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Summary of Contents for Pfeiffer Vacuum OKTA 500 ATEX
- Page 1 OPERATING INSTRUCTIONS Translation of the Original OKTA 500 ATEX Roots pump...
- Page 2 Dear Customer, Thank you for choosing a Pfeiffer Vacuum product. Your new roots pump should support you in your individual application with full performance and without malfunctions. The name Pfeiffer Vacuum stands for high-quality vacuum technology, a comprehensive and complete range of top-quality products and first-class service.
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Page 3: Table Of Contents
Table of contents Table of contents About this manual Validity 1.1.1 Applicable documents 1.1.2 Variants Target group Conventions 1.3.1 Instructions in the text 1.3.2 Pictographs 1.3.3 Stickers on the product 1.3.4 Abbreviations Trademark proof Safety General safety instructions Safety instructions Safety precautions ATEX classification and safety measures 2.4.1 Labeling of the vacuum pump... - Page 4 Cleaning the overflow valve Decommissioning Shutting down for longer periods Recommissioning Disposing of the vacuum pump Malfunctions Service solutions from Pfeiffer Vacuum Spare parts 11.1 Ordering spare parts packs Accessories 12.1 Accessory information 12.2 Ordering accessories Technical data and dimensions 13.1 General...
- Page 5 List of tables List of tables Tbl. 1: Variants Tbl. 2: Stickers on the product Tbl. 3: Abbreviations used Tbl. 4: ATEX designations Tbl. 5: Potential hazards Tbl. 6: Measures and safety equipment Tbl. 7: Permissible ambient conditions Tbl. 8: Maximum permissible forces and torques on the intake flange Tbl.
- Page 6 List of figures List of figures Fig. 1: Position of the labels on the product Fig. 2: Okta 500 ATEX design Fig. 3: Transporting the vacuum pump using a belt Fig. 4: Dismantle the fittings to vent the vacuum pump Fig.
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Page 7: About This Manual
Keep the manual for future consultation. 1.1 Validity These operating instructions are for customers of Pfeiffer Vacuum. They describe the function of the designated product and provide the most important information for safe usage of the product. The de- scriptions comply with applicable directives. All information provided in these operating instructions refer to the current development status of the product. -
Page 8: Target Group
About this manual Variant Description Overflow valve active In the design with overflow valve, the weight-loaded valve plate opens in the overflow valve when the maximum pressure differential is exceeded, and it allows, depending on the gas accumulation, a more or less large part of the in-coming gas to flow back from the pressure side to the intake side. -
Page 9: Pictographs
About this manual Sequence of multi-part action steps The numerical list indicates an action with multiple necessary steps. 1. Step 1 2. Step 2 3..1.3.2 Pictographs Pictographs used in the document indicate useful information. Note 1.3.3 Stickers on the product This section describes all the stickers on the product along with their meaning. -
Page 10: Abbreviations
About this manual Fig. 1: Position of the labels on the product 1 Rating plate Note: Filling with lubricant 2 Note: ATEX overflow valve Note: Fill with lubricant (special model) 3 Magnetic field warning sign Hot surface warning sign 4 Direction of rotation arrow (cast in pump housing) 1.3.4 Abbreviations Abbreviation Explanation... -
Page 11: Safety
Safety 2 Safety 2.1 General safety instructions This document includes the following 4 risk levels and 1 information level. DANGER Imminent danger Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ► Instructions on avoiding the hazardous situation WARNING Possibly imminent danger Indicates a hazardous situation which, if not avoided, could result in death or serious injury. - Page 12 Safety WARNING Risk of serious injury from swinging, toppling or falling objects During transport, there is a risk of crushing and impact on swinging, toppling or falling objects. There is a risk of injuries to limbs, up to and including bone fractures and head injuries. ►...
- Page 13 Safety CAUTION Danger of injury from moving parts After a power failure or a standstill as a result of overheating, the motor restarts automatically. There is a risk of injury to fingers and hands if they enter the operating range of rotating parts. ►...
- Page 14 Safety Risks during maintenance, decommissioning and malfunctions DANGER Risk of explosion when carrying out installation and maintenance work in potentially explo- sive atmospheres There is a risk of explosion if unsuitable tools are used in potentially explosive atmospheres. ► Transport, installation and maintenance work may not be performed in potentially explosive at- mospheres.
