diameter of the hose will generate minimal conductance loss. For best results, Welch recommends the length of the tubing between the pump and the apparatus be kept as short as possible. Hose clamps should be used to hold the hose in place. The hose barb in the outlet port of the pump accepts ¼” (7mm) I.D. hose. A vent line can be attached to the outlet hose barb which allows gases and vapors pumped through the pump to be piped to a fume hood. If you any questions, be sure to call
technical service prior to start-up. Contact your closest Gardner Denver Welch Vacuum Technology sales office.
WARNING
Never Block The Outer Port. If the outlet is blocked, pressure will buildup in the pump which can lead to the pump head bursting creating the potential of serious injury. Remove plug from outer port.
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PROPERLY IDENTIFY THE INLET AND OUTLET OF THE PUMP
Outlet Port
Inlet Port
WARNING:
(Model 2028 shown) Remove Plug From Exhaust Port Before Operating.
2.20Electrical Power
2.21Power Source Review
Review the power source and the voltage rating on the units serial number tag to be sure they agree in voltage, phase and frequency. Serious damage may occur to the system if it is connected to an improper voltage. All Welch systems must be grounded. Grounding reduces the risk of electric shock in the event of an electrical short circuit. The plug must be plugged into an outlet properly grounded. Consult your local electrical codes if you have doubts.
2.22 Identification Symbols |
OFF (Power) on Models: |
on Model: |
|
ON (Power) 2025, 2026 & 2027 |
2028 |
2.23Grounding Instructions
This product should be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.
WARNING
Improper installation of the grounding plug can result in a risk of electrical shock.
If repair or replacement of the cord or plug is necessary, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.
Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if in doubt as to whether the product is properly grounded. Do not modify the plug provided; if it will not fit the outlet, have the proper outlet installed by a qualified electrician.
Model’s 202501, 202601, 202701 and 202801 are for use on a nominal 120V circuit, and has a grounding plug that looks like the plug illustrated in Sketch A in Figure #1. A temporary adapter, which looks like
the adapter illustrated in sketches B and C, may be used to connect this plug to a 2-pole receptacle as shown in sketch B if a properly grounded outlet is not available.
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The temporary adapter should be used only until a properly grounded outlet (Sketch A) can be installed by a qualified electrician. When using the temporary adapter, the green colored rigid ear, lug, etc. extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover. Whenever the adapter is used, it must be held in place by a metal screw.
2.24Extension Cords
If necessary to use an extension cord, use a 3-wire extension cord that has a 3-blade grounding plug, and a 3-slot receptacle that will accept the plug on the product. Make certain your extension cord is in good condition. Make certain your extension cord wire size is not less than 18 gauge for 25 feet, 16 gauge for 50 feet, and 14 gauge for 100 feet. An undersized cord will cause a drop in line voltage
resulting in loss of power and overheating. If in doubt, use the next heavier cord. The smaller the gauge number, the heavier the cord. Avoid routing the extension cord through areas that could result in damage to the cord.
2.30Traps
2.31When To Use A Trap
The Self-Cleaning Dry Vacuum System is constructed of PTFE or fluorinated plastics on all wetted surfaces to resists chemical attack from aggressive solvent, base and acid vapors. A totally oil free diaphragm mechanism removes the need for lubricating and sealing fluids for pulling a vacuum. When pumping gases or low vapor loads, a trap is not necessary unless you want to capture vapors evolved from the process. When a heavy load of water or organic vapor is evolved from the vacuum process, condensation of vapor in the pump mechanism may occur. The reason is the pump is compressing the vapor as it passes through the pump. If the vapor is dense enough, the compression will cause condensation of the vapor in the pump mechanism. The valve system in the pump mechanism is designed to pass the small quantity of liquefied vapor formed when pumping heavy vapor loads. The
liquid formed will be ejected from the outlet port. The self-cleaning purge feature of the Self-Cleaning Dry Vacuum System is designed to eject condensed vapors left in the pump up on shut-done.
The advantage of a cold trap when pumping heavy vapor loads is that it will increase the effective pumping speed of the Self-Cleaning Dry Vacuum System. The trap acts as an additional pumping mechanism, increasing the effective pumping speed. This higher effective pumping speed will shorten the time needed to strip solvent. The time savings will depend on such factors as the solvent stripped, solvent temperature and operating temperature of the cold trap.
The cold trap is installed between the pump and the vacuum chamber. The water or organic vapors evolved from the vacuum process entering the cold trap will come in contact with the cold surfaces of the trap and condense. Commonly used refrigerants are liquid nitrogen or dry ice with alcohol slurry. Dry ice provides sufficient cooling to freeze out most heavy water vapor loads. A variety of cold traps are available from Welch. Visit the Welch Web-Site at www.welchvacuum.com.
2.32Solvent Traps
Your Self-Cleaning Dry Vacuum System comes with a basic solvent removal capability to remove readily condensable solvents prior to pump ingestion and to collect solvent accumulated during pump
condensation and the Self-Cleaning cycle. Solvent removal can be further enhanced to provide additional pumping efficacy, safety, solvent fate control, and pump life. Depending upon your application, additional solvent trapping may be desirable. Solvent trapping configurations are discussed below; consult your Welch representative for application specific trapping recommendations.
