Summary of Contents for vacuubrand PC 3002 VARIO select
Page 1
Chemistry pumping unit series PC 3002 VARIO select PC 3003 VARIO select PC 3004 VARIO select PC 3004 VARIO select EKP Instructions for use Original instructions EN-US 20901334...
Page 2
Head office: +49 9342 808-0 Sales: +49 9342 808-5550 Service: +49 9342 808-5660 Fax: +49 9342 808-5555 E-mail: info@vacuubrand.com Web: www.vacuubrand.com Thank you for purchasing this product from VACUUBRAND GMBH + CO KG. You have chosen a state-of-the-art, high-quality prod- uct. 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
TABLE OF CONTENTS About this manual User information ..............5 Instruction manual layout ............. 6 Presentation conventions............7 Symbols and pictograms ............8 Action instructions ..............9 Abbreviations ................. 10 Explanation of terms.............. 11 Safety instructions Use ..................12 2.1.1 Proper use..............
Page 4
4.3.2 Exhaust connection (OUT) ..........35 4.3.3 Coolant connection on the condenser......36 4.3.4 Venting connection ............37 4.3.5 Gas ballast (GB) ............. 39 Electrical connection ............. 40 Operation Switching on................43 Operation with controller ............44 5.2.1 Operator interface............44 5.2.2 Operation...............
About this manual About this manual This User manual is part of the product you have purchased. This instruction manual is valid for all pumping unit models, to- gether with the instruction manual of the VACUU SELECT controller, and is intended specifically for operators. 1.1 User information Safety Instruction manual...
In case of an incomplete User manual, you can request a re- placement from us. Alternatively, our download portal is avail- able to you: www.vacuubrand.com Call us or write to us if you have any other questions about the product, need additional information or want to give us feed- back on the product.
About this manual 4 Optional instruction manual: Accessories 1.3 Presentation conventions Warning messages Presentation of DANGER warning messages Warning of imminent danger. Failure to observe this warning may result in imminent danger to life or severe injury. Please follow the instructions for prevention! Ø...
About this manual 1.4 Symbols and pictograms This instruction manual uses symbols and pictograms. These safety symbols and pictograms indicate specific dangers or requirements when handling the product. Warning signs with safety symbols on the product provide a visualization of the potential hazard. Safety symbols Explanation of General danger sign.
About this manual 1.5 Action instructions Action instructions (simple) Action instructions ð You are requested to take action. Result of the action Action instructions (multiple steps) 1. First action step 2. Next action step Result of the action Action instructions that require several steps must be followed in the order they are described.
About this manual 1.6 Abbreviations Abbreviations used >/ No greater than abs. Absolute Separator flask Atmospheric pressure (bar graph, program) Diameter Diameter nominal Emission condenser Peltronic emission condenser or Peltronic EK Outlet (exhaust, exit), exhaust gas connection ATEX device marking Fluoropolymer rubber Gas type ind.
Dry ice condenser Cooling condenser with receiving flask and dry ice as cooling medium installed at the outlet (pressure side). VACUU·BUS VACUUBRAND bus system for the communication of pe- ripheral devices with VACUU BUS-capable measuring equipment and controllers. VACUU·BUS ad-...
Safety instructions Safety instructions The information in this chapter must be observed by all persons who work with the device described here. The safety instructions are valid for all life stages of the product. 2.1 Use The device may only be used in perfect technical condition. 2.1.1 Proper use Proper use A chemistry pumping unit of the PC 300x VARIO select product series...
Safety instructions 2.1.2 Improper use Improper use Improper use or any use that does not correspond with the technical data can lead to personal or material damage. Improper use is considered: use that contradicts the proper use, operation in unauthorized ambient and operating conditions, operation with obvious faults, damages or defective safety equipment, unauthorized extensions and modifications, especially when...
Safety instructions 2.2 Responsibilities Follow the instructions for all actions as they are specified in this in- struction manual. Responsibilities of the operator Operator responsibil- The operator defines the responsibilities and ensures that only ities trained or qualified personnel work on the vacuum system. This ap- plies in particular to connection, assembly work, maintenance tasks and fault elimination.
Fault elimination Device fuse replacement Maintenance Repair Repair order Cleaning, simple Emptying separator Decommissioning Decontamination 3 See also homepage: VACUUBRAND > Support > Repair instructions 4 Or have decontamination carried out by a qualified service provider. 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Safety instructions 2.4 General safety information Quality standards Products of VACUUBRAND GMBH + CO KG are subject to high qual- and safety ity control requirements in terms of safety and operation. Each product is put through an extensive test program before delivery. Follow the instructions for all actions as they are specified in this in- struction manual.
