Alcatel 2005X Specifications

Alcatel 2005X Specifications
Presentation of the product range
A wide range
Specific solutions adapted to various
applications
Alcatel oil seal rotary vane pumps are used in all vacuum technology
applications.
They can be used on their own to achieve a maximum vacuum of 10-3 Torr
(10-3 mbar), or in pumping assemblies, e.g. at the exhaust of a diffusion pump
or turbomolecular pump.
SD series
Standard pumps for several purposes (non-corrosive applications).
Manufacture of light bulbs, production of TV tubes, manufacture of electronic
tubes, metallurgy, centrifuges, etc.
I series
Pumps designed to meet the requirements of analytical instrumentation and
R&D.
Mass spectrometer, electronic microscopes, GC/MS, LC/MS, gas analyzers,
leak detectors, sterilizers, etc.
C1 series
Pumps suited to the pumping of corrosive gases.
R&D, laboratories, freeze-drying, pumping of solvents, etc.
C2 series
Pumps with increased resistance to meet the requirements of the more
aggressive processes of the semiconductor industry.
Ion implantation, sputtering, etc.
H1 series
Sealed pumps offering maximum tightness.
Pumping of pure or precious gases.
Nom. fl. rate
I series
SD series
C1 series
54
m3/h
5
10
15
21
2 stages
2005I
2010I
2015I
2021I
1 stage
1005SD
1010SD
1015SD
1021SD
2 stages
2005SD
2010SD
2015SD
2021SD
1 stage
1005C1
1010C1
1015C1
1021C1
2 stages
2005C1
2010C1
2015C1
2021C1
2010C2
2015C2
2021C2
C2 series
2 stages
H1 series
2 stages
2005H1
2015H1
Four 5 to 21 m3/h pump models with
the following main characteristics:
Presentation
5 to 21 m3/h rotary vane pumps.
I, SD, C1, C2 Pascal series
10
8
- A direct drive motor, making them
very compact.
9
11
5
12
- An electrically insulated fold-away
handle is used for easy carrying.
4
- An anti-suckback system ensures
the tightness of the pump during
accidental or voluntary shutdowns.
6
- A gas ballast enables the pumping
of condensable vapours (except for
C2 series).
- The universal three-phase or singlephase motor can be disassembled
independently of the rest of the
pump, without the need to drain
the oil case.
- On the oil case, a vertical sight
glass can be used to inspect the oil
level easily when filling the tank and
during the operation of the pump.
- A neutral gas purge is used to
degas oil and dilute pumped gases
on C2 series models.
2
1.
2.
3.
4.
5.
6.
Oil case
Gas ballast control
Base
Oil level sight glass
Filling plugs
Draining plug
3
1
7.
8.
9.
10.
11.
12.
7
Frame
Inlet end fitting
Exhaust end fitting
Fold-away handle
Electric motor
IEC electric socket
The inlet and exhaust end fittings are PNEUROP ISO-KF standardized.
They are fitted vertically on the pump at delivery but can be positioned on
the horizontal openings if required by operating conditions.
They can also be used to connect many of our accessories (see page 63).
The main remplacement parts are interchangeable: This enables easier
disassembly-assembly operations and replacement without changing the
pump’s performance.
Various accessories can be used to adapt the pump to meet the requirements
of your application.
The moulded aluminium pump frame supports the pumping module and the
motor. All the parts of the pumping module in contact with gases are free of
zinc, copper and cadmium.
The other construction materials include cast iron, aluminium alloy, stainless
steel, fluorocarbons (FPM), nitril (NBR) and chemically resistant polymers.
55
Operating principle of the rotary vane pump
Single-stage
rotary vane pump
This is a volumetric pump, with a functional part composed of:
- A hollow cylindrical stator with inlet and exhaust valves.
- A rotor mounted eccentrically inside the stator for pumping.
- Two vanes sliding in the rotor, forced against the stator by centrifugal force
and springs.
The pumping cycle is
given below:
In.
Exh.
In.
Exh.
Inlet
As the vane passes in front of the
inlet orifice, an increasing space is
formed into which the gas from the
chamber to be evacuated expands.
When the second vane passes, the
space is closed.
The gas trapped in the space
between the two vanes is transferred
to the exhaust orifice as the rotor
rotates.
Transfer
In.
Exh.
Compression
The space communicates with the
exhaust, which is fitted with a valve:
the gas is compressed until the safety
valve is opened.
In.
Exh.
Exhaust
The gas is expelled into the oil
casing when the pressure is sufficient
to open the valve.
Application
56
Single stage rotary vane pumps are the best choice for continuous pressures
above 1.0 Torr (1,3 mbar), as well as applications where large amounts of
condensable gases are present.
Two-stage
rotary vane pump
To improve the backing pressure and flowrate at low pressure, two stages are
connected in series. The second is similar to the first both structurally and
operationally. The gases pulled in by the first (low pressure) stage are transferred
to the second (high pressure) stage and discharged through the high pressure (HP)
valve.
Exh.
Presentation
In.
Low pressure stage
Application
High pressure stage
Two stage rotary vane pumps are the best choice for application requiring an
ultimate vacuum as low as 10-3 Torr (1.33 x 10-3 mbar).
Note : when operating a two stage vane pump continously, greater than half an
hour, above 1.0 Torr, the unit should be equipped with an oil mist eliminator and
oil return system, see oil draining kit (page 63), or a single stage pump should be
used.
57
Oil
Its function
Choosing the right oil
Lubrication and anti-noise
device
Gas ballast
Oil has several important functions in the pump:
- It lubricates mechanical components (bearings, seals, rotor, vanes, etc.).
- It makes moving parts relatively tight by limiting internal leakage.
- It carries away the heat produced by the compressed gases.
Not all oils produce the same ultimate pressure in a given pump. Ultimate pressure
depends on the saturated vapour pressure of the oil, its viscosity and its ability to
dissolve gases.
Good pumping conditions are related to the type of oil used.
The choice depends on:
- Expected pump performance.
- Chemical aggression and corrosion of pumped gases.
- Accessories used.
- Desired maintenance intervals and total operating cost.
ALCATEL has selected various types of oil for its pumps (see page 67).
The pump is equipped with a lubrication system which regulates the oil flow rate
required in the vacuum pump. In addition this system also ensures the gassing of
the lubrication oil and therefore the low noise level of the pump.
When condensable vapours are being
pumped, gas is compressed beyond its
saturated vapour pressure in the
"compression" phase and can
condense, impairing pump
performance.
In.
Exh.
air
The gas ballast can be used to inject a
certain quantity of air (neutral or dry
COMPRESSION
gas) into the last stage of the pump
during the "compression" phase so that the partial pressure of the pumped gas is
less than its saturated vapour pressure at the temperature of the pump.
Condensation is therefore impossible if this limit is not reached. The maximum
admissible vapour pressure is obtained at pump inlet for this value.
At the end of "compression", the pressure in the exhaust chamber is greater than
atmospheric pressure. An anti-suckback device (valve + spring) prevents the gases
and oil from being drawn back into the inlet.
The saturated vapour pressure of a body is higher when the system is hot than
when it is cold; therefore, the pump must reach operating temperature before
pumping condensable vapours.
- Using the gas ballast increases the ultimate pressure of the pump as well
as the temperature.
- The gas ballast control, located at the front of the oil case cannot be used
to set the gas injection flow rate.
- When the gas ballast control is open, the pump is not tight when stopped. To
guarantee this tightness, install an automatic gas ballast.
