Laboratory-Vacuum-System
Operation Manual
(EN)
Translation of the german original manual
Laboratory-Vacuum-System
Ultimate pressure < 2 mbar
Model:
► LVS 105 T – 10 ef
114184
2017-02-01
Gardner Denver Thomas GmbH
Am Vogelherd 20
98693 Ilmenau
Germany
T +49 3677 604 0
F +49 3677 604 131
[email protected]
www.welchvacuum.com
We are constantly working on the further
development of all our product models.
Reprinting or reproduction of this manual,
including extracts, is not allowed without
the prior written permission of Co. Gardner
Denver Thomas GmbH.
Customer Support +49 3677 604 0
We reserve the right to make changes and
amendments.
All rights under the copyright laws are
expressly reserved by Co. Gardner Denver
Thomas GmbH.
Contents
Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.1.1
3.1.2
3.1.3
3.2
3.3
3.4
3.5
4
4.1
4.2
4.3
5
5.1
5.2
5.2.1
5.3
5.4
6
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.4
6.5
6.5.1
6.5.2
6.5.3
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Important Information ............................................................................................................. 5
General Information .................................................................................................................. 5
Target Groups ........................................................................................................................... 5
Intended Use ............................................................................................................................. 5
Use for an Unauthorized Purpose ............................................................................................ 5
Safety Devices .......................................................................................................................... 6
Meaning of the Warning Notes ................................................................................................. 6
Product Standards, Safety Regulations .................................................................................... 6
Basic Safety Instructions ....................................................................................................... 7
General Information .................................................................................................................. 7
Electricity ................................................................................................................................... 7
Mechanical Systems ................................................................................................................. 8
High Temperatures ................................................................................................................... 8
Hazardous Substances ............................................................................................................. 9
Description ............................................................................................................................ 10
Design and Function ............................................................................................................... 10
Laboratory-Vacuum-System ................................................................................................... 10
Diaphragm Pump .................................................................................................................... 11
Vacuum Controller 521 ........................................................................................................... 11
Areas of Application ................................................................................................................ 12
Example of Application ........................................................................................................... 12
Accessories ............................................................................................................................. 13
Scope of Delivery .................................................................................................................... 13
Technical Data ....................................................................................................................... 14
View of Device and Dimensions ............................................................................................. 14
Intake Pressure / Pumping Speed – Diagram ........................................................................ 14
Device Data............................................................................................................................. 15
Assembly and Installation.................................................................................................... 16
Unpacking ............................................................................................................................... 16
Installation and Connection ..................................................................................................... 16
General Instructions ................................................................................................................ 16
Storage.................................................................................................................................... 17
Scrap Disposal ........................................................................................................................ 17
Operation ............................................................................................................................... 18
Starting Up .............................................................................................................................. 18
Operating modes of the Controller .......................................................................................... 18
Mode 1, Manual operation ...................................................................................................... 18
Mode 2, Automatic operation .................................................................................................. 18
Mode 3, Ultimate pressure ...................................................................................................... 18
Mode 4, Self cleaning ............................................................................................................. 19
Monitoring by Level Sensor .................................................................................................... 19
Calibrating the Pressure Sensor ............................................................................................. 19
Handling .................................................................................................................................. 19
Control panel ........................................................................................................................... 19
Operating via Buttons and Encoder ........................................................................................ 20
Menu Guidance ....................................................................................................................... 20
3
Contents
6.6
6.6.1
6.6.1.1
6.6.2
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.8
7
7.1
7.2
7.2.1
7.2.1.1
7.2.1.2
7.2.1.3
7.2.2
7.2.3
7.3
7.4
8
9
9.1
9.2
9.2.1
Electrical parameters.............................................................................................................. 25
Printed circuit board – Layout and Connections .................................................................... 25
Electrical Interfaces ................................................................................................................ 25
Software-Update .................................................................................................................... 28
Operation using the "WELCH-Control 521" PC program ....................................................... 29
Menu item: „File“ .................................................................................................................... 30
Menu item: „Settings!“ ............................................................................................................ 31
Menu item: „Calibrate“ ............................................................................................................ 33
Menu item: „Factory settings“ ................................................................................................. 34
Table of solvents .................................................................................................................... 35
Maintenance and Servicing ................................................................................................. 36
General Requirements ........................................................................................................... 36
Maintenance Performed by the User ..................................................................................... 36
Maintenance of the Diaphragm Pump.................................................................................... 36
Disassembly ........................................................................................................................... 37
Assembly ................................................................................................................................ 38
Test......................................................................................................................................... 39
Maintenance of the Vacuum Controller .................................................................................. 39
Maintenance of other Components ........................................................................................ 39
Maintenance by the Manufacturer .......................................................................................... 39
Damage Report ...................................................................................................................... 39
Troubleshooting ................................................................................................................... 40
Spare Parts Overview .......................................................................................................... 41
Service kit - Diaphragm Pump ............................................................................................... 41
Spare Parts View.................................................................................................................... 42
Spare Parts List ...................................................................................................................... 43
EC Declaration of Conformity
4
114184
Important Information
1
Important Information
1.1
General Information
The Laboratory-Vacuum-System LVS 105 T – 10 ef conform to the:
2006 / 42 / EC
Machinery Directive
2014 / 30 / EU
Electromagnetic Compatibility Directive
The CE sign is located on the rating plate. Observe the binding national and local regulations
when fitting 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
Laboratory-Vacuum-Systems.
This group of people includes:
Designers and fitters of vacuum apparatus,
Employees working on commercial laboratory and industrial vacuum technology applications and
Service personnel for Laboratory-Vacuum-Systems.
The personnel operating and maintaining the Laboratory-Vacuum-Systems 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 Laboratory-Vacuum-Systems.
The Operating Manual must be kept at the place of use and be available to the personnel
when required.
1.3
Intended Use
The Laboratory-Vacuum-System 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.
Laboratory-Vacuum-Systems 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.
Laboratory-Vacuum-Systems are intended for generating vacuums with ultimate pressures of around 2 mbar.
The in-built diaphragm pump has been designed to have high resistance to aggressive
gases.
The active heating of the pump heads eliminates the need for a gas ballast valve.
–
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.
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5
Important Information
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
fine-wire fuse (slow-blow)
“Hot Surface" label on the pump body - warning notice
completely enclosed casing
identification WEEE
glass components with a transparent plastic coating which protects them against bursting
and cracking, cooler isolated
The Laboratory-Vacuum-System 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
Laboratory-Vacuum-System meet the following product standards:
DIN EN ISO 12100:2011-03
DIN EN ISO 13857:2008-06
DIN EN 1012-2:2011-12
DIN EN ISO 2151:2009-01
DIN EN 60204-1:2014-02
DIN EN 61000-6-2:2011-06
DIN EN 61000-6-4:2011-09
DIN EN 61010-1/A1:2015-04
DIN EN 50110-1:2014-02
Directive 2012/19/EU
Directive 2011/65/EU
China - RoHS II
Safety of machinery General principles for design - Risk assessment and risk reduction
Safety of machinery - Safety distances to prevent hazard zones being reached
by upper and lower limbs
Compressors and vacuum pumps - Safety requirements Part 2: Vacuum pumps
Acoustics - Noise test code for compressors and vacuum pumps - Engineering
method (grade 2)
Safety of machinery - Electrical equipment of machines Part 1: General requirements
Electromagnetic compatibility (EMC) Part 6-2: Generic standards - Immunity for industrial environments
Electromagnetic compatibility (EMC) Part 6-4: Generic standards - Emission standard for industrial environments
Safety requirements for electrical equipment for measurement, control and
laboratory use - Part 1: General requirements
Operation of electrical installations
Electrical and electronics - old devices (WEEE)
Dangerous materials in electrical and electronics devices (RoHS II)
Environment protection law - China 2016-01
The following additional safety regulations apply in the FR Germany:
BGV A3
VBG 5
BGR 120
BGI 798
BGG 919 (VBG 16)
BGR 189 (BGR 195;192;197)
Electrical equipment and operating materials
Power-driven machines
Guidelines for laboratories
Hazard assessment in the laboratory
Accident prevention regulations for "compressors"
Use of protective working clothes
Observe the standards and regulations applying in your country when you use the LVS.