Safety instructions 2.7 Laboratory and work materials DANGER Hazardous materials leak at the outlet. When operating the vacuum, hazardous, toxic substances can leak into the ambient air at the outlet. Please observe the safety regulations for handling haz- Ø ardous materials and media. Remember that adhesive process media can present a Ø...
Page 18
Safety instructions Preventing foreign bodies inside the pump Observing the vac- Particles, liquids and dust are not permitted inside the vacuum uum pump design pump. ð Do not pump any substances that can form deposits inside the vacuum pump. ð Install suitable separators and/or filters in front of the inlet. Suitable filters are chemical resistant, clog-free and ensure a constant flow rate.
Safety instructions 2.8 Possible sources of danger Considering mechanical stability Observing mechani- Due to the high compression ratio of the pumps, a higher pressure cal stability can build up at the outlet than the mechanical stability of the sys- tem allows. ð...
Page 20
Safety instructions Dangers during ventilation Looking out for dan- Depending on the process, a potentially explosive mixture can form gers during ventila- in installations or other dangerous situations can occur. tion Dangers due to residual energy Possible residual en- After the vacuum pump has been switched off and disconnected ergies from the power network, dangers may still be present due to resid- ual energies:...
Safety instructions ð Remove the cover hood used as transport protection before you put the device into operation. ð Avoid applying too much heat due to hot process gases. ð Observe the maximum permissible media temperature accord- ing to the technical data. Ensure that signs are readable Labels and signs Make sure that instructions and signs attached to the device remain...
Page 22
Safety instructions The product is designed for a low degree of mechanical danger and must be installed so that it cannot be mechanically damaged from the outside. ATEX device category The ATEX device category of the of the vacuum pump depends on and peripheral de- the connected components and the periphery.
Safety instructions 2.11 Disposal NOTICE Improper disposal of electronic components can result in damage to the environment. Electronic equipment contains hazardous materials that can dam- age the environment or human health. Discarded electronic equip- ment also contains valuable raw materials, which can be recov- ered if properly disposed of for recycling.
Product description Product description Pumping units of the PC 300x VARIO select series essentially consist ® of membrane pump, regulated by VARIO drive, a VACUU·SELECT vacuum controller as well as a cooler with a separator. Coolers are available in different designs. The coolers differ in how they func- tion.
Product description 15 Round flask at outlet 3.2 Chemistry pumping unit series Overview of chem- istry pumping unit models Meaning Steps Chemistry pumping unit Pump head PC 3002 VARIO select ● ● PC 3003 VARIO select ● ● PC 3004 VARIO select ● ● PC 3004 VARIO select EKP ● ● Product-specific abbreviations Product-specific ab- Separator flask, installed at inlet or outlet breviations...
Product description 3.3 Condensers and coolers 3.3.1 Separator/condenser at inlet Connection on separator flask Connections on AK Meaning 1 Vacuum inlet connection IN 3.3.2 Condenser at outlet Connection and coolant on emission condenser Connections on EK Meaning 1 Outlet connection coolant EX 2 Inlet connection coolant IN, e.g.
Page 27
Product description Connections on the Peltronic emission condenser Connections on EKP 1 Outlet connection EX 2 Vacuum pump connection 3 VACUU BUS connection 4 Power connection with on/off switch ð For detailed information and descriptions about the Peltronic emission condenser -> see the Peltronic EK instruction manual.
Product description 3.4 Application example Local area vacuum network -> Example Local area vacuum network Description ® Process example: VACUU·LAN , local area vacuum network with three valve modules Vacuum hose (permanently installed PTFE hose lines) Lab furniture Exhaust gas hose (diverted into a fume hood) PC 3004 VARIO select EKP vacuum pumping unit 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Page 29
Product description Drying -> Example Drying Description Chiller Coolant hoses Exhaust gas hose (diverted into a fume hood) PC 3002 VARIO select vacuum pumping unit Vacuum hose Process example: drying cabinet 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Installation and connection Installation and connection 4.1 Transport Products from VACUUBRAND are packaged in stable, recyclable packaging. The original packaging is customized to your product for safe transport. ð If possible, keep the original packaging, e.g. for sending in for re- pairs.
Page 31
Installation and connection Please note that the pumping unit can weigh more than 20 kg. Lift the device out of the packaging using the recessed grips on the sides. Never use attachment parts such as brackets or glass flasks to aid in lifting. Use only the recessed grips on the sides and/or the handle to transport it to the installation location.
