vacuubrand MZ 2 VARIO-SP Instructions For Use Manual
The Vacuubrand MZ 2 VARIO-SP diaphragm pump is a powerful and versatile laboratory vacuum pump designed for a wide range of applications, including filtration, degassing, and drying. It features a chemically resistant PTFE diaphragm and valves, making it suitable for pumping aggressive and corrosive gases and vapors. With its adjustable pumping speed, the MZ 2 VARIO-SP can be tailored to specific application requirements, ensuring optimal performance and energy efficiency.
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Technology for Vacuum Systems
Instructions for use
ME 2 - ME 4 - MZ 2 - MZ 2D
Diaphragm pumps
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Dear customer,
Your VACUUBRAND diaphragm pump shall support you at your work for a long time without any trouble and with full load output. Thanks to our large practical experience we attained much information how you could add to an efficient application and to personal safety. Please read these instructions for use prior to the initial start-up of your pump.
VACUUBRAND diaphragm pumps are the result of many years of experience in construction and practical operation of these pumps combined with the latest results in material and manufacturing technology.
Our quality maxim is the ”zero fault principle”:
Every delivered diaphragm pump is tested extensively including an endurance run of 18 hours. Due to this endurance run, also faults, which occur rarely, are reported an can be corrected. Every single diaphragm pump is tested on achievement of the specification after the endurance run.
Every VACUUBRAND pump leaving our factory achieves the specification. We feel obliged to this high quality standard.
We are aware that the vacuum pump should not draw a part of the real work and we hope to contribute with our products to an effective and troublefree realisation of your work.
Yours
VACUUBRAND GMBH + CO KG
After sales service: Contact your local dealer or call +49 9342 808-193.
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Contents
Attention! Important notes!
Not permitted! Misuse may cause damage.
Caution! Hot surface!
Isolate equipment from mains.
Note.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 4 of 24
Safety information!
Remove all packing material, remove the product from its packing-box, remove the protective covers from the inlet and outlet ports and keep, inspect the equipment.
If the equipment is damaged, notify the supplier and the carrier in writing within three days; state the item number of the product together with the order number and the supplier’s invoice number. Retain all packing material for inspection.
Do not use the equipment if it is damaged.
If the equipment is not used immediately, replace the protective covers. Store the equipment in suitable conditions.
☞ Read and comply with this manual before installing or operating the equip- ment.
☞ Transport the pump at the provided handles.
Use the equipment for the intended use only (for generation of vacuum).
☞ Prevent any part of the human body from coming in contact with the vacuum.
☞ Comply with notes on correct vacuum and electrical connections, see section ”Use and operation”.
☞ Make sure that the individual components are only connected, combined and operated according to their design and as indicated in the instructions for use.
Comply with national safety regulations and safety requirements concerning the use of vacuum and electrical equipment.
☞ Equipment must be connected only to a suitable fused and protected electrical
supply and a suitable earth point. Failure to connect the motor to ground may result in deadly electrical shock.
☞ The supply cable may be fitted with a moulded European IEC plug or a plug suitable for your local electrical supply. If the plug has been removed or has to be removed, the cable will contain wires colour coded as follows: green or green and yellow: earth; blue or white: neutral; brown or black: live.
☞ Check that mains voltage and current conform with the equipment (see rating plate):
Pumps with dual-voltage motor (100-120 V / 200-230 V; 50/60 Hz):
☞ The equipment must be connected to a suitable fused and protected electrical
supply and a suitable earth point only, provide slow-blow fuse according to voltage supply (see ”Technical data”).
☞ Check that the voltage changeover switch is positioned correctly.
Attention: If the pump is switched on with the voltage not correctly selected, the motor may be damaged!
☞ If the equipment is brought from cold environment into a room for operation, allow the equipment to warm up (pay attention to water condensation on cold surfaces).
☞ Make sure ventilation is adequate if pump is installed in a housing or if ambient temperature is elevated.
Comply with all relevant safety requirements (regulations and guidelines) and adopt suitable safety measures.
☞ Provide a firm level platform for the equipment and check that the system to be evacuated is mechanically stable and that all fittings are secure.
Attention: Flexible elements tend to shrink when evacuated.
Due to the high compression ratio of the pumps, pressure at the outlet port might be generated being higher than the max. permitted pressure compatible with the mechanical stability of the system.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
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☞ Comply with maximum permitted pressures and pressure differences, see section ”Technical data”. Do not operate the pump with overpressure at the inlet.
Do not permit any uncontrolled pressurizing (e. g. make sure that the exhaust pipeline cannot become blocked). If you have an exhaust-isolation valve, make sure that you cannot operate the equipment with the valve closed. Risk of bursting!
☞ Ensure that the system design does not allow the exhaust pipeline to become blocked.
☞ Avoid overpressure of more than 0.2 bar in case inert gas is connected.
☞ The diameter of the inlet and outlet pipeline should be at the least as large as the diameter of the pump connection pipelines.
To the best of our knowledge the equipment is in compliance with the requirements of the applicable EC-directives and harmonized standards (see ”Declaration of conformity”) with regard to design, type and model, especially directive IEC 1010. This directive gives in detail conditions, under which the equipment can be operated safely (see also
IP degree of protection).
☞ Adopt suitable measures in case of differences, e. g. using the equipment outdoors, installation in altitudes of more than 1000 m above mean sea level, conductive pollution or dewiness.
