page 1 of 46 Technology for Vacuum Systems Instructions for use PC 500 LAN PC 600 LAN Chemistry pumping units 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 46 Dear customer, Your VACUUBRAND diaphragm pumps should support you for a long time without trouble and with maximal power. Thanks to our long practical experience we have much information how you could ensure powerful application and personal safety. Please read these instructions for use before the initial operation of your pump.
page 3 of 46 Contents Safety information! .................................................................................................... 4 Technical data ............................................................................................................ 8 Use and operation ................................................................................................... 12 Description ...........................................................................................................
page 4 of 46 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 and check oil level. 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 46 Permissible maximum pressure at the pressure transducer: 1.5 bar (absolute). ☞ At pressures higher than 1060 mbar the display flashes. Error message ”p Error” appears, four beeps. ➨ Immediate pressure relief necessary! Risk of bursting! Attention: At pressures above 1100 mbar the device does no longer display the correct pressure values (pressure transducer saturated). ☞ Ensure that the system design does not allow the coolant outlet pipeline to become blocked.
page 6 of 46 In case of overload 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 46 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.
page 8 of 46 Technical data Type PC 500 LAN PC 600 LAN m 3/ h 1.9 / 2.1 3.0 / 3.5 (max.) Ultimate vacuum (absolute) mbar 9 2 Ultimate vacuum (absolute) with gas ballast mbar 15 9 Max. per missible outlet pressure (absolute) bar 1.1 Max. per missible pressure at gas ballast (absolute) bar 1.
page 9 of 46 C o n t ro l l e r VNC 1 P r e s s u r e t ra n s d u c e r capacitive absolute pressure transducer made of aluminium oxide ceramic Display alphanumer ical LCD display, 2 x 8 characters 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 ( a b s o l u t e ) 1100 mbar - 1 mbar (825 Torr - 1 Torr) Maximum range of vacuum control (absolute)* 1060 mbar - 1 mbar (795 Torr - 1Torr) U n c e r t a i n t y ( w i t h t ra n s d u c e r
page 10 of 46 Components Pumping unit Outlet Inlet Hose Fitting O-r ings at the catchpot Over pressure safety relief device Catchpot cover plate Exhaust waste vapour condenser, collecting flask Pump Housing cover inser t Head cover D i a p h ra g m c l a m p i n g d i s c Valve D i a p h ra g m Vacuum controller Vacuum connection / hose connection Seal Sensor housing Sensor Wetted par ts PBT ETFE / ECTFE PTFE ETFE / ECTFE FPM PTFE foil / silicon r ubber PP Borosilicate glass; borosilicate glass coated PT
page 11 of 46 PC 500 LAN vacuum connection VNC 1 controller VNC 1 on/off switch controller connection pump exhaust waste vapour condenser with cover mains connection VNC 1 overpressure safety relief device at the exhaust waste vapour condenser fuse pump MZ 2C on/off switch diaphragm pump (at the terminal box) gas ballast valve inlet (vacuum connection) round bottom flask to collect condensate PC 600 LAN vacuum connection VNC 1 controller VNC 1 connection pump exhaust waste vapour condenser with
page 12 of 46 Use and operation Assembly of enclosed components Round bottom flasks: The catchpot at the inlet prevents droplets and particles from entering the pump. ☞ Lifetimes of diaphragms and valves are enhanced. ☞ Improves vacuum in case of condensation. Both round bottom flasks are coated with a protective layer to prevent disintegration in case of breakage or implosion.
page 13 of 46 Prior to use: ☞ Maximum ambient temperature: 30 °C or 40 °C (See ”Technical Data - VNC 1”). ☞ Make sure ventilation is adequate if pump is installed in a housing or if ambient temperature is elevated. Keep a distance of minimum 20 cm between fans and ambient parts. ☞ 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).
page 14 of 46 Attention: Important notes regarding the use of gas ballast ☞ Make sure that air/gas inlet through the gas ballast valve never lead to hazardous, explosive or otherwise dangerous mixtures. If in doubt, use inert gas. ☞ When using air rather than inert gas, risk of significant damage to equipment and/or facilities, risk of personal injury or even loss of life exists due to the formation of hazardous and/or explosive mixtures if air and pumped media react inside or at the outlet of the pump.
page 15 of 46 Catchpot at inlet: ➨ Admit air or inert gas (via inlet of pumping unit) to atmospheric pressure. Remove joint clip, remove catchpot and drain condensate. ➨ Reassemble drained catchpots. Important: Comply with regulations when disposing solvents/condensates. Reuse if possible, purify if contaminated. Shutdown: Short-term: Has the pump been exposed to condensate? ☞ Allow the pump to continue to run at atmospheric pressure for a few minutes.