6
114184
Basic Safety Instructions
2
Basic Safety Instructions
2.1
General Information
CAUTION !
Warning notices must be observed. Disregarding them may lead to damage to health
and property.
The Laboratory-Vacuum-System must be operated by personnel who can detect impending
dangers and take action to prevent them from materialising.
The user/operator is responsible for correct installation and safe operation.
Prevent condensate collecting in the pump. When pumping vapours which tend to condense
please ensure that the pump is at operating temperature and that the gas ballast valve is
open when the pump is switched on.
If there is more than one load on one LVS, they must be separated by check valves.
The manufacturer or authorized workshops will only service or maintain the Labo-ratoryVacuum-System 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 Laboratory-Vacuum-System are legally binding parts of the contract.
Contaminated laboratory vacuum systems 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 LVS 105 T - 10 ef are supplied for operating mode S1. Please note that the testing must
be repeated in accordance with DIN EN 0105, DIN EN 0702 and BGV A2 in case of portable
devices.
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.
All interfaces are under low voltage according to DIN VDE 0100-410.
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7
Basic Safety Instructions
2.3
Mechanical Systems
Improper use can lead to injuries or material damage. Observe the following instructions:
Only operate the LVS with hoses of the specified dimensions.
The maximum permissible pressure of 1 bar at the suction connection must not be exceeded.
Solid particles in the pumping medium impair the pumping action and can lead to damage. Prevent solid particles penetrating into the pump.
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 laboratory vacuum systems.
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.
When handling glass vessels, pay attention to:
Only use glass vessels with a plastic coating for splinter protection.
Only use vessels which are suitable for use with vacuums (e.g. round-bottomed flasks).
We recommend that only glass components supplied by the manufacturer are used.
Do not use Erlenmeyer flasks.
Before each evacuation, check glass vessels for damage which might impair their
strength, replace them if any such damage is found.
Do not heat glass vessels on one side only.
Retardation of the boiling of the gases to be pumped can lead to a sudden pressure increase. Prevent retardation of boiling by means of suitable measures (e.g. turbulent agitation).
2.4
High Temperatures
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.
8
114184
Basic Safety Instructions
2.5
Hazardous Substances
WARNING !
The operating company bears the responsibility for the use of the laboratory
vacuum system.
Hazardous and harmful substances must be effectively prevented from escaping!
Ensure that all lines and connections are leak tight.
Handle exhaust gases in accordance with the requirements of the emission protection regulations.
Do not operate the Laboratory-Vacuum-System without a separator. The separator can only
be emptied after the apparatus has been vented.
Dispose the condensate in an environmentally compatible manner!
Do not operate the Laboratory-Vacuum-System without a separator without a emission condenser. The separator can only be emptied after the apparatus has been vented.
Dispose the condensate in an environmentally compatible manner!
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
The user must assess the process in accordance with Directive 1999/92/EC (ATEX 137) for
the extraction of explosive gas/air mixtures inside or outside a similar environment. In accordance with the requirements indicated by this assessment, a suitable device must be selected which fulfils the specifications of Directive 2014/34/EU.
Aggressive Gases
The diaphragm pump used is highly resistant to chemicals. In the case of particularly aggressive gases or products, the materials used for the pump parts in contact with gas must
be assessed (as described in chapter 3.1.2).
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.
The diaphragm pump, control valves and hose lines can be damaged by poisonous or aggressive gases.
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
Regulations 2016/1179/EU
(classification, packaging and identification of hazardous sub-stances),
Manufacturer's safety data sheets on hazardous substances.
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9
Description
3
Description
3.1
Design and Function
3.1.1
Laboratory-Vacuum-System
A rotary evaporator can achieve its full performance capability as a result of precisely controlled, analytically pure vacuum.
The Laboratory-Vacuum-System LVS 105 T – 10 ef has been specifically designed to meet
these requirements.
The chemically resistant diaphragm pump MPC 104 T provides an oil-free, dry and thus analytically pure vacuum to an ultimate pressure of < 2 mbar. The maximum pumping speed of
3
1.2 m /h is matched directly to the actual requirement by the speed control of the powerful
and extremely quiet 24 V EC drive of the diaphragm pump.
The LVS thus always works optimally. With a high quantity of gas under full power = maximum speed, with a low quantity of gas correspondingly slower. That protects the diaphragm
pump, reduces the already low energy consumption, and considerably reduces the noise
level. At the same time, this desired reduction of the stroke rate leads to a reduction of the
pump temperature and to increased condensation. To prevent this, the pump heads are held
at a constant temperature by a control system.
Investigations have shown that this eliminates the need for a gas ballast valve. A gas ballast
valve (see chapter 3.4) can be optionally mounted if this is not possible under certain conditions.
The new design, the functional and well-arranged structure, and the smaller dimensions allow trouble-free, time-saving cleaning.
The LVS 105 T – 10 ef is supplied complete with a suction-side separator and a pressureside emission condenser in the form of an intensive cooler.
10
1
Suction side connection
hose nozzle for hose DN8
2
Separator (round-bottomed flask) suction side
3
Casing
Diaphragm pump MPC (see fig. 2)
(fitted in the casing) with main switch
4
Control level Vacuum Controller 521
with integrated grip recess
5
Emission condenser KD 500/1
vacuum-isolated
at the pressure side with safety valve and
cooling water connections, outgoing air
connection (hose nozzle for hose DN8)
6
Separator (round-bottomed flask)
outgoing air side
7
Cooling water (feed flow / back flow)
8
Connection outgoing air
hose nozzle for hose DN8
9
Main switch (power)
10
Main device fuse
11
Plug for non-heating device power cable
(main in)
12
PC connector (RS 232)
13
Connector socket for water valve (optional)
14
Inert gas connection DN 4
Fig. 1a LVS - Front view
Fig. 1b LVS - Rear view
114184
Description
3.1.2
Diaphragm Pump
Design:
The diaphragm pump MPC 104 T
consists of a pump body and a drive
motor.
The pump body consists of a drive
shaft and four pump heads.
Each pump head contains the form
diaphragm and the work valves.
The two pump heads are arranged
opposite each other.
In a three-stage (T) diaphragm pump,
the two pump heads are connected
in parallel, two further pumps in
series.
The pump heads are driven via an
eccentric shaft with a connecting rod.
Fig. 2 Diaphragm pump MPC 104 T
Function:
Motor, eccentric shaft and connecting rod set the form diaphragms in stroke movement.
This changes the size of the space between the form 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.
Materials of the Medium-affecting Pump Parts:
Component
Seal
Screw Fitting / Connecting Elements
Valve
Form Diaphragm
Vacuum Hose
Connection Head / Pump Head
*)
3.1.3
Materials
EPDM
PP, PVDF
PEEK
Elastomer + PTFE Layer
PTFE
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)
Vacuum Controller 521
Into the existing hardware of the vacuum controller 521 a particularly developed software
was installed.
Technical Data: see chapter 4
Operation: see chapter 6
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11
Description
3.2
Areas of Application
The Laboratory-Vacuum-Systems are intended for:
vacuum filtration, vacuum distillation and vacuum drying
use in physical and chemical laboratories in trade and industry
pumping and compressing neutral and aggressive gases and vapours
generating a vacuum up to an ultimate pressure of 2 mbar
Special Designs:
Special LVS can be supplied after consultation with the manufacturer or for a corresponding supply contract.
Motors for different voltages.
3.3
Example of Application
1
LVS 105 T – 10 ef
2
Suction line *
3
Outgoing air
4
Rotary vaporizer *
5
frequency-regulated
pump motor
6
Coolant system,
un pressurised run
back *
7
Water valve WV *
Fig. 3 Example of Application
* Not included in the scope of delivery
12
114184
Description
3.4
Accessories
Operating Software „WELCH-Control 521“ on CD
to connect the vacuum controller to the PC
Order No. 620637
Vacuum Control Box VCB 521 cv
Table model as digital, chemical-resistant vacuum regulator.