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Page 15: Safety Precautions
Safety WARNING Health hazard and environmental damage from toxic contaminated lubricant Toxic process media can cause lubricant contamination. When changing the lubricant, there is a health hazard due to contact with poisonous substances. Illegal disposal of toxic substances causes environmental damage. ►... -
Page 16: Labeling Of The Vacuum Pump
Safety 2.4.1 Labeling of the vacuum pump Classifica- Description tion Device Devices which can be used for applications in potentially explosive atmospheres are group divided into two groups: Device group I: Devices for mines susceptible to firedamp (will not be discussed in any more detail here) Device group II: Devices for all other potentially explosive areas with the exception of underground operations in mines and their surface installations which are susceptible... -
Page 17: Potential Hazards
Safety 2.4.2 Potential hazards The ignition hazard assessment for the roots pumps in the ATEX series was performed in accordance with the harmonized standard ISO 80079-36 (Non-electrical equipment for explosive atmospheres - Ba- sic method and requirements). This assessment includes the identification of hazards described as fol- lows which will not occur if the system is operated properly with the respective safety measures. -
Page 18: Product Usage Limits
► Only use the vacuum pump to create a vacuum in connection with a suitable backing pump. ► To protect the lubricant, use sealing gas if high boiling or corrosive media (e.g. solvents) are pumped. ► Adhere to the installation, commissioning, operating, and maintenance instructions. ► Use only accessory parts recommended by Pfeiffer Vacuum. 18/60... -
Page 19: Foreseeable Improper Use
● Using the vacuum pump without blocking the overflow valve for pumps with blocked version ● Use of the vacuum pump with open vacuum and/or fore-vacuum flange open to the atmosphere ● Using lubricants not specified by Pfeiffer Vacuum ● Using pipes to lift the vacuum pump ●... -
Page 20: Product Description
6 Sealing gas connections (4×) Overflow valve 3.2 Product identification 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 plate: ●... - Page 21 Product description ● Screw kit for the connection flange ● 2 eye bolts for lifting the Roots pump ● Lubricant P3 (for standard pump) ● Thermometer ● Ball valve ● Locking screw ● Operating instructions of the roots pump ● Operating instructions of the motor ●...
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Page 22: Transportation And Storage
● Fill the gear and bearing chambers with lubricant only once the final installation posi- tion is reached. Pfeiffer Vacuum recommends keeping the transport packaging and original protective cov- General information regarding safe transport 1. Observe weight specified on the rating plate. -
Page 23: Storing The Vacuum Pump
– In rooms with humid or aggressive atmospheres, seal the roots pump airtight in a plastic bag, together with a drying agent. – After a storage period of 2 years, Pfeiffer Vacuum recommends changing the lubricant. The best corrosion protection for the roots pump is achieved by evacuating and then filling the suction chamber with nitrogen. -
Page 24: Installation
Installation 5 Installation 5.1 Preparatory work WARNING Risk of crushing from rotating parts Fingers and hands may be caught by rotating pistons within the connection flange. This results in se- vere injuries. ► Keep limbs out of the reach of the roots pump. Filling the nitrogen The vacuum pump is filled with nitrogen to protect against corrosion, therefore the suction chamber has a slight over pressure (200 hPa) upon delivery... -
Page 25: Filling With Lubricant
Attainment of product-specific performance data is not ensured. If non-approved lubricants are used, all liability and warranty claims against Pfeiffer Vacuum are excluded. ► Use approved lubricant only. ► Use alternative, application-specific lubricants only following consultation with Pfeiffer Vacuum. Required tools ● Open-end wrench, SW 17 ●... -
Page 26: Connecting The Vacuum Side
Installation max. min. max. min. Fig. 5: Filling with lubricant 1 Filler screws Sight glass, gear chamber 2 Sight glass, bearing chamber Procedure 1. Unscrew the filler screws. 2. Fill the lubricant on both sides according to the sight glass. –... -
Page 27: Connecting The Fore-Vacuum Side
Installation Fig. 6: Loading capacity of the connection flange Installation of superstructural parts on the connection flange is the responsibility of the op- erating company. The loading capacity is specific for the roots pump used. The total weight of superstructural parts must not exceed the maximum values specified. Maximum permissible forces Maximum permissible torques [Nm]... -
Page 28: Setting And Checking The Temperature Monitoring
Installation 6. Install the pipes downward from the roots pump, so that condensate does not flow back into the roots pump. 7. Install a condensate separator if necessary. 8. If an air trap is created in the system, then install a condensate drain facility at the lowest point. 5.6 Setting and checking the temperature monitoring WARNING Risk of explosion when the ignition temperature of the pumped medium is reached... -