58
For analycal
instrumentation: I Series
Two-stage pumps
Characteristics
Unit
Frequency
Number of stages
Rotation speed
Nominal flow rate
Hz
2005 I
50
60
2010 I
50
2
Flow rate Pneurop method
Partial ultimate pressure*
(with Alcatel 120 oil)
Ultimate pressure
with gas ballast closed
Ultimate pressure
with gas ballast open
Oil capacity
Maximum water vapour pumping
capacity (Ballast flowrate 1.1 m3/h)
Water vapour pumping capacity
Weight (pump + motor)**
Inlet and exhaust end fittings
60
2015 I
50
50
60
2
2
rpm
1500 1800
m3/h
5.4
6.5
cfm
3.8
m3/h
4.8
5.7
cfm
3.4
Torr/mbar
/Pa
Torr/mbar
/Pa
Torr/mbar
/Pa
l
0.83
60
2021 I
2
1800 1500 1800
15
18
11.6
10.6
6.8
12.5
15
8.5
10.2
8.8
6
7.5.10-5 / 1.10-4
1.10-2
1.5.10-3 / 2.10-3
2.10-1
7.5.10-3 / 1.10-2
1
0.950
0.950
1500
9.7
mbar
35
25
12
10
20
15
Pa
35.102 25.102 2.103 15.102 12.102 1.103
120
110
110
100
g/h
125
100
25 (55)
27 (59.5)
kg (Ibs)
26 (57)
ISO-KF
DN 25
1500
20.7
1800
24.8
14.6
20
11.8
16.5
0.98
7
7
7.102 7.102
90
90
28 (62)
For industry: SD Series
Two-stage pumps
Characteristics
Frequency
Number of stages
Rotation speed
Nominal flow rate
Flow rate Pneurop method
Partial ultimate pressure*
with Alcatel 120 oil
Ultimate pressure
with gas ballast closed
Ultimate pressure
with gas ballast open
Oil capacity
Weight (pump + motor)**
Maximum water vapour pumping
capacity (Ballast flowrate 1.1 m3/h)
Water vapour pumping capacity
Inlet and exhaust end fittings
Unit
Hz
2005 SD
50
60
2
2010 SD
50
60
2
2015 SD
50
60
2021 SD
50
2
rpm
1500 1800 1500 1800 1500 1800
m3/h
5.4
6.5
9.7
11.6
15
18
cfm
3.8
6.8
10.6
m3/h
4.8
5.7
8.5
10.2
12.5
15
cfm
3.4
6
8.8
Torr/mbar
7.5.10-5 / 1.10-4
/Pa
1.10-2
Torr/mbar
1.5.10-3 / 2.10-3
2.10-1
/Pa
Torr/mbar
7.5.10-3 / 1.10-2
/Pa
1
l
0.83
0.950
0.950
kg (Ibs)
25 (55)
26 (57)
27 (59.5)
mbar
35
25
20
15
12
10
Pa
35.102 25.102 2.103 15.102 12.102 1.103
g/h
120
110
125
100
110
100
DN 25
ISO-KF
60
2
1500
20.7
16.5
1800
24.8
14.6
20
11.8
0.98
28 (62)
7
7
7.102 7.102
90
90
* Partial ultimate pressure measured according to Pneurop 6602 specifications. It may vary if other oils are used (See page 67).
** These values are for pumps equipped with universal single-phase motors.
Note:
The pressure measurements were made with a capacitive diaphragm pressure gauge measuring a total pressure in the absence of
a cold trap. Measurements using a Pirani type gauge can give different pressure values.
59
Presentation
Technical characteristics
Corrosive applications:
C1 Series
Two-stage pumps
Characteristics
Unit
Frequency
Number of stages
Rotation speed
Nominal flow rate
Hz
2005 C1
50
60
2010 C1
50
2
Flow rate Pneurop method
Partial ultimate pressure*
with Alcatel 120 oil
Ultimate pressure
with gas ballast closed
Ultimate pressure
with gas ballast open
Oil capacity
Weight (pump + motor)**
Maximum water vapour pumping
capacity (Ballast flowrate 1.1 m3/h)
Water vapour pumping capacity
Inlet and exhaust end fittings
60
2015 C1
50
2
60
2021 C1
50
2
60
2
rpm
1500 1800 1500 1800 1500 1800
m3/h
5.4
6.5
9.7
11.6
15
18
cfm
3.8
6.8
10.6
m3/h
4.8
5.7
8.5
10.2
12.5
15
cfm
3.4
6
8.8
Torr/mbar
7.5.10-5 / 1.10-4
/Pa
1.10-2
Torr/mbar
1.5.10-3 / 2.10-3
2.10-1
/Pa
Torr/mbar
7.5.10-3 / 1.10-2
/Pa
1
l
0.83
0.950
0.950
kg (Ibs)
25 (55)
26 (57)
27 (59.5)
mbar
35
25
20
15
12
10
Pa
35.102 25.102 2.103 15.102 12.102 1.103
120
110
125
100
110
100
g/h
ISO-KF
DN 25
1500
20.7
16.5
1800
24.8
14.6
20
11.8
0.98
28 (62)
7
7
7.102 7.102
90
90
Corrosive applications:
C2 Series
Two-stage pumps
Characteristics
Frequency
Number of stages
Rotation speed
Nominal flow rate
Flow rate Pneurop method
Partial ultimate pressure*
with Alcatel 113 oil
Ultimate pressure
Oil capacity
Weight (pump + motor)**
Inlet and exhaust end fittings
Unit
Hz
2010 C2
50
60
2
2015 C2
50
60
2
2021 C2
50
60
2
rpm
1500 1800 1500 1800 1500 1800
m3/h
9.7
11.6
15
18
20.7
24.8
cfm
6.8
10.6
14.6
m3/h
8.5
10.2
12.5
15
16.5
20
cfm
6
8.8
11.8
Torr/mbar
3.75.10-4 / 5.10-4
Pa
5.10-2
Torr/mbar
1.5.10-3 / 2.10-3
2.10-1
Pa
l
0.950
0.950
0.98
kg (Ibs)
26 (57)
27 (59.5)
28 (62)
ISO-KF
DN 25
* Partial ultimate pressure measured according to Pneurop 6602 specifications. It may vary if other oils are used (See page 67).
** These values are for pumps equipped with universal single-phase motors.
Note:
60
The pressure measurements were made with a capacitive diaphragm pressure gauge measuring a total pressure in the absence of
a cold trap. Measurements using a Pirani type gauge can give different pressure values.
For industry: SD Series
Characteristics
Unit
Frequency
Number of stages
Rotation speed
Nominal flow rate
Flow rate Pneurop method
Ultimate pressure*
with gas ballast closed
Ultimate pressure*
with gas ballast open
Oil capacity
Weight (pump + motor)**
Maximum water vapour pumping
capacity (Ballast flowrate 1.1 m3/h)
Water vapour pumping capacity
Inlet and exhaust end fittings
Hz
1005 SD
50
60
1010 SD
50
1
60
1015 SD
50
1
60
1021 SD
50
1
60
1
rpm
1500 1800 1500 1800 1500 1800 1500 1800
m3/h
5.4
6.5
9.7
11.6
15
18
20.7
24.8
cfm
3.8
6.8
10.6
14.6
m3/h
4.8
5.5
8.5
10
12.5
15
16.5
20
cfm
3.2
5.8
8.8
11.8
Torr/mbar
3.75.10-2 / 5.10-2
/Pa
5
3/4
5.25 / 7
Torr/mbar
4.102
7.102
/Pa
l
1.1
1.0
1.0
1.0
kg (Ibs)
21 (46)
22 (48)
24.5 (54)
25 (55)
mbar
30
25
40
35
35
30
25
22
Pa
3.103 25.102 4.103 35.102 35.102 3.103 25.102 22.102
120
130
260
280
330
370
340
340
g/h
ISO-KF
DN 25 ISO KF
Corrosive applications:
C1 Series
Single-stage pumps
Characteristics
Frequency
Number of stages
Rotation speed
Nominal flow rate
Flow rate Pneurop method
Ultimate pressure*
with gas ballast closed
Ultimate pressure*
with gas ballast open
Oil capacity
Weight (pump + motor)**
Maximum water vapour pumping
capacity (Ballast flowrate 1.1 m3/h)
Water vapour pumping capacity
Inlet and exhaust end fittings
Unit
Hz
1005 C1
50
60
1
1010 C1
50
60
1
1015 C1
50
60
1
1021 C1
50
60
1
rpm
1500 1800 1500 1800 1500 1800 1500 1800
20.7
24.8
m3/h
5.4
6.5
9.7
11.6
15
18
14.6
cfm
3.8
6.8
10.6
16.5
20
m3/h
4.8
5.5
8.5
10
12.5
15
11.8
cfm
3.2
5.8
8.8
3.75.10-2 / 5.10-2
Torr/mbar
5
/Pa
3/4
5.25 / 7
Torr/mbar
4.102
7.102
/Pa
1.0
l
1.1
1.0
1.0
25 (55)
kg (Ibs)
21 (46)
22 (48)
24.5 (54)
25
22
mbar
30
25
40
35
35
30
Pa
3.103 25.102 4.103 35.102 35.102 3.103 25.102 22.102
340
340
120
130
260
280
330
370
g/h
ISO-KF
DN 25
* Pressure measured according to Pneurop 6602 specifications with Alcatel 120 oil charge. It may vary if other oils are used (See page 67).
** These values are for pumps equipped with universal single-phase motors.
Note:
The pressure measurements were made with a capacitive diaphragm pressure gauge measuring a total pressure in the absence of
a cold trap. Measurements using a Pirani type gauge can give different pressure values.
61
Presentation
Single-stage pumps
Pump dimensions
Filling
Bubbler C2 Series
3/8 G
Inlet
Exhaust
DN25 ISO KF
DN25 ISO KF
4.5 (113.5)
7.6 (192)
A
3.8 (96.5)
2.4
(63)
3.6
(91.5)
1.5
(37)
1.77
(45)
1.41
(36)
3.9 (98)
10.2 (259)
B
5.5 (141)
9.3 (237)
Pump type
Dim.