With integrated sensor, airing -, control- and check valve.
Connection vacuum apparatus: DN 8
Connection vacuum pump: DN 8
Connection inert gas: DN 4
Connection water valve: Binder plug 4-pole 24V DC
Order No. 600053
Gas Ballast Valve
Order No. 400599-01
Inlet Fitting PP, DN 16 KF – ¼“
Order No. 710116
Mains Connection Cable IEC with Plug Type 12 (CH)
for LVS … in 230 V
Order No. 825877
3.5
Scope of Delivery
The scope of delivery is specified in the supply contract.
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13
Technical Data
4
Technical Data
4.1
View of Device and Dimensions
(H)
(D)
(W)
Fig. 4 View of Device, Dimensions see chapter 4.3
4.2
Intake Pressure / Pumping Speed – Diagram
Fig. 5 Intake Pressure / Pumping Speed – Diagram
14
114184
Technical Data
4.3
Device Data
Parameter
Pumping speed 50/60 Hz
at speed of 1500 rpm (DIN 28432)
Ultimate pressure at speed of 1500 rpm
Max. inlet pressure
Max. outlet pressure
Intake and pressure ports
Ambient temperature
Max. Operating gas temperature
Bearing
Reference surface sound pressure level
DIN EN ISO 2151
Voltage / Frequency
(generally with motor protection switch, switch and cable)
Power
Operating mode
Type of protection DIN EN 60529
Motor / Class of insulation DIN EN 600034-1
Fine fuse (slow-acting)
Dimensions (W/D/H)
Weight
Order no.
Vacuum Controller :
Sensor interface :
- Scan frequency
- Resolution ADC
- Power supply
- Sensor signal
Display of pressure
Switching accuracy / control accuracy
Switching outputs :
- Voltage level
- Control power, single
- Control power, total
Switching outputs used :
- Ventilation valve
- Water valve
Output frequency changer :
- Voltage level
- Resolution DAC
Communication interface
Power consumption - controller in normal operation
Fuse (internal controller)
Sensor :
Sensor type
Measuring range
Accuracy in sum
linearity, hysteresis and reproducibility
Power pack :
Operating voltage
Operating frequency
Output voltage
Output current
Output power
Connections :
IN/OUT :
RS 232
OUT:
Water valve
Connection: Inert gas
Data
Unit
1.2
20
2
1
1
Hose nozzle DN8
for hose inside diameter 8 mm
+ 10 to + 40
+ 60
maintenance-free
m3 / h
l / min
mbar
44
bar
°C
dB (A)
90 – 260, 50 / 60
V-AC, Hz
90
S1
IP 20
F (160°C)
T 6.3
250 / 260 / 435
9.5
114184
W
3 conductor interface
10
12
+ 5 stabilized
0.5 to 4.5
(optionally also 4..20 mA per jumper possible)
digital or graphic
±1
digital
0; 24
2 x 6
24
2
x
x
analog
0 to 10
16
RS 232
max. 15 (depends upon the control power)
5
integrated
ceramic sensor
1 - 1100
< ± 0,3 % FS
integrated
90 – 260
50 / 60
24
1.25
100
SUB-D plug 9-pole
Binder socket 4-pole, 24 V DC
integrated, Hose nozzle DN 4
A
mm
kg
Hz
Bit
V
digit
V
W
V
Bit
W
A
mbar
V-AC
Hz
V DC
A
W
-
The information presented in this material is based on technical data and test results of nominal units. It is believed
to be accurate and reliable and is offered as and aid to help in the selection of products.
It is the responsibility of the user to determine the suitability of the product for the intended use and the user assumes all risk and liability whatsoever in connection therewith. Gardner Denver Thomas GmbH does not warrant,
guarantee or assume any obligation or liability in connection with this information.
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15
Assembly and Installation
5
Assembly and Installation
5.1
Unpacking
Carefully unpack the Laboratory-Vacuum-System.
Check the system for:
Transport damage,
Conformity with the specifications of the supply contract (type, electrical supply data),
Completeness of the delivery.
Please inform us without delay if there are discrepancies between the delivery and the contractually agreed scope of delivery, or if damage is detected.
Please take note of the general terms of business of the manufacturing firm.
In case of a claim under warranty, the device must be returned in packaging that is
suitable for protecting it during transport.
5.2
Installation and Connection
Set the Laboratory-Vacuum-System on a flat and horizontal surface.
Remove the protective caps on the connections.
Connect the intake connector of the LVS to your apparatus with vacuum hose DN 8.
Connect the cooling water tube to the emission condenser.
The cooling water return flow must be unpressurized.
Connect the air exhaust to the central air exhaust system.
Connect the Laboratory-Vacuum-System to the power supply.
Check that the connections are properly seated.
5.2.1
General Instructions
CAUTION !
Observe the basic safety instructions when using the LVS.
The pressure device regulation 2014/68/EU must be observed if devices with an
overpressure of 0.5 bar or more are connected.
The pressures at the suction and pressure sides of the diaphragm pump at the time it is
switched on must correspond to the specifications of DIN 28432.
In order to avoid pumping speed losses, all the vacuum connecting hoses used should have
a large nominal diameter and should be laid out so that the lengths are as short as possible.
Avoid rigid connections. They must be assembled carefully in order to achieve a low leak
rate.
We recommend fitting non-return valves (order no. 720327) for applications with several
consumers.
16
114184
Assembly and Installation
The upstream separator on the suction-side serves to protect the diaphragm pump and the
vacuum sensor from condensates and mechanical contamination. It must be used for an application.
The level in the separator must be monitored and the separator emptied regularly. The currently valid regulations must be observed when disposing of waste. The separator on the
suction-side can only be removed and emptied after the system has been vented.
The emission condenser enables a 100 per cent recovery of the solvents led through the
vacuum pump. Cooling takes place via the DN 8 hose nipples. Ensure that the outflow is
clear. The safety valve is located at the gas inlet. The rubber valve seal must be checked
for cracks at regular intervals and exchanged when necessary. The exhaust connection must
be unpressurized. The exhaust can be led off through a DN 10 hose into a suitable evacuation duct. There is common solvent reclamation for all the connected systems. Mixing media
must not lead to a hazard for persons, the environment of for the equipment.
In case of soiling by solid matter, the pump heads must be opened and the entire interior
space, including valves and diaphragm, cleaned mechanically (see chapter 7.2.1).
5.3
Storage
The pumps are to be stored in a low-dust, interior room within the temperature range from
+ 5 to + 40 °C and at a relative air humidity < 90%.
Leave the protective elements on the intake and exhaust ports. Another equally good protection may be used.
5.4
Scrap Disposal
CAUTION !
The Laboratory-Vacuum-Systems must be disposed of in accordance with the
2012/19/EU guideline and the specific national regulations.
Contaminated pump systems must be decontaminated according to the laws.
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17
Operation
6
Operation
6.1
Starting Up
The LVS is switched on by the rocker switch POWER located on the device.
The device is ready for operation after a short initializing routine, during which a signal tone
sounds and all light elements light up briefly.
6.2
Operating modes of the Controller
The following modes are available:
0
1
2
3
4
6.2.1
-
STOP
Manual operation
Automatic operation
Ultimate pressure
Self cleaning
Controller is inactive and can be configured
With specification of the setpoint and, if required, lowering
The setpoint is detected automatically from the pressure development
Pumping out at maximum motor output
Motor runs for 2 minutes at open ventilation valve
Mode 1, Manual operation
The vacuum valve is closed when the pressure reaches the setpoint. Closed-loop control between the set hysteresis and the setpoint has been started.
For operation with a frequency converter, an analog voltage is output, which controls the
speed according to the standard tolerance. If the set pressure is not reached, the speed is
automatically adjusted to the pressure loss.
If the pressure is actively lowered, after the setpoint has been reached for the first time, it is
lowered still further within a settable timeframe. The number of ramps can be set up to a
maximum of 3. Each ramp starts with a holding time. The setpoint then falls in one step to
the defined starting pressure. The setpoint then falls to the final value over the set time.