Installation and connection 4.2 Installation NOTICE Condensate can damage the electronics. A large difference in temperature between the storage location and the installation site can lead to the formation of condensate. ð After receipt or storage, allow your vacuum to acclimatize for at least 3–4 hours before putting it into operation.
Installation and connection Observing the limitations of use Ambient conditions Ambient conditions (US) Ambient temperature 10–40 °C 50–104°F Installation height, max. 2000 m 6562 ft above sea level above sea level Humidity 30–85 %, non-condensing Degree of contamination Impact energy 5 J Protection class (IEC 60529) IP 20 Protection class (UL 50E) Type 1...
Page 34
Installation and connection NOTICE Foreign bodies in the suction line can damage the vacuum pump. ð Prevent particles, liquids or contaminants from being vacu- umed or from being able to flow back. Connecting the vacuum hose -> Example Vacuum connection at inlet IN 1.
Installation and connection 4.3.2 Exhaust connection (OUT) WARNING Risk of bursting due to excess pressure in the ex- haust line. Unacceptably high pressure in the exhaust line may cause the vacuum pump to burst or damage seals. The exhaust line (outlet, gas outlet) must always be open Ø...
Installation and connection 4.3.3 Coolant connection on the condenser Coolant connection An emission condenser EK has one connection for coolants. Water or Inflow and outflow liquid in the circuit of a recirculating chiller, for example, is suitable for cooling. In a closed, internal coolant circuit, the pressure should be lim- ited to 3 bar (44 psi).
Installation and connection 4.3.4 Venting connection DANGER Explosion risk due to air ventilation. Depending on the process, a potentially explosive mixture can form during ventilation, or other dangerous situations can occur. Never ventilate processes with air in which a potentially Ø...
Page 38
Installation and connection Vent with inert gas – connect venting valve Required connection material: Hose for inert gas connection (Ø 4 mm), e.g., silicone tube 4/6 mm. Venting valve inert gas connection 1. Insert hose (b) into VENT connection (a) and secure the hose with the union nut. 2.
Installation and connection 4.3.5 Gas ballast (GB) Use ambient air as gas ballast DANGER Explosion risk due to air as gas ballast. By using air as a gas ballast, a small amount of oxygen en- ters the inside of the vacuum pump. Depending on the process, a potentially explosive mixture can form due to oxygen in the air, or other dangerous situations can occur.
Installation and connection Use of inert gas as gas ballast – OPTION Prepare the inert gas connection (GB) ð Remove the black gas ballast cap and connect a gas ballast adapter in its place. On request, we can send you connection options and adapters for hose nozzles or small flanges.
Page 41
Installation and connection Power connections with country code -> Example Diagrams of standard Power plug types power connections with ground contact 1 UK 2 CN 3 IND 4 US 5 CEE 6 CH The vacuum pump is delivered ready for use with the matching power plug.
Page 42
Installation and connection -> Example Schematic drawing of controller with connected valve and sensors Accessories -> see chapter Ordering information 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
1. Switch on the rocker switch (a) – switch position I. 2. Press the ON/OFF button (b) on the controller. Display with start screen. After approx. 30 seconds, the process display appears with the control elements in the display of the controller. WEB: VACUUBRAND/Produkte/Messgeräte und Controller/Vakuum regeln 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Operation 5.2 Operation with controller 5.2.1 Operator interface Operator interface ® VACUU·SELECT with process display Process display Pressure display for a process 1 Status bar 2 Analog pressure display – pressure curve 3 Digital pressure display – pressure value (target value, actual value, pres- sure unit) 4 Process display with context functions 5 Screen navigation...
Page 45
Operation Controls Controls Button Function Vacuum controller Start Start an application – only in the process display Stop Stop an application – always possible. VENT – Ventilate system (Option) Button press < 2 Sec. = briefly ventilate, regulation continues. Button press > 2 Sec. = ventilate to atmospheric pres- sure, vacuum pump is stopped.
Operation 5.2.3 Operation with gas ballast Meaning The supply from the gas ballast (= gas addition) ensures that vapors are not condensed in the vacuum pump; instead, they are emitted out of the pump. This allows greater amounts of condensable va- pors to be pumped, which extends the service life.
Operation 5.3 Switching off (decommissioning) Switching off the pumping unit Switching off, e.g. 1. Stop the process and allow the pumping unit to continue run- taking the pumping ning for approx. 30 minutes with open gas ballast or open inlet unit out of operation (IN).
Operation 5.4 Storage Storing the pumping unit 1. Clean the The pumping unit if it is dirty. 2. Recommendation: Carry out preventative maintenance before you put The pumping unit into storage. Especially if it has been in operation for more than 15,000 hours. 3.