62
6.5 (164)
4 x 8 mm diam. holes
Drain 3/8 G
A
B
C
8.5 (216)
0.86 (22)
1.76
(4.5)
8.9 (226)
3.9 (100)
4.8 (122)
6.5 (165)
2.18
(55.5)
0.8
(19.5)
8.7 (221)
9.5 (240)
C
3.8 (95.5)
inch/(mm)
1.5
(37)
1005
1010
2005
1015
2010
1021
2015
2021
9 (229)
9.8 (249)
10.6 (270)
11.5 (291)
7 (183)
8 (204)
8.9 (225)
9.7 (246)
4.55 (115.5) 5.4 (136.5) 4.55 (115.5) 6.2 (157.5) 5.4 (136.5) 7.03 (178.5) 6.2 (157.5) 7.03 (178.5)
NAME
PART NUMBER
Oil mist
OME 25 S 104200
eliminator
OME 25 CH 066849
OME 25 S/OME 25 CH
LOCATION
FUNCTIONS
Exhaust
• Separates oil droplets and particles contained
in exhaust gases emitted by the pump.
High pressure oil mist
eliminator
OME 25 HP
104199
Exhaust
• Separates oil droplets and particles contained in
exhaust gases emitted by the pump.
For high pressure pumping and/or frequent
cycles. Can be fitted to the ODK 1 and ODK 2
kits.
Oil draining kit
ODK 1
104360
Gas ballast
• Connected to the OME25HP, it is used to recover
oil via the gas ballast. Note: the pump is not
sealed when switched off.
Oil draining kit
ODK 2 ★
104361 230V 50/60Hz
104362 115V 60Hz
Gas ballast
• Connected to the OME25HP, it is used to recover
oil via the gas ballast. Equipped with an electrovalve which seals the pump when switched off.
Condensate trap
CT 25
104201
Inlet or exhaust
Dust filter
DFT 25
104202
Inlet
• Prevents dust particles larger than 6 microns
from entering the pump.
Liquid nitrogen trap
LNT 25 S or LNT 25 C
Aluminum 104197
St. steel 066889
Inlet
• Protects the pump against condensable vapours.
• Prevents oil from backstreaming into pumped
chamber.
Sorption trap
ST 25 S or ST 25 C
Aluminum 104107
St. steel 066841
Inlet
• Prevents oil backstreaming when pumping in a
"clean" vacuum.
Automatic gas ballast 104086 230V 50/60Hz
AGB 4 ★
104087 115V 60Hz
• Prevents liquids and solids contained in the
pumped gases from entering the pump, or traps
condensable vapors at the exhaust.
Gas ballast
• Remote control for gas ballast.
• Allows the gas ballast to be closed when the
pump is off, ensuring that the pump is tight.
• In the event of a power failure, it isolates the
vacuum chamber from the pumping unit and
ensures chamber venting.
Isolating safety valve
ISV 25 ★
066832
220V 50Hz
Inlet
Oil filter DE
066890 220V 50/60Hz
104373 115V 50/60Hz
External device
Shock mount
082691
LAX 100 model D
• Filters and/or neutralizes oil when pumping
gases which are corrosive and could rapidly
degrade oil quality.
Between base and • Helps isolate pump vibration.
machine frame
• Allows pump to be mounted on a frame.
★ Other voltages and frequencies available in the Alcatel catalog
In general, use accessories in which the tightness and materials are compatible with the pumped gases and the required
safety conditions at both the inlet and the exhaust.
At the pump exhaust, the discharge circuit must be such that the resulting excess pressure in the oil case is as low as possible.
The maximum excess pressure recommended for correct pump operation is 0.5 bar (6 PSI).
A slight negative pressure in the oil case (0.1 to 0.2 bar / 1.5 PSI), at the exhaust, will prevent gases from accumulating and reduce
pump corrosion and pollution.
If the exhaust orifice is connected to an extraction duct or an oil mist eliminator, you must remove the exhaust safety valve
mounted in the pump's exhaust orifice.
63
Presentation
Accessories
64
Safety instructions concerning the installation and
operation of pumping systems
Before switching on the equipment, the user must read all of the start-up
and operation sections of this manual and observe the safety instructions
listed in the booklet of declarations of compliance supplied with the unit.
Unpacking
When you receive the equipment, unpack it carefully. Do not discard the
packaging until you have ensured that the pump has not been damaged
during transport. Otherwise, take the necessary measures with the transporting
company and, if necessary, notify ALCATEL.
The pump is not supplied filled with oil. The oil is contained in separate
bottles. Similarly, it is recommended to drain the pump before redispatching
the equipment.
Storage
• If the pump is to be stored, we guarantee the reliability of our equipment
without particular storage precautions for up to 3 months (ambient
temperature between 41°F and 149°F or 5 and 65°C).
• For storage periods of over 3 months, we recommend to fill the pump with
oil during storage. For this, fill the pump and run it at ultimate vacuum (inlet
orifice blocked) for approximately 1 hour in order to lubricate all the parts of
the functional block (see page 76).
Then, stop the pump and store it with the inlet and exhaust orifices sealed:
clamping ring, centring ring, plug, etc.
The shaft should be rotated by hand or by starting the pump every six months
following this storage procedure.
• After 6 months storage without oil, factors such as temperature, degree of
humidity, salt air, etc. may cause the deterioration of the pump components,
particularly the hardening of O-rings and the "sticking" of lip seals on shafts
and the gumming of oil. In this state, a pump may have operational problems,
particularly oil leaks. Before any start-up (new pump as well as used), the
pump must be disassembled (see page 91), and all the seals changed.
Note 1:
The seal kits must be stored with caution. Keep them away from heat and
light (sunlight and ultraviolet light) in order to prevent the elostomers from
hardening (AFNOR standard FD T 46.022).
65
Start-up
For all handling, only use the devices provided for this purpose (lifting rings,
handle, etc.).
Installation and
start-up
• The machines must be connected to an electrical installation in compliance
with decree 88-1056 dated 14th November 1988, as well as any local
electrical codes that apply.
• lt is important to isolate the machine from the power source before any
intervention on the equipment (for maintenance purposes).
• When switching off the power of equipment containing capacitors loaded
with over 60 VDC or 25 VAC, take precautions when accessing the connector
pins (single-phase motors, equipment with mains filter, frequency converter,
monitor, etc.).
• Vane roughing pumps use lubricants, it is recommended to request
information from the manufacturer on the safety data sheets concerning the
product used.
• Our pumps are tested in the factory with ALCATEL 120 oil or Alcatel 119
for the USA (Alcatel 113 oil for the C2 series). It is recommended to use the
same oil during operation.
If changing the type of oil, refer to the chapter concerned for the procedure
and the type of lubricant required.
• Our pumps are designed to prevent any thermal risk for user safety.
However, specific operating conditions may generate temperatures which may
justify particular attention on the part of the user (outer surfaces > 70°C).
66
Table of recommended oils
OIL
In the vane pumps, we recommend to use only the ALCATEL oils in the table
below:
APPLICATION
I SD C1 C2
Total
ultimate
pressure*
(mbar)
Viscosity
mm2/s
(cst)
Vapour
tension
25°C
(mbar)
Anti-emulsion mineral oil
ALCATEL - Drying
102 - Pumping water vapour
- Freeze-drying
≤ 3.10-2
Hydro-carbon based synthetic oil with good heat
ALCATEL resistance:
111 - Pumping at high pressures
- Operating at high ambient temperatures
≤ 1.10-2
Highly stable synthetic oil.
ALCATEL Perfluoropolyether.
- Highly inert to chemicals
113 - Pumping oxygen
- Plasma etching
≤ 5.10-3
ALCATEL Mineral oil distilled under vacuum
- Pumping non-corrosive products
119 - Low viscosity
40°C/54
≤ 3.10-3 100°C/8.1 < 4.10-5
ALCATEL General-purpose paraffin-based refined mineral oil
- Good ultimate pressure
120 - Low backstreaming
40°C/98
< 1.10-3
100°C/11.1
40°C/100
< 1.10-3
100°C/7.8
40°C/90
100°C/11
Flash point/
self-ignition
temperature
230°C
260°C
212°C
245°C
none
< 3.10-5
none
≤ 2.10-3
40°C/120
< 4.10-5
100°C/12.5
ALCATEL Special hydrocarbon based mineral oil
121
≤ 3.10-3
40°C/64
100°C/10
< 1.33.10-7
ALCATEL Mineral oil distilled under vacuum:
- Pumping corrosive products
200 - Low backstreaming
≤ 2.10-2
40°C/58
100°C/8.5
< 1.10-5
Hydrocarbon-based mineral oil distilled under
ALCATEL vacuum:
Pumping corrosive products
300 - Plasma etching
- Operating at high temperatures
≤ 5.10-3
213°C
244°C
260°C
295°C
268°C
296°C
223°C
40°C/56
< 1.10-5
100°C/8.9
259°C
243°C
270°C
* Ultimate pressure measured according to Pneurop 6602 specifications on 2015 ALCATEL pump.
These values are given as a rough guide only. They may vary according to the type of pump and the pumping conditions.
Requires special preparation of pump (see page 88).