Pay attention to symbol ”hot surfaces” on the equipment (according to IEC 1010 recommendation).
☞ Adopt suitable measures to prevent any danger arising from the formation of hot surfaces or electric sparks.
The pumps have no approval for operation in or for pumping of potentially explosive atmospheres.
If pumping different substances, purge the pump with inert gas prior to changing the pumped media in order to pump out residues and to avoid reactions of the pumped substances with each other with and the pump material. Ensure that the materials of the wetted parts are compatible with the pumped substances, see section ”Technical data”.
Take into consideration interactions and chemical reactions of the pumped media.
The pumps are not suitable for pumping substances which may form deposits inside the pump.
☞ If there is a danger of the formation of deposits in the pump chamber (check inlet and outlet of the pump) inspect the pump chamber regularly and clean if necessary.
The pumps are not suitable to pump unstable substances and substances which react explosively under impact (mechanical stress) and/or when being exposed to
elevated temperatures without air.
The pumps are not suitable to pump self inflammable substances, substances which are inflammable without air and explosive substances.
The pumps are not suitable for pumping dust and have no approval for operation below ground.
Ensure that the materials of the wetted parts are compatible with the pumped substances, see section ”Technical data”.
☞ Adopt suitable measures to prevent the release of dangerous, explosive, corrosive or polluting fluids.
☞ Use inert gas for gas ballast or venting if necessary.
☞ The user must take suitable precautions to prevent any formation of explosive mixtures in the expansion chamber or at the outlet. In case of a diaphragm crack, mechanically generated sparks, hot surfaces or static electricity may ignite these mixtures.
☞ Take adequate precautions to protect people from the effects of dangerous substances (chemicals, thermal decomposition products of fluoroelastomers), wear appropriate safety-clothing and safety glasses.
☞ Comply with applicable regulations when disposing of chemicals. Take into consideration that chemicals may be polluted.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
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Due to the residual leak rate of the equipment, there may be an exchange of gas, albeit extremely slight, between the environment and the vacuum system.
☞ Adopt suitable measures to prevent contamination of the pumped substances or the environment.
The motor is shut down by a thermal cutout in the winding.
☞ Attention: Manual reset is necessary. Switch off the pump or isolate the equipment from mains. Wait approx. five minutes before restarting the pump.
☞ Attention: In case of supply voltage below 100V, the lock of the cutout might be restricted and the pump might restart on its own after sufficient cooling down. Take suitable precautions, if an automatic restart of the pump may lead to a critical dangerous situation.
☞ Avoid high heat supply (e. g. due to hot process gases).
☞ Ensure sufficient air admittance if pump is installed in a housing.
Ensure that in case of failure the pump and the vacuum system always will turn into a safe status.
☞ In case of diaphragm cracks or leaks in the manifold pumped substances mighty be released into the environment or into the pump housing. To reduce the risk of leaks, ask for a diaphragm pump with additional safety diaphragm.
☞ Comply especially with notes on operation and use and maintenance.
Use only genuine spare parts and accessories.
☞ Otherwise safety and performance of the equipment as well as the electromagnetic compatibility of the equipment might be reduced. Possibly the CE mark or the C/US conformity becomes void if not using genuine spare parts.
The A-weighed emission sound pressure level of the pump does not exceed 70 dB(A).
Measurement according to EN ISO 2151:2004 and EN ISO 3744:1995 with standard silencer or exhaust tube at outlet.
Ensure that maintenance is done only by suitably trained and supervised technicians.
Ensure that the maintenance technician is familiar with the safety procedures which relate to the product processed by the vacuum system and that the equipment, if necessary, is appropriately decontaminated before starting maintenance.
Comply with local and national safety regulations.
Wear parts have to be replaced regularly. In case of normal wear the lifetime of the diaphragms and valves is > 10000 operating hours. Bearings have a typical durability of 40000 h. Motor capacitors have a typical durability in the range of 10000 to 40000 h depending strongly on the operation conditions like ambient temperature, humidity or load.
☞ Check every capacitor regularly by measuring its capacity and estimating its operation time. Exchange old capacitors early enough to prevent a failure. If an overaged motor capacitor fails it might get hot and even melt and may cause a flame to form which could be dangerous for persons and equipment in the vicinity. The capacitors have to be replaced by an electrician.
Before starting maintenance vent the system, isolate the pump and other components from the vacuum system and the electrical supply, drain condensate and allow sufficient cooling of the pump.
Before starting maintenance, wait two minutes after isolating the equipment from mains to allow the capacitors to discharge.
