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Summary of Contents for Heidolph ROTAVAC
- Page 1 1 of 61 ROTAVAC vario Pumping unit Instruction manual 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.: 999248 / 28/04/2011...
- Page 2 page 2 of 61 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.: 999248 / 28/04/2011...
- Page 3 page 3 of 61 [GB] It is imperative to read this instruction man- ual prior to initial operation! Comply with safety instructions! Keep for further use! This documentation is not subject to revision service! 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.
- Page 4 page 4 of 61 ➨ Danger! Immediate danger. Death or severe injuries as well as damage to equipment and environment can occur. ☞ Warning! Possible danger. Severe injuries as well as damage to equip- ment and environment can occur. • Caution! Possible danger. Slight injuries as well as damage to equip- ment and environment can occur.
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Page 5: Reset / Language Selection
page 5 of 61 Reset / Language selection press both switch off V 2. 12 De utsch P o r tu g uê E ngli sh Ρ y ccкий Françai s P o l ski It alia no N ed er l. E spaño l 日本語... -
Page 6: Table Of Contents
page 6 of 61 Contents Reset / Language selection ..................5 Safety information! .....................7 1.1 General information ........................7 1.2 Intended use ..........................7 1.3 Setting up and installing the equipment ..................7 1.4 Ambient conditions ........................8 1.5 Operating conditions ........................8 1.6 Safety during operation ........................9 1.7 Maintenance and repair ...................... -
Page 7: Safety Information
page 7 of 61 Safety information! 1.1 General information NOTICE Read and comply with this manual before installing or operating the equipment. 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. -
Page 8: Ambient Conditions
page 8 of 61 ☞ Always provide a free and pressureless exhaust pipeline. ☞ Max. permitted pressure at the pressure transducer: 1.5 bar (absolute). ☞ Avoid overpressure of more than 0.2 bar in case inert gas is connected to the pump, the gas ballast connection or to a venting valve. • Comply with maximum permissible pressures at inlet and outlet and pressure differences, see section ”Technical data”. -
Page 9: Safety During Operation
page 9 of 61 • The pumps are not suitable for pumping substances which may form deposits inside the pump. Deposits and condensate in the pump may lead to increased temperatures even to the point of excessing the maximum permitted tempera- tures! • If there is a danger of formation of deposits in the pump chamber (check inlet and outlet of the pump), inspect the pump chambers regularly and clean if neces-... - Page 10 page 10 of 61 • Comply with applicable regulations when disposing of chemicals. Take into con- sideration that chemicals may be polluted. Take adequate precautions to protect people from the effects of dangerous sub- stances (chemicals, thermal decomposition products of fluoroelastomers), wear appropriate safety-clothing and safety glasses. • Use only genuine spare parts and accessories. Otherwise safety and perform- ance of the equipment as well as the electromagnetic compatibility of the equip- ment might be reduced.
