page 1 of 68 Technology for Vacuum Systems Instructions for use BVC control BVC control G BVC professional BVC professional G BioChem-VacuuCenter
page 2 of 68 Dear customer, Your VACUUBRAND diaphragm pumps are designed to provide you with many years of trouble-free service with optimal performance. Our many years of practical experience allow us to provide a wealth of application and safety information. Please read these instructions for use before the initial operation of your pump.
page 3 of 68 Contents Safety information!.........................................................................4 Important information!....................................................................................... 4 General information........................................................................................... 6 Intended use..................................................................................................... 6 Setting up and installing the system................
page 4 of 68 Safety information! Important information! + Keep this manual complete and accessible to personnel at all times! + Read this manual carefully before installing or operating the equipment. Observe the instructions contained in this manual. + Do not modify the equipment without authorization. NOTICE This manual is an integral part of the equipment described therein. It describes the safe and proper use of the vacuum pump.
page 5 of 68 ➨ DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. + WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE • CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. Caution! Hot surface! Disconnect equipment from AC power.
page 6 of 68 General information ☞ Read and comply with this manual before installing or operating the equipment. ☞ Before operating the equipment read and comply with the section ”Cleaning and decontamination”! NOTICE 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.
page 7 of 68 NOTICE Ensure that the equipment and all components are suitable for the intended application. Use the system only for aspiration of liquids and filtration. Setting up and installing the system ➨ Equipment must be connected only to a suitable electrical supply and a suitable ground point. Failure to connect the motor to ground may result in deadly electrical shock. The supply cable may be fitted with a molded European IEC plug or a plug suitable for your local electrical supply.
page 8 of 68 NOTICE Provide a firm level platform for the equipment. Ensure a stable position of the pump without any mechanical contact except of the pump feet. Comply with all applicable safety regulations. Check fan regularly for dust/dirt, clean if necessary to avoid reduced ventilation. Avoid high heat supply. If the equipment is brought from cold environment into a room for operation, allow the equipment to warm up. (Watch for water condensation on cold surfaces.
page 9 of 68 Operating conditions ➨ The devices have no approval for operation in or for pumping of potentially explosive atmospheres. ➨ The devices 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, - self inflammable substances, - substances which are inflammable without air and - explosive substance ➨ The pumps have no approval for operation below ground.
page 10 of 68 Safety during operation ➨ Avoid interactions of the media in the collection bottle absolutely. Comply with material safety data sheets and notes on safe use of the manufacturer. Do not mix incompatible disinfectants and/or incompatible reagents / solvents as well as unknown substances. For example sodium hypochlorite (chlorine bleach) Incompatible chemicals and agents Acids or acidic compounds (e. g. hydrochloric acid, aluminium chloride) Ammonia containing compounds (e. g.
page 11 of 68 ➨ Adopt suitable measures to prevent the release of dangerous, toxic, explosive, corrosive, noxious or polluting fluids, vapors and gases. In such cases, install an appropriate collecting and disposal system and take protective action for pump and environment. ➨ If the equipment is used in combination with hazardous materials (e. g.
page 12 of 68 ☞ Comply with applicable regulations when disposing of chemicals. Take into consideration that chemicals may be polluted. 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.
page 13 of 68 NOTICE Electronic equipment is never 100% fail-safe. This may lead to an indefinite status of the equipment. Failure of the pumping unit (e. g., by power failure) or connected components, or change of parameters must not lead to a critically dangerous situation under any circumstances. In case of diaphragm cracks or leaks in the manifold, pumped substances might be released into the environment or into the pump housing. Comply especially with notes on operation and use and maintenance.
page 14 of 68 ➨ Never operate the pump if covers or other parts of the pump are disassembled. Ensure that the pump cannot be operated accidentally. ➨ Isolate equipment from power supply before removing the cover! ➨ Before starting maintenance, unplug the equipment and wait 5 seconds to allow the capacitors to discharge. ➨ ��������������������������������������������������� Attention: The pump might be contaminated with noxious or otherwise dangerous process chemicals that have been pumped during operation.
