page 1 of 51 Technology for Vacuum Systems Instructions for use MD 8C VARIO MV 10C VARIO PC 2008 VARIO PC 2010 VARIO PC 2012 VARIO Chemistry pumping units with speed control 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.
page 2 of 51 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.
page 3 of 51 Contents Safety information! .................................................................................................... 4 Technical data ............................................................................................................ 8 Description ..............................................................................................................12 Notes on operation ................................................................................................
page 4 of 51 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.
page 5 of 51 ☞ 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.
page 6 of 51 In case of overload the motor is shut down by a thermal cutout in the winding. ☞ Manual reset is necessary. Switch off the pump or isolate the equipment from mains. Wait approx. five minutes before restarting the pump. ☞ Avoid high heat supply (e. g. due to hot process gases). ☞ Ensure sufficient air admittance if pump is installed in a housing.
page 7 of 51 ➨ Isolate equipment from mains and wait two minutes before starting maintenance to allow the capacitors to discharge. ☞ 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. ☞ Attention: The pump might be contaminated with process chemicals which have been pumped during operation.
page 8 of 51 Technical data MD 8C VARIO / PC 2008 VARIO MV 10C VARIO / PC 2010 VARIO PC 2012 m 3/ h 7.5 8.2 9,4 Ultimate vacuum* (absolute) according to DIN 28432 mbar 2 0.6 2 Ultimate vacuum* (absolute) with gas ballast according to DIN 28432 mbar 9 9 9 Type Max. pumping speed* according to DIN 28432 Max. per mitted outlet pressure (absolute) bar 1.1 Max. per mitted pressure at iner t gas connection (absolute) bar 1.2 Max.
page 9 of 51 C V C 2 0 0 0 II Controller P r e s s u r e t ra n s d u c e r exter nal, capacitive absolute pressure transducer made of aluminiumoxide ceramic Electronic scale conversion (to be switched b e t we e n ) mbar, Torr or hPa M e a s u r e m e n t ra n g e 1 mbar - 1100 mbar (1 Torr - 825 Torr) M a x . p r e s s u r e c o n t r o l ra n g e * 1 mbar - 1060 mbar (1 Torr - 795 Torr) C o n t r o l ra n g e m o t o r s p e e d 1,0 - 60,0 Hz at steps of 0,5 Hz or "HI" (max.
page 10 of 51 MD 8C VARIO handle gas ballast valve outlet rating plate inlet pump MD 8C VARIO with frequency converter controller CVC 2000II pressure transducer VSK 5 MV 10C VARIO handle gas ballast valve outlet rating plate inlet pump MV 10C VARIO with frequency converter controller CVC 2000II pressure transducer VSK 5 Documents are only to be used and distributed completely and unchanged.
page 11 of 51 controller CVC 2000II PC 2008 VARIO exhaust waste vapour condenser with protective cover handle outlet (gas!) (hose nozzle 10 mm) rating plate inlet (vacuum connection) cooling water outlet (hose nozzle 6 mm) separator at the inlet pump MD 8C VARIO with frequency converter cooling water inlet (hose nozzle 6 mm) overpressure safety relief device at the exhaust waste vapour condenser collecting flask for condensate pressure transducer VSK 5 controller CVC 2000II PC 2010/2012 VARIO (Fi
page 12 of 51 Description The controller can be adapted to the specific application by choosing another basic setup than ”Vacuum control” (factory-set), see section ”General view basic setups”. The status of the controller respectively of the connected accessories is displayed by corresponding symbols on the LCD. After switching on the version of the software is displayed. Then the basic setup is displayed as well as the symbols ”coolant valve” and ”venting valve”, if the valves are preselected.
page 13 of 51 Keys • setting frequency • setting time for switch-off (only VACUU•LAN) • switching (toggling) in setups • ”key ▲” or ”key ▼” • pressure setting (only vacuum control) • adapting process pressure • ”key p▲” or ”key p▼” • operating venting valve valve is connected and lected) (only if prese- • start or stop of process control or • confirmation of selected values or mode • switch on/off automatic mode (only vacuum control) • special function (in combination with another key) Rear side CVC
page 14 of 51 Notes on operation Assembling the enclosed components (PC 2008/2010/2012 VARIO): ➨ Assemble separator with centring ring and clamping ring to the inlet of the pump. The separator at the inlet prevents droplets and particles from entering the pump. ☞ Lifetimes of diaphragms and valves are enhanced. ☞ Improves vacuum in case of condensation. inlet ➨ Assemble controller CVC 2000II with fixing screw at the controller support.