However, the following replacement fluids can be used:
Mineral oil:
ELF MOVIXA PV 100, TURBELF SA 100,
BP CS 100 (BP registered trademark)
SHELL VITREA 100 (SHELL registered trademark)
TOTAL CORTIS PV 100 (TOTAL registered trademark)
INLAND 19, INLAND 20 (INLAND registered trademark)
MR 200 (MATSUMURA registered trademark)
Ester type synthetic oils:
ANDEROL 555 (HÜLS registered trademark)
ANDEROL RCF 96 N (HÜLS registered trademark)
Mineral-based synthetic oils:
ELF BARELF F 100, ELF BARELF C 68 (ELF registered trademark)
INVOIL 20 (INLAND registered trademark)
INLAND TW (INLAND registered trademark)
ELITE Z (CAMBRIGE MILL PRODUCTS, INC. reg. trademark)
Fluorocarbon synthetic oils:
FOMBLIN YL VAC 25-6 (MONTEDISON registered trademark)
KRYTOX 15-25 (DU PONT DE NEMOURS registered trademark)
HALOVAC 100 (HALOCARBON registered trademark)
AFLUNOX 15.25 (SCM registered trademark)
Note: In this case, pump performances may be slightly different from those given in pages 59, 60, 61.
67
Start-up
Recommended oils
Filling with oil
Alcatel 5 to 21 m3/h I, SD, C1 series pumps are tested in the factory with
ALCATEL 120 oil (or Alcatel 119 for USA).
Alcatel 5 to 21 m3/h C2 series pumps are tested in the factory with Alcatel
113 oil.
At delivery, there is some oil remaining in the functional block.
Our pumps are tested in the factory with Alcatel oil: it is recommended
to use the same oil during operation. To change the type of oil, refer to
the Maintenance Chapter, "replacement of type of oil" section.
In all cases, follow the recommendations of the pump specifier for the choice
of oil to be used.
If necessary, carry out the special
preparation procedure for the pump,
then, remove the filling cap and fill with
oil until the oil reaches the highest mark
on the sight glass.
This operation must be performed with
the pump switched off. The second
filling orifice is used if an external oil
filtration device is connected (see
accessories p. 63).
Checking the oil level
To use the pump in optimum conditions, the oil level must be observed and
checked regularly. This level is checked with the pump switched off, hot and
on a horizontal plane.
Oil level sight glass for
“I“, “C1, C2“ series and
1015 SD, 1021 SD pumps
Maximum level
Oil level sight glass for
“SD“ series pumps except 1015 SD,
1021 SD
Maximum level
Minimum level
Minimum level
Note: Optimum pump performance and service life are obtained when the oil
level is between the maximum level and the minimum level.
68
Mechanical connections
For a given application, pump performance, vacuum characteristics,
temperature and reliability depend on the following:
- assembly conditions, accessory filters.
- the oil used.
- mechanical connections: pipes, etc.
- maintenance frequency and quality.
For the assembly of the vacuum circuit, provide the accessories required for
maintenance: valves, purges, etc.
Mounting on a frame
The pump can be mounted on a frame using the 4 attachment holes on the base
and the shock mounts supplied.
Ventilation
Inlet and exhaust fitting
The pump and the motor are each equipped with a ventilation system. During pump
installation, the pump should be placed in ventilated place. Provide a minimum gap
of 25 mm around the pump.
The vents on the pump and the motor should be checked regularly to ensure that
they are not blocked.
Pascal Series ALCATEL pumps are designed for operation at an ambient temperature
between 53°F and 113°F (12 and 45°C).
Remove the protective caps on the inlet and exhaust orifices; these
components prevent foreign bodies from entering the pump during transport
and storage. It is dangerous to leave them on the pump during operation.
The pump inlet and exhaust orifices are equipped with DN 25 ISO-KF end fittings
which can be used to fit various line components made of stainless steel, plastic,
etc. (see Alcatel catalog).
Inlet
Make sure that all the components
or chamber connected to the
pump inlet withstand a negative pressure
of 1 bar relative to atmospheric pressure.
Also make sure that the maximum
excess pressure does not exceed
1 bar relative to atmospheric pressure
(for security).
Exhaust
It is recommended to connect the
pump exhaust to a smoke
evacuation duct.
• If the pump exhaust orifice is
connected to an extraction duct or an
oil mist eliminator, the exhaust stop
valve fitted in the pump exhaust orifice
must be removed.
• At the pump exhaust, the evacuation
circuit must be such that the resulting
excess pressure in the oil case is as low
as possible: for correct pump operation
the max. exhaust pressure recommended
should be 1,125 Torr (1.5 bar) absolute
pressure.
69
Start-up
Note: Special shock mounts, effective against the pump's own vibrations, can also
be used but they do not ensure correct attachment during the transfer of equipment.
In this case, the pump should be clamped onto its support.
Changing position of inlet
and exhaust fittings
Depending on the types of accessories used and the pumping conditions,
these orifices can be fitted vertically on the pump or horizontally as shown on
the diagram below.
Note: The pump is supplied in configuration A.
In.
Exh.
In.
Exh.
B
A
In.
Exh.
C
Disassembling the fittings
In.
Exh.
D
Unfasten the attachment screw from
the end fitting to be removed.
Unfasten the end fitting and remove
it from its housing along with the
O-ring. In the case of the inlet end
fitting, also remove the inlet filter.
30
Horizontal reassembly
70
Remove the attachment screw
from the lateral cap and
using a wide screwdriver, remove the
cap.
- Position the end fitting in the
corresponding lateral orifice taking care
to fit the O-ring.
Attach the end fitting with the screw.
In the case of the inlet end fitting, fit the filter at the bottom of the orifice.
- Close unused orifices with plugs and fasten the screws.
The pumps must be connected to an electrical installation in compliance
with the decree 88-1056 dated 14 November 1988, as well as any local
electrical codes that apply.
• Our products are designed to meet current EEC regulations. Any
modification on the part of the user is liable to cause non-compliance with
regulations or even affect the EMC (Electromagnetic compatibility) performance
and safety of the product. Alcatel cannot be held responsible for consequences
resulting from such an intervention.
• Before any maintenance is performed on a product by a maintenance operator
who has not been trained on safety regulations (EMC, electrical safety, chemical
pollution, etc.), isolate the product from its various energy sources
(electricity, compressed air, etc.).
• As a general rule, it is recommended to protect the motor for 120% of its
nominal current (see page 72).
• Check that the electrical wiring and the voltage selector position of the motor
correspond to the line voltage, before starting up the pump.
• Ensure that the electrical installation conforms with your local safety
requirements. It must include the appropriate fuse and reliable earthground.
Three-phase version
Electrical motor is in accordance with major international standards (UL, CSA, CE)
and offers two voltage ranges:
- Law voltage:
170 V to 254 V 50Hz - 170 V to 300 V 60Hz,
- High voltage: 342 V to 460 V 50Hz - 342 V to 520 V 60Hz.
All three phase motors (protection level IP 43. TEFC type) must be protected by a
customer supplied starter consisting of a suitably rated contactor and thermal overload.
Furthermore, they are equipped with a dry contact (NC) thermal protection which
is available in the therminal box.
Wire the motor according to the line voltage. The connections to be made are
shown on a diagram inside the terminal box or on its lid.
Check the direction of rotation of the motor (direction of arrow located on the
motor cover). For this:
- Remove the protective caps on the inlet and exhaust orifices.
- Vent the pump to atmospheric pressure.
- Switch on the pump for 2 to 3 seconds, with your hand on the inlet orifice
if suction is felt, the wiring is correct.
Otherwise, invert 2 consecutive phases.
The earth terminal must be connected correctly.
Single-phase version
Electrical motor is in accordance with major international standards (UL, CSA, CE)
and offers two voltage ranges:
- Low voltage:
90 V to 132 V 50/60Hz,
- High voltage: 180 V to 254 V 50/60Hz.
Note: single-phase motors (protection level IP 43 - TEFC type) have a thermal circuit
interruptor with an automatic starting device: when the internal motor temperature
reaches a value over the preset limit value, the motor stops.
However, when the motor is cooled, it will start up again automatically.
Before connecting to the mains, check the position of the voltage selector: High
Voltage (HV) or Low Voltage (LV) (see table page 73).
The plug is equipped with a ground pin which must be connected.
The motor rotation direction is set at the factory.
71
Start-up
Electrical connections
External motor protection, electrical protection
Motor characteristics,
connection, protection
The information below is given as a recommendation.
The user must comply with the electrical standards or recommendations (IEC, VDE,
UL, CSA, etc.) applicable in the country in which the pump is used.
The use of electrical protection for the pump motor makes it possible to protect:
- The motor: in the event of excess voltage or rotor blocking, the resulting excess
current may destroy the coil and possibly the start-up system (for a single-phase
motor).
- The pump: in the event of a lubrication fault (contaminated oil, presence of
particles), increased resistance will draw excessive motor current.
Differential thermal circuit-breakers should be used, in which the mechanism contains
an instantaneous disconnection controlled by a bi-metal blade.
Never protect a three-phase motor with fuses not equipped with a differential system:
if three phase motors are powered on 2 phases without a differential system, the
motor could burn.
➧ single-phase motor:
The table on the following page gives the characteristics at start-up (for temperatures
≥ 12°C) and in permanent operation.