In order to comply with law (occupational, health and safety regulations, safety at work law and regulations for environmental protection) vacuum pumps, components and measuring instruments returned to the manufacturer can be repaired only when certain procedures (see section ”Notes on return to the factory”) are followed.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
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Technical data
T y p e
P u
5 0 / m
6 p i
0 n g
H z s p e e d
D I N 2 8 4 3 2
U
( a l t i m b s o a l t e u t e
( t o t a l )
) D I N v a c u u m
2 8 4 3 2
M a x .
p e r m i t t e d p r e s s u r e ( a b s o o l u u t l t e ) e t
M a x .
p e r m i t t e d p r e s s u r e a n d o u t l e t b e t w e d i e n f f e r e n i n l e t c e
M t e a x m
.
p p e r e a r m i t u r t e t e d d u s t o r a g e / o p e r a t r a i m n g b i e n t i o n
M a x .
p e r m i t t a t d u m r i o n s g p h o e r p e i c r a e d m t i o o r i e s l t a t u r i v e e n ( n o s e p a r a t i o n o f c o n d e n s a t )
M o t o r p o w e r
M o t o r p r o t e c t i o n
R a t e d
1
1
0
2
0
0 c u r r e n t d r a w
V ~
V ~
5 0
6 0
/ 6 0
H z
H z
2 3 0 V ~
1 0 0 1 2 0
5 0 /
/ 2 0 0
6 0
2 3
H z
0 V ~ 5 0 H z
1 0 0 1 2 0 / 2 0 0 2 3 0 V ~ 6 0 H z
M s u a p x .
p l p e r m i t t e d y v o l t a g e
P a y a r a t i n g t t e n p l a t i o n t e !
r t o a n g e m o o f t o r m 3 / h m b a r
M E 2
1 .
9 / 2 .
2 m a x i m u m
< 8 0 b a r b a r
W
A
A
A
A
A
2
2
1 2 0
M E 4
3 .
6 / 4 .
0 m a x i m u m
< 8 0
4
2
3 0 t o 8 5
M Z 2
1 .
9 / 2 .
2
9
2
2
1 0 t o + 6 0 / + 1 0 t o + 4 0
1 8 0 1 8 0 t h e r m a l c u t o u t
M Z 2 D
2 .
2 / 2 .
4
4
1 .
1
1 .
1
1 8 0
-
-
1 .
1 / 1 .
1
2 .
6 / 1 .
3 *
2 .
6 / 1 .
3 *
-
3 .
0
1 .
6 / 1 .
6
-
-
3 .
6 / 3 .
8
3 .
0
1 .
6 / 1 .
6
-
-
1 0 0 V ~ + / 1 0 % 5 0 / 6 0 H z
1 2 0 V ~ + 5 % / 1 0 % 6 0 H z
2 3 0 V ~ + / 1 0 % 5 0 / 6 0 H z
1 0 0
2 0
1
0
2
2
0
3
V ~
0
+
V ~
5
+
%
/ -
/ 1 0 %
1 0 % 5
5
0
0 / 6
/ 6 0
0
H
H z * z *
-
3 .
0
1 .
6 / 1 .
6
3 .
6 / 1 .
7 *
3 .
8 / 1 .
8 *
I
D e g r e e
I E C
R a n l e
5 t e d t
2 9 o f s p e p r o e d t e c t i
5 0 / o n
6 0 H z m i n 1
I P
I P
5 4
4 0 *
1 5 0 0 / 1 8 0 0 1 5
I
0
P
0
-
/
5
1
4
8 0 0 h o s e n o z z l e D N 1 0 G 1 / 4 "
I P
-
5 4
1 5 0 0 / 1 8 0 0
I P
I P
5 4
4 0 *
1 5 0 0 / 1 8 0 0 s m a ll
D N f l a n g e
1 6
O u t l e t
O v e r a l l
L
W x e i
W g h t x d i m e
H n s i o n s m k m g
2 7 5
3 0 0 x 1 6 4
2 4 9 x 1 6 4
2 4 9 * x x
6 .
3
7 .
5 *
* Pump with dual-voltage motor (100-120/200-230 V 50/60 Hz) s i l e n c e r
2 5 4 x
1 7 7
-
2 3 5 x 2 5 4 x
1 7 7
-
2 3 5 x
1 0
-
.
4 1 0
-
.
7
2 5 4
1 6 2 x 2 3 5
1 7 7 x 2 6 5
1 7 1 * x x
1 0 .
7
1 0 .
4 *
We reserve the right for technical modification without prior notice!
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 8 of 24
C o m p o n e n t s h o u s i n g c o v e r / h e a d c o v e r d i a p h r a g m h o s e c l a m p i n g d i s d i h o a p h s e r a g m n o z z l e
/ h o s e s m a l l n o z z l e f l a n g e s i l e n c e r v a l v e
( M E 2
(
( M
M
E
Z
/
4 )
2 D )
M Z c
2 ) f i t t i n g s s e e a a l l
( M E
( M Z
2 /
2 D )
M E 4 / M Z 2 )
W e t t e d a l u m i n i u m p a r t s a l l o y ( A l S i 1 2 ) a l u m i n i u m
F P M
P B T s t a i n l e s s s t a i n l e s s
P A / P E
P E a l l o s t e e l s t e e l y ( A l S i 1 2 ) a l u m i n i u m , a n o d i z e d
P V C
F P M
We reserve the right for technical modification without prior notice!