page 15 of 51 outlet port (gas!) (hose nozzle Ø 10 mm) cooling water inlet (hose nozzle Ø 6 mm) cooling water outlet (hose nozzle Ø 6 mm) Exhaust waste vapour condenser: ➨ Assemble hose nozzles for coolant inlet and coolant outlet pipelines at the exhaust waste vapour condenser. The exhaust waste vapour condenser enables an efficient condensation of the pumped vapours at the outlet. ☞ No backflow of condensates. ☞ Controlled recovery of condensates. ☞ Next to 100% solvent recovery.
page 16 of 51 ☞ Use and operation of the controller see section ”Working with the controller”. ☞ Setting of interface parameters, see section ”Interface parameters”. ☞ Preselections at the controller, see section ”Basic setups”. During operation: 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.
page 17 of 51 Attention: Notes concerning the operation of the exhaust waste vapour condenser ➨ Check hose connections prior to starting operation of the cooling system. ➨ Check coolant hoses regularly during operation. ☞ Ensure that the coolant outlet pipeline is always free and that it cannot get blocked. ☞ Maximum permissible coolant pressure at the exhaust waste vapour condenser: 6 bar (absolute) ☞ Comply with the maximum permissible coolant pressures of additional components in the coolant circuit (e.
page 18 of 51 Shutdown: Short-term: 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 forms deposits? ☞ Check and clean pump heads if necessary. Long-term: ➨ Take measures as described in section short-term shutdown. ➨ Separate pump from the apparatus. ➨ Drain catchpots. ➨ Close inlet and outlet port (e. g. with transport caps). ➨ Store the pump in dry conditions.
page 19 of 51 General view basic setups CVC 2000II setting pressure unit (mbar / Torr / hPa) setting basic setup basic setup ”vacuum control” (factory set) controller controls - pump according to preset pressure value or in automatic mode - coolant valve (optional) - venting valve (optional) basic setup ”continuous pumping” controller controls - pump according to preset pumping speed - coolant valve (optional) - venting valve (optional) basic setup ”VACUU•LAN” controller controls - pump according to pr
page 20 of 51 Working with the controller How to configurate the controller The controller CVC 2000II can be adapted to the specific application by choosing the appropriate mode, vacuum control with or without automatic, continuous pumping with preset pumping speed or VACUU•LAN: The components of the chemistry vacuum system (coolant valve, venting valve) have to be preset once only. The mode as from last operation and the preselected values (e. g. for pressure, speed or time for switching off) are stored.
page 21 of 51 VACUU•LAN: ☞ Operation of the pump depending on actual pressure demand. ☞ The cooling water is switched off if no more pumping is required, it is switched on again if gas or vapour occur. ☞ The basic setup for decentralized vacuum network systems (for vacuum in laboratories, vacuum lines for weekend, night or trainee operations). Continuous vacuum without continuous pumping. ☞ Additional extension of the lifetime of diaphragms and valves (only as many diaphragm strokes as necessary).
page 22 of 51 If the automatic mode has been preselected ”End” is displayed. ☞ Switching between automatic switching off activated or not activated is possible by pressing key ▲ or ▼. ➨ Confirm by pressing key START/STOP. ☞ Automatic switching off as soon as the controller detects that evaporation is completely finished. The pump is switched off, the cooling water is running on, if a coolant valve is preselected.
page 23 of 51 General view basic setup ”vacuum control” selection of the basic setup basic setup vacuum control connect and configurate cooling water valve yes switching coolant valve? no connect and configurate venting valve yes switching venting valve? no yes pre-set switching off at end of process? yes automatic mode? no set pressure for switching off or automatic switching off ”AE” no manual settings: process pressure and speed if applicable process control Documents are only to be use
page 24 of 51 Basic setup vacuum control After switching on The process control is not active, i. e. the controller is ready for vacuum control, but control operation has not been started. ☞ The basic setup as from last operation is reactivated (after first switching on ”vacuum control” (factory-set) is displayed). ☞ The actual pressure is displayed. ☞ Parameters as from last operation are reactivated. ☞ Press key START/STOP to start process control.
