Pfeiffer Vacuum OKTA 2000 ATEX, Operating Instructions Manual

Page 1: ...OPERATING INSTRUCTIONS EN Translation of the Original OKTA 2000 ATEX Roots pump ...

Page 2: ...feiffer vacuum de Further operating instructions from Pfeiffer Vacuum can be found in the Download Center on our website Disclaimer of liability These operating instructions describe all models and variants of your product Note that your product may not be equipped with all features described in this document Pfeiffer Vacuum constantly adapts its products to the latest state of the art without pri...

Page 3: ...pe of delivery 23 4 Transportation and Storage 24 4 1 Transporting the vacuum pump 24 4 2 Storing vacuum pump 25 5 Installation 26 5 1 Preparatory work 26 5 2 Setting up vacuum pump 26 5 3 Filling with lubricant 27 5 4 Connecting the vacuum side 28 5 5 Connecting the fore vacuum side 29 5 6 Setting and checking the temperature monitoring 30 5 6 1 Check thermometer installation dimension 30 5 6 2 A...

Page 4: ... 47 7 5 Cleaning the overflow valve 47 8 Decommissioning 49 8 1 Shutting down for longer periods 49 8 2 Recommissioning 49 9 Recycling and disposal 50 9 1 General disposal information 50 9 2 Dispose of Okta roots pumps 50 10 Malfunctions 51 11 Service solutions by Pfeiffer Vacuum 53 12 Spare parts 55 12 1 Ordering spare parts packs 55 13 Accessories 56 13 1 Accessory information 56 13 2 Ordering a...

Page 5: ...ion level 31 Tbl 11 Evaluated frequency ranges 39 Tbl 12 Characteristic bearing damage frequencies of the roots pump 40 Tbl 13 Characteristic frequencies of the roots pump 40 Tbl 14 Relevant frequency range of the motor 40 Tbl 15 Maintenance intervals 44 Tbl 16 Overflow valve maintenance intervals 44 Tbl 17 Troubleshooting 52 Tbl 18 Accessories 56 Tbl 19 Consumables 56 Tbl 20 Conversion table Pres...

Page 6: ...ig 7 Filling with lubricant 28 Fig 8 Loading capacity of the connection flange 29 Fig 9 Check temperature monitoring 30 Fig 10 Delta connection for low voltage 32 Fig 11 Star circuit for high voltage 33 Fig 12 Checking the direction of rotation 33 Fig 13 Connection example with PTC thermistor tripping unit 34 Fig 14 Position of the vibration sensors 38 Fig 15 Draining lubricant 46 Fig 16 Filling w...

Page 7: ...ument Operating instructions for the motor Supplier document Operating instructions for the coupling Supplier document You can find these documents in the Pfeiffer Vacuum Download Center 1 1 2 Variants These instructions apply for different roots pump designs Permissible temperature range Lubricant type 5 C Ta 40 C P3 20 C Ta 40 C H1 Tbl 1 Variants 1 2 Target group These operating instructions are...

Page 8: ...y Mod No PP W73 n max 3600 1 min Oil P3 7 0 l S N max 5190 m h 06 2019 II 3 3G Ex h IIB T3 Gc X Ser No 1234567895 5 C T 40 C a Rating plate example The rating plate is located on the front side above the sight glass Motor rating plate not shown Vor Inbetriebnahme Pumpe mit Öl füllen Fill the pump with oil before putting into operation Remplir la pompe d huile avant la mise en route Sticker red Fil...

Page 9: ...eviations Abbreviation Explanation AS Sealing gas content at the operating gas flow OI Operating instructions DIN German Institute for Standardization Deutsches Institut für Normung EPL Equipment Protection Level ISO International Organization for Standardization n Rotation speed Hz p Intake pressure hPa PE Protective earth earthed conductor p0 Ambient pressure hPa pV Fore vacuum pressure hPa PN N...