In this table, you will find, for each pump, a standard fuse or motor-associated value.
➧ three-phase motor:
The table on the following page gives, for each pump, the electrical characteristics in
permanent operation and the proposed circuit breaker.
Single-phase motors
72
Specific internal protection
Single-phase motors have a thermal circuit switch with automatic starting device (CSA
standard): when the internal motor temperature reaches a value over the preset limit
value, the motor stops. However, when the motor is cooled, it will start-up again
automatically.
Voltage range change
The voltage range can be read beside the motor switch: the dual frequency
single-phase motor can be configured for low voltage (LV) or high voltage (HV).
To change this type of connection, proceed as follows:
- make sure that the motor is not switched on, and the power cord is removed,
- unfasten the 4 attachment screws on the motor upper cover and remove it,
- remove the voltage selector cover marked with the voltage, press on the voltage
selector (position II).
- invert the position of the voltage selector cover in order to show the other voltage
at the outside of the motor cover: “HV“ for high voltages, or “LV” for low voltages.
Check to be sure that the voltage selector has fully latched the rocket switch when
the voltage selector cover is replaced.
- install the upper cover and refasten the 4 screws.
- secure the upper cover as follows:
• Center it on the front motor flange,
• Install the connector between the relay and condensor,
• Close the upper cover,
• Install and tighten the 4 screws, starting installing the screws on the pump
handle side first.
Three-phase motors
The pumps are equipped with 9 wire terminal box motors, the wiring diagram
of the terminals is given as a rough guide only. In the event of doubt, only the
plate in the terminal box should be used as a reference.
Terminal box (9 wires)
LOW VOLTAGE CONNECTION
HIGH VOLTAGE CONNECTION
Parallel coupling
Serial coupling
6
5
4
9
8
7
3
2
1
1
7
4
5
6
9
5
4
9
8
7
3
2
1
7
1
4
5
2
6
9
8
3
Summary tables of various
types of motors
6
3
2
8
The characteristics and ratings of fuses and circuit breaker associated with
standard ALCATEL pump motors, 5 to 21 m3/h, single-phase or three-phase.
Start-up
Electrical connections
Single-phase motor
Current at
Ultimate Pressure (A)
Voltage/Frequency
100V
115V
200V
220V
230V
50/60Hz
60Hz
50/60Hz
60Hz
50Hz
*Start-up
current (A)
Proposed
Fuse protection (A)
50 Hz
60 Hz
50 Hz
60 Hz
Standard
Type aM**
5.0
3.5
4.0
2.0
2.0
30.0
34.0
35.0
19.0
20.0
20/20
20
10/16
16
10
8/6
6
4/4
4
4
2.5
3.5
14.0
8.0
* Temperature = 12°C
** aM : Motor-associated type fuse
Three-phase motor
*Start-up
current (A)
Voltage/Frequency
Proposed Circuit
Breaker protection (A)
50 Hz
60 Hz
50Hz
60Hz
3.1
3.5
4.0
2.8
3.1
4
4.5
5
3.5
4
Low voltage
200V
220V
240V
280V
50/60Hz
50/60Hz
50Hz
60Hz
3.7
4.5
High voltage
380V 50Hz
415V 50Hz
480V 60Hz
1.5
1.6
2
2
1.6
2
* Temperature = 12°C
73
74
Operation
Preliminary precautions
• The performance and operating safety of this product can only
be guaranteed if it is operated according to normal conditions of
use.
• The vacuum pump is also a compressor: incorrect operation may be
dangerous. Study the user manual before starting up the pump.
• The pumps are designed to prevent any thermal risk for user safety.
However, specific operating conditions may generate temperatures which
may justify particular attention on the part of the user > 70°C).
• Product tightness is guaranteed for normal operating conditions when the
product leaves the factory. It is the user’s responsibility to maintain the level
of tightness particularly when pumping dangerous products (on C series
pumps).
Be sure to fill the pump with oil (see page 68).
Operating
temperature
- At start-up, before switching on the motor, check that the oil bath
temperature is greater than 53°F (12°C).
- The ambient operating temperature for the pump must be between 53°F
(12°C) and 113°F (45°C).
- Under these conditions, the stabilized pump temperature (at the front of the oil
case) will be between 140°F and 158°F (60 and 70°C) (depending on
operating conditions).
Before starting-up
the pump
Operation
Special case - Synthetic oils
Synthetic oils are much more viscous when cold than mineral oils.
Do not start up the pump at ambient temperatures below 59°F (15°C).
For the same reason and to facilitate lubrication of the pump, pour a few
drops of oil (l to 2 cm3) through the inlet orifice before starting.
Check that the exhaust orifice is not blocked.
In certain cases, when the pump is started up in cold ambient conditions, or
with slightly contaminated oil, the current after start-up may remain high until
the oil in the pump is heated up. These conditions are sufficient for the
internal thermal protection to be activated, making start-up impossible (see
pages 72 & 73).
75
Start-up
• When using a three phase motor, check the direction of rotation of the
motor (see electrical connections start-up chap. page 71).
• Check the oil level (See page 68).
• Start-up the pump.
• Allow the pump to run for one hour with the inlet blocked at ultimate
vacuum:
During this operation, make sure that the oil circuit is operating. Remove one
of the oil fill plugs to listen to the pump.
At start-up, the oil enters the lubrication circuit of the vacuum pump. As a
result, noises will be heard (first irregularly, then regularly) which will reduce
as the oil heats up. These noises will no longer be heard when the fill plug
has been replaced.
Under normal temperature conditions, the oil circuit should start less than
1 minute after start-up (this time may vary with the type of oil and its degree
of contamination).
• Using the gas ballast:
- to decontaminate the pump’s oil;
- to accelerate heating. It is normal for the oil level to change (as can be seen
through the oil sight glass) when the pump is hot, due to expansion of the oil,
starting of the oil circuit and the operating conditions of the pump (inlet pressure). If necessary, stop the pump and adjust the oil level between the "max"
and "min" levels on the sight glass.
In the event of a malfunction, refer to the "Troubleshooting and corrective
actions" table (page 84).
76
Operation of gas ballast
Regeneration of
pump oil
In a pump stored with the same oil for a long time, condensed vapours may
contaminate the oil bath and affect performance. This is also the case after
pumping vapours and when the oil appears cloudy or discolored through the
sight glass.
- Run the pump, shutting it off from the system at the inlet by a valve or a
plug.
- Open the gas ballast and allow the pump to operate for 1/2 hour to
1 hour, or longer if the oil remains cloudy. This operation accelerates the
temperature rise of the pump while eliminating residual vapours present in
the oil bath.
Choice of pump and system
Choice of oil
Assembly
To pump with condensable products, it is necessary to operate with a hot
pump. For this, isolate the pump from the system and allow it to operate for
1/2 hour with the gas ballast open, or 1 hour (if possible) with the gas
ballast closed. When the oil bath is hot, the condensation of vapours in
the pump is reduced or prevented.
The pump’s capacity to eliminate condensable vapours is related to their type,
the pump temperature and the quantity of air introduced by the gas ballast.
Thus, for high vapour levels in a system, the single-stage pump is more
suitable. However, when not pumping vapours, its ultimate pressure is higher.
Care should be taken to limit the inlet pressure of the pump to its maximum
admissible water vapor pressure with the pumped product. This is obtained
by reading the pump characteristic table for water vapour.
The use of cold traps or condensers are recommended when large quantities
of vapours are to be extracted. Excessively intense or prolonged pumping may
cause the products condensed in the trap to be evaporated a second time.
Choose an oil which facilitates the separation of pumped products which may
be condensed in the oil bath (anti-emulsion oil for water-based compounds,
etc.) (see page 67).
The condensation of vapours at the pump exhaust is reduced if:
- the pump and oil temperature are high;
- the pressure at the exhaust is as low
as possible (removal of the oil mist
eliminator...);
- the condensates are collected
In.
separately from the oil bath and do not
block the exhaust duct.
Exh.
For this:
- avoid using any vertical ducting which
promotes the condensation of products
and the return of these products to the
pump.
- use a condensate collector;
77
Operation
Pumping condensable
vapours
Assembly (continued)
- we do not recommend an oil mist
eliminator when pumping condensable
vapors: if it is essential, do not connect
it directly to the pump exhaust but place
it outside the condensation zone.
- remove the stop valve from the pump
exhaust;
- if possible, connect the exhaust to a
mechanical device creating a negative
pressure from 0.1 to 0.2 bar.
In.
Exh.
Condensate
trap
Vapor pumping procedure
78
- Valve off the pump from the system and increase the pump temperature,
30 minutes with gas ballast (see page 76).
- Start pumping and check the oil level:
• the level drops, oil is being lost;
• the level rises, condensates have been added to the oil.
- After pumping, regenerate the oil using gas ballast if it is cloudy or
discoloured.
• if the level is too high, change the oil and regenerate.
- Change the oil as soon as inlet pressure characteristics drop and are not
improved by regeneration.