After the last ramp, there is a waiting time until the automatic STOP
(0 – the last set pressure is held indefinitely until STOP is pressed manually).
CAUTION !
When setting the ramps make sure that the set value is greater than or equal to the
starting value of the first ramp.
The closed-loop control and hysteresis are always related to the current (reduced) setpoint.
The changed setpoint always applies until the STOP button is pressed, then the configuration value applies once more. When the pressure reduction has finished, the control is
stopped, and the system waits until the STOP button is pressed.
6.2.2
Mode 2, Automatic operation
After selection of the operating mode, the controller starts the evacuation. The pressure drop
per minute is determined during this process. If increases during distillation by incipient boiling of the pressure, then this pressure value is taken as the setpoint and proceeds in the
normal control operation.
6.2.3
Mode 3, Ultimate pressure
By pressing of the key P min evacuation takes place at maximum pump speed until the user
presses STOP.
18
114184
Operation
6.2.4
Mode 4, Self cleaning
The Mode "Self cleaning" is used for flushing the pump and can, if desired, also be carried
out several times in succession. After a waiting period of 5 seconds, the evacuation for 2
minutes (at maximum pump power and open vent valve) is carried out. A aborting the process at any time by pressing the encoder (4) possible.
Self cleaning for Controller-version „cv“: The control valve (cv) remains closed when the
mode Manual or Automatic the "ventilation at STOP" parameter = "0".
6.3
Monitoring by Level Sensor
If the level sensor input is activated (optional), the device goes into STOP status when "Tank
full" is signalled.
6.4
Calibrating the Pressure Sensor
A two-point calibration is made with a comparison measurement device.
Calibration at ambient pressure:
- The diaphragm pump is switched off.
- The venting valve is open.
- The vacuum valve is closed.
- The ambient pressure to set.
Calibration at ultimate pressure:
- The diaphragm pump is switched on.
- The venting valve will be closed.
- The vacuum valve will be open.
- The ultimate pressure to set.
CAUTION !
Instead of measuring the pressure with a comparison measurement device, the ultimate pressure of the pump used may also be input if this is known with sufficient
accuracy (take note of evacuation time).
Ensure that the set pressure is also present at the sensor.
6.5
Handling
6.5.1
Control panel
1
2
3
START - STOP
AIR - ventilation
P min - pressure drop
4
5
Encoder (turn / press)
with marking point on encoder
Display
Fig. 6 Control panel
114184
19
Operation
6.5.2
Operating via Buttons and Encoder
The menu is operated with the encoder.
The menu option is selected by turning the encoder anticlockwise, and then confirmed by
pressing.
A pop-up window is provided for changing numerical values. They are accepted by pressing
the encoder.
The process can be cancelled by pressing START - STOP.
Key:
Meaning
AIR
- Switches the venting valve on if the control is inactive.
- Opens the venting valve as long as the button remains pressed while
control is active.
P min
- Starts "ultimate pressure" mode directly.
START
STOP
- Starts the operating mode currently selected in the main menu and the
corresponding set value.
- Starts the operating mode manually with the currently selected setpoint
in the solvent table, see chapter 6.9.
- Stops the active mode
- Cancels the input in the pop-up window.
- Jumps back to the main menu from submenus.
Encoder:
Meaning
- Turn to select the operating mode.
- Press to select the setting menu for the corresponding operating mode.
- Turn to select menu items.
- Press to open Change pop-up window.
- Turn to change values.
- Press to confirm the changed value.
- When active: Turn to change setpoint.
- When active: Press to accept current value as setpoint.
After the current operating mode has been stopped by pressing STOP, the vacuum valve is
closed.
The venting valve takes the selected status (Option: AIR_ON_STOP).
The originally selected values are retained on start.
6.5.3
20
Menu Guidance
After the start, the main menu appears with its 5 submenus, which are shown below:
Manual
Automatic
Low pressure
Configuration
Self cleaning
114184
Operation
Configuration: language
Configuration: display settings
MAIN-MENU
Manual
MAIN-MENU
Manual
VCZ 521
V 1.15
Automatic
Low pressure
Configuration
Configuration
Self cleaning
Self cleaning
960 mbar
P=
Configuration
language
V 1.15
language
pressure unit
calibrate
calibrate
back
back
960 mbar
contrast
V 1.15
display interval
Español
min. pressure
back
max. pressure
back
960 mbar
Select one of the available languages
V 1.15
P=
960 mbar
Select contrast in the display
Select brightness in the display
Graphic display:
–
–
–
114184
VCZ 521
brightness
Français
P=
960 mbar
display settings
VCZ 521
Deutsch
V 1.15
P=
language
English
VCZ 521
display settings
pressure unit
P=
960 mbar
Configuration
VCZ 521
display settings
V 1.15
Automatic
Low pressure
P=
VCZ 521
Number of measurements per second
Display of min. pressure
Display of max. pressure
21
Operation
Configuration: pressure unit
Configuration: calibrate
MAIN-MENU
Manual
MAIN-MENU
VCZ 521
V 1.15
Automatic
Manual
VCZ 521
Low pressure
Low pressure
Configuration
Configuration
Self cleaning
Self cleaning
P=
960 mbar
Configuration
language
P=
V 1.15
language
VCZ 521
pressure unit
calibrate
calibrate
back
back
960 mbar
P=
pressure unit
mbar
V 1.15
display settings
pressure unit
P=
960 mbar
Configuration
VCZ 521
display settings
V 1.15
Automatic
960 mbar
calibrate
VCZ 521
V 1.15
torr
Cal. Start pressure
VCZ 521
V 1.15
Cal. Low pressure
back
psi
hPa
back
P=
960 mbar
Select measured values for display
P=
960 mbar
Selection of the upper pressure value
Calibration of the lower pressure value
The current value of the comparison measurement
device must always be entered for calibration. The
correction values are then calculated from this. It is
recommended to always make both calibrations.
22
114184
Operation
Self cleaning:
Low pressure:
MAIN MENU
Manual
MAIN MENU
VCZ 521
V 1.15
Automatic
Manual
Low pressure
Low pressure
Configuration
Configuration
Self cleaning
Self cleaning
P=
960 mbar
VCZ 521
V 1.15
Automatic
P=
960 mbar
MAIN MENU
Manual
Self cleaningVCZ
521
V 1.14
Attention: system is aired
Automatic
Start in seconds
Low pressure
Configuration
5
Cancel with <OK>
Self cleaning
P=
960 mbar
MAIN MENU
Manual
Self cleaningVCZ
Automatic
Cleaning in action
521
V 1.14
Remaining seconds
Low pressure
120
Configuration
Cancel with <OK>
Self cleaning
P=
960 mbar
Selection self-cleaning for flushing the pump (Process several times in
succession possible)
114184
Starting the pump system
All control settings are ignored (P min).
23
Operation
Automatic:
Manual:
MAIN-MENU
Manual
MAIN-MENU
VC 521
V 1.15
Automatic
Low pressure
Configuratio
Configuration
Self cleaning
Self cleaning
Parameter for mode:
Parameter
start graphic
start numeric
auto limit
auto speed
hysteresis
auto stop time
No. of pressure ramps
VENTILATE on STOP
Auto Restart
back
Parameter for mode:
Parameter
start graphic
start numeric
auto limit
auto speed
hysteresis
auto stop time
No. of pressure ramps
start cycle 1
cycle time 1
cycle pressure 1
VENTILATE on STOP
Auto Restart
back
960 mbar
Automatic
Value Unit
--------100
50 %
0 mbar
0 sec
0
0
0
-----
Automatic
Value Unit
--------100
50
0
0
1
2
600
600
0
0
-----
%
mbar
sec
mbar
sec
mbar
Select and set the displayed values.
Values that are not required are not displayed.
Parameter display: "Hysteresis" only when
operating without a FU-Motor (Factory settings!)