Page 10: ...Abbreviation Explanation WAF Width Across Flats Ta Permissible ambient temperature Tbl 3 Abbreviations used 1 4 Trademark proof Loctite is a trademark of HENKEL IP HOLDING GMBH About this manual 10 62 ...

Page 11: ...is docu ment 2 2 Safety instructions All safety instructions in this document are based on the results of the risk assessment carried out in accordance with Machinery Directive 2006 42 EC Annex I and EN ISO 12100 Section 5 Where applica ble all life cycle phases of the product were taken into account Risks during transport DANGER Risk of explosion from electrostatic charging during transport There...

Page 12: ...ient lubrication can lead to bearing damage There is a risk of explosion due to causing an ignition hazard and a risk of serious injuries Exclusively utilize the permissible lubricants for the intended temperature range When filling refilling or changing the lubricant always utilize the lubricant type specified on the rating plate WARNING Risk of fatal injury due to electric shock on account of in...

Page 13: ...vent of a process independent in crease of the motor current 10 the roots pump is switched off As an alternative perform a vibration measurement at the defined measuring points with the pre scribed time intervals WARNING Risk of crushing on rotating parts when reaching into the open flange The pistons continue to run in the vacuum after switching off the motor and can trap fingers and hands within...

Page 14: ... maintenance work there is a risk to health from contact with these poisonous substances Illegal disposal of toxic sub stances causes environmental damage Take suitable safety precautions and prevent health hazards or environmental pollution by toxic process media Decontaminate affected parts before carrying out maintenance work Wear protective equipment WARNING Danger to life from electric shock ...

Page 15: ...is product Every person who is involved in the installation operation or maintenance of the product must read understand and adhere to the safety related parts of this document Infringement of conformity due to modifications to the product The Declaration of Conformity from the manufacturer is no longer valid if the operator changes the original product or installs additional equipment Following t...

Page 16: ...re Note The device may only be used in atmospheres susceptible to explo sion due to gases or vapors Operation in dust charged potentially explo sive atmospheres is not permitted Type of protec tion Identification code Ex h designated in the standard DIN EN ISO 80079 36 for non electrical equipment A protection type established for electrical equipment is not used Explosion groups Gases and vapors ...

Page 17: ... in structions Hot gases Compression of the re quired gases Measure the gas temperature in the exhaust channel using the supplied thermometer and evaluate the temperatures Note the information in the operating instructions of the thermometer Mechanical sparks Contact of the pistons in the suction chamber The air gaps for the maximum gas temperature are de signed taking into account a safety factor...

Page 18: ...nge to the shaft in accordance with standard EN 50347 2001 the table values reduced to 50 are valid Or Regular vibration measurement at the defined measuring points and required time intervals x x Gas outlet tempera ture Monitor the gas outlet temperature with the supplied thermometer see chapter Setting and checking the temperature monitor ing page 30 x x Tbl 6 Measures and safety equipment 2 5 L...

Page 19: ...ss until it can be operated with the minimum rotation speed 2 7 Foreseeable improper use Improper use of the product invalidates all warranty and liability claims Any use that is counter to the purpose of the product whether intentional or unintentional is regarded as improper use in particular Pumping media that can corrode or not be withstood by the vacuum pump materials Components contained in ...

Page 20: ...Use of mineral based lubricant such as P3 with an oxygen concentration 21 Mineral based lubricants are combustible and ignite at high temperatures and when they come into contact with pure oxygen These lubricants oxidize heavily and thus lose their lubricating ca pacity Safety 20 62 ...

Page 21: ...ter 1 2 3 4 5 6 7 9 10 11 12 8 Fig 2 Okta 2000 ATEX design 1 Blank flange mounted on the vacuum flange 7 Thermometer 2 Eye bolts 8 Fore vacuum flange 3 Valve for inert gas filling mounted on the measurement connection 9 Drain screw 4 Motor ATEX design 10 Sight glass 5 Magnetic coupling hidden by the lantern 11 Filler screw 6 Sealing gas connections 4 12 Overflow valve 3 1 1 Design with overflow va...