page 16 of 46 Description After the connection of components the controller can be operated in different basic modes, see ”Basic modes and menu structure”. When switching on the controller, the current basic mode and the number of version are displayed for 2s.
page 17 of 46 Connections vacuum connection cover fuse switch output 8-pin socket for connection of coolant valve or isolation valve or speed control signal (PWM) serial interface RS 232 C connection of pump or of valve according to power supply (switch output) connection mains cable 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 18 of 46 Assignment of pins 3 7 5 8 2 4 6 1 1 2 3 4 5 6 7 8 coolant valve + 24V isolation valve external error external error + mass (PWM -) PWM + (speed control signal for VARIO pumps) +12 V Notes on operation For operation it is necessary to install valves and/or vacuum pumps. Note: Texts written in Courier font mirror the display of the LCD of the controller. vacuum connection Max. permitted pressure at pressure transducer: 2 bar (absolute).
page 19 of 46 General view of factory-set modes VNC 1 press key Esc during switching on factory-set mode Factory-set mode ”Vacuum control” (pControl) Controller controls - pump and / or isolation valve according to preset pressure in twopoint controller continuous pumping - VARIO pump exactly according to preset pressure* - coolant valve Factory-set mode ”VACUU•LAN” (VACUULAN) Controller controls - pump according to preset pressure and time - VARIO pumps according to preset pressure and time* - coolant
page 20 of 46 Menu structure of controller after 2 sec VACUULAN V. 2.00 Switch on 1013mbar Start ↵ co ntr ol” Esc on ly p os sib le Esc Function menu Function Cont.
RS 232 Databits RS 232 Parity Cal.Sens Cal.Atm not possible see section RS 232 Remote Sound On Sound Off Select Sound ”Interface parameters” ”Readjustment” see section RS 232 Baud Cal.Sens Cal.Vac RS 232 Handsh. Select RS 232 Select Cal.Sens Units hPa Units Torr Units mbar ☞ ☞ ☞ ☞ ☞ Esc Select Units Esc Sprache Francais Language Deutsch Language English Select Language ↵ 1013mbar Start Delay xxxx min Select Delay Control Pump Control Valve Select Control ext.
page 22 of 46 Working with the controller Notes on selecting the basic mode The controller VNC 1 can be adapted to the specific application by choosing the appropriate mode, VACUU•LAN, continuous pumping, vacuum control, pressure check or RC 5/RC 6 management. The components of the chemistry vacuum system (e.g. ”Valve”, ”VARIO”) have to be preset once only. The basic mode as from last operation and the preselected values (e. g. for pressure, pumping speed or switch-off time) are stored.
page 23 of 46 Program menu in mode VACUULAN and VCL 8cyl 1013mbar Start Esc VACUULAN p Set ↵ ↵ p Set 25mbar ☞ ☞ ☞ ☞ VACUULAN t Off VACUULAN p On VACUULAN tProcess ↵ ↵ t Off 15 min p On 150mbar tProcess 99 h Use keys ▲ or ▼ in the program menu to select an item. Confirm selection with key ”Enter”. Adjust parameters with keys ▲ or ▼. Confirm with key ”Enter” or return to original setting pressing ”Esc”.
page 24 of 46 Manually controlled vacuum applications: In general: Avoid parallel processes which differ strongly in their demands concerning pumping speed or ultimate vacuum as well as their simultaneous operation. If several manually controlled ports are operated simultaneously, it is recommended to install a flow control, such that the required process pressures of the applications are just attained.
page 25 of 46 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 from time to time and readjust if necessary. For readjustment, the device has to be adjusted both at atmospheric pressure as well as under vacuum.
page 26 of 46 Interface parameters The controller VNC 1 is equipped with a serial interface (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). The controller can be operated via serial interface.
page 27 of 46 Read commands Function Command Response Description Actual pressure IN_PV_1 XXXX mbar or XXXX Torr or XXXX hPa Unit according to preselection Actual pumping speed IN_PV_2 XX.
page 28 of 46 Read commands Function Command Response Error status IN_ERR Description XXXX 1: Last command to interface incorrect 1: Failure at pressure transducer 1: Overpressure 1: See ERR_1 Error status IN_ERR_1 XXXX 1: Temperature error 1: Error isolation valve 1: Error coolant valve 1: External errorr (e.g.
