Pfeiffer Vacuum OnTool Booster 150 Manual de usuario

Translation of the original instructions

Operating Instructions

PU 0058 BEN/% (1)

OnTool BoosterTM 150

Side Channel Pump with TCP 2000

Index

Page

1. Safety Instructions.......................... 3

1.1. For Your Orientation ......................................... 3

1.2. Pictogram Definitions ....................................... 4

2. Understanding The Pump ............. 5

2.1. Main Features................................................... 5

Proper Use........................................................ 5

Improper Use.................................................... 5

2.2. Delivery Content ............................................... 6

3. Installation....................................... 7

3.1. Preparations For Installation ............................. 7

3.2. Transportation Of The Pump ............................ 7

3.3. Setting Up The Pump And Fastening the

Mounting Brackets ........................................... 7

3.4. Filling In And Checking The Lubricant............... 8

3.5. Connecting The Vacuum Side........................... 8

3.6. Connecting The Exhaust Flange ....................... 9

3.7. Connecting The Cooling Unit .......................... 10

3.8. Connecting The Pump To The Electronic Drive

Unit TCP 2000................................................. 11

3.9. Using Sealing Gas .......................................... 12

3.10. Pumping Of Vapors ........................................ 13

3.11 Pumping Of Light Or Heavy Gases................. 13

4. Operations..................................... 14

4.1. Before Switching On The Pump ..................... 14

4.2. Switching The Pump ON ............................... 14

4.2.1.Motor Temperature Monitoring...................... 14

4.3. Gas Type Dependent Operations ................... 14

4.4. Switching The Pump OFF............................... 15

4.5. Preparation For Transport And Shutting Down

The Pump For Longer Periods ........................ 15

5. What To Do In The Case Of

Breakdowns .................................. 16

6. Maintenance.................................. 17

6.1. Precautionary Measures During Maintenance

Work ............................................................... 17

6.2. Replacing The Lubricant ................................. 17

7. Service ........................................... 19

8. Technical Data ............................... 20

8.1. Dimensions Diagram ...................................... 20

9. Accessories.................................... 21

Declaration of Conformity ...... Last Page

Please note:

Current operating instructions are also available via

www.pfeiffer-vacuum.net.

☞Read and follow all instructions in this manual.

☞Inform yourself regarding:

– Hazards which can be caused by the pump;

– Hazards which can be caused by your system;

– Hazards which can be caused by the media being pumped.

☞Avoid exposing any part of the body to vacuum.

☞Observe the safety and accident prevention regulations.

☞Regularly check that all accident prevention measures are

being complied with.

☞Operate the pump with only in conjunction with the

TCP 2000.

☞Do not operate the pump with open vacuum flange.

☞Do not carry out any unauthorised conversions or alterati-

ons to the pump and the TCP 2000.

☞Operate the pump only when the lubricant reservoirs are

filled

☞Operate the pump only with water cooling

☞When returning the pump observe the shipping

instructions.

☞The pump must be anchored in accordance with the instal-

lation instructions.

☞Operate the pump only with fastening brackets mounted.

☞Do not disconnect any plug between the pump and the

TCP 2000 during operations.

☞When the vacuum flange is open disconnect the voltage

supply to the TCP 2000.

☞When working on the pump, the vacuum flange should

only be opened once the rotor is at rest.

☞During operations temperatures of up to 65 °C can arise of

the pump. Take care to avoid burns !

☞The unit has been accredited protection class IP 51. When

the unit is operated in environments which require other

protection classes, the necessary measures must be

taken.

☞The mains connection must be subject to a safe

connection to the PE (protection class 1).

1. Safety Instructions

1.1. For Your Orientation

Instructions in the text

➡ Operating instructions: Here, you have to do something.

Symbols Used

The following symbols are used throughout in the illustrations:

Vacuum flange

Exhaust flange

Cooling water connection

Mains connection

Gas ballast connection

Sealing gas connection

Abbreviations Used

TCP 2000 = Electronic Drive and Control Unit

fend = Final pump rotation speed

Position Numbers

Identical pump and accessory parts have the same position

numbers in all illustrations.

Modifications reserved.

Danger of damage to the pump or system.

CAUTION

Important note.

☞

PLEASE NOTE

Danger of burns from touching hot parts.

WARNING

Danger of an electric shock.

WARNING

Danger of injury from rotating parts.

WARNING

Danger of personal injury.

WARNING

1.2. Pictogram Definitions

Danger of poisoning.

DANGER

Excessive noise!

Wear suitable ear protection!

WARNING

2.1. Main Features

The Pump OnToolTM Booster is driven and controlled by the

Electronic Drive Unit TCP 2000 (not depicted in the

illustration). The power pack is integrated in the Electronic

Drive Unit TCP 2000.

Operating Method

The OnToolTM Booster is a multistage side channel blower

combined with drag stages.

For pump operation there are two kinds of operating media

required:

– Water cooling for the drive components and the suction

chambers inside the pump,

– Lubricant to oil the ball bearings on both ends of the rotor.

2. Understanding The Pump

Proper Use

– The pump may only be used for the purpose of generating

vacuum - primarily for pumping out chambers.