Page 22: ...rcumstances remove the blocked overflow valve As an alternative use the optionally available ATEX compliant overflow valve Fig 4 Okta ATEX overflow valve blocked 3 2 Identifying product To ensure for a clear identification of the product when communicating with Pfeiffer Vacuum always keep all of the information on the rating plate to hand The following information is shown on the rating plates Pum...

Page 23: ...ve cover for the connection flange Screw kit for the connection flange 2 eye bolts for lifting the roots pump Lubricant Thermometer Ball valve Locking screw Operating instructions of the roots pump Operating instructions of the motor Additional documents for the thermometer Additional documents for the coupling incl declaration of conformity Product description 23 62 ...

Page 24: ...ies Secure the danger zone if necessary Pay attention to the center of gravity of the load during transport Ensure even movements and moderate speeds Observe safe handling of the transport devices Avoid sloping attachment aids Never stack products Wear protective equipment e g safety shoes Instructions for safe transport Only remove the protective cover for the connection flange once the pipes hav...

Page 25: ...e roots pump in the roots pump interior are provided with corrosion protection Storage Pfeiffer Vacuum recommends storing the products in their original transport packaging Procedure 1 Vacuum seal both connection flanges 2 Store the roots pump only in dry dust free rooms within the specified ambient conditions 3 Evacuate and then fill the suction chamber with nitrogen to achieve the best corrosion...

Page 26: ... 3 1 Fig 6 Dismantle the fittings to vent the vacuum pump 1 Protective cover 5 Small flange 2 Measurement connection 6 Circlip 3 Seal 7 Ball valve 4 Locking screw Draining the nitrogen 1 Open the ball valve and establish the pressure compensation 2 Undo the circlip and at the same time remove the ball valve 3 Unscrew the small flange on the measurement connection 4 Lock the measurement connection ...

Page 27: ...ible 8 Ensure that the motor rating plate remains accessible at all times for a clear view of the voltage and frequency specifications 9 Maintain the minimum distances to bordering surfaces to guarantee sufficient air circulation 10 Fill with lubricant prior to first commissioning 5 3 Filling with lubricant The operating fluid type specified for the roots pump and the respective filling quantity a...

Page 28: ...oots pump NOTICE Property damage from intake of solid particles During commissioning there is a risk of damage to the suction chamber from dirt from the system or the pipes Use a suitable protective strainer start up strainer in the intake flange Ensure that this strainer is only removed when the risk of solid particles entering the vacuum pump can be excluded Observe any pumping speed decrease Co...

Page 29: ...he roots pump CAUTION Danger of injury from bursting as a result of high pressure in the exhaust line Faulty or inadequate exhaust pipes lead to dangerous situations e g increased exhaust pressure There is a danger of bursting Injuries caused by flying fragments the escaping of high pressure and damage to the unit cannot be excluded Route the exhaust line without shut off units Observe the permiss...

Page 30: ...eratures are generated in the exhaust channel of the roots pump In order to avoid effective sources of ignition due to prevailing gas temperatures the roots pump is equipped with a thermometer that measures the gas temperature in the exhaust channel Thermometer Characteristics Thermometer with flat TA30A connection head 68 5 mm 2 thermocouples in the protective pipe 1 TMT82 type head transmitter i...

Page 31: ...tion protection system on the operator side in accordance with the requirements for the device category or EPL Observe the necessary ignition protection system type Regular check Check the thermometer at regular intervals Compare with other process temperatures You can obtain information on calibration directly from Endress Hauser 5 7 Connect to mains power supply DANGER Danger to life from electr...

Page 32: ... range specified in the technical data The vacuum pumps are equipped with three phase motors for different voltages and frequencies The applicable motor type is shown on the motor rating plate Standard versions Three phase motor with PTC without switch and mains cable 5 7 1 Connecting three phase motor with 6 pin terminal board NOTICE Property damage from high starting torque The specific load beh...