Gas inlet temperatures:
O p e r a t i n g c o n d i t i o n I n l e t p r e s s u r e
C o n t i n u o u s o p e r a t i o n
C o n t i n u o u s o p e r a t i o n
S h o r t t i m e o p e r a t i o n ( < 5 m i n u t e s )
> 1 0 0 m b a r ( h i g h g a s l o a d )
< 1 0 0 m b a r ( l o w g a s l o a d )
< 1 0 0 m b a r ( l o w g a s l o a d )
➨
➨
➨
P e r m i t t t e m p e r e d a t u r a r e n g s e a t o f i n g a l e t s
0 ° C t o + 6 0 ° C
-
+
1
1
0
0
°
° C
C t t o o
+
+
8
4
0
0
°
° C
C
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page 9 of 24
ME 2 outlet with silencer inlet pump rating plate handle mains cable on/off switch
ME 2 with dual voltage motor 100-120/200-230 V handle outlet with silencer inlet pump rating plate on/off switch underneath warning label terminal box voltage changeover switch underside terminal box
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page 10 of 24
ME 4 inlet outlet with silencer pump rating plate
MZ 2 / MZ 2D
(fig.: MZ 2D) inlet (MZ 2: hose nozzle) on/off switch mains cable motor rating plate outlet on/off switch mains cable motor rating plate pump rating plate
MZ 2D with dual-voltage motor 100-120/200-230 V inlet outlet on/off switch motor rating plate connection mains cable pump rating plate voltage changeover switch
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page 11 of 24
Use and operation
Installing in a vacuum system:
☞ Avoid throttling losses by using connecting pipes with large diameter and keep them as short as possible.
☞ Reduce the transmission of vibration and prevent loading due to rigid pipelines.
Insert elastic hoses or flexible elements as couplings between the pump and rigid pipes.
☞ Use a suitable valve to isolate the pump from the vacuum system if you need to allow the pump to warm up before you pump condensable vapours or if you clean the pump before it is switched off.
☞ Connect the exhaust to a suitable treatment plant to prevent the discharge of dangerous gases and vapours to the surrounding atmosphere. Use a catchpot to prevent the drainage of contaminated condensate back into the pump.
☞ Before switching on the pump check that mains voltage and current conform with the equipment!
Pump with dual-voltage motor:
☞ Check that the voltage changeover switch at the terminal box is positioned correctly.
Attention: If the pump is switched on with the voltage not correctly selected,
the motor may be damaged! Pay attention to the warning label on the on/off switch (ME 2 only) and remove after having set the voltage changeover switch to the correct position!
Selecting the supply voltage:
Attention:
Before starting the pump, check that the voltage changeover switch at the terminal box is correctly positioned. Change the selection at the voltage changeover switch only if the pump is separated from mains.
Voltage changeover switch:
Use a screw driver to adjust the supply voltage on the voltage changeover switch at the terminal box of the pump:
”115” corresponds to 100-120V and
”230” corresponds to 200-230V.
ME 2 with dual-voltage motor MZ 2D with dual voltage motor
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During operation:
Max. ambient temperature: 40 °C
☞ Make sure ventilation is adequate if pump is installed in a housing or if ambient temperature is elevated.
☞ If pump is installed in altitudes of more than 1000 m above mean sea level check compatibility with applicable safety requirements, e. g. IEC 60034 (motor may overheat due to insufficient cooling).
The motor is shut down by a thermal cutout in the winding.
☞ Attention: Manual reset is necessary. Switch off the pump or isolate the equipment from mains. Wait approx. five minutes before restarting the pump.
☞ Attention: In case of supply voltage below 100V, the lock of the cutout might be restricted and the pump might restart on its own after sufficient cooling down. Take suitable precautions, if an automatic restart of the pump may lead to a critical dangerous situation.
Due to the high compression ratio of the pumps, pressure at the outlet port might be generated being higher than the max. permitted pressure compatible with the mechanical stability of the system.
Do not start pump if pressure difference between inlet and outlet port exceeds
max. 1 bar. Attempts to start pump at higher difference may cause blockade and damage of the motor.
☞ Check compatibility with max. permitted pressure at outlet and max. pressure
difference between inlet and outlet ports.
Prevent internal condensation, transfer of liquids or dust. The diaphragm and valves will be damaged, if liquids are pumped in significant amounts.
A warm up period (approx. 15 min.) is required to ensure that the rated ultimate total pressure and pumping speed are attained.
Shutdown:
Has the pump been exposed to condensate?
☞ Allow the pump to continue to run at atmospheric pressure for a few minutes.
Has the pump been exposed to media which may damage the pump materials or form deposits?
☞ Check and clean pump heads if necessary.
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page 13 of 24
Accessories - Installation
ME 2 / MZ 2
Small flange DN 16 .................................................. 662590
Clamping ring DN 10/16 (aluminium) ......................... 660000
Centring ring DN 10/16 (NBR) ................................... 660190
Hose nozzle (for MZ 2D) ............................................ 639758
ME 4
Small flange DN 16 .................................................... 639861
Clamping ring DN 10/16 (aluminium) ......................... 660000
Centring ring DN 10/16 (NBR) ................................... 660190
Gas ballast valve ....................................................... 685812
(Note seal rings when assembling.)
Digital vacuum gauge DVR 2 .................................... 682902
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page 14 of 24
Vacuum adjustment device (inlet) ........................... 696840
Pressure adjustment device (outlet) ......................... 696841
Installation vacuum and / or pressure adjustment device at
ME 2 / MZ 2
Installation vacuum adjustment device at ME 4
(omit extra parts)
Installation pressure adjustment device at ME 4
(use extra seal rings of the pressure adjustment device)
Additional parts are necessary:
Swivelling screw-in fitting ............................................ 638548
Ring type nipple .......................................................... 638197
Hose (PE), 185 mm ..................................................... 639861
Ring nut .................................................................... 3120348
Assemble control valve first, then align and fasten gauge.