– The pump may only be operated with the Electronic Drive

and Control Unit TCP 2000.

– The pump may only be used with both lubricant reservoirs

filled.

– The pump may only be operated with water cooling.

– Only use the pump for clean processes and where the inci-

dence of particles is not involved.

– Only use gas ballast when pumping condensating vapours.

– Do not pump explosive gases (special operation conditions

should be checked with Pfeiffer Vacuum).

– Installation, start-up, operating and maintenance

instructions must be observed.

– Accessories other than those named in this manual may

not be used without the agreement of Pfeiffer Vacuum.

– Max. permissible intake pressure for continous operation:

1000 mbar --> for N2 and air.

– Max. permissible vacuum chamber volume for loadlock

applications: <1 m3

Improper Use

The following are regarded as improper:

– The pumping of liquids.

– The pumping of corrosive and explosive gases.

– The pumping of other gases than air or nitrogen without

the express agreement of Pfeiffer Vacuum.

– Do not operate the pump in locations where there is an

explosion hazard.

– The pump may not be used for the purpose of generating

pressure.

– Operation in the sphere of magnetic fields (only after

consulting the manufacturer).

– Installation in systems where the pump is subjected to

impact-like stress and vibrations or the effect of

periodically occuring forces.

– Uses not covered above, and, in particular:

– Connection to pumps and units which is not permitted

according to their operating instructions.

– Operating the pump in environments which require a

protection class superior to IP 51.

– The use of other power pack units or accessories which

are not named in this manual or which have not been

agreed by the manufacturer.

Improper use will cause any rights regarding liability and

guarantees to be forfeited.

93231

253

81/82

OnToolTM Booster

1 Vacuum flange (various position available)

2 Exhaust flange

9 Sight glass

31 Lubricant filler screw

32 Lubricant drain screw

53 Flange socket for the connecting cable for the pump drive

electronics TCP 2000

80 Cooling water connection, Input

81 Cooling water connection, Outlet

2.2. Delivery Content

– Lubricant F3 included with the delivery (50 ml), inital oil

filling for each lubricant reservoir is 24 ml.

– Cable socket (counter-piece to the mains connection

plug).

– Hose nozzles for the cooling water monitor and the cooling

water connection (input / output) including sealing rings.

– Reducing nipple for the cooling water monitor

– Cooling water monitor

– Blank flange DN 50 ISO-KF (intake side), mounted with

4 claw grips, centering ring and screws.

– Blank flange DN 25 ISO-KF for exhaust flange, mounted

with centering ring and clamping ring.

– Operating Instructions, PU 0058 BN.

3. Installation

3.1. Preparations For Installation

Do not carry out any unauthorised conversions

or alterations to the pump.

➡Fill up both lubricant reservoirs (see Section 3.4. Filling And

Checking The Lubricant).

➡Install cooling water monitor and connect inlet and outlet

line of the water cooling connection.

➡Ensure free air flow for the ventilator in the electronic

drive unit.

– Only remove the blank flange from the vacuum flange

and exhaust flange immediately before connection.

– Max. permissible ambient temperature for the pump is

40 °C.

3.2. Transportation Of The Pump

➡Only lift and move the pump while maintaining it horizontal-

ly (see figures below).

– For this use suitable transport straps or screw an eye

bolt into the transport bores T and lift the pump with

lifting bar.

Ensure even distribution of weight when lifting.

--> Danger of tilting!

WARNING

3.3. Setting Up The Pump And Fastening

The Mounting Brackets

➡Fasten the mounting brackets (3 Stk.).

No forces from the piping system must be

allowed to act on the pump.

Suspend or support all pipes to the pump.

Permissible Installation Positions For The Pump

The pump may only be operated in the horizontal

position, with the lubricant reservoirs 16 face

down (see figure below). The maximum deviation

from the horizontal is ± 3°.

CAUTION

Transportation the pump

T Tapped holes for screw in eye bolts

1 ... 2 mm

3°

B1 B

Setting up the pump and fastening the mounting brackets

B Mounting brackets (3 x)

B1 Screw, short M6 (3 x)

B2 Screw, long M6 (3 x)

16 Lubricant reservoirs

3.5. Connecting The Vacuum Side

As standard, the pump is equipped with an inlet opening poin-

ting vertically up for fitting a vacuum flange (DN 50 ISO-KF) or

a corrugated hose. Upon delivery, this opening has been

blanked off with a blank flange including a centering ring, for

the purpose of the protecting the inside of the pump.

The vacuum side of the pump must not be

flanged directly to the vacuum chamber; it must

be flanged via a bellows.

Never suspend the pump on the vacuum flange,

always set up on the standing surface or screw

down.

➡Loosen the screws from the claws and disassemble the

blank flange.

➡Fit the desired component part directly to the inlet opening

using claws; note the centering ring.

Shifting the inlet opening

Depending on the installation situation, the inlet opening may

be shifted to the side or the bottom.

During assembly of component parts do not lay

the pump on the side or the back

➡Disassemble the blank flange (flange cover) at the desired

inlet opening.