Page 33: ...edure When switching on for the first time check the roots pump s direction of rotation 1 Switch the vacuum pump on briefly 2 to 3 seconds The motor and coupling must rotate clockwise see directional arrow on housing cover 2 If the direction of rotation is incorrect exchange the two phases on the connection cable in the terminal box 5 7 3 Connecting the PTC thermistor tripping unit Tripping units ...

Page 34: ... inner and outer coupling The eddy currents that are caused as a result lead to the overheating of the magnetic coupling When the vacuum pump is used as intended the magnetic coupling is unlikely to become overloaded Causes of overloading if not used as intended The backing pump cannot handle the volume of gas required by the Okta ATEX increased pres sure build up between the roots pump and the ba...

Page 35: ... modulated PWM motor voltage that comprises voltage blocks with a relatively steep rise and fall speed The steepness of the flanks of the voltage blocks de fine the voltage slew rate SR Δu Δt Factors which influence the voltage slew rate are the line length line cross section and shielding Information is provided by the motor manufacturer in accordance with IEC60034 and IEC61800 2 Configuring the ...

Page 36: ...at which the backing pump can handle the conveyed volume of gas Depending on the pumping speed of the backing pump S V the fore vacuum pressure for the roots pump is calculated as pV 70 hPa 1 SV Sth Example Okta ATEX with nominal pumping speed Sth 2155 m3 h at 50 Hz Backing pump with pumping speed SV 250 m3 h at 50 Hz Cut in pressure pV 70 hPa 1 250 m3 h 2155 m3 h 79 2 hPa Impermissible continuous...

Page 37: ...ated volume flow rate of the roots pump m3 h Example for Okta 2000 ATEX with e g 20 hPa intake pressure and 8 sealing gas content QS 2065 20 0 08 1013 QS 3 26 Nm3 h At discharge pressures 100 mbar QS Sth pV p AS p0 6 5 Checking the power input DANGER Risk of injury due to the bearing bursting after overheating During longer operation with defective bearings there is a risk of explosion due to hot ...

Page 38: ...otating parts Part 1 DIN ISO 10816 3 Mechanical vibrations Evaluation of machine vibration by meas urements on non rotating parts Part 3 Assess the condition of pump motor and bearing over the service life of the roots pump using changes in the trend of characteristic variables compared with a defined reference value from the start up phase Due to the different set up and process conditions Pfeiff...

Page 39: ...ition monitoring define limit values that result in a motor replacement in the event of a change in trend 6 6 1 Monitor the operating condition You must evaluate the vibrations in two relevant frequency ranges in accordance with the broadband method Frequency range A incorporates the significant mechanical and aerodynamic vibration stimula tions of the roots pump Frequency range B takes into accou...

Page 40: ... 4 n Hz Tooth engagement frequency 67 n Hz Harmonic integral numbers of multiples of these frequencies can also be of relevance for the diag nosis Tbl 13 Characteristic frequencies of the roots pump Evaluating the vibration spectrum Due to the early and clearer diagnosis for bearing damage Pfeiffer Vacuum recommends using the envelope curve spectrum Optional method for the overall roots pump The c...

Page 41: ...se the shut off valve in the vacuum line and disconnect the vacuum pump from the process 2 Switch off the vacuum pump 3 Vent the vacuum pump via the intake side 4 Make sure that you do not vent the vacuum chambers through the vacuum pump 5 Switch off the process and pump specific media supply e g the sealing gas supply Procedure with contaminated medium With media that heavily contaminate the suct...

Page 42: ...s Keep limbs out of the reach of the roots pump WARNING Danger of injury from strong magnetic field There is a risk of injury for people with pacemakers and medical implants Make sure that such individuals do not enter the sphere of influence 2 m of the magnetic field Identify rooms in which magnetic couplings are openly accessible with the symbol No access for people with pacemakers Always keep d...