2.33Self-Cleaning Dry Vacuum System Solvent Removal
When pumping gases or low vapor loads, a trap is not necessary unless you want to capture vapors evolved from the process. When a heavy load of water or organic vapor is evolved from the vacuum process, condensation of vapor in the pump mechanism may occur due to compression. The valve system in the pump mechanism is designed to pass a small quantity of liquefied vapor formed when pumping heavy vapor loads. The liquid formed will be ejected from the outlet port. The self-cleaning purge feature of the Self-Cleaning Dry Vacuum System is designed to eject condensed vapors left in the
pump upon shut-down and collect condensate in the side-mounted jar.
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2.34Cold Trap Solvent Removal
Condensation of organic solvent fumes is typically accomplished by suspending a trap in a Dewar flask containing dry ice / isopropanol slurry or liquid nitrogen. Alternatively low maintenance cooling to -100oC can be achieved using a refrigerated cold trap. The cold trap is connected between the application and the pump unit to prevent solvent ingestion. Installation of a cold trap when pumping heavy vapor loads offers several advantages:
•The Self-Cleaning Dry Vacuum System will operate more efficiently. The trap acts as an additional pumping mechanism, increasing the effective pumping speed. This higher effective pumping speed will shorten the time needed to strip solvent.
•The absence of a high solvent load in the pump diaphragm mechanism promotes pumping efficiency and extends diaphragm life.
•Vacuum pump pass-through of solvents is reduced, preventing possible discharge into the laboratory atmosphere and enabling responsible control of chemical usage and potential solvent recycling. A variety of cold traps are available from Welch. Contact your closest Gardner Denver Welch Vacuum Technology sales office or visit the Welch Web-Site at www.welchvacuum.com.
2.35CAPTURETM Cold trap
Your Welch Self-Cleaning Dry Vacuum System can be extended to include a CAPTURETM cold trap. This trap is a pump-mounted condenser utilizing recirculating chilled water can be configured to remove solvent fumes from the vacuum stream either prior to the pump inlet to lessen solvent ingestion or on the pump outlet to reduce emissions. The CAPTURE trap provides continuous solvent condensation without the need to recharge a cold trap with dry ice / isopropanol or liquid nitrogen. Contact your Welch representative for more CAPTURE information or see www.welchvacuum.com
2.36The Care of a Liquid Trap
A liquid trap needs no refrigerant. The key maintenance issue when pumping high vapor loads is to regularly drain the trap of liquid ejected from the dry vacuum pump.
2.37The Care of a Cold Trap
When using a cold trap the refrigerant should be maintained at a high level in the flask to keep the trap at a uniformly low temperature. If the trap is rewarmed it may allow re-evaporation of the condensate. If the trap becomes saturated it should be disconnected from the system, drained and cleaned. An increase in pressure in the vacuum system will normally indicate that the trap has become saturated. To clean the trap, remove the trap from the system and allow the trap to warm up and rinse off the condensate with a suitable solvent in a fume hood. Thoroughly clean and dry the trap before reinstalling the system. If a liquid nitrogen trap is used, the refrigerant add tube on the liquid nitrogen trap should not be obstructed as the refrigerant boil-off can produce dangerously high pressures.
2.38Application Note for Cold Trap
Cold traps employing a dry ice slurry or liquid nitrogen are effective as long as the refrigerant level is maintained. If the trap warms up while the pump is running, all of the trapped condensable will be ingested by the vacuum pump. Cold traps must be cleaned out at the end of each day. If the pump is
run overnight, the trapped condensable will ultimately be ingested by the pump as the trap warms up. Cleaning a Dry Ice Slurry/Liquid Nitrogen trap is easy. The steps are:
1.Turn off the pump.
2.Leak air into the trap.
3.Remove the center well and Plexiglas ring to a hood. The center well can be washed off into a beaker or the condensable can be allowed to evaporate in the hood.
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Section 3: COMPONENTS, SYSTEM AND UNIT OPERATION
3.10Components
-3.20 Control Locations
-3.21 Control Locations for Models 2025, 2026 and 2027
-3.22 Control Locations for Model 2028
-3.30 Vacuum Gauge / System Function
-3.31 Vacuum Gauges for Models 2025 and 2026
-3.32 Vacuum Gauge / System Control Function for Model 2027
-3.33 Vacuum Gauge / System Control Function for Model 2028
-3.40 Vacuum Level Regulation
-3.50 Gas Ballast
-3.60 Rapid Response Vacuum Adjustment
-3.70 Inlet and Outlet Separators (all Models)
3.20Control Locations
3.21Control Locations for Models 2025, 2026 and 2027
VACUUM CONTROL KNOB 
GAS BALLAST SWITCH
POWER
3.22 Control Locations for Model 2028 |
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MANUAL |
VENT |
AUTO |
Anti BUMPING/FOAMING |
MENU |
MAXIMUM VACUUM |
NUMERIC KEY PAD |
UP/DOWN ARROWS |
VACUUM CONTROL |
POWER |
KNOB |
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Push to select menu options |
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