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Page 11: Maintenance And Repair
page 11 of 61 1.7 Maintenance and repair Wear parts have to be replaced regularly. In case of normal wear the lifetime of the NOTICE diaphragms and valves is > 10000 operating hours. Bearings have a typical durability of 40000 h. ➨... -
Page 12: Standard Items And Options
2 Standard items and options Item 200-240 V 100-120 V 50/60 Hz 50/60 Hz ROTAVAC vario Pumping unit 591-00142-00 591-00142-01 Standard items ROTAVAC vario control / ROTAVAC vario tec ROTAVAC vario control (pump) Power cord 14-007-003-81 14-007-003-89 Instruction manual 01-005-005-24 Warranty card / 01-006-002-58... -
Page 13: Technical Data
13 of 61 3 Technical data Type ROTAVAC vario Pumping unit Maximum pumping speed (ISO 21360) Ultimate vacuum (absolute) without gas mbar ballast* Ultimate vacuum (absolute) with gas bal- mbar last* Maximum permissible inlet pressure (absolute) Maximum permissible outlet pressure (absolute) Maximum permitted pressure difference between inlet and outlet Maximum permissible pressure (absolute) at gas ballast valve... -
Page 14: Gas Inlet Temperatures
page 14 of 61 Controller ceramic diaphragm (alumina), capacitive, abso- Pressure transducer lute pressure, gas type independent Display LCD graphic display, illuminated Pressure units / scale (selectable) mbar, Torr or hPa Measuring range (absolute) 1080 mbar - 0.1 mbar (810 Torr - 0.1 Torr) Maximum control range with internal pressure 1060 mbar –... -
Page 15: Wetted Parts
page 15 of 61 3.2 Wetted parts Components Wetted materials Pump Housing cover PTFE Head cover ETFE carbon fibre reinforced Diaphragm clamping disc ETFE carbon fibre reinforced Diaphragm PTFE Valves FFKM / PTFE Inlet PP, stainless steel, FPM Distributor (at inlet) O-ring Outlet ETFE Tubing PTFE Screw-in fittings ETFE / ECTFE Controller Sensor Aluminium oxide ceramic... - Page 16 16 of 61 ROTAVAC vario Pumping unit Rear side controller connection plug of the venting connection VACUU • BUS line to VARIO pump jacks for connection of serial interface VACUU•BUS components (e.g., RS 232 C coolant valve) external venting valve) rating plate vacuum connection Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully...
- Page 17 17 of 61 ROTAVAC vario Pumping unit with condensate cooler (accessory) 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.: 999248 / 28/04/2011...
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Page 18: Use And Operation
It is possible to access the language selection menu at any time by switching on the controller while keeping the selection knob pressed. 4.1 Using a ROTACOOL reflux cooler If using the ROTAVAC vario Pumping unit together with the ROTACOOL reflux cooler, place the ROTAVAC vario Pumping unit directly on top of the ROTACOOL. -
Page 19: Condensate Cooler (Accessory)
page 19 of 61 After switching off the pump, wait 60 sec. minimum until next switching on. NOTICE Avoid throttling losses by using connecting pipes with large diameter and keep them as short as possible. In case of perturbing exhaust noise connect an exhaust hose. Install outlet pipelines always falling to avoid backflow of condensate towards the pump. When assembling, ensure vacuum-tightness. After assembly, check the complete system for leaks. Secure hose connections at the pump appropriately against accidental detaching. The controller can only be operated with components which are compatible to the BUS system, e. -
Page 20: During Operation
page 20 of 61 • The gas outlet (hose nozzle 10 mm) must not be blocked. The exhaust pipeline has always to be free and pressureless to enable an unhindered discharge of gases. • If necessary connect the exhaust to a suitable treatment plant to prevent the dis- charge of dangerous gases and vapors to the surrounding atmosphere. • Attention: Install hoses of the cooling system in a way to avoid flow / dropping of condensed water onto the pumping unit (especially cables and electronic parts). • Ensure that the coolant outlet pipeline is always free and that it cannot get blocked. -
Page 21: Attention: Important Notes Regarding The Use Of Gas Ballast
page 21 of 61 4.5 Attention: Important notes regarding the use of gas ballast ➨ 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. ➨ Make sure that air/gas inlet through the gas ballast valve never leads to hazard- ous, explosive or otherwise dangerous mixtures. If in doubt, use inert gas. In case of condensable vapors (water vapor, solvents, ...): ☞ Do not pump vapor until the pump has reached its operat- ballast ing temperature. -
Page 22: Shutdown
page 22 of 61 Do not allow the catchpot to get overfilled. Maximum liquid level approx. 80% to NOTICE avoid problems when removing the catchpot. Check liquid level in the catchpot regularly and drain catchpot in time. Permissible range of coolant temperature at the condensate cooler: -15°C to +20°C. Check hose connections prior to starting operation of the cooling system. Check coolant hoses regularly during operation. Removing the catchpot: Remove joint clip, remove catchpot and drain condensate. -
Page 23: Controller
page 23 of 61 5 Controller When switching on the controller for the very first time, a menu to select the language of the controller menu is displayed. Select the desired language e.g., ”English” by turning the selection knob and press to confirm. Then select the pressure unit (”mbar”, ”Torr” or” hPa”) in the same way. It is possible to access the language selection menu at any time by switching on the controller while keeping the selection knob pressed. - Page 24 page 24 of 61 Display and symbols Function of the device: Vac control (displayed in the upper left corner) Pump down Vac control Auto mode Program Configuration 1013 . 2 1013.2 Actual absolute pressure at the pressure transducer mbar mbar Preselected pressure unit Torr Vacuum control to a preset vacuum value (here 100 mbar/Torr/hPa)
- Page 25 page 25 of 61 Notes on selecting the function The controller can be adapted to the specific application by choosing the appropriate function depending on the connected components and the requirements of the application. Automatic detection of the components When switching on the controller the actual configuration of the connected components is checked automatically. Connected components are detected automatically and used and supervised until the controller is switched off. Switch off/on the controller to renew the configuration.