page 25 of 51 Setting of set point p (e. g. boiling point) p 267 mbar ➨ Setting of the set point by using the keys p▲ or p▼ (factory set: 100 mbar): ☞ To activate set mode: Press key shortly. ”Set p” appears. ☞ Short tips toggle p in steps of 1 mbar ☞ Continuous pressing activates ramp: Set-point changes with increasing speed. Adjusting of set point p during process control p 520mbar p 67mbar Adjusting the process pressure upwards ➨ Press key p▲.
page 26 of 51 Automatic mode Switching on the automatic mode ➨ Press key MODE. ☞ ”Auto” is displayed. ☞ After starting process control, the pressure is adapted to the process automatically: The controller determines the boiling point and adapts if the boiling pressure changes. ☞ If automatic mode is switched on while process control is active, the process pressure is adapted. MODE Switching off the automatic mode ➨ Press key MODE. ☞ Switching off the automatic mode is possible at any time.
page 27 of 51 Automatic switching off To chose a pressure value for automatic switching off is only possible if automatic switching off is activated (in basic setup vacuum control with automatic). ➨ Press key MODE simultaneously with ▼ (arrow down). ☞ When the key is pressed shortly, the current pressure for automatic switching off is displayed for one second (”AE”, i.e. automatic switching off, is preselected at the factory).
page 28 of 51 Basic setup continuous pumping After switching on The process control is not active, i. e. the controller is ready for vacuum control, but control operation has not been started. ☞ The mode as from last operation is reactivated (after first switching on ”vacuum control” (factory-set) is displayed). ☞ The actual pressure is displayed. ☞ Values as from last operation are reactivated. ☞ Press key START/STOP to start process control.
page 29 of 51 Setting the pumping speed 45.0 Setting of motor speed: Setting the value for the speed by using key ▲ or ▼: ☞ To activate set mode: Press key shortly. The current speed is displayed for one second. ☞ With a second tip within one second or continuous pressing: ☞ Set speed. The new set point is stored when the key is released. ☞ The maximum speed restricts the evaporation rate in case of low boiling solvents and a carry over of substances. ☞ Setting the motor speed ”HI” (max.
page 30 of 51 General view basic setup VACUU•LAN setting the basic setup basic setup VACUU•LAN connect and configurate cooling water valve yes switching coolant valve? no connect and configurate venting valve yes switching venting valve? no setting process parameters ➨ lower pressure value (condition for automatic shut down) ➨ upper pressure value (condition for restart) ➨ time for automatic shut down start: pump down ☞ The pump (and the coolant valve if applicable) is switched off if the press
page 31 of 51 Basic setup VACUU•LAN After switching on The process control is not active, i. e. the controller is ready for vacuum control, but control operation has not been started. ☞ The mode as from last operation is reactivated (after first switching on ”vacuum control” (factory-set) is displayed). ☞ The actual pressure is displayed.
page 32 of 51 Setting the process parameters 015 67mbar p Setting the time for automatic shut down: ➨ Press key ▲ or ▼. ☞ ”Set”, the clock symbol and the time for automatic shut down are displayed for approx. 1 s. ☞ With a second tip within one second or continuous pressing: ➨ Press key ▲ or ▼ to set the value for the time for shut down (1 - 200 min). ☞ The value for the shut down time is stored as the new set point when the key is released.
page 33 of 51 Readjustment The vacuum gauge was adjusted using factory standards, which are traceable through regular calibration in an accredited laboratory (German Calibration service) to the national standard. Depending on the process and/or accuracy requirements, check the adjustment and readjust if necessary. For readjustment, the device has to be adjusted both at atmospheric pressure as well as under vacuum. The adjustment mode can be activated only if the process control is inactive.
page 34 of 51 How to determine the best distillation conditions Determine the temperature of the available coolant. ☞ In most cases the coolant temperature is given (e. g. tap water, in house cooling water circuit). For maximum solvent recovery, carefully choose the boiling point of the product (by choosing the vacuum level) and the bath temperature accordingly. ☞ Determine the lowest boiling point of the product (solvent).
page 35 of 51 Interface parameters The controller CVC 2000II is equipped with a serial interface at the rear side of the housing (RS 232C, nine-pole Sub-D-plug). ☞ Respectively plug-into or remove the cable (cable RS 232C, nine-pole Sub-D) from the interface only if the equipment is switched off. ☞ The interface is not electrically isolated from the measuring circuit. ☞ For optimal electromagnetic compatibility assemble an interface filter (cat. no.: 63 82 35).