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page 15 of 24
Troubleshooting
F a u l t
P u m p f a i l s t o i m m e d i a t e l y .
s t a r t o r s t o p s
P u u l t i m m p a t d o e e s t o t a n o t l a c h i e v p r e s s u r e e o r n o r m a l p u m p i n g s p e e d .
P u m p t o o n o i s y .
P u m p s e i z e d .
P o s s i b l e c a u s e
Î
M a i e l e c n s t r i c n o t a l s p l u g g e d u p p l y i n , f a i l u r e ?
Î P r e s s u r e t o o h i g h ?
i n o u t l e t p i p e l i n e
Î M o t o r o v e r l o a d e d ?
Î
Î
Î
V o l t a g e n o t p i p e c s y s t e m ?
L o n g l i o n r e c o h r a r e c t l y n a r r o w n g p e o o v e r s i t i o s n e w i t d ?
c h
C e n t e r i n g p o s i t i o n e d r i n g o r n o l e a k t c i n o t r r e h e c t l y v a c u u m l i n e ?
Î
P u m p h a s b e e n c o n d e n s a t e ?
e x p o s e d t o
Î i
D e n s i p o s d e i t s t h e h a v e p u m b e p ?
e n f o r m e d
Î V a l v e s o r d a m a g e d ?
d i a p h r a g m
Î
O u t v a p g a s o u r i n g g e n s u b s e r a t e t a n c d i n e s o r t h e p r o c e s s ?
Î
A t m o s p h e r i c p r e s s u r e a t o r i n l e t h i g h p o r t ?
Î
D i a p h r a g m l o o s e ?
c l a m p i n g d i s c
Î
N o n e o f c a u s e s ?
a b o v e m e n t i o n e d
R e m e d y
)
P l u g i n .
C h e c k f u s e .
) R e m o v e o p e n v a l b l o v e .
c k a d e i n l i n e ,
) A l l o w m o t o r t o c o o l , i d e n t i f y c a u s e a n d o f f a i l e l i m u r e .
i n a t e
M a n u a l r e s e t p u m p f r o m n e c e s s a r y .
o r i s o m a i n s .
l a t e
S w i t c h o f f e q u i p m e n t
) S e s w i t t t h e c h v t o o l t h t a e g e p c o s h a n i t i o n g e b o v e r e i n g c o n f o r m v o l t a g e .
w i t h t h e s u p p l y
)
C h e c k p u m p v a c u u m g a u w g e i t d h i a r e c t l y p u m p c o n n e i n c t i l e o t n p s o r t , a n d c h e c k l i n e .
a t
)
U s e l i n e d i a m e t e r , w i t h l a r l e n g t h g e a s r a s p o s s i b l e .
s h o r t
)
R u p r e n s p s u u m r e p f o a t r a a t m o s p h e r i c f e w m i n u t e s .
) C l e a n h e a d s .
a n d i n s p e c t p u m p
)
)
R e p l a c e v a l v e s d i a p h r a g m s .
C h e c k a n d / o r p r o c e s s p a r a m e t e r s .
)
C o n n e c t o u t l e t .
h o s e t o p u m p
)
P e r f o r m m a i n t e n a n c e .
)
C o n t a c t l o c a l d i s t r i b u t o r .
) C o n t a c t l o c a l d i s t r i b u t o r .
A service manual with exploded view drawings, spare parts list and directions for repair is available on request.
☞ The service manual is for trained service people.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 16 of 24
Replacing diaphragms and valves
All bearings are encapsulated and are filled with long-life lubricant. Under normal operating conditions, the pump is maintenance free. The valves and the diaphragms as well as the motor capacitors are wear parts. If the rated ultimate vacuum is no longer achieved or in case of increased noise level, the pump interior, the diaphragms and the valves must be cleaned and the diaphragms and valves must be checked for cracks or other damage.
Depending on individual cases it may be efficient to check and clean the pump heads on a regular basis. In case of normal wear the lifetime of the diaphragms and valves is
> 10000 operating hours.
☞ Prevent internal condensation, transfer of liquids or dust. The diaphragm and valves will be damaged, if liquids are pumped in significant amount.
If the pump is exposed to corrosive gases or vapour or in case of deposits, maintenance should be carried out frequently.
☞ Regular maintenance will improve the lifetime of the pump and also protect both man and environment.
Before starting maintenance vent the system, isolate the pump and other components from the vacuum system and the electrical supply. Drain condensate if applicable, avoid the release of pollutants. Allow sufficient cooling of the pump. Ensure that the pump cannot be operated accidentally. Never operate the pump if covers or other parts of the pump are disassembled. Never operate a defective or damaged pump.
Ensure that the maintenance technician is familiar with the safety procedures which relate to the products processed by the pumping system.
The pump might be contaminated with the process chemicals that have been pumped during operation. Ensure that the pump is decontaminated before maintenance and take adequate precautions to protect people from the effects of dangerous substances if contamination has occurred.
☞ Wear appropriate safety-clothing when you come in contact with contaminated components.
Set of seals (diaphragm, valves) for ME 2 .................................................................................... 696810
Set of seals (diaphragms, valves) for ME 4 / MZ 2 ....................................................................... 696811
Set of seals (diaphragms, valves) for MZ 2D ................................................................................ 696835
O-ring (FPM) 48 x 3 (head cover of MZ 2D) ............................................................................... 3120544
O-ring (FPM) 28 x 1,5 (head cover of MZ 2D) .............................................................................. 637090 ing maintenance.