page 15 of 68 Technical data BVC control / G BVC professional / G Type Maximum pumping speed (ISO 21360) at 50/60 Hz Ultimate vacuum (absolute) Maximum permissible inlet pressure (absolute) Maximum permissible outlet pressure (absolute) Rated power No-load speed 50/60 Hz Control range Permissible ambient temperature storage / operation Maximum installation altitude Permissible relative atmospheric moisture during operation (no condensation) Maximum permissible range of supply voltage: Attention: Observe s
page 16 of 68 BVC control / G BVC professional / G Type gal Volume of collection bottle (l) Connection at the inlet hose nozzle DN 3/5mm Connection at the outlet Hydrophobic filter Type Manufacturer Nominal pore diameter Dimensions L x W x H approx. BVC control BVC control G BVC professional BVC professional G BVC control BVC control G BVC professional BVC professional G Weight approx.
page 17 of 68 Wetted parts Components Wetted materials Pump Housing cover insert Head cover Diaphragm clamping disc Diaphragm Valve Inlet Outlet Silencer PTFE, carbon reinforced ETFE, carbon fibre reinforced ETFE, carbon fibre reinforced PTFE PTFE / FFKM ETFE ETFE silicone rubber Filter Diaphragm Housing Tubing PTFE PP silicone rubber Collection bottle 4l Bottle / screw cap Hose nozzle at bottle head (connection VHCpro) Hose in bottle Hose nozzle (connection filter) Counter nut Closing screw PP PP P
page 18 of 68 System parts Position Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pump ME 1C Mains connection Fuse holder On / Off switch Touch panel Rating plate Outlet Connection tubing Hydrophobic protection filter Connection filter Connection VacuuHandControl VHCpro Closing screw (optional: connection second VHCpro) Screw cap / bottle cap with insert Collection bottle Handle Level sensor BVC control 10 11 12 13 9 8 15 14 7 1 6 5 2 4 3
page 19 of 68 BVC control G 9 10 11 8 12 15 13 14 7 1 6 5 2 3 4 BVC professional 10 11 12 13 14 9 8 15 16 7 1 6 5 2 4 3
page 20 of 68 BVC professional G 9 10 11 8 12 15 13 16 14 7 1 6 5 2 3 4 On / Off switch System switched off System switched on Attention: Operate the on/off switch only by hand.
page 21 of 68 Use and operation First steps: Installation Unpack the equipment.
page 22 of 68 Operation BVC control / BVC control G Do not press the keys. Only touch the keys of the touch panel. The keys “+“ and “-“ have to be touched > 0.25 seconds to be actuated. A successful action is confirmed by a blip and the flashing of LEDs. 1 + 2 3 Position Designation 1 2 Key to reduce suction power Display suction power Key to increase suction power 3 Use the keys to set suction power of the system.
page 23 of 68 NOTICE Depending on ambient atmospheric pressure (depending on altitude or weather conditions) and on the vapor pressure of the media inside the collection bottle, the setting of a high underpressure (e. g., 850 mbar, 8 LEDs flash) may lead to continuous operation of the pump. In this case a reduction of the suction power is recommended.
page 24 of 68 Operation BVC professional / BVC professional G Do not press the keys. Only touch the keys of the touch panel. The keys “+“ and “-“ have to be touched > 0.25 seconds to be actuated. The other keys have to be touched > 0.5 seconds. Touch the keys with LED below the LED. A successful action is confirmed by a blip and the flashing of LEDs.
page 25 of 68 NOTICE Depending on ambient atmospheric pressure (depending on altitude or weather conditions) and on the vapor pressure of the media inside the collection bottle, the setting of a high underpressure (e. g., 850 mbar, 8 LEDs flash) may lead to continuous operation of the pump. In this case, a reduction of the suction power is recommended.