Purges for pumping condensable, corrosive, and
hazardous gases
All pumps models
Purges
Oil case purges
The use of vane pumps may result in pumping gases or vapours which are
flammable or that could contaminate the oil. In this case, these products must
be diluted using purges supplied with dry gases, such as nitrogen to avoid
undesirable reactions.
For this purpose, a filtered dry nitrogen supply or other inert gas with the
same characteristics is required:
- condensation point < 22°C,
- dust < 1µm,
- minimum absolute pressure 2 bar.
The purge dilutes pumped gases with a neutral gas:
it makes it possible to limit corrosion in the oil case, condensation and
accumulation of gases in dead spaces of the pump.
Connect the nitrogen supply to one of the unused filling plugs on the oil case
(BSPP 1/8 Gas connection).
Set the nitrogen pressure to approximately 1,2 PSIG (0.1 relativ bar) (flow 50
to 300 SCCM) and the flow rate so as to satisfy the dilution conditions.
Caution: do not generate an excess pressure > 14 PSIG (1 relativ bar).
Use of purge with gas ballast
A neutral gas supply can also be connected via the gas ballast (BSPP 1/8
Gas connection).
Purge with gas ballast
Due to the danger represented by the accidental opening of the gas ballast
on a C2 series pump, manual operation of the gas ballast has been disabled.
However, it is possible to disassemble it and connect it directly to a neutral
gas line (BSPP 1/8 Gas connection).
The nitrogen flow rate should be from 900 to 1000 l/h with a pressure of
1 to 1,2 PSIG (0.05 to 0.1 relativ bar).
Use of the bubbler
The bubble device is composed of an air tube with several holes, located at
the bottom of the oil case, which releases bubbles of neutral gas in the oil. In
this way, the oil is saturated with neutral gas, which reduces its capacity to
dissolve pumped gases. The bubbles of neutral gas released make it possible
to eliminate the volatile vapours or acids condensed in the oil. The bubbler
flow also lowers the pumps temperature which slows corrosion.
Setting
The gas flow rate is adapted according to the application and the installation,
taking the following criteria into account (flow 60 to 500 SCCM):
• When pumping high quantities of gas, a highly corrosive gas or an easily
condansable gas, it is recommended to use a high nitrogen flow rate.
Caution ! It is assumed that a sufficient quantity of nitrogen is available.
• The pump exhaust circuit must be such that, for discharged flow rates,
pressure drops do not cause an abnormal excess pressure in the oil case.
• The nitrogen flow rate must be such that oil losses have no effect on the
operation of the pump throughout the pumping cycle (the oil level must be
above the lower limit of the sight glass at the end of pumping).
79
Operation
C2 models
Settings (continued)
Run the pump at ultimate vacuum for one hour and set the nitrogen flow rate
as follows (at atmospheric pressure and at 20°C).
C2 Series Pumps
Nitrogen flow rate in l/h
Min
Average
Maxi
60
200
500
Corresponding
absolute pressures (bar)
1.05 to 1.10
Note: these characteristics apply for pumps operating at a constant inlet
pressure (1 to 5 mbar): they are adapted for each case of pumping.
80
Start-up
Start-up the pump at ultimate vacuum. When it is hot, run the nitrogen purge.
Use it from the beginning and throughout pumping.
Stop
When pumping stops, allow the purge to operate for approximately 1 hour
(depending on the quantity of pumped gas) at ultimate vacuum, with the
purge, in order to degas the oil effectively and clean the pump with nitrogen
to eliminate the traces of pumped gases.
Oxygen pumping
In certain applications, mixtures containing oxygen at different concentrations,
or even pure oxygen, are used.
Oils of mineral origin are combustible. Exposure to pure oxygen at high
temperatures may cause them to self-ignite. In addition, they are highly
oxidized during pumping and quickly lose their lubricating properties. Mineral
oils must not be used for oxygen levels of over 21 % in pumped gases. In this
case, perfluorinated synthetic oils must be used, see list on page 67.
The use of these oils requires a special pump preparation (see page 88).
The pump must be completely disassembled and all traces oil mineral oil
removed. Flushing the oil case is not adequate.
In addition, it is strongly recommended not to use fluids such as
tri-aryl-phosphate-ester which are know to cause accidents.
Certain combustible or explosive gases require a higher degree of dilution.
Our International Support Services and Customer Services can advise you to
help solve problems of this kind.
81
Operation
Any accumulation of oxygen in the installation should be avoided and the
oxygen or combustible mixture should be diluted with a neutral gas at the
exhaust: the gas flow rate should be 4 times the oxygen flow rate.
Recovery of oil (high pressure and cycling)
When the pump operates at high pressure, the oil heats up, becomes more fluid
and is flushed out of the functional block by the gas stream.
Oil losses at the exhaust are increased.
For intermittent
pumping
If the pump only operates for a very short time at high pressure,
the lubricating oil is replaced when the pump returns to low pressure. The use of
a oil mist eliminator prevents losses due to intermittent high pressure operation.
For cyclical pumping
If the pump operates at high pressure in a cyclical fashion, oil consumption may
reach sufficiently high levels (according to the pumped volume and pumping
cycle rates) causing the level to drop in the oil case.
There is then a risk of seizure due to a lack of oil. In addition, the high flow of
gas passing through the eliminator prevents oil from returning to the oil case.
In order to pump in these conditions, the pump must be equipped with an OME
25 HP type oil mist eliminator and an ODK oil draining kit, which enables oil
recovery via the gas ballast.
Cyclical pumping:
ODK type oil recovery device
In.
Exh.
OME 25 HP + ODK 1
Device is not tight
when switched off.
For continuous pumping at
high pressure
82
In.
Exh.
OME 25 HP + ODK 2
An electrovalve ensures
tightness when switched off.
In this case, or when very large volumes (requiring several hours of pumping)
are being pumped, it is recommended to recover the oil via the pump inlet.
In this case, please consult Alcatel directly.
Maintenance
For normal operation, the maintenance of ALCATEL 5 to 21 m3/h series
pumps only require regular oil changes.
Before any draining or maintenance operation, check the pumping
conditions of the installation: potential toxicity, corrosion or radioacitivity
of pumped gases.
Depending on the case, we recommend:
- to purge the pumping installation with dry nitrogen before maintenance;
- wear gloves, protective goggles and, if necessary, a breathing apparatus;
- ventilate the premises well and disassemble the equipment under a suction
hood;
- not to dispose of used oils and residues using the standard system and, if
necessary, have them destroyed by a specialized company.
After a complete maintenance operation, it is recommended to perform
a helium leak tightness test.
Maintenance
General precautions
83
Troubleshooting and corrective actions
Incidents
The pump is not running
Causes
• Incorrect motor power supply.
• Temperature too low.
• Gumming of seals after
prolonged storage.
• Oil contaminated after pumping.
• Motor coupling damaged.
• Pump seized, due to a stopping
after pumping in difficult
conditions (no draining or
flushing).
The pump does not start
• Oil cold.
• Insufficient oil in the oil case.
• Oil contaminated.
• Oil pump inlet partially blocked.
• Lubrication holes blocked.
• Vane or spinner-cam (SD models)
damaged.
• Incorrect anti-suckback system
assembly.
The vacuum pump does not
produce a vacuum
Check the power supply.
Reheat the pump and its oil.
1 - Disassemble the motor and try
to turn the fan manually.
2 - Disassemble, clean the pump,
replace seals, reassemble.
Drain, flush and refill with clean
oil.
Replace by disassembling the motor.
Disassemble, clean, hone the
scratched metal parts (replace them
if necessary) and reassemble.
Warm pump.
Fill up to the level.
Drain, flush and refill with clean
oil.
Drain, and clean the oil pump inlet
duct.
Disassemble and clean.
Replace them.
Repeat the assembly and the setting.
Ultimate pressure obtained: a few mbar, Torr
• Direction of motor rotation
incorrect (three phase).
• Insufficient motor power.
• Inlet filter blocked.
• Insufficient oil in the oil case.
• Oil cold,
oil pump inlet blocked.
• Oil contaminated.
• Oil pump inlet partially blocked.
• One of the LP safety valves is
damaged.
• Part forgotten in reassembly.
84
Corrective actions
Rewire.
Check the power supply.
Clean it.
Add oil.
Warm, disassemble, clean.
Drain, flush and start again with
clean oil.
Drain and clean the oil pump inlet
duct.
Replace.
Repeat the reassembly.
Incidents
The vacuum pump does not
produce a vacuum (continued)
DiagnosticCauses
et remèdes
Corrective actions
Ultimate pressure obtained: a few 10-2 Torr (10-2 mbar)
• Gas ballast adjustment button
open.
• O-ring pinched.
• One of the seals is
damaged.
• One of the HP safety valves is
damaged.
• Lubrication holes blocked.
• Incorrect anti-suckback assembly.
• Part forgotten in reassembly.
Close.
Replace.
Replace.
Replace.
Disassemble and clean.
Repeat the assembly and setting.
Repeat the reassembly.
Accessories
Pump too hot
Check the installation.
• Oil level too high.