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Page 26: Menu Guide
page 26 of 61 5.1 Menu guide Vac control Pump down Set vacuum 100 mbar Speed Speed Minimum Maximum Delay Delay Duration Duration - - - - - - Graphic - - - - - - - - - - - - Graphic - - - - - - - - - - - - - Back - - - - - - - - - - - - - - Back - - - - - - - Vac control... -
Page 27: Function Pump Down
page 27 of 61 5.2 Function Pump down ➨ Continuous pumping with pressure and time settings • Operation on demand of a speed controlled pumping unit Preselections ☞ Use the selection knob to select the parameters. All parameters can be altered even while operation control is running. ☞ Speed: Preselection of the motor speed for pump down. The selection ”HI” effects the maximum speed and best ultimate vacuum of the pump (with automatic speed reduction at ultimate vacuum). - Page 28 page 28 of 61 Temporary switching from ”Pump down” to ”Vac control” or ”Auto mode” (only if control is run- ning): ☞ Press key ”MODE”. The controller switches to function ”Vac control”, the current vacuum is used as set value. ☞ Pressing key ”MODE” again switches to function ”Auto mode”. The controller adapts the boiling pres- sure starting from the current vacuum. ☞ The preset function of the controller does not change due to this temporary switching. When pressing key ”STOP” the controller is set again to the function ”Pump down”.
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Page 29: Function Vac Control
page 29 of 61 5.3 Function Vac control ➨ Vacuum control to a preset vacuum value • Operation on demand of a speed controlled pumping unit Preselections ☞ Use the selection knob to select the parameters. All parameters can be altered even while operation control is running. ☞ Set vacuum: The ”Set vacuum” is the set point for vacuum control with pinpoint precision. The selec- tion ”Turbo” leads to the optimum backing pressure for a turbomolecular pump. - Page 30 page 30 of 61 Temporary switching from ”Vac control” to ”Auto mode” while process control is running: ☞ Press key MODE. The controller switches to ”Auto mode” and adapts the boiling pressure starting with the actual set value. The preset function of the controller does not change due to this switching. When pressing key ”STOP” the controller is in function ”Vac control” again. Adjustment of the set vacuum during vacuum control: Dynamic, interactive adaptation: ☞ Press the selection knob and keep pressed.