page 26 of 68 Level sensor of BVC professional / BVC professional G The sensor foil is located on the bottle support. The level sensor gives an alarm and switches off the pump to avoid an overfilling of the collection bottle, if the liquid level in the collection bottle reaches the height of the level sensor, approximately 80% of the maximum bottle capacity (grey marked range with bottle symbols on the sensor foil, both for the 2l or 4l bottle).
page 27 of 68 NOTICE Use only the original VACUUBRAND BVC bottle or the original spare bottle (see “Accessories - Spare parts”). Do not fix adhesive foil or something near it at the bottle side next to the sensor foil or directly at the sensor foil.
page 28 of 68 During operation ➨ Attention: When removing the aspiration controller VHCpro liquid in the tube may leak! Adopt suitable measures to prevent the release of dangerous, toxic, explosive, corrosive, noxious or polluting fluids, vapors and gases. In such cases, use an appropriate collecting and disposal system and take protective action for personnel, equipment and environment. max. 40°C ✔ ☞ Max.
page 29 of 68 Silencer at the outlet Attention: Dust-laden gases, deposits and condensed solvent vapor can restrict air flow out the silencer. The resultant back pressure can lead to damage of pump bearings, diaphragms, and valves. Under those conditions, a silencer must not be used. Check the silencer regularly and replace if necessary. In case of harmful / poisonous gases or condensate at the outlet, remove silencer and replace with an exhaust tube.
page 30 of 68 NOTICE The pump achieves its pumping speed, ultimate vacuum and vapor pumping rate only at operating temperature (after approx. 15 minutes). Prevent internal condensation, transfer of liquids or dust. The diaphragm and valves will be damaged, if liquids are transferred through the pump in significant amounts. In case of excess temperature the motor is shut down by a thermal cutout in the winding. Manual reset is necessary. Switch off or unplug the pump.
page 31 of 68 Filter and collection bottle The hydrophobic filter retains water and aqueous solutions also in the form of aerosols. When using solvents or due to evaporation of water, formation of condensate at the outlet of the BVC is possible. NOTICE ☞ Important: Comply with applicable regulations when disposing of solvents. ☞ Attention: Do not remove connections in case of liquid in the tube. Do not touch contaminated parts when removing the screw cap.
page 32 of 68 Emptying the collection bottle of the BVC control and BVC control G max. 80% atmospheric pressure Check liquid level in the collection bottle regularly. Maximally admissible liquid level in collection bottle: approx. 80 %, depending on the application. (In case of low boiling liquids or in case of suction of liquids which tend to foam, the admissible liquid level might be reduced.) Switch of the BVC. Vent the collection bottle.
page 33 of 68 Emptying the collection bottle of the BVC professional and BVC professional G Check liquid level in the collection bottle regularly. Maximally admissible liquid level in collection bottle: approx. 80 %, depending on the application. (In case of low boiling liquids or in case of suction of liquids which tend to foam, the admissible liquid level might be reduced.) The level sensor switches off the pump at a liquid level of approx.
page 34 of 68 atmospheric pressure Vent the collection bottle. Remove the tubing at the inlet of the pump or disconnect coupling. Remove screw cap from the collection bottle after venting. Remove bottle from the support. Sterilize and dispose of collected liquid according to appropriate regulations. NOTICE or After changing the bottle touch the key to restart the pump or switch on the pump.
page 35 of 68 Cleaning and decontaminating Autoclaving The collection bottle with bottle head and screw cap, the quick coupling and the filter are designated for steam sterilization at 121°C and 2 bar absolute (1 bar overpressure). Time of exposure according to DIN 58946 te = 20 minutes. isart® 20 Mid0 µm PTF00 E 0.2 IN sartorius stedim NOTICE Prior to autoclaving loosen or remove the bottle head from the bottle. 121°C 2 bar absolute It is the user´s responsibility to ensure effective autoclaving.