• Oil contaminated (presence of
particles).
• Pump not prepared for the oil
used.
• Incorrect motor power supply.
• Motor bearings damaged.
• Motor coupling incorrectly set or
damaged.
• Incorrect fan assembly.
• Incorrect anti-suckback device
assembly
• Vanes damaged or stuck.
Drain and fill with a new oil.
Drain, flush and refill with clean
oil.
Check the pump configuration or
the type of oil.
Check the power supply.
Replace the motor after inspection.
Check the setting.
• Ambient temperature too high.
• Pump placed in a poorly
ventilated place or vents
blocked.
• Operation at high pressure
P > 22 Torr (30 mbar).
• Excess pressure at exhaust.
• Motor in over-voltage or
Motor in short-circuit.
• Oil contaminated.
• Pump not prepared for the oil
used or oil unsuitable.
Replace.
Check the assembly.
Repeat the assembly.
Replace.
Check the installation.
Check for system leaks.
Check
Check
motor.
Drain,
oil.
Check
of oil.
the exhaust line.
the voltage, replace the
flush and refill with clean
pump configuration or type
85
Maintenance
Noisy pump
• At the pump exhaust, the
installation produces an exhaust
pressure of 1,125 Torr (1.5 bar).
• Oil mist eliminator cartridge
clogged.
Incidents
Considerable oil losses.
DiagnosticCauses
et remèdes
• Oil level too high.
Drain and fill with new oil.
• Operation at high pressure.
Use an HP type oil mist eliminator
with oil recovery.
• Gas ballast open:
1 - accidentally,
2 - pumping of condensable
vapours.
• Leak at oil case seal or at front
seal.
Poor pump tightness when switched
off.
•
•
•
•
•
•
Oil in base.
• Oil case and frame cleaned
poorly during reassembly.
• Oil case seal pinched.
Gas ballast open.
Safety valve damaged.
Incorrect anti-suckback assembly.
O-ring pinched.
Seals damaged.
Oil contaminated.
• Front seal damaged or felt
saturated.
86
Corrective actions
1 - Close.
2 - Use a condensate collector.
Check the assembly and replace
the seals if necessary.
Close.
Replace.
Repeat the assembly.
Replace.
Replace.
Drain, flush and refill with clean
oil.
Remove the base and clean.
Disassemble the oil case, clean the
faces and refit a new seal.
Replace.
Maintenance
Maintenance frequency
An incorrect ultimate vacuum or a reduction in pumping speed are signs that the
oil has deteriorated.
The periodic inspection of the state of the oil is performed by comparison with
a sample of new oil in order to check the level of contamination or deterioration
of the lubricant.
The frequency at which oil is renewed is adapted to the type of operation:
- if the oil is cloudy, this indicates that condensables have been absorbed during
pumping. The oil can be regenerated using the gas ballast (see page 77).
- a thickening of the oil, together with a blackish color and a "burnt" smell
indicate that the oil has deteriorated.
Drain the pump and flush it.
Normally, for a pump operating continuously at a pressure lower than 0.75 Torr
(1 mbar) with a clean gas (dry air), the oil should be changed every 6 months.
This value is given as a guide only. It may be extended to 1 year if the ultimate
vacuum required is sufficient (for primary vacuum pumps).
Similarly, if the pump is stopped frequently for long periods, the oil should be
changed at intervals of 6 months to a maximum of 1 year (oil may become
sticky).
Note: Every pumping operation is different. This oil must therefore be changed at
intervals adapted to each specific application. The use of certain accessories (see
page 63) can reduce the frequency of these maintenance operations.
The draining operation places the contaminated pumping circuit in
communication with the outside atmosphere. Take all necessary steps to
ensure personal safety.
The pump must be drained when hot and after the oil case has been vented to
atmospheric pressure. For this:
- switch off the pump;
- isolate the pump or disconnect from the
installation;
- tilt the pump;
- unscrew the draining plug on the side of
the oil case and the filling plug on the top
of the oil case.
When all the oil has drained, replace the
two plugs temporarily and run the pump
for about 10 seconds leaving the intake
open. Take care with the oil mist which
may appear at the exhaust. This operation
removes the oil from the functional block;
- drain this oil by removing the draining
plug;
- replace the draining plug and fill with fresh oil to the appropriate maximum level
of the oil case oil sight glass through the filling orifice (see page 69).
87
Maintenance
Draining
Flushing
The draining operation can be followed by a flushing operation if the oil is
particularly dirty. This operation requires a volume of oil equal to the capacity of
the pump.
After draining the oil case (see page 87), replace the draining plug. Remove the
intake filter, clean it and replace it. Run the pump at atmospheric pressure, pour
the flushing oil very slowly through the inlet orifice. Take care with oil mist which
may develop at the exhaust. Stop the pump and drain the flushing oil via the
draining plug. Replace the plug and fill with fresh oil (see page 68).
Change of type of oil
ALCATEL 5 to 21 m3/h series pumps are tested in the factory with ALCATEL
120 oil or Alcatel 119 for USA (ALCATEL 113 for C2 series pumps) unless
specified otherwise in the order. When the pump is delivered, a certain
quantity of oil remains in the functional block
Thus, if you wish to use another type of oil, proceed as follows:
Compatible oils
Mineral oil can be replaced by another type of mineral oil. Simply flush the
pump (see above) using the new oil and fill the pump (see page 68).
Mineral oils are also compatible with mineral-based synthetic oils
(see page 67).
Incompatible oils
This is the case when, for example, a mineral oil is replaced by a synthetic oil
(e.g. ALCATEL 120 by ALCATEL 113).
Synthetic oils are considered to be incompatible with each other for practical
reasons: they are expensive. A mixture may cause slight cloudiness of the
resulting mixture, which could be interpreted mistakenly as a sign of
contamination or deterioration.
For the same reasons, clear synthetic and mineral oils (ALCATEL 300), which
are also expensive, are treated as synthetic oils.
These remarks apply to ester or fluorocarbon type synthetic oils and the oils
Alcatel 111, 113 and 300 (see page 67).
Proceed as follows:
- Disassemble the pump completely and clean it (see page 91).
- Reassemble it.
- Connect an oil mist eliminator to the pump exhaust.
- Fill the pump with the new oil (see page 68).
NOTE: to replace a synthetic oil by a mineral oil, proceed as for compatible
oils.
88
Replacement of front seal
In the event of an external oil leak
on the pump, it is necessary to change
the shaft seal on the motor side.
You will need:
- a front seal replacement kit
(see page 90),
- a screwdriver,
- a 3, 4 and 5 mm Allen wrench.
Maintenance
• Stop the pump and disconnect the
power cord motor.
• Disconnect the pump from the
installation to which it is connected.
• If possible, position the pump
vertically, with the motor at the top,
resting on the front side of the oil case; in this position, it is not necessary to
drain the oil case. Otherwise, disassemble the pump in the horizontal position,
resting it on its base, after it has been drained.
• Disconnect the motor by unscrewing the 4 fastening screws, simultaneously
and alternately.
• Remove the motor vertically.
• Unscrew the fan fastening screw. Remove the fan, the key and the support
washer.
• With a screwdriver, remove the shaft sleeve and its O-ring.
• Unscrew the two seal-holder fastening screws and remove the seal-holder.
• Remove the seal from the seal-holder as described on page 95 and discard
it.
• Clean the metal parts. Inspect the wearing side of the shaft sleeve: after
cleaning, the sleeve may show a perfectly normal trace of rubbing (caused by
polishing). Should the sleeve show any signs of indentation or grooves, it must
be replaced.
• Preferably use new parts from the seal kit or set of seals.
• Reassemble the lip seal in its housing as described on page 95.
• Reinsert the new O-ring on the seal-holder.
• Insert the shaft sleeve inside the seal-holder.
• Engage the reassembled seal-holder on its axis and screw onto the frame.
• Insert the O-ring in the shaft sleeve. Position the support washer. Then, install
the key, reassemble the fan and the motor in the reverse order of disassembly.
• Immediately order a replacement maintenance set or kit (see page 90).
89
Tools and consumable products
Special precautions
•
•
•
a
Read the warning at the beginning of the maintenance chapter.
Before disassembling the pump, drain it (see page 87).
All the seals and faulty parts should be replaced, provide for a seal kit or
maintenance kit.
Spare parts
Minor kit
This contains all the seals on the
pump which must be replaced at
each complete disassembly.
Pump models
Part No.
SD
I / C1 / C2
103911
103912
Keep this kit in a dry place, away from heat and light (sunlight and ultraviolet
light), in order to prevent any hardening of the elastomers (see AFNOR
standards: "storage conditions for vulcanized elastomer based products" FD T.46 022).
Major kit
Front seal replacement kit
(parts for shaft passage tightness on
motor side)
Screw kit
Specific tools
Recommended tools
In addition to the seal kit, this kit contains a set of spare parts to perform
maintenance operations on the pump for a two year period, under normal
operating conditions.
Pump models
Part No.
Pump models
Part No.