Partially the pictures show pumps in other versions. This doesn’t influence replacing diaphragms and valves of the pump.
Tools:
Phillips screw driver size 2
Open-ended wrench w/f 17
Hex key size 5
Face wrench with torque indicator
(Fig. VACUUBRAND face wrench, cat. no.: 637580)
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 17 of 24
Cleaning and inspecting the pump heads:
➨ Use open-ended wrench, remove the screw-in fittings together with the hose from all pump heads.
➨ To check the valves use hex key to remove four sockethead screws from pump head and remove housing cover with head cover, valves and O-ring (MD 4 / MV 2 only).
☞ Never remove parts by using a spiky or sharp-edged tool
(e.g. screw driver), we recommend to use a rubber mallet or compressed air (to be blown carefully into port).
➨ Remove head cover carefully from housing cover. Note position of valves and remove them.
☞ Replace valves if necessary.
☞ Use petroleum ether or industrial solvent to remove deposits. Do not inhale.
View of the disassembled pump head parts with different technical design
6
7
8
9
4
5
1
2
3 diaphragm with round hole; clamping disc with countersunk head screw
1 housing
2 rod
3 diaphragm support disc
4 diaphragm
5 diaphragm clamping disc
6 head cover diaphragm with square hole; clamping disc with square head screw
7 seal ring (only MZ 2D)
8 valve
9 housing cover
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 18 of 24
☞ Check diaphragm for damage and replace if necessary.
➨ To do so use Phillips screw driver to remove four countersunk head screws and lift off housing plate with rating plate.
☞ Use petroleum ether or industrial solvent to remove deposits if necessary. Do not inhale.
Notes regarding the assembling of the diaphragm
The set of seals is designated for diaphragm pumps with different technical performance.
Delivering pumps with square hole diaphragm starts in the second term of 2002, but not at the same time for all types of pumps. (Exception MZ 2D: Always diaphragm with round hole.)
Replacing a diaphragm with round hole, use the delivered diaphragm completely.
Replacing a diaphragm with square hole, remove the punched part in the centre of the diaphragm before assembling.
+
Replacing a diaphragm with round hole
➨ Use Phillips screw driver, remove countersunk head screw in the centre of the diaphragm clamping disc.
☞ Note: Screw is secured by adhesive to prevent it from being detached. Clean screw or use new one (cat. no.: 639847).
☞ If the old diaphragm is difficult to separate from the support disc, immerse assembly in naphtha or petroleum ether. Do not inhale!
OmniFit ® and Loctite ® are registered trade marks of Henkel Technologies
➨ Check for washers. Do not mix the washers from the different heads. Make sure that the original number is reassembled at the individual pump head.
☞ Smaller number of washers: The pump will not attain ultimate vacuum. More washers: Clamping disc will hit head cover; noise or even blockade of the pump.
➨ Insert diaphragm support disc and new diaphragm.
Note: Double diaphragm.
➨ Insert diaphragm clamping disc, apply a drop of adhesive
(OmniFit ® 50M or Loctite ® 243) to lowerside of screw head and thread and screw diaphragm clamping disc, diaphragm and diaphragm support disc to connecting rod.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 19 of 24
Replacing a diaphragm with square hole
➨ Use a face wrench to remove diaphragm support disc.
➨ Check for washers under clamping disc. Do not mix the washers from the different heads. Make sure that the original number is reassembled at the individual pump head.
☞ Smaller number of washers: The pump will not attain ultimate vacuum. More washers: Clamping disc will hit head cover; noise or even blockade of the pump.
➨ Position new diaphragm between diaphragm clamping disc with square head screw and diaphragm support disc.
☞ Note: Double diaphragm.
Assembling pump heads:
➨ Use the face wrench with torque indicator to assemble diaphragm clamping disc, diaphragm and diaphragm support disc (and eventually washers) to the connecting rod.
☞ Make sure that the square head screw of the diaphragm clamping disc is correctly seated in the guide hole of the diaphragm support disc.
Optimum torque for the diaphragm support disc: 6 Nm.
☞ The optimum torque is achieved if the pointer in the handle of the VACUUBRAND face wrench shows to the longer marking line.
➨ By turning eccentric bushing (front of connecting rod), bring connecting rod into a position in which diaphragm is in contact with housing and centred with respect to bore.
Reassemble in reverse order.
➨ Install head cover (with O-ring if applicable), valves and housing cover.
☞ Make sure that the valves are correctly seated: Valves at the outlet with round centred opening under valve, valves at the inlet with kidney-shaped opening beside valve.
➨ By turning eccentric bushing, bring connecting rod into upper turning point position (Max. stroke of the rod).
☞ Pay attention that the diaphragm stays positioned centrally so that it will become clamped uniformly between housing and head cover.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 20 of 24 pumps type MZ 2D ensure that the head covers are not exchanged. Always assemble the housing cover with groove at the outlet side of the pump.
➨ Screw in four socket head screws fixing housing cover crosswise (e. g. in the sequence ➀, ➁, ➂, ➃) first slightly, then tighten.
☞ Do not tighten until head cover is in contact with housing, torque 12 Nm.