Page 29: Arrange A Signal Evaluation For The Thermometer
Installation Checking the installation of the thermometer ► Check the installation dimension "X" and tighten the clamping screw if necessary. – X = 127 mm 5.6.2 Arrange a signal evaluation for the thermometer A restart following "zero potential" without resetting the interlock of the ignition system is not permissible. -
Page 30: Connect Three Phase Motor With 6-Pin Terminal Board
► Route the mains connection in accordance with locally applicable provisions. ► Always provide a suitable mains fuse to protect the motor and supply cable in the event of a fault. – Pfeiffer Vacuum recommends the circuit breaker type "K" with slow tripping characteristic. NOTICE Motor damage from overheating Limited motor fan cooling capacity, caused by low speeds, causes the motor to overheat. -
Page 31: Checking The Direction Of Rotation
Installation Fig. 9: Star circuit for high voltage The ends of the 3 phases are connected in the star point. The terminal voltage is √3 times the phase voltage, the mains current is equal to the phase current. The star circuit is marked with the Y symbol. 5.7.2 Checking the direction of rotation Fig. -
Page 32: Observing The Motor Torque
≤ 10:1 between the roots pump and the backing pump. ● Failure of the backing pump. In this case, you must switch the roots pump off immediately. ● Increased starting torque, e.g. caused by a motor not specified by Pfeiffer Vacuum. ● The piston is blocked due to deposits. -
Page 33: Operation
Operation 6 Operation 6.1 Putting the vacuum pump into operation Before switching on 1. Check the lubricant levels on both sight glasses. 2. Compare the specifications on the motor rating plate with the available mains voltage and fre- quency. 3. Make sure that the suction chamber is free from all foreign matters. 4. -
Page 34: Switching On The Vacuum Pump
Operation 6.3 Switching on the vacuum pump WARNING Danger of poisoning due to toxic process media escaping from the exhaust pipe During operation with no exhaust line, the vacuum pump allows exhaust gases and vapors to escape freely into the air. There is a risk of injury and fatality due to poisoning in processes with toxic process media. -
Page 35: Checking The Power Input
≤ 0.08) ● S = Rated volume flow rate of the roots pump [m Example for Okta 500 ATEX with e.g. 50 hPa intake pressure and 8 % sealing gas content = (490 × 50 × 0.08)/1013 = 1.93 Nm At discharge pressures >... -
Page 36: Vibration Monitoring
It is not possible to specify a precise switch-off threshold as the power input depends on the process and motor as well as other parameters, such as rotation speed and pressure differential. ► Pfeiffer Vacuum recommends that you determine the comparison value for the max. permissible power input in the first operating year. -
Page 37: Condition Monitoring Of The Vacuum Pump
● Assessment of the root-mean-square-value of the vibration acceleration and / or the maximum value amount of the vibration acceleration in a band. Evaluating the vibration spectrum Due to the early and clearer diagnosis for bearing damage, Pfeiffer Vacuum recommends using the envelope curve spectrum. 37/60... -
Page 38: Monitoring The Motor Condition
Operation Bearing Bearing damage frequency Okta 500 ATEX Fixed bearing Cage rotation frequency (0.41 × n ) Hz Rollover frequency of an irregularity on the outer ring (5.36 × n) Hz Rollover frequency of an irregularity on the inner ring (7.64 ×... - Page 39 Operation NOTICE Property damage from impermissibly high sealing gas pressure Excessive sealing gas pressure leads to damage to the seals after switching on the vacuum pump. ► Observe the max. permissible sealing gas pressure. ► Reduce the sealing gas pressure to < 1200 hPa. ►...
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Page 40: Maintenance
NOTICE Damage from incorrect maintenance work Unprofessional work on the vacuum pump will lead to damage for which Pfeiffer Vacuum accepts no liability. ► Ensure that only the following categories of persons are authorized to perform servicing tasks: – Pfeiffer Vacuum employees with corresponding qualifications. -
Page 41: Checklist For Inspection And Maintenance
(inspection). 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. -
Page 42: Changing The Lubricant
The usable life may deviate from the reference value specified depending on thermic and chemical loads, or due to penetrating process media in gear and bearing chambers. Safety data sheets You can obtain the safety data sheets for lubricants from Pfeiffer Vacuum on request, or from the Pfeiffer Vacuum Download Center. - Page 43 Maintenance Fig. 13: Drain the lubricant 1 Filler screws O-rings 2 O-rings Collection receptacle 3 Drain screws Drain the lubricant The change interval of the lubricant depends on the vacuum pump's application and is highly dependent on the operating conditions. 1.