CAUTION

Filling In The Lubricant

Fill only when the pump is in the horizontal posi-

tion. Do not fill when the pump is running and

not in evacuated condition.

➡Unscrew both lubricant filler screws 31, taking care with

the sealing.

➡Slowly fill in 24 ml of the accompanying lubricant into each

lubricant reservoir.

➡Screw back in lubricant filler screws 31 with the sealing.

➡During operations or at pump still stand check the

lubricant level on both sight glasses; the permissible level

is shown in the illustration.

➡Switch off pump if lubricant is to be replenished.

➡In non-stop operations check the lubricant monthly, on

both sight glasses 9 after each switch-on.

CAUTION

3.4. Filling In And Checking The

Lubricant

Before first-time starting ensure that both lubri-

cant reservoirs have been filled with each 2244mmll

of Lubricant F3.

The delivery consignment for the standard

pump contains suffient lubricant (50 ml) for one

filling.

If ‘’F3’’ is heated above 300°C, toxic vapours

which can harm the respiratory tract are

emitted. Do not allow ‘’F3’’ to come into contact

with tobacco products (danger of poisoning

when ignited). The precautions necessary in

the handling of chemicals must be observed.

WARNING

CAUTION

V 10 ml

max.

min.

24 ml F3

Filling In And Checking The Lubricant

9 Sight glass (of lubricating pump)

31 Lubricant filler screw

32 Lubricant drain screw

3.6. Connecting The Exhaust Flange

Use usual small flange components (DN 25 ISO-KF) or

screwed hose connections for connecting the exhaust line.

➡Provide the flange connection with clamping ring and

centering ring at the exhaust flange (DN 25 ISO-KF).

➡With rigid pipe connections fit a bellows in the connecting

line to reduce vibration.

➡Vacuum chambers with a volume of > 2 litres must have a

non-return valve on the exhaust side to prevent their

venting via the exhaust flange after switching off the

pump.

Connecting the vacuum flange

1 Flange position at delivery

B Blank flange for all alternative of flange positions

Alternative flange positions (viewed from the bottom)

The utmost cleanliness must be observed when

fitting all high vacuum parts. Unclean

components prolong the pumping time.

➡Fit a vacuum safety valve (Accessory) in the vacuum line.

This prevents the vacuum chamber being ventilated via the

backing pump.

☞

PLEASE NOTE

➡Cover and bolt down with a blank flange the inlet opening

pointing vertically up; note the sealing ring.

➡Fit the desired component part to the inlet opening using

claws; note the centering ring.

non-return

flap

exhaust flange

DN 25 ISO-KF

OnTool

Booster 150

Mounting the non-return flap

➡Lay piping from the pump sloping downward so that no

condensate can flow back into the pump; otherwise fit a

condensate separator.

Be sure to conduct away the exhaust gases

from the pump. Do not reduce the free cross

section of the exhaust flange with following

components. The exhausted process gases and

vapours can represent a health hazard and can

also be environmentally damaging.

Use an exhaust silencer or connect the exhaust

flange to an exhaust line if requested.

WARNING

CAUTION

➡Fit the cooling water monitor in the return line 42..

➡Use the provided cable to connect the terminal box 53 with

the X2 connector of the cooling water monitor 85.

The operation without cooling water monitor is

not permissible.

The actual flow rate will be indicate by a LED

line at the cooling water monitor housing and

controlled at the electronic drive unit.

Cooling water monitor states

Red: Flow rate is below switching point

Yellow: Flow rate reached switching point (preset at works)

Green: Flow rate is higher than switching point

(the requested flow rate is reached)

➡Connect the return line to the cooling water connection 81.

➡Tighten all hose clips and check for firm seating of the

hoses.

☞

PLEASE NOTE

3.7. Connecting The Cooling Unit

The pump housing must be water cooled.

The TCP 2000 electronic drive and control unit is fan-cooled.

Cooling from the cooling water mains

To prevent deposits collecting in the pump the cooling water

must be filtered.

Minimum cooling water requirements:

Mechanically clean, optically clear, no turbidity, no sediment,

chemically neutral.

Oxygen content: max. 4 mg/kg

Chloride content: max. 100 mg/kg

Carbonate hardness: max. 10° dH

Consumption of

potassium permanganate: max. 10 mg/kg

Carbon dioxide: Undetectable

Ammonia: Undetectable

pH-value: 7-9

Fore-line over pressure: max. 6 bar

Minimum flow rate at gas load max.: 120 l/h at 15 °C

320

340

360

300

280

260

240

220

200

180

160

140

120

15 20 25 30

Cooling water consumption against cooling water temperature

Cooling water inlet temperature (T) [°C]

Consumption (Q) [l/h]

Q (water) = 16 x T (water) - 120

Cooling from the cooling water mains

41 Supply line

42 Return line

43 Dirt trap

53 Terminal box

80 Cooling water, IN

81 Cooling water, OUT

85 Cooling water monitor

Connection to the cooling water mains

➡Fit the dirt trap (Accessory) in the supply line.

➡Connect the supply line with hose clips onto the cooling

water connection 80.

➡Fit reducing nipple and hose nozzles at the cooling water

monitor.

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