VC 521
V 1.15
Automatic
Low pressure
P=
24
Manual
P=
Parameter for mode:
Parameter
start graphic
start numeric
Setpoint numeric
setpoint table
hysteresis
auto stop time
No. of pressure ramps
VENTILATE on STOP
Auto Restart
back
Parameter for mode:
Parameter
start graphic
start numeric
Setpoint numeric
setpoint table
hysteresis
auto stop time
No. of pressure ramps
start cycle 1
cycle time 1
cycle pressure 1
VENTILATE on STOP
Auto Restart
back
960 mbar
Manual
Value
--------123
123
0
0
0
0
0
-----
Unit
mbar
mbar
mbar
sec
Manual
Value
--------123
123
0
0
1
2
600
600
0
0
-----
Unit
mbar
mbar
mbar
sec
mbar
sec
mbar
Select and set the displayed values.
Values that are not required are not displayed.
Parameter display: "Hysteresis" only when
operating without a FU-Motor (Factory settings!)
114184
Operation
6.6
Electrical parameters
6.6.1
Printed circuit board – Layout and Connections
X2
X7
X9
Fig. 7 Positions of components and interfaces
6.6.1.1
Electrical Interfaces
Location of interfaces, see Figure 6
The device is supplied with 24 V DC.
X1
Power supply input
Spring contact clamp Wago type 236 / 2-pole
Pin no.
114184
Function
1
GND
2
Primary power supply
Specification
Comment
reverse polarity protected /
blue
24V DC ± 10%, 1.5 A
reverse polarity protected /
orange
25
Operation
X2
LCD Display BP320240E / INTERNAL
FFC Würth 686124144 24-pole / RM 1mm
Pin no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
X3
Specification
Comment
PLC input 1- Level sensor
Spring contact clamp Wago type 236 / 3-pole
Pin no.
Function
1
2
GND
SENSOR 1 or PCL input 1
3
Sensor supply
X4
Specification
I in approx. 10 mA /
Uthreshold approx. 13 V
Corresponds to the voltage at
X1 / protected by 200 mA
self-resetting circuit-breaker
Comment
bl
gn
orange
Pressure sensor 1 input
Spring contact clamp Wago type 236 / 4-pole
Pin no.
1
2
3
26
Function
RESET
/RD
/WR
/CS
A0
D0
D1
D2
D3
D4
D5
D6
D7
VDD
VSS
VLCD
free
SK/X1
D0/X2
D1/Y1
CS/Y2
INT
LED+
LED-
Function
GND
SENSOR 1 Signal
Sensor supply
Specification
0..5 V or 0..20 mA
5 V ± 5% or
Corresponds to the voltage at
X1 / protected by 200 mA
self-resetting circuit-breaker
Comment
blue
Resolution 5 mV / green
Not fused / beige
114184
Operation
The input can be configured with jumper J2:
J2 open:
J2 plugged:
(Default) Voltage: 0..5 V
current 0..20 mA
The sensor supply voltage can be configured with jumper J3:
J3 1-2:
J3 2-3:
24 V needed for current output
5 V (Default) needed for voltage output (depending on sensor data sheet)
X5
PLC output 1 – vacuum valve
X6
PLC output 2 – venting valve
Spring contact clamp Wago type 236 / 2-pole
Pin no.
1
2
X7
Function
GND output
Output
Corresponds to the voltage
infeed at X1 / pnp max. 0.5 A
Comment
bl
with freewheeling diode /
orange
RS232 to the PC
Tub plug connector, 10 pin via FB to
Sub-D-plug, 9-pin (Würth 618009221823)
Function
Pin at tub plug connector
Pin at SUB - D
RXD
TXD
GND
3
5
9
2
3
5
Comment
Analog output 1 – Frequency converter pump speed
Spring contact clamp Wago type 236 / 2-pole
X8
Pin no.
1
2
X9
Function
GND
Output 1
Specification
0..10 V max. 10 mA
Comment
bl
Resolution 2 mV / gr
DEBUG / INTERNAL
Tub plug connector, 10 pin / RM 2.5mm
Pin no.
1
2
3
4
5
6
7
8
9
10
114184
Specification
Function
Specification
Level converter supply
5 V ± 5%
TXD
RXD
GND
5 V level
5 V level
Comment
not fused
27
Operation
6.6.2
Software-Update
The software in the controller can be updated.
It can be re-input by the user. The Fujitsu Flash tool must be used for the Fujitsu 16FX CPU
range.
The factory default settings can be made with a corresponding sequential number input
again (VCZ521_XXX.mhx).
NOTE !
The highest sequential number VCZ521_XXX.mhx is always the most current software version. (currently: VCZ521_115.mhx)
The following steps must be carried out:
Switch off the controller
Call the flash program.
Select the processor MB96F348A/R/Y
Select the quartz frequency 4 MHz
Select the program file
(Most Current Version = Highest Sequential Number, VCZ521_XXX.mhx)
Select the serial interface used (Option / Set Environment)
Start the programming with "Full Operation"
Confirm the Box (PC) „Reset ...“ with OK
Switch on the controller quickly (don't forget timeout of approx. 15 seconds!)
The programming runs automatically.
Switch off the controller again after the OK message
Switch on the controller, and check the functions of the controller
CAUTION !
The controller should be switched off during each interruption.
28
114184
Operation
6.7
Operation using the "WELCH-Control 521" PC program
The "WELCH-Control" enables the vacuum controller to be operated simply and easily from
the PC. The program can be purchased and installed as an option.
Make the cable connection (O-Modem) between PC and controller.
PC program
Most Current Version
Order no.
WELCH-Control 521
V 1.15
620637
CAUTION !
1.) "WELCH-Control 521" is currently version V 1.15.
2.) Flash software is also currently version VCZ521_115.mhx.
3.) Version 1.) and 2.) need not be identical!
The program attempts to find a switched-on controller on COM1 to 20. A COM-Port 1..255
can also be defined as a command line parameter: VCZ521.EXE 2 -> select COM2
If a controller cannot be found, the program goes into offline mode.
Here, a previously saved curve can be reloaded and printed out.
Internal wiring of the controller RS 232 port
PIN
2
3
5
9
Cable colour
white
brown
green
yellow
Connection on the main board
16
17
18
19
RS 232 - RXD
RS 232 - TXD
GND
Flash - sets software update mode if on GND (18)
The following screen appears after the start:
The graph shows the pressure development. Both the chronological and the pressure display range can be set. Data can also be recorded in the PC memory, which can then be
stored as an ASCII file in the "File / Save memory" menu.
114184
29
Operation
In the PSI pressure range, the pressure values for the curve are multiplied by 100 to remain
with integers.
The curve can be printed out by the system printer via the "File / Print curve" menu.
The buttons largely correspond to the buttons on the controller. However, the buttons cannot
be held down.
In active mode, the AIR button can be used with the mouse like on the controller.
Pressing the mouse button opens the valve, releasing it closes the valve again.
However, this only works if the mouse pointer is still on the AIR button.
The Up and Down arrow buttons change the temporary setpoint in active mode.
The OK button only works in active mode, and sets the current pressure as the new set
value.
The Start button starts or ends in the current operating mode.
The Pmin button functions the same as without a controller.
The following menu items can be selected from the menu bar:
File
Measure!
Settings!
Calibrate!
Factory settings!
6.7.1
Menu item: „File“
File
Save settings
Saving the Settings dialog settings in a file
Load settings
Loading the Settings dialog settings from a file
Print settings
Printing out an image of the Settings dialog on the standard printer
Save memory
Saving the pressure data in a file
Load memory
Load the print data from a file
Print curve
Printing out the current pressure curve on the standard printer
Password
Changing the basic setting of the controller is password-protected.
Release is given by inputting the date as a hex number.
Example : 25.03.2015 = 250315 = 3D1CB
(Required for activating the "Calibrate" and "Factory settings" menus and the direct input
of pressure offset und pressure factor in the „Calibrate“ Dialog)
30
Info
Information about the program version
Exit <ESC>
Exit program
114184
Operation
6.7.2
Menu item: „Settings!“
CAUTION !
Settings not required for the selected operating mode are disabled and grayed out in
the display. Appropriate error messages are displayed if the data ranges are exceeded or if inputs are illogical.