Individual performance check of a pump head :
By measuring the pressure at the inlet port of the individual head:
Use a suitable vacuum gauge (e. g. DVR 2, cat. no.: 68 29 02), make sure that it is correctly calibrated, and measure the pressure at the inlet port. A vacuum of less than 85 mbar should be indicated.
☞ If the reading is higher, recheck the pump chamber and make sure that the valves and the diaphragms are correctly seated
(diaphragms concentric with bore).
Assembling fittings:
➨ Use open-ended wrench to assemble fittings with connection hoses to all pump heads.
If the pump does not achieve the ultimate vacuum:
☞ In case the diaphragms and valves have been replaced, a run-in period of several hours is required before the pump achieves its ultimate vacuum.
If all pump heads achieve a vacuum below 85 mbar but pump does not achieve the ultimate total pressure:
Check hose connectors between pump heads and manifolds for leaks. If necessary recheck pump chamber.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 21 of 24
Notes on return to the factory
Repair - return - DKD calibration
Safety and health of our staff, laws and regulations regarding the handling of dangerous goods, occupational health and safety regulations and regulations regarding safe disposal of waste require that for all pumps and other products the ”Health and safety clearance form”.
must be send to our office duly completed and signed before any equipment is dispatched to our premises.
Fax or post a completed copy of the health and safety clearance form to us in advance.
The declaration must arrive before the equipment. Enclose a second completed copy with the product. If the equipment is contaminated you must notify the carrier.
No repair / DKD calibration is possible unless the correctly completed form is returned. Inevitably, there will be a delay in processing the equipment if information is missing or if this procedure is not obeyed.
If the product has come in contact with chemicals, radioactive substances or other substances dangerous to health or environment, the product must be decontaminated prior to sending it back to the factory.
☞ Return the product to us disassembled and cleaned and accompanied by a certificate verifying decontamination or
☞ Contact an industrial cleaning and decontamination service directly or
☞ Authorize us to send the product to an industrial cleaning facility at your expense.
To expedite repair and to reduce costs, please enclose a detailed description of the problem and the product´s operating conditions with every product returned for repair.
We submit quotations only on request and always at the customer´s expense. If an order is given, the costs incurred are offset from the costs for repair or from the purchase price, if the customer prefers to buy a new product instead of repairing the defective one.
be returned to you disassembled and at your charge!
In many cases, the components must be cleaned in the factory prior to repair.
For cleaning we use an environmentally responsible water based process. Unfortunately the combined attack of elevated temperature, cleaning agent, ultrasonic treatment and mechanical stress (from pressurised water) may result in damage to the paint. Please mark in the health and safety clearance form if you wish a repaint at
your expense just in case such a damage should occur.
We also replace parts due to optical aspects upon your request.
Before returning the equipment ensure that (if applicable):
☞ Oil has been drained and an adequate quantity of fresh oil has been filled in to protect against corrosion.
☞ Equipment has been cleaned and/or decontaminated.
☞ All inlet and outlet ports have been sealed.
☞ Equipment has been properly packed, if necessary, please order an original packaging (costs will be charged), marked as appropriate and the carrier has been notified.
☞ Ensure that the completed health and safety declaration is enclosed.
We hope for your understanding for these measures, which are beyond our control.
Scrapping and waste disposal:
Dispose of the equipment and any components removed from it safely in accordance with all local and national safety and environmental requirements. Particular care must be taken with components and waste oil which have been contaminated with dangerous substances from the process. Do not incinerate fluoroelastomer seals and “O“ rings.
☞ You may authorize us to dispose of the equipment at your expense.
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 22 of 24
Health and safety clearance form
Declaration concerning safety, potential hazards and safe disposal of waste, e. g. used oil.
Safety and health of our staff, laws and regulations regarding the handling of dangerous goods, occupational health and safety regulations, safety at work laws and regulations regarding safe disposal of waste, e. g. waste oil, require that for all pumps and other products this form must be sent to our office duly completed and signed before any equipment is dispatched to our premises. Products will not be accepted for any procedure and handling and repair / DKD calibration will not start before we have received this declaration.
a) Fax or post a completed copy of this form to us in advance. The declaration must arrive before the equipment. Enclose
a second, completed copy with the product. If the product is contaminated you must notify the carrier (GGVE, GGVS,
RID, ADR).
b) Inevitably, the repair process will be delayed considerably, if this information is missing or this procedure is not obeyed. We hope for your understanding for these measures which are beyond our control and that you will assist us in expediting the repair procedure.
c ) Make sure that you know all about the substances which have been in contact with the equipment and that all questions have been answered correctly and in detail.
1. Product (Model): ........................................
5. Way of transport / carrier:
2. Serial No.: ..................................................
3. List of substances in contact with the equipment or reaction products:
3.1 Chemical/substance name, chemical symbol: a) ...................................................................
b) ...................................................................
...........................................................................................
Day of dispatch to VACUUBRAND:
...........................................................................................
If the paint is damaged, we wish a repaint or a replacement of parts due to optical
aspects at our expense (see ”Notes on return to the factory”):
❑ yes ❑ no c) ...................................................................
d) ...................................................................
3.2 Important information and precautions, e. g. danger classification: a) ...................................................................
b) ...................................................................
c) ...................................................................
d) ...................................................................
