page 1 of 41 Technology for Vacuum Systems Instructions for use MD 4 VARIO MV 2 VARIO MV 10 VARIO Diaphragm pumps 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 41 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 41 Contents Safety information! .................................................................................................... 4 Technical data ............................................................................................................ 8 Description ..............................................................................................................12 Notes on operation ................................................................................................
page 4 of 41 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 41 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.
page 6 of 41 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.
page 7 of 41 ☞ Before starting maintenance vent the pump, isolate the pump and other components from the vacuum system and the electrical supply. 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. ☞ Attention: The pump might be contaminated with process chemicals which have been pumped during operation.
page 8 of 41 Technical data Type Max. pumping speed* 50/60 Hz (DIN 28432) Ultimate vacuum* (absolute) Max. per missible outlet pressure (absolute) MD 4 VARIO MV 2 VARIO MV 10 VARIO m 3/ h 4,6 2,8 10,0 mbar 1** 0,3** 0,3** bar 1,1 1,1 1,1 Per missible ambient t e m p e ra t u r e s t o ra g e / o p e ra t i o n °C -10 to +60 / +10 to +40 Per missible relative atmospher ic moisture dur ing o p e ra t i o n ( n o c o n d e n s a t i o n ) % 30 to 85 M a x .
page 9 of 41 C V C 2 0 0 0 II Controller exter nal, capacitive absolute pressure transducer made of aluminiumoxide ceramic P r e s s u r e t ra n s d u c e r Electronic scale conversion (selectable) 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), or "LO" (<1 mbar, in TURBO MODE only).
page 10 of 41 MD 4 VARIO rating plate handle inlet small flange NW 16 controller CVC 2000II outlet silencer pump MD 4 VARIO with frequency converter pressure transducer VSK 5 MV 2 VARIO rating plate handle inlet small flange NW 16 controller CVC 2000II outlet silencer pump MV 2 VARIO with frequency converter pressure transducer VSK 5 Documents are only to be used and distributed completely and unchanged.
page 11 of 41 MV 10 VARIO handle pump MV 10 VARIO with frequency converter outlet rating plate controller CVC 2000II inlet small flange NW 25 pressure transducer VSK 5 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 12 of 41 Description The controller can be adapted to the specific application by choosing another basic setup than ”TURBO•MODE” (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 symbol “air admittance valve” (if the valve is preselected) together with ”CAL”.
page 13 of 41 keys • setting of speed • switching in programs • ”key ▲” or ”key ▼” • pressure setting (only pressure control) • adapting process pressure • ”key p▲” or ”key p▼” • operating air admittance valve (only if valve is connected and preselected) • start or stop of process control • confirmation of selected values or mode • special function (in combination with another key) rear side CVC 2000II female connector to connect the gauge head VSK 5 connection power supply frequency converter serial
page 14 of 41 Notes on 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. Attention: Flexible elements tend to shrink when evacuated.
page 15 of 41 female connector to connect gauge head VSK 5 gauge head VSK 5 ➨ Connect the cable of the gauge head to the female connector at the rear side of the vacuum controller. ➨ Connect the gauge head to the vacuum system by using a small flange connection or a hose connection. ☞ The device is adjusted together with the gauge head at the factory. If the gauge head is replaced a readjustment is recommended.
page 16 of 41 General view basic setups CVC 2000II setting pressure unit (mbar / Torr / hPa) setting basic setup basic setup ”TURBO•MODE” (factory set) controller controls - pump according to preset pressure value (backing pressure) - setting ”Lo”: minimum pressure with preselected gas flow - air admittance valve (optional) basic setup ”pressure control” controller controls - pump according to preset pressure value - air admittance valve (optional) basic setup ”continuous pumping” controller controls -
page 17 of 41 How to configurate the controller The controller CVC 2000II can be adapted to the specific application by choosing the appropriate basic setup, TURBO•MODE, pressure control or continuous pumping with preset pumping speed: The components of the chemistry vacuum system (air admittance valve) have to be preset once only. The basic set up as from last operation and the preselected values (e. g. for pressure, speed) are stored.
page 18 of 41 Setting the basic setup MODE + (mains switch) Starting the program: ➨ Press key MODE while switching on the controller. ☞ The basic setup ”TURBO•MODE” (factory-set) is displayed on the LCD. To change the basic setup: ➨ Press key ▲ or ▼ until the symbol of the desired basic setup is displayed. ➨ Press key START/STOP to confirm the selected basic setup. TURBO•MODE pressure control continuous pumping ☞ The symbol of the air admittance valve is displayed and ”yes” or ”no”.