page 36 of 68 NOTICE Over time, discoloration and material changes (e.g., resiliency, elasticity/tightness, cracking) due to repeated steam sterilizations may occur. Important notes on use of disinfectants, see also “Safety during operation” BVC control BVC professional Chlorine bleach BVC control G BVC professional G Chlorine bleach Aggressive disinfectants which release chlorine or oxygen radicals, e.g.
page 37 of 68 Sekusept® Plus The use of the disinfectant Sekusept® Plus (Manufacturer: Ecolab GmbH & Co OHG, Düsseldorf, Germany) in extensive in-house testing did not cause any damage to the collection bottle. Hence the disinfectant Sekusept® Plus - even when used in the collection bottle during suction - is preferred to chlorine bleach.
page 38 of 68 Adjustment of the BVC level sensor to work properly with a new bottle, or to correct false alarms Pertains only to the BVC professional / BVC professional G NOTICE At the factory, the level sensor is adjusted either to the 4l polypropylene bottle or to the coated 2l glass bottle (G version) at standard conditions. It may be necessary to adjust the sensor to compensate for changes in bottle material, bottle size or changed ambient conditions.
page 39 of 68 adhesive foil NOTICE Do not attach adhesive foil or anything similar to level sensor or to the side of the bottle directly next to the sensor.
page 40 of 68 Adjustment routine for BVC professional with 4l polypropylene bottle from software version V1.6, see rating plate Attention: Do not interrupt the adjustment routine once you have begun, even if there is an alarm. Complete the entire routine, and repeat if necessary. Action Reaction Meaning Step 1 Case 1: Touch and hold “4l P” key. The LED of the “4l PP“ bottle symbol flashes blue.
page 41 of 68 Adjustment routine for BVC professional with 2l glass bottle from software version V1.6, see rating plate Attention: Do not interrupt the adjustment routine once you have begun, even if there is an alarm. Complete the entire routine, and repeat if necessary. Action Reaction Meaning Step 1 Case 1: Touch and hold “2l Glass” The LED of the “2l Glass“ key. bottle symbol flashes blue.
page 42 of 68 Assembling of components Replacing the filter Vent the collection bottle. Ensure that there is no liquid in the tube to avoid risk of contamination. atmospheric pressure Remove connecting tube from the filter. Remove the filter from the piece of tube at the hose nozzle. isart® 20 Mid0 µm PTF00 E 0.2 IN sartorius stedim Attach new filter. Observe flow direction. Position filter with the printed side “IN” towards the bottle. Attach the connecting tube.
page 43 of 68 Assembling a second VHCpro connection set (with / without coupling) or conversion to quick coupling VHCpro - bottle) Empty bottle. Decontaminate equipment if necessary. Remove filter with connection tubing from bottle head. Remove screw cap from the collection bottle. Unscrew closing screw. Only BVC with polypropylene bottle: Remove counter nut inside the screw cap.
page 44 of 68 BVC with polypropylene bottle 1b 1a 2 3 Insert hose connection (1a) with seal ring (2) or coupling (1b) with seal ring (2) in the screw cap. Secure lead through with counter nut (3). Assemble hose (4) under the screw cap to the lead through. 4 Screw screw cap to bottle. Assemble filter. Assemble VHCpro.
page 45 of 68 Assembling quick coupling bottle - pump unit (extension set) Attention: The extension set “Quick coupling bottle - pump unit” is designated for two different extension versions. Therefore the set consists of parts, which may not be necessary in the individual case. Redundant parts are not credited by VACUUBRAND. Assembling to pump inlet Remove tubing. Disassemble hose nozzle. Hold counter piece with open-ended wrench size 19 mm.
page 46 of 68 Assembling a hose nozzle at the bottle head of the BVC Hose nozzle (638509), see “Accessories”, e.g., for filtration applications Empty bottle. Decontaminate equipment if necessary. Remove filter with connection tubing from bottle head. Remove screw cap from the collection bottle. Unscrew closing screw. Only BVC with polypropylene bottle: Remove counter nut inside the screw cap. Screw hose nozzle with seal ring into the screw cap.