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Page 31: Function Auto Mode
page 31 of 61 5.4 Function Auto mode ➨ Control of a pump in function auto mode: Automatic determination of the boiling vacuum and automatic adaptation of the boiling vacuum in case of changing process parameters. Preselections ☞ Use the selection knob to set the parameters. ☞ Sensitivity: The ”Sensitivity” of the control effects the control speed. High sensitivity leads to a reduced pumping down speed, e. -
Page 32: Function Program
page 32 of 61 5.5 Function Program ➨ Ten programs with up to ten program steps with preset values for vacuum and time can be set and stored. ☞ Edit: Preset values for the process run can be edited: Time: Process runtime for each program step to reach a preset vacuum level or if setting ”Step” runtime after having achieved the vacuum level. -
Page 33: Example For Use
page 33 of 61 The last process is stored in the temporary data memory as long as the controller stays switched on. This program can be transferred to a storage space and edited. Once the program is finished, the clock symbol starts to flash. Confirm the end of the program by press- ing START/STOP (clock symbol will disappear). Attention: If ”Autostart” is set to ”On”, the program will start again (time will be reset to 00:00:00) after a power failure or after switching the controller off/on. Only if the end of the program (clock symbol flashing) has been confirmed by pressing START/STOP, the program will not start again. -
Page 34: Function Vacuulan
page 34 of 61 5.6 Function VACUULAN ➨ Optimised vacuum control for vacuum networks • Operation on demand of a speed controlled pump (VARIO) Preselections ☞ Use the selection knob to select the parameters. ☞ Set vacuum (lower switch-off value): If the pressure drops below the ”Set vacuum” a time-meter starts to run; additionally the motor speed is reduced. The time-meter is reset, if the pressure ex- ceeds the pressure value for switching on again (”Switch on”). -
Page 35: Examples For Use
page 35 of 61 5.7 Examples for use Assembly of a vacuum system ☞ Assemble vacuum connection lines between controller, vacuum pump and apparatus. ☞ Assemble electrical connections. ☞ Connect coolant if necessary. 5.7.1 Vacuum for filtration and suction ☞ Select function ”Pump down”. ☞... -
Page 36: Vacuum For Distillation And Evaporation (E. G. Rotary Evaporator)
page 36 of 61 5.7.3 Vacuum for distillation and evaporation (e. g. rotary evaporator) Semi-automatic distillation and evaporation ☞ Select function ”Pump down”. ☞ Start process by pressing key ”START/STOP”. ☞ Observe process. As soon as evaporation starts, press key ”MODE” (switching to ”Vac control”). The vacuum level is kept constant (at the boiling pressure). Fine tuning of the vacuum value is possible by turning the selection knob. Pressing key ”MODE” a second time switches to ”Auto mode” causing the vacuum level to be auto- matically adapted to changes of the boiling pressure. alternatively: ☞ Select function ”Vac control”. ☞... -
Page 37: Function Configuration
page 37 of 61 5.8 Function Configuration In the menu ”Configuration” the device parameters are preselected. Preselections ☞ Use the selection knob to select the parameters. ☞ Adjustment: Adjustment of the pressure transducer under vacuum and/or at atmospheric pressure, see also section ”Readjustment the controller”. Adjustment at atmospheric pressure is carried out at an absolute pressure value between 1060 - 700 mbar and under vacuum at an absolute vacuum value between 0 - 20 mbar. In the range between 20 and 700 mbar no adjustment is possible;... -
Page 38: Readjustment Of The Controller
page 38 of 61 6 Readjustment of the controller The vacuum gauge was adjusted using factory standards, which are traceable NOTICE through regular calibration in an accredited laboratory (German Calibration service) to the German national pressure standard. Depending on the process and/or ac- curacy requirements, check the adjustment and readjust if necessary. For readjust- ment, the device has to be adjusted both at atmospheric pressure as well as under vacuum but only if the reference pressures are certainly known. The adjustment... -
Page 39: Interface Parameters
page 39 of 61 7 Interface parameters The controller is equipped with a serial interface (RS 232C, nine-pole Sub-D-plug). ☞ Plug-in or remove the cable (cable RS 232C) 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.: 638235). -
Page 40: Read Commands
page 40 of 61 7.2 Read commands Operation Command Response Description unit according to preselections current IN_PV_1 XXXX.X mbar/Torr/hPa pressure 1-100% or HI current speed IN_PV_2 XXX% process runtime time IN_PV_3 XX:XX h:m pressure of all connected sensors pressure IN_PV_X XXXX.X XXXX.X ...mbar operation time in days and hours operation time IN_PV_T... - Page 41 page 41 of 61 Read commands Operation Command Response Description Status IN_STAT XXXXXX process control 0 control off 1 pump down/ determining boiling point 2 set vacuum reached/ boiling pressure found 3 current pressure below set vacuum/ automatic switch-off 0 VACUULAN 1 Pump down 2 Vac control 3 Auto mode 4 Program 5 measurement device 0: venting valve closed...