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Page 44: Cleaning The Suction Chamber
Maintenance Filling with lubricant 1. Fill the lubricant on both sides until the max. fill level is reached (see chapter “Filling with lubri- cant”, page 25). 2. Screw in the filler screws again. – Tightening torque: max. 32 Nm 7.4 Cleaning the suction chamber WARNING Risk of crushing from rotating parts Fingers and hands may be caught by rotating pistons within the connection flange. - Page 45 Maintenance Fig. 15: Overflow valve 1 Allen head screws Pressure screw 2 Valve cover Compression spring 3 O-ring Valve plate 4 O-ring Housing 5 Friction pin Remove the overflow valve 1. Unscrew the screws and remove the valve cover. 2. Be careful with the O-ring. 3.
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Page 46: Decommissioning
The useful life of the lubricant is limited (max. 2 years). Prior to recommissioning, carry out the follow- ing operations following inactivity of 2 years or more: ► Observe the maintenance instructions – consult Pfeiffer Vacuum where necessary. ► Change the lubricant. -
Page 47: Disposing Of The Vacuum Pump
Decommissioning 8.3 Disposing of the vacuum pump WARNING Health hazard through poisoning from toxic contaminated components or devices Toxic process media result in contamination of devices or parts of them. During maintenance work, there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub- stances causes environmental damage. -
Page 48: Malfunctions
► Wear personal protective equipment if necessary. NOTICE Damage from incorrect maintenance work Unprofessional work on the vacuum pump will lead to damage for which Pfeiffer Vacuum accepts no liability. ► Ensure that only the following categories of persons are authorized to perform servicing tasks: –... -
Page 49: Tbl. 17: Troubleshooting
● Damage to the bearing ● Switch the roots pump off immedi- or gear wheels ately; contact Pfeiffer Vacuum Serv- ● Damage to motor ● Switch the roots pump off immedi- bearing ately ●... -
Page 50: Service Solutions From Pfeiffer Vacuum
We are consistently striving to perfect our core competence, service for vacuum components. And our service is far from over once you’ve purchased a product from Pfeiffer Vacuum. It often enough really just begins then. In proven Pfeiffer Vacuum quality, of course. - Page 51 Service solutions from Pfeiffer Vacuum 5. Prepare the product for transport in accordance with the details in the declaration of contamination. a) Neutralize the product with nitrogen or dry air. b) Close all openings with airtight blank flanges. c) Seal the product in appropriate protective film.
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Page 52: Spare Parts
Spare parts 11 Spare parts 11.1 Ordering spare parts 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. 52/60... -
Page 53: Accessories
12.2 Ordering accessories Description Order number Sealing gas set for Okta 500 ATEX, G 3/8"(4×) PP 042 753 -T Screw set for Okta 300/M | Okta 500/M/ATEX | Okta 600/M | Okta 800/M, DN PP 042 663 -T... -
Page 54: Technical Data And Dimensions
Technical data and dimensions 13 Technical data and dimensions 13.1 General Basis for the technical data of Pfeiffer Vacuum roots pumps ● Specifications according to PNEUROP committee PN5 ● ISO 21360-1: 2016 “Vacuum technology - Standard methods for measuring vacuum-pump per- formance - General description”... -
Page 55: Tbl. 22: Technical Data For Category 3G
Technical data for category 3G Order number PP W33 400 PP W33 450 Classification Okta 500 ATEX Okta 500 ATEX Version Ex II 2/2G Ex h IIB T3 Gb X Ex II 2/2G Ex h IIB T3 Gb X +5 °C ≤ T ≤... -
Page 56: Dimensions
102 H11 x 4,5 depth Ø 149,8 max. 102 H11 x 4,5 depth Ø DN 100 PN 16 sealing groove inner Ø outer Ø depth 3,4 mm M16 -20/22 depth (8x) ATEX temperature sensor Fig. 16: Okta 500 ATEX 56/60... -
Page 57: Declaration Of Conformity
DIN ISO 21360-1: 2016 ISO 21360-2: 2012 DIN EN ISO 13732-1: 2008 The authorized representative for the compilation of technical documents is Mr. Sebas- tian Oberbeck, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Asslar, Germany. Signature: Pfeiffer Vacuum GmbH Berliner Straße 43... -
Page 58: Declaration Of Conformity
DIN ISO 21360-1: 2016 ISO 21360-2: 2012 DIN EN ISO 13732-1: 2008 The authorized representative for the compilation of technical documents is Mr. Sebas- tian Oberbeck, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Asslar, Germany. Signature: Pfeiffer Vacuum GmbH Berliner Straße 43... - Page 59 59/60...
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