Page 43: ...se If the required intervals listed below are exceeded or if maintenance work is carried out improperly no warranty or liability claims are accepted on the part of Pfeiffer Vacuum This also applies if original spare parts are not used Action Inspec tion Mainte nance level 1 Mainte nance level 2 Mainte nance level 3 Required mate rial described in document OI OI Not rel evant SI Interval daily 1 ye...

Page 44: ...vice instructions Depending on the process the required maintenance intervals can be shorter than the reference val ues specified in the table Please consult Pfeiffer Vacuum if necessary Tbl 15 Maintenance intervals Action Inspec tion Mainte nance level 1 Maintenance level 2 Maintenance level 3 Required material described in document OI OI OI OI Interval daily 1 year After 5000 cy cles or 2 years ...

Page 45: ...ironmental damage Wear suitable personal protective equipment when handling these media Dispose of the lubricant according to locally applicable regulations CAUTION Scalding from hot lubricant Danger of scalding when draining lubricant if it comes into contact with the skin Wear protective equipment Use a suitable collection receptacle Pfeiffer Vacuum recommends determining the precise service lif...

Page 46: ...p application and is highly dependent on the operating conditions 1 Place the collection receptacle underneath 2 Unscrew the filler screws 3 Unscrew both drain screws 4 Fully drain the lubricant 5 Screw the drain screws back in Tightening torque max 32 Nm max min max min 1 2 3 Fig 16 Filling with lubricant 1 Filler screws 3 Sight glass gear chamber 2 Sight glass bearing chamber Maintenance 46 62 ...

Page 47: ...mination of the lubricant and bearing chambers The clearance between pistons and housing are within a tenth of a centimeter range Sustained accu mulating contamination has the following effect the friction heat inside the roots pump increases the power consumption of the roots pump increases the pistons jam Required aids Brushes and cleaning agents Suitable vessel for collecting the cleaning fluid...

Page 48: ... 5 Clean and dry the guide pin from the valve cover 6 Lightly rub the surface with emery cloth grain size 180 Never oil the guide pin this has an adverse effect on damping If necessary replace completely if there are pronounced traces of wear 7 Clean the other parts 8 Inspect all parts for wear and replace if necessary Install the overflow valve 1 Lock the thread on the pressure screw with Loctite...

Page 49: ...achines traffic routes etc as strong vibrations may damage the bearing 8 2 Recommissioning DANGER Risk of explosion from electrostatic charging during transport There is a risk of fatalities when transporting packaging material foil and plastic containers in poten tially explosive areas Ignition can cause very serious injuries and even fatalities Only unpack the vacuum pump outside of potentially ...

Page 50: ...s must be disposed of in accordance with the applica ble regulations relating to environmental protection and human health with a view to reducing natural resource wastage and preventing pollution 9 1 General disposal information Pfeiffer Vacuum products contain materials that you must recycle Dispose of our products according to the following Iron Aluminium Copper Synthetic Electronic components ...

Page 51: ... Industrial Safety and Health We recommend taking advantage of our service training offering Problem Possible causes Remedy Roots pump will not start up Mains voltage is miss ing or the incorrect op erating voltage is present Check mains voltage Check mains fuse protection Check motor switch Thermal protection switch has triggered Detect and fix the cause allow roots pump to cool down if necessary...

Page 52: ...ff immedi ately and clean the suction chamber Damage to the bearing or gear wheels Switch the roots pump off immedi ately contact Pfeiffer Vacuum Serv ice Damage to motor bearing Switch the roots pump off immedi ately Replace the motor contact Pfeiff er Vacuum Service Tbl 17 Troubleshooting Malfunctions 52 62 ...

Page 53: ...lity You can find more detailed information and addresses on our homepage in the Pfeiffer Vacuum Service section You can obtain advice on the optimal solution for you from your Pfeiffer Vacuum representa tive For fast and smooth service process handling we recommend the following 1 Download the up to date form templates Explanations of service requests Service requests Contamination declaration a ...