page 36 of 51 Read commands Function Command Response Description actual pressure IN_PV_1 XXXX mbar or XXXX Torr or XXXX hPa unit according to preselections actual frequency IN_PV_2 XX.
page 37 of 51 Write commands Function Command Parameter Description selected pressure OUT_SP_1 XXXX unit according to preselection (0001 to 1060 mbar (hPa) or 0001 to 0795 Torr) selected pressure with venting* OUT_SP_V XXXX unit according to preselection (0001 to 1060 mbar (hPa) or 0001 to 0795 Torr) selected frequency OUT_SP_2 XX.X Hz (01.0 to 60.0 in steps of 0.5 Hz or 99.
page 38 of 51 Accessories Base plate with exhaust waste vapour condenser and collecting flask ........................... 69 99 49 Set of casters ......................................................... 69 99 81 Minimising cooling water consumption Coolant valve 24 V= .................................................
page 39 of 51 Troubleshooting Fault Possible cause R e m e dy No display. Î Mains not plugged in? ) Inser t mains plug, switch on. Check mains fuse in the building. Î Other cause (device defective)? ) Retur n the device to the factor y for repair. Display disappears, Î Ther mal over load, is inter nal over load protection a m b i e n t t e m p e ra t u r e t o o becomes actuated. high? ) Make sure ventilation is a d e q u a t e. Î Shor t circuit at the connected valves? ) Replace valves.
page 40 of 51 Fault Possible cause Controller does not react when operating keys. No change after switching off/on. R e m e dy ) Contact local distr ibutor. Pump fails to star t or stops immediately. Î Pump has been exposed to condensate? ) A l l ow t h e p u m p t u r u n w i t h inlet por t open for some minutes at max. frequency. Pump does not achieve ultimate vacuum or nor mal pumping speed.
page 41 of 51 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 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.
page 42 of 51 Disassembling the pump from the pumping unit PC 2008/2010 VARIO: ➨ Disconnect pump from controller (power supply and trip line). ➨ Detach separator from pump inlet. ☞ Avoid the release of pollutants. ➨ Observe applicable regulations when disposing of condensate which may be contaminated by pumped chemicals. ➨ Disconnect hose connection between pump and exhaust waste vapour condenser. Loosen union nut at exhaust waste vapour condenser and pull hose out of the inlet of the condenser.
page 43 of 51 ➨ To check valves use hex key to remove four socket head screws from pump head and remove upper housing (housing cover with housing cover insert), head cover, valves and O-rings. ☞ 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 from housing cover insert and check valves. Note position of valves and remove. ☞ Replace valves if necessary.
page 44 of 51 Replacing the diaphragm: ➨ Use a face wrench to remove diaphragm support disc. ➨ Check for washers under support 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.
page 45 of 51 ➀ ➨ 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. ➃ ➂ ➁ 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.
page 46 of 51 Changing the valve at the outlet manifold (only MV 10C VARIO / PC 2010 VARIO) ➨ Use open-ended wrench (w/f 17) to loosen the union nut of the hose, which runs directly to the cover plate of the outlet manifold, at the pump head. ➨ Use open-ended wrench (w/f 15) to turn elbow fitting 1/4 of a turn, remove hose. Do not remove the elbow fitting from the pump head. ➨ Unscrew the countersunk head screws at the manifold cover and remove cover plate and manifold cover.
page 47 of 51 Cleaning and assembling components Overpressure safety relief device ......................... 63 88 21 (at the exhaust waste vapour condenser) ☞ Remove union nut at the condenser and remove hose from the inlet of the condenser. ☞ Pull off old overpressure safety relief device and install new one. ☞ Connect hose to the inlet of the exhaust waste vapour condenser and tighten union nut. Spare parts: Exhaust waste vapour condenser ................................................................
page 48 of 51 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 sent to our office duly completed and signed before any equipment is dispatched to our premises.
page 49 of 51 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.
page 50 of 51 Konformitätserklärung Declaration of conformity Déclaration de conformité Chemie-Pumpstand / Chemistry pumping unit / Groupe de pompage chimique PC 2008 VARIO (230V; 683476, 683477, 683478) PC 2010 VARIO (230V; 710350, 710351, 710352) PC 2012 VARIO (230V; 710370) MD 8C VARIO (230V; 683471, 683472, 683473) MV 10C VARIO (230V; 710250, 710251, 710252) Hiermit erklären wir, dass das oben bezeichnete Gerät in Konzeption und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den grundlege
page 51 of 51 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.