page 29 of 46 Read command Function Command Response Status of process control IN_STAT_1 XXXXX Description Mode : see IN_STAT Status of operation : see IN_STAT Isolation valve 0: closed 1: open Cooling water 0: closed valve 1: open Relay 0: not operated 1: operated Write commands Function Command Parameter Description Preset pressure OUT_SP_1 XXXX In unit according to selection at controller (0001 to 1060 mbar (hPa) or 0001 to 0795 Torr) Pumping speed OUT_SP_2 XX.X In Hz (01.0 to 60.0, 99.
page 30 of 46 Write commands Function Configuration Command Parameter OUT_CFG XXXXXXX Control Description 0: Remote off 1: Remote on 0: Unit of pressure mbar 1: Unit of pressure Torr 2: Unit of pressure hPa 0: External error off 1: External error on (evaluation) 2: Stop (control is stopped) 0: Acoustic signal not configured 1: Acoustic signal configured 0: Isolation valve not existing 1: Isolation valve existing 0: Coolant valve not existing 1: Coolant valve existing 0: Valve 1: Pump 2: VARIO Start pr
page 31 of 46 Installation and accessories 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 VCL 10 VACUU•LAN® manual flow control module VCL 01 ........................................................................ 677106 VCL 01 VACUU•LAN® shut off / manual flow control module VCL 02 .........................................................
page 32 of 46 Troubleshooting Fa u l t Possible cause R e m e dy No display. Î Mains cable not plugged in? ) Plug in mains cable. Switch on device. Check fuse in building. Î Fuse defective? ) Check fuse in building and fuse at switch output of VNC 1, replace if necessar y. Î Other cause (device defective)? ) Retur n controller to the factor y for repair. Display disappears, Î Ther mal over load at controller, ambient inter nal over load protection t e m p e ra t u r e t o o h i g h ? activated.
page 33 of 46 Fault Possible cause R e m e dy P u m p d o e s n o t wo r k . Î Ther mal over load of the pump? ) A l l ow t h e p u m p t o c o o l down, check system. Pump fails to star t or stops immediately. Î Mains not plugged in, electr ical supply failure? ) Plug in. Check fuse. Î Pressure in outlet pipeline too high? ) Remove blockade in line, open valve. Î Motor over loaded? ) A l l ow m o t o r t o c o o l , identify cause of failure.
page 34 of 46 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 46 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.
page 36 of 46 Disassembling the pump from the pump support ➨ Use open-ended wrench (w/f 17) to remove union nut on the fitting of the cover plate. ➨ Use open-ended wrench (w/f 14) to turn elbow fitting 1/4 of a turn, remove hose. ☞ Do not remove the elbow fitting from the cover plate. Through reassembly a leak may result. ➨ Remove union nut at the exhaust waste vapour condenser and remove hose from the inlet of the condenser.
page 37 of 46 ➨ Use open-ended wrench (w/f 14) to turn elbow fitting 1/4 of a turn, remove hose. ☞ Do not remove the elbow fitting from the pump head. Through reassembly a leak may result. ➨ 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 and valves. ☞ Never remove parts by using a spiky or sharp-edged tool (e.g.
page 38 of 46 ☞ 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. ☞ Use petroleum ether or industrial solvent to remove deposits if necessary. Do not inhale. Replacing the diaphragm ➨ Use face wrench to remove diaphragm support disc. ➨ 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.
page 39 of 46 Assembling pump heads ➨ 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, valves and housing cover with housing cover insert. ☞ 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.
page 40 of 46 ➨ Tighten union nuts first by hand and then tighten one full turn using open ended wrench (w/f 17). 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 120 mbar but pump does not achieve the ultimate total pressure: Check hose connectors between pump heads and manifolds for leaks.
page 41 of 46 ➨ Tighten union nut first by hand and then tighten by one full turn using open-ended wrench. Cleaning and assembling components Overpressure safety relief device ............................. 638821 (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.
page 42 of 46 Calibration in the factory Control of measuring equipment The VACUUBRAND DKD calibration laboratory is accredited by the Physikalisch-Technische Bundesanstalt (PTB; German national institute for science and technology and the highest technical authority of the Federal Republic of Germany for the field of meteorology and certain sectors of safety engineering) for the measurable variable pressure in the pressure range from 10-3 mbar to 1000 mbar in accordance with the general criteria for the o
page 43 of 46 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 44 of 46 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 45 of 46 Konformitätserklärung Declaration of conformity Déclaration de conformité Chemie-Pumpstand / Chemistry pumping unit / Groupe de pompage chimique PC 500 LAN (230 V; 688140, 688141, 688142) PC 600 LAN (230 V; 688160, 688161, 688162) 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 46 of 46 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.