page 19 of 41 Basic setup TURBO•MODE 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 ”TURBO•MODE” (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 20 of 41 Setting the process parameter p p ➨ Press p▲ or p▼. ☞ The backing pressure (factory set: ”Lo” ) is displayed. ☞ If ”Lo” is selected, an automatic control program is started to determine the optimum motor speed to reach the best ultimate vacuum of the diaphragm molecular pump. Changing the backing pressure: ➨ Press p▲ or p▼. ☞ Set p and the backing pressure are displayed for approx. 1s.
page 21 of 41 Basic setup pressure 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 “TURBO•MODE” (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 22 of 41 Adjusting of set point p during pressure control p 520mbar p 67mbar Adjusting the process pressure upwards ➨ Press key p▲. ☞ When the key is pressed shortly, the current pressure is displayed for one second. ☞ With a second tip within one second or continuous pressing: The air admittance valve is opened if connected or pressure increase due to system parameters, the current pressure is displayed. ☞ The achieved pressure is stored as new set point when the key is released.
page 23 of 41 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 basic setup as from last operation is reactivated (after first switching on ”TURBO•MODE” (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 24 of 41 Temporary switching to setting pressure control ☞ Switching to pressure control, if pumping down is activated (after pressing key START): ➨ Press key MODE. ☞ The actual pressure is stored as new set point, i.e. the controller keeps the pressure constant. MODE ☞ Switching if process control is inactive: ➨ Keep key MODE pressed while pressing key ▲. MODE Documents are only to be used and distributed completely and unchanged.
page 25 of 41 Interface parameters The controller CVC 2000II is equipped with a serial interface at the rear side of the housing (RS 232C, ninepole Sub-D-plug). ☞ Respectively plug-into or remove the cable from the interface (cable RS 232C, nine-pole Sub-D) 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 26 of 41 Read commands Function Command Response Description actual pressure IN_PV_1 XXXX mbar or XXXX Torr or XXXX hPa unit according to preselections preset pressure (set point p) IN_SP_1 XXXX mbar or XXXX Torr or XXXX hPa unit according to preselections actual pumping speed IN_PV_2 XX.
page 27 of 41 Write commands Function Command Parameter Description remote operation* REMOTE X 0: set controller to local operation 1: set controller to remote operation preset pressure (set point p) OUT_SP_1 XXXX unit according to preselection (0001 to 1060 mbar (hPa) or 0001 to 0795 Torr) (only setup TURBO•MODE: setting 0000 corresponds to ”Lo”) preset pressure OUT_SP_V (set point p) with venting** XXXX unit according to preselection (0001 to 1060 mbar (hPa) or 0001 to 0795 Torr) (only setu
page 28 of 41 Accessories Venting Venting valve VB M 24 V= ....................................... 66 68 17 Vacuum distribution The VACUU•LAN® modules allow process orientated, flexible and cost effective connections according to the requirements: One vacuum pump for multiple work stations. VCL 11 VCL 02 VACUU•LAN® manual flow control module VCL 01 ....................................................... 67 71 06 VCL 10 VCL 01 VACUU•LAN® shut off / manual flow control module VCL 02 ...................
page 29 of 41 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 30 of 41 Fault Possible cause Controller does not react when operating keys. No change after switch 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 o 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 31 of 41 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 32 of 41 Replacing diaphragms and valves All bearings are encapsulated and are filled with long-life lubricant. Under normal operating conditions they are 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 33 of 41 Cleaning and inspecting the pump heads ➨ Use open-ended wrench, remove screw-in fittings 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 12 / MV 10 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.
page 34 of 41 ☞ 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 together with fittings and manifold. ☞ 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.
page 35 of 41 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.
page 36 of 41 Montage of the connecting hose ➨ Use open-ended wrench to assemble fittings with connection hoses to all pump heads. If the pump does not achieve the ultimate pressure: ☞ 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 110 mbar but pump does not achieve the ultimate total pressure: Check hose connectors between pump heads and manifolds for leaks.
page 37 of 41 Changing the valve at the outlet manifold (only MV 10 VARIO) ➨ Use open-ended wrench to remove the screw-in fitting, which runs directly to the cover plate of the outlet manifold, at the pump head. ➨ Unscrew the countersunk head screws at the cover plate of the manifold and remove cover plate. ➨ Note position of valve and remove. ☞ Check valve for damage and replace if necessary. Make sure that the valve is correctly seated. ➨ Reassemble cover plate.
page 38 of 41 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.
page 39 of 41 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 40 of 41 Konformitätserklärung Declaration of conformity Déclaration de conformité Membranpumpe / Diaphragm pump / Pompe à membrane MD 4 VARIO (230V; 683415, 683416, 683417) MV 2 VARIO (230V; 683410, 683411, 683412) MV 10 VARIO (230V; 710100, 710101, 710102) 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 EURichtlinien entspricht.
page 41 of 41 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.