Troubleshooting Troubleshooting 6.1 Technical assistance To find and eliminate errors, use the table g Error – cause – correc- tive measure on page 50. For technical assistance or in case of faults, please contact our Ser- vice department. The device should only be operated in perfect technical condition. ð...
Page 51
Troubleshooting Error Cause Corrective measure Personnel Use another external ventilation valve if necessary. Ventilation valve Ventilation valve sen- Replace defective Qualified does not switch sor defective. components. employee Vacuum pump does Pumping unit Switch on Pumping Operator not start switched off. unit.
Page 52
Troubleshooting Error Cause Corrective measure Personnel Check the gas ballast cap. Replace defective components. No suction capacity Deposits in the vac- Clean and test pump Qualified or very little uum pump. heads. employee Membrane or valves Replace the mem- defective. brane and valves.
Page 53
Troubleshooting Error Cause Corrective measure Personnel Default setting of the speed on the con- troller too low, e.g. draining with speed Controller regulates the motor with a speed that is too low. 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Cleaning and maintenance Cleaning and maintenance WARNING Danger due to electrical voltage. Switch off the device before cleaning or maintenance. Ø Disconnect the power plug from the power outlet. Ø Danger due to contaminated components. When pumping dangerous media, hazardous materials can adhere to interior pump components.
Cleaning and maintenance 7.1 Information on service activities Recommended maintenance interval Maintenance inter- Maintenance intervals As required 15,000 h vals Replace membranes Replace valves Replace O-rings Clean or replace PTFE molded hose Replace pressure release valve on EC Clean pumping unit Recommended auxiliary equipment ->Example Recom- mended auxiliary...
Page 56
Cleaning and maintenance Tools needed for maintenance -> Example Tools Meaning No. Tool Size 1 Seal set Seal set PC 5xx #20696869 Seal set PC 6xx #20696870 2 Membrane wrench #20636554 SW66 3 Flat-nose pliers Closing hose clamps 4 Flat-head screwdriver Opening hose clamps Size 1 5 Hexagon socket wrench Screw fasteners for head cover...
Cleaning and maintenance 7.2 Cleaning This chapter does not describe how to decontaminate the product. Simple cleaning and care measures are described here. ð Before cleaning, switch off the pumping unit. CAUTION Risk of burning due to hot surfaces An elevated exhaust gas temperature can lead to hot sur- faces on the instrument and on attached components, such as glass flasks.
Cleaning and maintenance 7.2.2 Emptying the glass flask Removing and emptying the glass flask -> Example Emptying the glass flask 1. Open the joint clamp and re- 2. Empty the glass flask into a move the glass flask. suitable container, e.g. a chemical-resistant canister.
Cleaning and maintenance 7.3 Vacuum pump maintenance 7.3.1 Maintenance items Items to receive maintenance -> Example Maintenance of pump heads Meaning Maintenance items 1 Pump heads, power connection side 2 Pump heads, EK side ð Carry out maintenance on pump heads in succession. ð...
Page 60
Cleaning and maintenance Exploded-view drawing of pump head (example) -> Example Exploded-view draw- ing of pump head Meaning Valve maintenance 1 Head cover + screw fasteners 2 Clamping bracket + screw fasteners 3 Cup springs 4 Valve clusters 5 Valves 6 O-rings size 26 x 2 Membrane maintenance 7 Head cover + screw fasteners 8 Membrane spring washer with square head screw...
Cleaning and maintenance Membrane maintenance 11 Spacers, max. 4 pieces per pump head 7.3.2 Changing the membranes and valves Preparation -> Example Preparing for mainte- nance 1. Switch off the pumping unit 2. Remove the glass flask and and disconnect the power connected hoses.
Page 62
Cleaning and maintenance 5. Unscrew the cap nut, pull 6. Put the cooler down safely off the molded hose and re- so that no liquid can leak move the cooler. out. Here you can check the pressure release valve of the EK and re- place it in case of damage.
Page 63
Cleaning and maintenance Dismantling device and housing parts -> Example Dismantling housing parts, left side 1. Undo the screw fasteners 2. Remove the head cover and from the head cover; Torx set it aside. screwdriver TX20. 3. Open the hose clamps of the 4.
Page 64
Cleaning and maintenance 5. Unscrew the hexagon 6. Set the screw fasteners socket screws from the head aside and take off the pump covers. Hexagon socket head pair. wrench size 5. Replacing membranes -> Example Membrane replace- ment 1. Gently press against one of 2.
Page 65
Cleaning and maintenance Do not let any spacers fall into the aluminum housing. Make sure there are no spac- ers stuck to the connecting rod. Keep the spacers for later use. It is imperative that these are re-installed in the same quantity.