114184
31
Operation
Settings required for the control behaviour of the controller:
Designation
Software
WELCH-Control
521
mode
MAIN MENU
language
Configuration,
language
-
32
Explanation
Control panel
at the controller
pressure unit
pressure unit
VENTILATE
on STOP
-
-
VENTILATE
on STOP
Auto Restart
-
-
Auto Restart
manual, setpoint
setpoint
manual, hysteresis
pressure drop,
ramp num
P start, ramp 1 – 3
P lower, ramp 1 – 3
T lower, ramp 1 – 3
auto stop time
hysteresis
No. of pressure
ramps
start cycle 1 – 3
cycle time 1 – 3
cycle pressure 1 – 3
auto stop time
auto limit
auto limit
auto speed
auto speed
read config
-
send config
-
1 - manual
(manual pressure setting for boiling pressure)
2 - automatic
(automatic finding of the boiling pressure)
3 - low pressure
Operation without regulation
There are only the modes meaningful for their application adjustable.
english, german, french, spain
English, Deutsch, Français, Español
mbar, torr, psi, hPa
ON - automatic venting after STOP is on
OFF - automatic venting after STOP is off
0
- closed
1
- open
OFF - no function
ON - The program works automatically continues
after power failure or shutdown.
0
- no function
1
- The program works automatically continues
after power failure or shutdown.
Enter a setpoint pressure value between 0 and 1100
mbar.
Enter a hysteresis value between 0 and 1100 mbar.
Number of possible ramps 1, 2 , 3
in adjusted pressure value (example: mbar)
in second absolute
in adjusted pressure value absolute (example: mbar)
Hunting time in second
Threshold value for detecting the boiling point
(selected pressure unit / min)
0 ... 100%
Reduces the frequency of rotation / rotational speed
to a percentage of the maximum speed
of the pump motor in order to determine the
boiling point smoothly.
Read out current parameter values from the
controller and display in the Settings dialog.
Values changed in the Settings dialog are stored in
the controller. The controller confirms reception with
a signal tone.
114184
Operation
6.7.3
Menu item: „Calibrate“
Calibration:
When search lower point (Pmin) is activated, evacuation is to the lower point. If the pressure does not fall any further, the value can be entered by using a comparison measurement
device and confirmed with Ok. The system is vented and the ambient barometric pressure
entered as the upper point (Pmax). Do not confirm until the value has been established.
If the controller is integrated in a complete system or pump system (LVS), evacuation and
venting take place automatically when the stated buttons are pressed.
The calculated correction values are displayed and can be stored with save.
CAUTION !
Ensure that the set pressure is also present at the sensor.
Designation
Software
WELCH-Control 521
114184
Control panel
at the controller
Explanation
Lower point
CL
at low pressure pressure of comparison measurement device
(at lowest possible pressure, e.g. 10 mbar)
Upper point
CH
at normal pressure (high) barometric pressure
33
Operation
6.7.4
Menu item: „Factory settings“
Designation
Software
WELCH-Control 521
Explanation
Control panel
at the controller
FU motor
not settable
calibration allowed
not settable
analog output active
= present
= not present
read
not settable
Reading the set values
Confirmation of acceptance by signal tone
send
not settable
Transmission of changed values to the controller
Confirmation of acceptance by signal tone
CAUTION !
These settings are adapted by the manufacturer to match the supplied configuration.
The user can change the settings after inputting the password (“File” menu item).
34
114184
Operation
6.8
Table of solvents
Solvent
Acetone
n-amyl alcohol, n-pentanol
Benzole
n-butanol
tert-butyl alcohol, 2-methyl-2-propanol
Tetrachlorometane
Chlorobenzene
Chloroform
Cyclohexane
Diethyl ether
1, 2, -dichlorethane
1, 2, -dichlorethylene (cis)
1, 2, -dichlorethylene (trans)
Diisopropyl ether
Dioxan
DMF
Ethanol
Ethyl acetate
Heptane
Hexane
Isopropyl alcohol
Isoamyl alcohol, 3-methyl-1-butanol
Ethyl methyl keton
Methanol
Methylene dichloride, dichloromethane
Pentane
n-propyl alcohol
Pentachlorpethane
1, 1, 2, 2, -tetrachloroethane
1, 1, 1, -trichloroethane
Tetrachloroethylene
THF
Toluol
Trichloroethylene
Water
Xylol
Formula
C3H6O
C5H12O
C6H6
C4H10
C4H10O
CCl4
C6H5Cl
CHCl3
C6H12
C4H10O
C2H4Cl2
C2H2Cl2
C2H2Cl2
C6H14O
C4H8O2
C3H7NO
C2H6O
C4H8O2
C7H16
C6H14
C3H8O
C5H12O
C4H8O
CH4O
CH2Cl2
C5H12
C3H8O
C2HCl5
C2H2Cl4
C2H3Cl3
C2Cl4
C4H8O
C7H8
C2HCl3
H2O
C8H10
Vacuum (mbar)
for boiling point at 40 °C
556
11
236
25
130
271
36
474
235
no vacuum
210
479
751
375
107
11
175
240
120
335
137
14
243
337
no vacuum
no vacuum
67
13
35
300
53
357
77
183
72
25
Vacuum in Torr/mmHg = X mbar x 0.75
114184
35
Maintenance and Servicing
7
Maintenance and Servicing
7.1
General Requirements
Repairs of the Laboratory-Vacuum-Systems may only be performed by the manufacturer or
authorized workshops.
The prerequisites are a complete and factually correct damage report, and a clean and, if
necessary, a decontaminate device.
The operator may perform maintenance work to the extent indicated below:
7.2
Maintenance Performed by the User
WARNING !
Only perform the work that is described here, and that which is permitted to be done
by the user.
All other maintenance and service work may only be performed by the manufacturer
or a dealer authorized by him.
Beware of the pump parts being possibly contaminated by hazardous substances.
Wear protective clothing if there is contamination.
7.2.1
Maintenance of the Diaphragm Pump
Check the pump daily for unusual running noises and heat building up on the surface of
the pump.
We recommend changing the diaphragm after 10,000 operating hours. The user may
specify that the exchange be made earlier, depending upon the application process.
Check the electrical and vacuum connections daily.
WARNING !
Before opening the unit unplug it from the mains.
Scope of permissible work:
Inspect the pump chambers, diaphragms and valves,
Deposits in the inside of the pump must be cleaned out,
Change the diaphragms, valves and seals.
Tools required:
Tool kit: Order no. 402107, consists of:
Order no. 826801-4
Cross-head screwdriver, size 2,
Order no. 826801-2
Open spanner, size SW 14.
36
114184
Maintenance and Servicing
7.2.1.1
Disassembly
Disconnect the power supply and ensure that it cannot be switched on again.
Open the cover of the casing at the following operational sequence:
1. Release the suction and pressure
side connections to the pump.
Remove the holding bracket (A)
with the separator.
2. Remove the elbow unions (B).
3. Loosen at the device lower surface
the four cross-head M4 (C).
4. Pull the hood off upwards, and
unplug the plug from the display
panel.
Fig. 8 Disassembly - lower surface casing
Open the screw clamps of the hose link on the pump bodies with the SW 14 open spanner.
Remove 2 x 4 screws (1) from each connecting head (2) with a cross-head screwdriver,
size 2.
Lift off the connecting head (2) and the pump head (5). The diaphragm is now freely exposed.
Loosen the defective diaphragm (6) by turning it anticlockwise.
Valves (4) (see Fig. 10) and o-rings (3) are located between the connecting and the
pump head. When dismounting both heads these parts are accessible.
Clean the valves (4) (see Fig. 10), o-rings (3) and diaphragm (6) with a soft cloth and
ace-tone and replace defective items if necessary.
Fig. 9 Disassembly, assembly
WARNING !
Renew defective parts, if necessary! Wear protective gloves!
Parts must be renewed at the intervals stated in this Operating Manual or as specified by the user internally! Do not clean with compressed air!
114184
37
Maintenance and Servicing
7.2.1.2
Assembly (see Fig. 8 - 11)
Place the pump so that the diaphragm (6) is lying in a horizontal position.