Page 54: ...oduct in suitable stable transport containers only e Maintain applicable transport conditions ERKLÄRUNG KONTAMINIERUNG 6 Attach the contamination declaration to the outside of the packag ing 7 Now send your product to your local Service Center 8 You will receive an acknowledgment quotation from Pfeiffer Vac uum Our sales and delivery conditions and repair and maintenance conditions for vacuum devi...

Page 55: ...s packs Observe the following instructions when ordering spare parts Have the vacuum pump part number and any other necessary details from the rating plate to hand when ordering spare parts Install original spare parts only Spare parts 55 62 ...

Page 56: ... Description Order number Sealing gas kit PP 144 135 T Blank flange set for Okta 1000 M ATEX Okta 2000 M ATEX DN PN16 stainless steel PP 043 885 T Seal kit FKM for Okta 1000 M ATEX Okta 2000 M ATEX DN PN16 PP 043 886 T Screw set for Okta 2000 M ATEX DN PN16 zinc plated steel PP 144 117 T Tbl 18 Accessories Description Order number P3 mineral oil 1 l PK 001 106 T P3 mineral oil 5 l PK 001 107 T P3 ...

Page 57: ...0 1 59 2 0 75 0 987 Pa m3 s 10 1 592 7 5 9 87 sccm 1 69 10 2 1 69 10 3 1 1 27 10 2 1 67 10 2 Torr l s 1 33 0 133 78 9 1 1 32 atm cm3 s 1 01 0 101 59 8 0 76 1 Tbl 21 Conversion table Units for gas throughput Special versions The technical data and dimensions for the vacuum pump refer to the specified standard version For deviations in special versions please refer to the rating plates or the enclos...

Page 58: ... ISO 2151 at intake pressure 1 hPa 72 dB A 72 dB A Emission sound pressure level EN ISO 2151 at intake pressure 10 hPa 75 dB A 75 dB A Protection degree IP55 IP55 Cooling method Air Air Motor protection 3TF 3TF Ambient temperature 5 40 C 20 40 C Shipping and storage temperature 10 40 C 10 40 C Operating fluid P3 H1 Operating fluid amount 5 l 5 l Weight with motor 390 kg 390 kg Tbl 22 Technical dat...

Page 59: ... tief depth 8x Ø 2 4 0 Ø 2 8 5 375 Ø 220 Ø 180 DN 100 PN 16 M16 21 27 tief depth 8x 24 115 230 440 455 Ø18 4x 300 360 420 292 210 20 ATEX Thermoelement temperature sensor Dichtrille sealing groove Innen inner Ø162 Außen outer Ø174 Tiefe depth 3 4 mm Fig 18 Okta 2000 ATEX Technical data and dimensions 59 62 ...

Page 60: ...ion of the use of certain hazardous substances delegated directive 2015 863 EU Harmonized standards and applied national standards and specifications DIN EN ISO 12100 2011 DIN EN ISO 13857 2008 DIN EN 1012 2 2011 12 DIN EN 61000 6 2 2006 DIN EN ISO 2151 2009 DIN EN 61000 6 4 2011 DIN EN 1127 1 2019 DIN EN IEC 63000 2019 DIN EN ISO 80079 36 2016 12 DIN EN ISO 80079 37 2016 12 DIN ISO 21360 1 2016 I...

Page 61: ...ion of the use of certain hazardous substances delegated directive 2015 863 EU Harmonized standards and applied national standards and specifications DIN EN ISO 12100 2011 DIN EN ISO 13857 2008 DIN EN 1012 2 2011 12 DIN EN 61000 6 2 2006 DIN EN ISO 2151 2009 DIN EN 61000 6 4 2011 DIN EN 1127 1 2019 DIN EN IEC 63000 2019 DIN EN ISO 80079 36 2016 12 DIN EN ISO 80079 37 2016 12 DIN ISO 21360 1 2016 I...

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Page 64: ... PW0141 G Date 2202 P N PW0141BEN ...