page 47 of 68 Quick coupling sets Quick coupling set: VHCpro to bottle Quick coupling made of PVDF, with adapter to connect a VHCpro to a collection bottle. When disconnected, the collection bottle closes vacuum tight. Quick coupling set: Bottle to pump unit Quick coupling made of PVDF, to connect a collection bottle to a BVC basic / basic G. When disconnected, the collection bottle closes vacuum tight.
page 48 of 68 Accessories - spare parts Collection bottle 4L, made of PP, with protection filter and inlet tube...................635810 Collection bottle 2L glass, coated, with protection filter and inlet tube...................635809 Attention: Please order quick-couplings separately! Collection bottle 4L, made of PP, for BVC professional with quick coupling, protection filter and inlet tube.........................
page 49 of 68 Protection filter with connection hoses �����638266 Silicone hose 12/6 mm (length in cm)...........635741 VacuuHandControl VHCpro............................688061 Spare hose for VHCpro ..................................636156 (minimum order quantity 2 m) Silicone hose 9/6 mm (length in cm).............
page 50 of 68 Troubleshooting Fault ❑ Pump fails to start, system becomes vented. Possible cause Remedy ➨ Power switched off? ✔ Switch on power. ➨ Motor overloaded? ✔ Switch off, allow motor to cool, identify cause of failure and eliminate before switching on again. ➨ Internal fuse blown? ✔ Identify cause of failure, replace fuse (under the cover). ➨ Not plugged in, or failure ✔ Plug in, or check fuse of electrical supply? controlling power outlet.
page 51 of 68 Fault ❑ Pump is running continuously. Possible cause ➨ Leak in the system? Remedy ✔ Check tubing, seals, coupling, and blind cap. Screw in or replace if necessary. ➨ Too high underpressure ✔ Reduce underpressure / for altitude / weather aspiration power. conditions? Vapor pressure of the media inside the collection bottle too high? ➨ Other causes? ❑ Keys do not react. ✔ Contact your local distributor. ➨ Keys of the touch panel ✔ Wait 20 seconds and try touched long-lasting? again.
page 52 of 68 Replacing diaphragms and valves ➨ Never operate the pump if covers or other parts of the pump are disassembled. ➨ Before starting maintenance, disconnect the electrical power cord. Wait 5 seconds after isolating the equipment from AC power to allow the capacitors to discharge. ➨ Ensure that the pump cannot be operated accidentally. ➨ Note: The pump might be contaminated with the process chemicals that have been pumped during operation.
page 53 of 68 NOTICE Ensure that maintenance is done only by suitably trained and supervised technicians. The valves and 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. All bearings are encapsulated and are filled with long-life lubricant.
page 54 of 68 Cleaning and inspecting the pump heads ➨ Fix cover plate at the pump housing using adhesive tape. ➨ Unscrew elbow fitting with silencer at the outlet of the pump. ➨ Depending on BVC version, remove connection tubing at the hose nozzle or detach quick coupling. ➨ Remove bottle from support. ➨ Unscrew hose nozzle, or hose nozzle with coupling, using an open-ended wrench. ➨ Unscrew cover, paying attention to washers.
page 55 of 68 ➨ Remove the cover of the housing cover from the housing.
page 56 of 68 ➨ Unscrew four screws at the pump head, paying attention to washers. Remove housing cover. ➨ Unscrew union nut and remove hose from elbow fitting. Remove housing cover insert with elbow fitting. ➨ Note position of valves. ☞ Replace valves if necessary. Use petroleum ether or industrial solvent to remove deposits. Do not inhale vapors. ➨ Remove head cover and valves. ☞ Check diaphragm for damage and replace if necessary. ☞ Never remove parts by using a pointed or sharp-edged tool (e.g.