- Page 42 page 42 of 61 Read commands Operation Command Response Description IN_SP_1 XXXX mbar or set vacuum XXXX Torr or XXXX hPa IN_SP_2 XXX% maximum speed (100% = ”HI”) IN_SP_3 XXXX mbar or switching on pressure for VACUULAN or XXXX Torr or two point control XXXX hPa IN_SP_4...
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Page 43: Write Commands
page 43 of 61 7.3 Write commands Operation Command Parameter Description function OUT_MODE 0: VACUULAN 1: Pump down Attention: If control is running 2: Vac control 30: sensitivity: low only switching from 1 to 2, 2 to 3 3: Auto mode 31: sensitivity: normal and 3 to 2 is possible with takeo- 4: Program... - Page 44 page 44 of 61 Write commands Description Operation Command Parameter mode 1 started START 0 Stop and delete fault STOP 1 Stop 2 Stop with adopting the set vacuum REMOTE* 0 Remote off 1 Remote on ECHO** 0 Echo off 1 Echo on, write command with return value OUT_VENT 0 venting valve closed...
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Page 45: Assembling The Condensate Cooler (Accessory)
page 45 of 61 8 Assembling the condensate cooler (accessory) ➨ Unscrew the hose nozzle at the outlet of the pump using an open-ended wrench. ➨ Screw hose connection of the condensate cooler to the outlet of the pump using an open-ended wrench. ☞... -
Page 46: Troubleshooting
page 46 of 61 9 Troubleshooting Fault Possible cause Remedy ❑ No display. ➨ ✔ Mains not plugged in? Plug in mains plug. ➨ ✔ Controller or pumping unit Switch device on. switched off? ➨ ✔ BUS cable to internal power Plug in BUS cable at control- supply not plugged in? ler. - Page 47 page 47 of 61 Fault Possible cause Remedy ❑ Internal venting valve ➨ ✔ External pressure transducer Select internal pressure does not respond, valve connected and active? transducer or connect exter- symbol is not displayed. nal venting valve. ❑ Venting valve does not ➨ ✔ Valve soiled? Clean valve. respond, valve symbol is displayed.
- Page 48 page 48 of 61 Fault Possible cause Remedy ❑ Pump does not achieve ➨ ✔ Wrong settings at controller? Select function ”Pump down” ultimate vacuum or nor- with speed set to ”HI” and mal pumping speed. check again. ➨ ✔ Centring ring at a small flange Check pump directly - con- connection not correctly posi- nect controller directly at tioned or leak in the pipeline pump inlet - then check con-...
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Page 49: Cleaning The Pressure Transducer
page 49 of 61 10 Cleaning the pressure transducer The controller itself is maintenance free. Contamination of the pressure transducer or deposits will influence the accuracy of measurement. NOTICE Attention: Never use a spiky or sharp-edged tool to clean the pressure transducer. Clean a contaminated pressure transducer as follows: ➨ Disconnect vacuum connection. ➨ Fill the measurement chamber with a solvent (e. g. benzene) and allow sufficient cleaning time. Ob- serve all regulations concerning usage and disposal of solvents! ➨... -
Page 50: Replacing Diaphragms And Valves
Regular maintenance will improve the lifetime of the pump and also protect both man and environment. Ensure that maintenance is done only by suitable trained and supervised techni- cians. order no. Set of seals ROTAVAC vario Pumping unit ..............11-300-00-40 (4 diaphragms, 8 valves, diaphragm key) Valve ..........................23-30-01-01-91 Diaphragm ........................23-30-01-01-92 Diaphragm key ........................ 02-07-02-01-13 The pump may contain black and white colored valves. -
Page 51: Cleaning And Inspecting The Pump Heads
page 51 of 61 Tools required (metric): - diaphragm key w/f 46 (enclosed in the set of seals) - open ended wrench w/f 14 / 17 - hex key size 4 Phillips screw driver size 2 ☞ Please read section ”Replacing diaphragms and valves” completely before starting maintenance. Partially the pictures show pumps in other versions. This doesn’t influence replacing diaphragms and valves of the pump. 11.1 Cleaning and inspecting the pump heads ➨... - Page 52 page 52 of 61 ➨ Use open ended wrench (w/f 14) to turn the elbow fitting 1/4 of a turn, disconnect the hose. Do not remove the el- bow fitting from the pump head. ☞ Through reassembly a leak may result. View of the disassembled pump head parts 1: housing cover with inner part 6: diaphragm support disc 2: valve 7: washers 3: head cover 8: rod 4: diaphragm clamping disc with 9: housing connecting screw 10: bearing plate...