Tighten the diaphragm (6) with the torque of 5 - 6 Nm.
Bring the connecting rod (see Fig. 11) and the diaphragm (6) into the central position.
Replace the pump head (5).
Insert the valves (4) (see Fig. 10) and the o-rings (3).
Ensure that they are lying completely flat. Do not insert the burred side facing the sealing
surface.
Replace the connecting head (2) and tighten the 2 x 4 cross head screws (1) with a
torque of 3 - 4 Nm.
Use an analogue assembly sequence for all heads.
Reattach the hose connections with clamping ring screw fittings.
Close the casing in the reverse order.
CAUTION !
Please pay attention to the valve arrangements (C) and (D)!
(A)
(B)
(C)
(D)
-
Connection suction side
Connection pressure side
Valve (400656)
Valve with hole (400656-4)
Fig. 10 Valve arrangement
38
114184
Maintenance and Servicing
7.2.1.3
Test
Connect the system to the electrical supply.
Connect a vacuum measuring device to the intake connector and measure the ultimate
pressure.
If the device is working properly, then the figure stated in the technical data must be attained within a maximum of one minute.
The pump must not make any abnormal noises.
Moving parts must not touch each other.
7.2.2
Maintenance of the Vacuum Controller
The controller is maintenance-free.
In case of damage, return the device to the manufacturer or to an authorized workshop.
7.2.3
Maintenance of other Components
Empty the glass drip pan in a timely manner, observe all disposal specifications as applicable to hazardous substances.
Screw connections must be checked for tightness and tightened when necessary.
Check vacuum hoses for leaks and, if necessary, replace them.
Check that the glass vessels are undamaged and if necessary replace.
Check rubber gasket of the safety valve at the emission condenser and, if necessary, replace it.
7.3
Maintenance by the Manufacturer
Repairs and maintenance going beyond the extent of the work described in chapter 7.2 or
reconditioning or modification may only be performed by the manufacturer or authorized
workshops.
WARNING !
The user shall be liable for the consequences of an incorrect damage report or a
contaminated pump. The statements in the damage report are legally binding.
7.4
Damage Report
You find the form of the damage report to the Download on our web page in the menu "service" and "Downloads". www.welchvacuum.com
If you should not have an entrance to the Internet, you can request the form also gladly with
us, under phone +49 3677 604 0.
WARNING !
Incomplete or incorrectly completed damage reports may endanger the service personnel!
Provide full information about contamination, and clean the pump thoroughly before
handing it over to third parties.
114184
39
Troubleshooting
8
Troubleshooting
Only manufacturing firm and authorized service workshops may work on the LaboratoryVacuum-System and their accessories during the warranty period.
Trouble
Remedy
Cause
by:
Vacuum pump
does not start
Vacuum pump
does not
generate a
vacuum or
only an
inadequate
one
no power supply
Motor defective
Pump body defective
Connected apparatus
and/or
connecting elements
leaking
Qualified
electrician
Service
workshop
User or
Service
workshop
Vacuum pump leaking
40
Identify and seal the leak,
replace the seals and/or
hoses if necessary.
Check the hose
connections between the
pump heads, replace the
hoses and/or fittings if
necessary.
User or
Service
workshop
Exchange of the diaphragm
(see chapter 7.2)
Exchange of the valve
(see chapter 7.2)
General maintenance /
leaning
Cleaning condensates
and foreign objects out of
the valves.
User or
Service
workshop
General maintenance /
cleaning
User
Exchange of the glass parts
or seals
Qualified
electrician
Exchange of the cable(s)
no power supply
Qualified
electrician
Electrical system to be
checked
Electronics / display
defective
Service
workshop
Repair and/or exchange
Incorrect input
User
Diaphragm defective
Valves dirty
Running noise
Vacuum pump dirty
Glass
components
defective
and/or leaking
defective
and/or brittle
Missing
control signal
Exchange
Repair and/or exchange
Repair and/or exchange
Vacuum pump dirty
No pressure
indicated on
the controller
Controller
cannot be set
or programmed
Check electrical installation
Service
workshop
Pump head leaking
Valve defective
Cable(s)
with:
User
Controller defective
User or
Service
workshop
Check the input and
correct if necessary
Switch the device off,
and switch it on again after
three seconds
Replace the controller
114184
Spare Parts Overview
9
Spare Parts Overview
The spare parts list contains all the spare parts and all the information necessary for ordering.
When ordering, please quote the description, quantity, serial number and order number!
CAUTION !
We are not liable for any damage caused by the installation of any parts not supplied
by the manufacturer.
9.1
Service kit - Diaphragm Pump
Designation
Order no.
Service kit
402044
The service kit consists of:
Designation
114184
Piece
Order no.
O-Ring ø 25 x 2
8
829250-1
O-Ring ø 8 x 2
7
829210-3
Form diaphragm
4
828929-1
Valve
6
400656
Valve with hole
2
400656-4
41
Spare Parts Overview
9.2
Spare Parts View
Fig. 11a Exploded view – part 1
42
114184
Spare Parts Overview
Fig. 11b Exploded view – part 2
9.2.1
Spare Parts List
Item
- *)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
114184
Designation
Basic pump MPC 104 T (24 V)
on intermediate plate
- Pump casing
- Rubber element
- O-ring Ø 32 x 3
- Drive 1 complete
- Piston rod with ball bearing
- Eccentric
- Ball bearing
- Drive 2 complete
- Piston rod with ball bearing
- Eccentric
- Drive 3 complete
- Piston rod with ball bearing
- Eccentric
- Ball bearing
- Insulating washer
- Intermediate plate
- Space ring
- Direct current motor
- Shaft
- Adapter plate
- Printed circuit board
- Axial fan
- Cylinder
- Form diaphragm
(consisting of position: 1 - 21)
(consisting of position: 4 - 6)
(consisting of position: 7 - 8)
(consisting of position: 9 - 11)
Piece
Order no.
1
410202-03
1
4
2
2
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
4
400913
400916
829258
400919
400892-01
400915
824963-1
400919-01
400892-01
400915
400919-03
400892-01
400915-03
824963-1
400893-04
410215
400923
826393-1
400915-04
400949-04
825685
829820-1
400914
828929-1
43
Spare Parts Overview
Item
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
-
*)
44
Designation
Pump head, PTFE
Valve
Valve with hole
O-ring EPDM, Ø 25 x 2
Connection head - suction side
Connection head - pressure side
Pressure plate
Threaded elbow joint PVDF, 8 – 1/8“
Vacuum hose PTFE, 8 / 6 x 1 mm
Extension PP, G1/8“ – G1/8“
O-ring EPDM, Ø 8 x 2
Adapter plate
Insulating plate
Power pack 24V DC; 5.4 A
Sensor for built-in controller 521
Threaded elbow joint PVDF, 8 – 1/4“
Semiconductor resistance 20 Ohms, 50 W
Thermal switch (KO 140)
Aluminium-Profile 155
Aluminium-Profile 128
Foot plate
Casing foot
Switch panel
Screw-in socket
Intermediate piece M5/M5
Screw-in socket, modified
Silicone hose (inside Ø = 3 mm x wall thickness 1.5 mm)
Plug for non-heating apparatus - combination
Fine fuse T 6.3 A
Sub miniature round plug - flange box 4 pole
Casing cover
Casing
Holding bracket
Cooler holder
Emission condenser KD 500/1 vacuum-isolated, complete
Retaining strap 53 – 57 mm
Fixing PP, for separator
Hose nozzle PP, DN 8 – G ¼” with lug
Straight threaded joint PVDF 8 – 1/8”
Blind plug
Ball and socket clamp – KS 35
Round-bottomed flask 500 ml – KS 35
Mains connection cable IEC with plug CEE (D)
Mains connection cable IEC with plug BS (UK)
Mains connection cable IEC with plug NEMA5-15 (US)
Piece
Order no.