page 57 of 68 ☞ If the old diaphragm is difficult to separate from the diaphragm support disc, immerse assembly in naphtha or petroleum ether. Do not inhale vapors! ☞ Check for washers between the diaphragm support disc and the connecting rod. Make sure that the original number is reassembled. ➨ Position new diaphragm between diaphragm clamping disc with square head screw and diaphragm support disc. ☞ Note: Position diaphragm with pale side towards diaphragm clamping disc (facing pump chamber).
page 58 of 68 ➨ Position any washers that are present between diaphragm support disc and connection rod. ➨ Screw diaphragm clamping disc, diaphragm, diaphragm support disc, and washers to connecting rod. ➨ Bring the diaphragm into a position in which it is in contact with the housing and centered with respect to the bore so that it will become clamped uniformly between housing and head cover. Assembling the pump head ➨ Lay down the BVC on the side of the pump, e. g.
page 59 of 68 ➨ ������������������������������������������ Put on housing cover and housing cover insert. ☞ Move housing cover insert slightly to ensure that the head covers are correctly positioned. ➨ Pay attention to washers and position screws. Screw in 4 screws with washers at the housing cover diagonally, loosely at first with a Torx driver T20, then tighten. ☞ Do not tighten until head cover is in contact with housing, maximum torque: 2.2 ft.lbf (3 Nm).
page 60 of 68 ➨ Position bottle in the support. ➨ Depending on BVC version, position tubing to hose nozzle or quick coupling. ➨ Screw elbow fitting with silencer to the outlet of the pump (max. 5 turns). ➨ Remove adhesive tape at the cover plate. Checking the ultimate vacuum ➨ After any intervention at the equipment (e.g., repair / maintenance) the ultimate vacuum of the pump has to be checked.
page 61 of 68 Replacing the fuse ➨ Switch off the pump. ➨ Disconnect the electrical power cord before opening the terminal box. After disconnecting from power, wait 5 seconds to allow the capacitors to discharge. ☞ Identify and eliminate the cause of failure before switching on the equipment again. fuse holder ➨ Keep the snap-fit squeezed and pull the fuse holder out. ➨ The fuse holder contains two fuses of the same type.
page 62 of 68 Notes on return to the factory Repair - return - DAkkS calibration NOTICE 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 sent to our office fully completed and signed before any equipment is shipped to the authorized service center.
page 63 of 68 We submit repair quotations only on request and always at the customer’s expense. If an order is placed, the costs incurred for problem diagnosis 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. - If you do not wish a repair on the basis of our quotation, the equipment may be returned to you disassembled and at your expense.
page 64 of 68 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 your processes. Do not incinerate fluoroelastomer seals and O-rings. - You may authorize us to dispose of the equipment at your expense.
page 65 of 68 Health and safety clearance form Health and safety clearance form for BVC systems and accessories Devices will not be accepted for any handling before we have received this declaration. Please read and comply with ”Notes on return to the factory” in the instructions for use. Attention: Only devices free of contamination hazardous to health may be sent for inspection / repair! 1. Device (Model): ..................................................................................................
page 66 of 68 Description of the decontamination method: Outside: ................................................................................................................................................ Inside (e. g. bottle, screw cap, coupling, filter, hoses, handle):............................................................. .............................................................................................................................................................. ..............
page 67 of 68 EG-Konformitätserklärung für Maschinen EC Declaration of Conformity of the Machinery Déclaration CE de conformité des machines Hersteller / Manufacturer / Fabricant: VACUUBRAND GMBH + CO KG · Alfred-Zippe-Str. 4 · 97877 Wertheim · Germany Hiermit erklärt der Hersteller, dass die Maschine konform ist mit den Bestimmungen der Richtlinie 2006/42/EG. Hereby the manufacturer declares that the machinery is in conformity with the directive 2006/42/EC.
page 68 of 68 Disclaimer: Our technical literature is only intended to inform our customer. The applicability of general empirical values and results obtained under lab conditions to your specific operations depends on a number of factors beyond our control. It is, therefore, strictly the users’ responsibility to very carefully check the application of these data to their specific requirements. No claims arising from the information provided in this literature will, consequently, be entertained.