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Page 53: Replacing The Diaphragm
page 53 of 61 ➨ Use a hex key size 4 to loosen the six socket head screws at the pump head and remove the upper housing (housing cover with housing cover insert). ☞ Never remove parts 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). ➨ Take the head covers carefully off the housing to check the valves. -
Page 54: Replacing The Valves And Assembly Of The Pump Heads
page 54 of 61 ➨ Lift diaphragm at the side and position carefully together with diaphragm clamping disc and diaphragm support disc in the diaphragm key. ☞ Avoid damaging the diaphragm: Do not bend diaphragm too much. ➨ Check for washers. Do not mix the washers from the dif- ferent heads. Assemble the original number of washers between support disc and connecting rod at the individual pump head. - Page 55 ☞ Do not tighten until head cover is in contact with housing, max. torque 6 Nm. Replace diaphragms and valves similarly on the other side of the pump (only ROTAVAC vario control). ➨ Use open ended wrench (w/f 14) to reconnect hose to el- bow fitting. Documents are only to be used and distributed completely and unchanged. It is strictly the users´ responsibility to check carefully...
- Page 56 page 56 of 61 ➨ Tighten union nut first by hand and then tighten one full turn using open ended wrench. ➨ Assemble controller: Use Phillips screw driver to screw both screws through the fixing plate in the square nuts in the housing cover. ➨ Connect hose to the connection at the inlet of the pump. Tighten union nut first by hand and then tighten one full turn using open ended wrench.
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Page 57: Replacing The Overpressure Safety Relief Device At The Condenser
page 57 of 61 11.4 Replacing the overpressure safety relief device at the condenser Overpressure safety relief device ....................... 23-30-01-04-98 Round bottom flask 500 ml, coated ......................514-83000-02 ➨ Remove joint clip at the catchpot. ➨ Unscrew the four Torx screws at the counter holder of the condenser and remove condenser. Thereby remove the adapter from the inlet of the condenser. -
Page 58: Warranty, Liability, Copyright
12 Warranty, liability, copyright Warranty Heidolph Instruments provides a three-year warranty on the products described here (with the exception of glass and consumable parts) if registered with enclosed warranty card or via internet (www.heidolph. com). Warranty starts with the date of registration. Without registration warranty starts according to se- rial number. This warranty covers defects in materials and workmanship. Transit damage is excluded from this warranty. -
Page 59: Faq / Repair Work
If any aspect of installation, operation or maintenance remains unanswered in the present manual, please contact the following address. For repair services please call Heidolph Instruments or your local, authorized Heidolph Instruments Dealer. Note: You will receive approval for sending your defective item to the following address: Heidolph Instruments GmbH &... -
Page 60: Confirmation Of Condition Of Unit
Country _________________________ Phone _________________________ E-Mail _________________________ 5. Legally binding declaration The customer is aware of being legally liable to Heidolph Instruments for any damages arising from incomplete and incorrect information. Date _________________________ Signature _________________________ Company stamp Please note: The shipper is responsible for the return of the goods in wellpacked condition, suitable for the mode of transport. - Page 61 01-005-005-24_EN 28/04/2011 © HEIDOLPH INSTRUMENTS GMBH & CO KG We reserve the right to make technical changes without prior announcement. 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.: 999248 / 28/04/2011...
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