4. Declaration (please mark as applicable):
❑
4.1 for non dangerous goods:
We assure for the returned product that
- neither toxic, corrosive, biologically active, explosive, radioactive nor contamination dangerous in any way has occurred.
- the product is free of dangerous substances.
- the oil or residues of pumped media have been drained.
❑
4.2 for dangerous goods:
We assure for the returned product that
- all substances, toxic, corrosive, biologically active, explosive, radioactive or dangerous in any way which have pumped or been in contact with the product are listed in 3.1, that the information is complete and that we have not withheld any information.
- the product, in accordance with regulations, has been
❑ cleaned ❑ decontaminated ❑ sterilized.
We declare that the following measures where applicable - have been taken:
- The oil has been drained from the product.
Important: Dispose of according to national regulations.
- The interior of the product has been cleaned.
- All inlet and outlet ports of the product have been sealed.
- The product has been properly packed, if necessary, please order an original packaging (costs will be charged) and marked as appropriate.
- The carrier has been informed about the hazardous nature of the goods (if applicable).
We assure VACUUBRAND that we accept liability for any damage caused by providing incomplete or incorrect information and that we shall indemnify VACUUBRAND from any claims as regards damages from third parties.
We are aware that as expressed in § 823 BGB (Public
Law Code of Germany) we are directly liable for injuries or damages suffered by third parties, particularly
VACUUBRAND employees occupied with handling/ repairing the product.
Signature: ...........................................................................
Name (print): ......................................................................
Job title (print): ...................................................................
Company´s seal: ...............................................................
Date: ...................................................................................
VACUUBRAND GMBH + CO KG
-Technology for Vacuum Systems-
© 2003 VACUUBRAND GMBH + CO KG Printed in Germany
Alfred-Zippe-Str. 4 - 97877 Wertheim
Tel.: +49 9342 808-0 - Fax: +49 9342 808-450
E-Mail: [email protected]
Web: www.vacuubrand.de
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 23 of 24
Konformitätserklärung
Declaration of conformity
Déclaration de conformité
Membranpumpe / Diaphragm pump / Pompe à membrane
ME 2 (230V; 696120, 696126)
ME 4 (230V; 696140, 696146)
MZ 2 (230V; 696240, 696247)
MZ 2D (230V; 696258, 696268)
Hiermit erklären wir, dass das oben bezeichnete Gerät in Konzeption und Bauart sowie in der von uns in
Verkehr gebrachten Ausführung den grundlegenden Anforderungen der zutreffenden, aufgeführten EU-
Richtlinien entspricht. Bei einer mit uns nicht abgestimmten Änderung an dem Gerät verliert diese Erklärung ihre Gültigkeit.
We herewith declare that the product designated above is in compliance with the basic requirements of the applicable EC-directives stated below with regard to design, type and model sold by us. This certificate ceases to be valid if the product is modified without the agreement of the manufacturer.
Par la présente, nous déclarons que le dispositif désigné ci-dessus est conforme aux prescriptions de base des directives EU applicables et indiqués en ci que concerne conception, dessin et modèle vendu par nous-mêmes. Cette déclaration cesse d´être valable si des modifications sont apportées au dispositif sans notre autorisation préalable.
Maschinenrichtlinie (mit Änderungen) / Machine directive (with supplements) / Directive Machines (avec des suppléments)
2006/42/EG
Niederspannungsrichtlinie / Low-Voltage Directive / Directive Basse Tension
2006/95/EG
Richtlinie Elektromagnetische Verträglichkeit / Electromagnetic Compatibility Directive / Directive
Compatibilité Electromagnétique
2004/108/EG
Angewandte Harmonisierte Normen / Harmonized Standards applied / Normes Harmonisées utilisées
DIN EN 12100-2, DIN EN 61010-1, DIN EN 1012-2, DIN EN 61326-1
Managementsysteme / Management systems / Systèmes de Management
EN ISO 9001, EN ISO 14001 (1997-2006)
Wertheim, 06.10.2009
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ort, Datum / place, date / lieu, date
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Dr. F. Gitmans)
Geschäftsführer / Managing Director / Gérant
VACUUBRAND GMBH + CO KG
-Vakuumtechnik im System-
-Technology for Vacuum Systems-
-Technologie pour système à vide-
(Dr. J. Dirscherl)
Technischer Leiter / Technical Director / Directeur technique
Alfred-Zippe-Str. 4 - 97877 Wertheim
Tel.: +49 9342 808-0 - Fax: +49 9342 808-450
E-Mail: [email protected]
Web: www.vacuubrand.com
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
page 24 of 24
Disclaimer: Our technical literature is only intended to inform our customer. The validity of general empirical values and results obtained under test conditions for specific applications depend on a number of factors beyond our control. It is therefore strictly the users´ responsibility to very carefully check the validity of application to their specific requirements. No claims arising from the information provided in this literature will, consequently, be entertained.
VACUUBRAND GMBH + CO KG
-Technology for Vacuum Systems-
© 2009 VACUUBRAND GMBH + CO KG Printed in Germany
Alfred-Zippe-Str. 4 - 97877 Wertheim
Tel.: +49 9342 808-0 - Fax: +49 9342 808-450
E-Mail: [email protected]
Web: www.vacuubrand.de
Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully the validity of this document with respect to his product. manual-no.: 995652 / 08/10/2009
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