2010
2015
2021
1005
1010
1015
1021
1005
1010
1015
1021
104614
104615
104616
104617
104618
104619
104620
104622
104623
104643
104644
2005
2010
2015
2021
2005
2010
2015
2021
2005
2010
2015
2021
103902
103903
103904
103905
103906
103907
103908
103909
104976
104977
104978
104979
C2
C2
C2
C1
C1
C1
C1
SD
SD
SD
SD
This kit contains all the parts which
must be replaced in the event of a
leak on the shaft on the motor side.
Pump models
Part No.
SD
I /C1 / C2
065875
065612
This kit contains all screws and
washers for all pump models.
Screw kit
Part No.
All pumps
104919
Pump models
Part No.
All models
052993
Lip seal assembly mandrel.
• Two 5.5 x 100 flat screwdrivers
• Thin spanner: 10 mm on face
10
• Allen wrenches: 2.5 - 3 - 4 - 5 mm
• 12 mm box wrench
90
SD
SD
SD
SD
I
I
I
I
C1
C1
C1
C1
12
2,5
3
5
Disassembling the pump
Disassembling the motor
block
3 Remove the motor cover.
2
5 Remove the motor attachment
screws.
1
3
Replacing the front seal
Disassembling the gas
ballast (1)
Disassembling the oil sight
glass (2)
Removing the oil case (3)
Disassembling the bubbler
(C2 pump)
Remove the fan fastening screw
and the support washer.
Remove the key.
See page 89.
2,5 Remove the gas ballast cover
(2 screws), the adjustment button,
the spring and the sleeve.
Remove the tank feed-through
(2 screws) and its seal.
3 Remove the sight glass cover.
Remove the plate, the sight glass and
the O-ring.
5 Remove the oil case and its
O-ring after removing the 4 fastening
screws.
10
Disconnect the nitrogen inlet.
Remove the nitrogen inlet and
disconnect the connector (4).
Disconnect the nut which secures the
tube on the functional block and pull
the tube (5) to release it from the
frame.
4
5
91
Maintenance
Disassembling the fan
Disassembling the
exhaust valve cover (6)
Disassembling the SD pump
oil system
(except 1015 SD, 1021 SD)
Disassembling the I, C1, C2
pump oil system
also 1015 SD, 1021 SD
5 Remove the cover(s), the
exhaust valves and their springs.
6
The oil system is set in the factory, it
must be reset in the event of
disassembly (see reassembly). However,
the rear flange (7) can be disassembled
without modifying the setting.
Remove the spinner-cam (8) by removing
the circlip.
Do not disassemble the nozzle to clean
it. During the reassembly, check that it is
not blocked by sending a jet of
compressed air through it.
5 Remove the cover from the oil
pump (9). Release the cylinder (15)
equipped with the washer, piston and
spring.
Release the stop valve (10) from its
housing.
8
7
9
12 Unscrew the seat of the stop valve
(11) and remove the O-ring.
Then remove the vane (12), the oil
pump rotor (13) and the Oldham
coupling (14).
9
15
13
12
10
14
11
92
Disassembling the
rear flange
Disassembling the
HP stator and the rotor
(two-stage pumps)
10
Remove the 4 nuts (and washers). Release the flange in the axis.
Remove the stator by sliding it along the
rotor.
Release the rotor
and the vanes.
Disassembling the
LP stator and the rotor
Insert two screwdrivers in the notches
and release the flange in the axis.
Remove the LP stator.
Remove the rotor and the vanes
equipped with the springs.
Maintenance
Disassembling the
intermediate flange
(two-stage pumps)
93
Cleaning components
Cleaning metal components
Solvents are required to clean components.
Standard precautions should be taken in compliance with the manufacturer's
instructions.
After use in mineral or synthetic oil, clean the metal components with a
mineral products based solvent such as AXAREL(1) , CARECLEAN(2),
PREMACLEAN(3), NAPHTEOL(4). Proceed as follows:
• Clean when cold or hot (max. 45°C) by dipping or using a cloth
• Vacuum dry in a ventilated oven
• The component must be cleaned a second time with alcohol.
After use in (perfluorinate) synthetic oil, clean the metal components in a
solvent such as GALDEN S 90™(5) and proceed as follows:
• Clean when cold by dipping or using a cloth
• Dry the components in the air or with compressed air
After use in (non-perfluorinate) synthetic or mineral oil, clean the metal
components with a solvent such as alcohol and proceed as follows:
• Clean when cold by dipping or using a cloth
• Dry the components in the air
• Industrial washing solutions can also be used. The cleaning operation
should be followed by vacuum drying.
Cleaning the oil level sight
glass
I, SD, C2 series pumps
C1 series pumps
When cleaning this plastic sight glass, avoid contact with alcohol or alcoholbased washing solutions. Clean the component with a solvent, but do not
steep it, and rinse it immediately.
The sight glass of these pumps is made of glass.
(1)
(2)
(3)
(4)
(5)
94
DUPONT DE NEMOURS registered trademark
CASTROL registered trademark
DOW registered trademark
Nippon Chemical registered trademark
MONTEDISON registered trademark
Replacement of shaft seals
Specific tools
Recommended tools
Extracting a shaft seal from
its housing
Assembling the shaft seal
• Specific assembly mandrel.
• A support plate (or washer).
• A flat screwdriver
.
With the flange flat, the seal is extracted
using a screwdriver, resting on the plate
(or washer) so as not to damage the
seal housing.
The seal housing and the seal lip are
lubricated with the lubricant used in the
pump.
The flange is resting on a flat surface.
ø 24.5 ± 0.1
5.5 ± 0.2
According to the direction of assembly
specific to each pump, the seal is fitted on
the assembly mandrel.
+0.2
ø 14 0
+0.2
10
à 45°C
Mandrel
Using a press or a hammer, the seal is
inserted in its housing.
They are fitted using the assembly mandrel according to the direction of
assembly below:
HP stator
LP stator
LP rotor
HP rotor
frame
seal-holder
rear flange
median flange
95
Maintenance
Direction of assembly
of shaft seals
Reassembling the pump
Component preparation
• Rest the frame on a flat surface in order to raise the pump.
• All surfaces in contact are coated with oil.
• Observe a nominal clamping torque of 0.8 mdaN (5.8 ftlbs) for the
reassembly of the functional block.
The functional block is reassembled in the reverse order of disassembly.
Reassembling the
median flange
On the median flange, check that the lubrication hole is not
blocked.
New vanes are assembled on the rotors, with the rounded
edges facing outwards.
Reassembling the
exhaust valve cover
Reassembling the bubble
device - C2 series pump
Setting the oil system
Pour a small quantity of oil beforehand around the exhaust valve holes. Position
the exhaust valves, the springs and the exhaust valve covers.
This is performed after the reassembly of the functional block, before fastening
the nuts. Fit a new seal on the tube and connect the assembly to the frame.
Position the tube attachment on the pin and tighten the nut on the rear flange
(maximum clamping torque 0.8 mdaN (5.8 ft lbs)).
In the sleeve, fit the ball and the spring and fasten the connector. Then fasten
the assembly on the side of the frame.
SD series pump (except 1015 SD, 1021 SD):
Offset the spinner-cam (1) by pressing on
the blades.
2
Turn the shaft up to the maximum
displacement of the lever (2).
The distance between the seat (3) and
the stop valve (4) must be 0.9 to 1.2mm
1
(0.035 to 0.047 inch) :
it is set by adjusting the orientation of the lever.
4
3
0,9 to 1,2mm
The stop valve face must be perpendicular to the axis of the oil inlet hole; when
free, the stop valve should rest on its seat: check the parallelism of the lever in
relation to the bearing face of the stop valve seat. Orient the seat to obtain the
correct setting.
I, C1, C2 series pump (also 1015 SD, 1021 SD):
Position the rotor of the oil pump so that the slot is horizontal (or parallel with the
pump base). To turn it, use the fan. Do not forget the Oldham coupling.
96
Reassembling the oil case
Fit the oil case on the frame. Fasten the attachments after making sure that the seal
is positioned in its seal groove (clamping torque 0.8 mdaN (5.8 ft lbs)).
Reassembling the gas ballast
Position the oil case feed-through equipped with the seal in its housing by
centering it on the gas ballast tube. Assemble using the screws.
Equip the adjustment knob with the sleeve and the spring. Position the assembly in
the cover and secure on the oil case feed-through.
Reassembling the oil
level sight glass
Replace the O-ring (included in the seal kit).
Fit the sight glass and assemble with screws (clamping torque 0.3 mdaN
(2.14 ft lbs)).
C1 series pump: The sight glass is made of glass: gradually tighten the
two attachment screws in alternation to avoid placing the sight glass
under stress.
Reassembling the motor
side components
See page 89.
Fit the fan 1/2 sleeve.
Fit the drive key on the motor shaft.
Install the motor coupling sleeve down to the stop on the motor shaft.
Fit the motor on the frame and install the 4 mounting bolts (clamping torque
1 mdaN (7.14 ft lbs)).
Maintenance
Reassembling the
seal-holder
97
98
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