4
6
2
8
1
1
4
5
1m
2
3
1
1
1
1
1
1
1
2
2
1
4
1
2
1
1
0,3 m
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
400898-02
400656
400656-4
829250-1
400924
400924-01
400935
829936-1
828331
113527
829210-3
400949-01
113526
827397
620052-16
829929
825495
825158
400979
400979-01
410210
829112
114502
828791
160529
160837
H100085
825274
825372
825277-1
114506
113501
114503
114504-01
700183-11
824128
113525-1
710798-06
829919
400568
828845
828839
825885
825878
825903
The "basic pump" module (items 1 – 21) can only be supplied complete under order number
410202-03.
114184
EG - Konformitätserklärung
EC Declaration of Conformity / CE Déclaration de Conformité
DIN EN ISO / IEC 17050
Gardner Denver Thomas GmbH
Am Vogelherd 20
98693 Ilmenau
Germany
(de)
Hiermit erklären wir
T +49 3677 604 0
F +49 3677 604 131
[email protected]
www.welchvacuum.com
unter eigener Verantwortung, dass nachstehendes Produkt aufgrund seiner Konzipierung und Bauart sowie in den von uns in Verkehr gebrachten Unterlagen den nachfolgend aufgeführten EG-Richtlinien und Normen entspricht.
Bei einer nicht mit uns abgestimmten Änderung des Produkts verliert diese Erklärung ihre Gültigkeit.
(en) We (Gardner Denver Thomas GmbH) herewith declare under our sole responsibility that the product described below is in accordance with the following
Directives standards and other technical specifications regarding design and version when delivered from our factory.
This declaration becomes invalid whenever the product has been modified without our consent.
(fr) Nous (Gardner Denver Thomas GmbH) certifions par la présente, que le produit décrit ci-après est conforme, tant dans sa conception que dans sa réalisation,
aux normes de sécurité et d'hygiène exigées par les standards de la CE.
En cas de modification du produit sans notre accord, cette déclaration devient caduque.
Bezeichnung des Produkts (Pumpen / Pumpstände)
Description of product (pumps / pump systems)
Description du produit (pompes / pompe systèmes)
Labor-Vakuum-System
/ Laboratory-vacuum-system / Système de laboratoire à vide
LVS 105 T – 10 ef
114184
Artikel-Nr. / Fabrication No. / No. de fabrication
Baujahr / Year of manufacture / Annee de fabrication
2017
Das Produkt entspricht folgenden Richtlinien und Normen: / The product is in conformity with the following Directives and standards: / Le produit est conforme aux directives et standards suivants:
X
2006/42/EG
2014/34/EU
X
2014/30/EU
X
2011/65/EU
X
2012/19/EU
X
China – RoHS II
Maschinenrichtlinie / EC machinery directive / directive CE sur les machines (17.05.2006)
ATEX-Richtlinie für Verwendungen in explosionsgefährdeten Bereichen, Anhang III / ATEX Guideline for use in potentially
explosive atmospheres, Appendix III / ATEX Directive for applications in hazardous areas, Annex III
Elektromagnetische Verträglichkeit / EC Electromagnetic Compatibility Directive / Directive CE relative à la compatibilité électromagnétique
Gefährliche Stoffe in Elektro- und Elektronikgeräten (RoHS II) / Dangerous materials in electrical and electronics devices
(RoHS II) / Substances dangereuses dans les appareils électriques et électroniques (RoHS II)
Elektro- und Elektronik - Altgeräte (WEEE) / Electrical and electronics - old devices (WEEE) / Électro et électronique - appareils de
contralto (WEEE)
Umweltschutzgesetz – China 2016-01 / Environment protection law / Loi sur la protection de environnement
Angewandte harmonisierte Normen: / Applied harmonized standards: / Standards appliques et harmonises:
DIN EN 1127-1:
2011-10
DIN EN 13463-1:
2009-07
DIN EN 13463-5:
2011-10
Explosionsfähige Atmosphären – Explosionsschutz - Teil 1: Grundlagen und Methodik /
Explosive atmospheres - Explosion prevention and protection - part 1: Basic concepts and methodology /
Atmosphères explosives - Protection contre les explosions - partie 1 : prescriptions et méthodologie
Nicht-elektrische Geräte für den Einsatz in explosionsgefährdeten Bereichen - Teil 1: Grundlagen und Anforderungen / Nonelectrical equipment for use in potentially explosive atmospheres - part 1: Basic method and requirements / Appareils non électriques
destinés à être utilisés en atmosphères explosibles - partie 1 : prescriptions et méthodologie
Nicht-elektrische Geräte für den Einsatz in explosionsgefährdeten Bereichen - Teil 5: Schutz durch konstruktive Sicherheit
‚c’ / Non-electrical equipment for use in potentially explosive atmospheres - part 5: Protection by constructional safety 'c' / Appareils
non électriques destinés à être utilisés en atmosphères explosibles - partie 5 : protection par sécurité de construction « c »
Sicherheit von Maschinen - Allgemeine Gestaltungsleitsätze Risikobeurteilung und Risikominderung /
Safety of machinery - General principles for design - Risk assessment and risk reduction /
Sécurité des machines - / Principes généraux pour l'évaluation des risques et la réduction des risques
Sicherheit von Maschinen - Sicherheitsabstände gegen das Erreichen von Gefährdungsbereichen mit den oberen und
unteren Gliedmaßen / Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs /
Sécurité des machines - Distances de sécurité empêchant les membres supérieurs et inférieurs d'atteindre les zones dangereuses
Kompressoren und Vakuumpumpen - Sicherheitsanforderungen - Teil 2: Vakuumpumpen /
Compressors and vacuum pumps - Safety requirements - part 2: Vacuum pumps /
Compresseurs et pompes à vide - Exigences de sécurité - partie 2: pompes à vide
Akustik - Geräuschmessnorm für Kompressoren und Vakuumpumpen - Verfahren der Genauigkeitsklasse 2 /
Acoustics - Noise test code for compressors and vacuum pumps – Engineering method (grade 2) / Acoustique - norme de mesure des
émissions pour les compresseurs et les pompes à vide - Procédé de classe de précision 2
Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen - Teil 1: Allgemeine Anforderungen /
Safety of machinery - Electrical equipment of machines - part 1: General requirements /
Sécurité des machines - Equipement électrique des machines - partie 1: Prescriptions générales
Elektromagnetische Verträglichkeit (EMV) - Teil 6-2: Fachgrundnormen - Störfestigkeit für Industriebereiche /
Electromagnetic compatibility (EMC) - part 6-2: Generic standards - Immunity for industrial environments / Compatibilité électromagnétique (EMV) - partie 6-2: Normes génériques - Immunité pour les environnements industriels
Elektromagnetische Verträglichkeit (EMV) - Teil 6-4: Fachgrundnormen - Störaussendung für Industriebereiche / Electromagnetic compatibility (EMC) - part 6-4: Generic standards - Emission standard for industrial environments environments / Compatibilité
électromagnétique - partie 6-4: Normes génériques - Emissions de parasites pour les activités industrielles
X
DIN EN ISO 12100:
2011-03
X
DIN EN ISO 13857:
2008-06
X
DIN EN 1012-2:
2011-12
X
DIN EN ISO 2151:
2009-01
X
DIN EN 60204-1:
2014-10
X
EN 61000-6-2:
2011-06
X
EN 61000-6-4:
2011-09
X
DIN EN 50110-1:
2014-02
Betrieb von elektrischen Anlagen / Operation of electrical installations / Fonctionnement des installations électriques
X
DIN EN 610101/A1:2015-04
Sicherheitsbestimmungen für elektrische Mess-, Steuer-, Regel- und Laborgeräte - Teil 1: Allgemeine Anforderungen / Safety
requirements for electrical equipment for measurement, control and laboratory use - part 1: General requirements / Consignes de
sécurité pour les appareils électriques de mesure, de commande, de régulation ou de laboratoire - partie 1: Prescriptions générales
Datum / Data
Qualitätsbeauftragter / Quality representative / Délégué de qualité
Produktmanager / Product manager / Directeur de produit
2017-02-16
Name / Name / Nom
Gerd Reinhardt
Name / Name / Nom
Oliver Fickert
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