Page 66
Cleaning and maintenance 7. Place all spacers onto the 8. Attach the membrane as- threaded bolt. sembly in the membrane wrench. 9. Hold onto the spacers and 10. Tighten the assembly by carefully place all compo- hand at first using the mem- nents into the threaded hole brane wrench.
Page 67
Cleaning and maintenance 11. Then place a torque wrench 12. Repeat the steps for chang- with a hexagon socket bit ing the second membrane. onto the membrane wrench and tighten the assembly to 6 Nm. Replacing valves -> Example Valve change Fig.
Page 68
Cleaning and maintenance 5. Undo the Torx screws on the 6. Remove the clamping clamping brackets; Torx brackets from the valve screwdriver TX20. clusters. Top view: Components valve clusters, 7. Remove the valve clusters valves and pump head pair. with the cup springs. 8.
Page 69
Cleaning and maintenance 10. Carefully clean dirty sur- 11. Insert new sealing rings into faces. the notches. Top view detail: Correct positioning of 12. Apply the new valves and the valves. align them. IN = Inlet (Inlet) EX = Exhaust (Outlet) 13. Place both valve clusters 14.
Page 70
Cleaning and maintenance 15. Place both valve clusters 16. Place the clamping brackets with the plate washers onto on the valve clusters and the pump heads. tighten the screw fasteners by hand. Assembling device and housing parts Before you put the pumping unit back into operation, all device and housing parts that were removed must first be re-attached.
Page 71
Cleaning and maintenance 3. Tighten the screw fasteners 4. Slide the molded hoses crosswise to 12 Nm with a back onto the connections. torque wrench. 5. Close the hose clamps on 6. Put on the head cover so the hose nozzles, e.g. with that it fits.
Cleaning and maintenance 7. Tighten the screw fasteners 8. Tighten the screw fastener of the head cover; Torx and close the cover; Torx screwdriver TX20. screwdriver TX20. Changing the membranes and valves of the next pump head ð Turn the pumping unit to the other side. ð...
Page 73
Cleaning and maintenance 3. Replace defective fuses. 4. Slide the fuse holder back onto the fuse socket. 20901334_EN-US_PC3000 VARIO select Serie_V1.4_061022...
Annex Annex 8.1 Technical data Product description Chemical pump station series Product names PC 3002 VARIO select PC 3003 VARIO select PC 3004 VARIO select PC 3004 VARIO select EKP Technical data Technical data Ambient conditions (US) Ambient temperature 10–40 °C 50–104°F Installation height, max. 2000 m 6562 ft above sea level above sea level Humidity 30–85 %, non-condensing Degree of contamination...
Page 75
Annex Ventilation valve (ventilation Silicon rubber hose 3/6 with inert gas) – OPTION Coolant EK 2x (+ 2x) hose nozzle DN 6/8 Exhaust, outlet EX Hose nozzle DN 8/10 Cold-device plug + power connection CEE, CH, CN, UK, IN, US ® Plug connector VACUU·BUS Electrical data...
Page 76
Annex End vacuum with GB, absolute 12 mbar 9 Torr Number of cylinders/steps PC 3003 Pumping speed, max. 2.8 m 1.6 cfm End vacuum, absolute 0.6 mbar 0.45 Torr End vacuum with GB, absolute 1.5 mbar 1.12 Torr Number of cylinders/steps PC 3004 Pumping speed, max. 4.6 m 2.7 cfm End vacuum, absolute 1.5 mbar 1.1 Torr End vacuum with GB, absolute 3 mbar...
Annex Hose nozzle Seal on ventilation valve FFKM 8.3 Rating plate Specifications from ð In case of error, take note of the type and serial number from the the type plate type plate. ð When contacting our service department, provide the type and serial number from the type plate.
Annex 8.4 Order data Ordering information Chemistry pumping unit series *Order no. for pumping units PC 3002 VARIO select 207335xx PC 3003 VARIO select 207385xx PC 3004 VARIO select 207375xx PC 3004 VARIO select EKP 207375xx * Order no. depends on power cord CEE, CH, UK, US, CN, IN...
Page 80
International agents Purchase original accessories and original replacement parts from a and dealers branch office of VACUUBRAND GMBH + CO KG or from your local dealer. ð Information about the complete range of products can be found in the current product catalog.
Service procedure Follow the description at: VACUUBRAND > Support > Service Reduce downtimes, speed up processing. When contacting our service department, please have the required information and documents ready. ð Your order can be assigned quickly and easily.
Need help?
Do you have a question about the PC 3002 VARIO select and is the answer not in the manual?
Questions and answers