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Anest Iwata OCX-128 Instruction Manual

Maintenance tools and fixtures
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Instruction Manual
Maintenance Tools and Fixtures
OCX-128
This instruction manual includes very important warnings, cautions and operating
procedure in order to operate this pump safely and efficiently.
Be sure to read this instruction manual thoroughly and fully understand before
operation.
After reading it, store it in a convenient place for immediate and future reading.

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Summary of Contents for Anest Iwata OCX-128

  • Page 1 Instruction Manual Maintenance Tools and Fixtures OCX-128 This instruction manual includes very important warnings, cautions and operating procedure in order to operate this pump safely and efficiently. Be sure to read this instruction manual thoroughly and fully understand before operation.

  • Page 2: Important Information

    Important information Be sure to read this instruction manual to understand how to operate equipment correctly. Only operators, who fully understand warnings, cautions and instructions, are to operate the equipment. Improper operation (mishandling) can cause serious bodily injury, death, fire or explosion. Store this manual in a convenient place for immediate and future reference.

  • Page 3: For Safe Operation

    For safe operation Below is very important information about how to safely operate the equipment. Before inspection and maintenance, be sure to read and fully understand the contents. WARNING Danger of failure and bodily injury Danger of burns Conduct periodical maintenance and Conduct maintenance and inspection only inspection.

  • Page 4: Table Of Contents

    Contents Important information ........................ 1 For safe operation........................2 Contents............................3 1. Before use ..........................4 1.1 Check the product ......................4 1.2 Names of Fixtures and Tools ................... 4 2. How to use ..........................5 2.1 Maintenance standards ....................6 2.2 Necessary items for maintenance ...................

  • Page 5: Before Use

    1. Before use 1.1 Check the product ・Check that the package is right-side-up before opening. ・Check that the model of the product is the same as the one you ordered. ・Check that there is no shortage or damage. If there is any damage, contact either the dealer who sold it to you or us. ・Check the following accessories.

  • Page 6: How To Use

    2. How to use These are exclusive tools for doing the maintenance and inspection of Oil-Free Scroll Vacuum Pumps, ISP-250E. WARNING Danger of failure and bodily injury Conduct periodical maintenance and inspection. If not, it can cause insufficient performance, failure of vacuum pump, and bodily injury. Conduct periodical maintenance and inspection...

  • Page 7: Maintenance Standards

    2.1 Maintenance standards Do the maintenance according to maintenance standards which are shown in time and period, whichever comes first. The following parts are consumable and need to be replaced periodically. Whenever something goes wrong with them, replace them immediately. Maintenance standards Every 400 Parts...

  • Page 8: Necessary Items For Maintenance

    2.2 Necessary items for maintenance Prepare the following items before maintenance. 1. Block（large） 2pcs. (55mm×55mm×length 250mm wood which does not damage pump) 2. Block（small） 1pc. (20mm×10mm×length 250mm wood which does not damage pump) 3. Clean cloth 4. Spanners (･14mm wrench flat ･17mm wrench flat ･19mm wrench flat) 5.

  • Page 9: Annually Or Every 8000 Hours Maintenance And Inspection

    3. Annually or every 8000 hours maintenance and inspection WARNING Danger of failure and bodily injury Conduct periodical maintenance and inspection. If not, it can cause insufficient performance, failure of vacuum pump, and bodily injury. Conduct periodical maintenance and inspection Danger of burns Conduct maintenance and inspection only after vacuum pump becomes cool enough.
  • Page 10 3.1.2 Remove Inlet flange ①Remove Hex. socket head bolts which hold Inlet flange, and remove Inlet flange, O-ring, Inlet filter, Inlet adapter, Inlet gasket. Hex. wrench (Size 5mm) Hex. socket head bolt Inlet flange O-ring Inlet filter Inlet adapter Inlet gasket 3.1.3 Remove Body set ①Place the pump vertically with Motor downwards.
  • Page 11 3.1.4 Disassembly of Body set ①Place Body set with FS(1) downwards on 2 blocks (wood which height is over 55mm). ②Remove Hex. socket head bolt which fixes Fan(2) on FS(2) side, and remove Washer, Fan(2), Parallel key and Fan spacer. Hex.

  • Page 12: Clean Tip Seal

    ⑦Remove Hex. socket head bolt which holds Fan(1) on FS(1) side, and remove a Washer and Fan(1). ⑧Remove Parallel key and pull Crank shaft, O-ring and Inner ring. Fan(1) Crank shaft Hex. socket head bolt Washer Hex. wrench Parallel key (Size 5mm) FS(1) Crank shaft...
  • Page 13 3.2.1 Remove Tip seal Gradually remove old Tip seal from end of outer periphery edge. Important ・If you feel resistance when removing Tip seal, dust will attach to side and groove of Tip seal. Wipe out dust from the groove and Tip seal by using clean cloth and bamboo spatula. ・Remember each Tip seal position to return it to original position.

  • Page 14: Maintenance Of Fs(1)

    3.3 Maintenance of FS(1) 3.3.1 Clean FS(1) ①Wipe out dust on wall and bottom of scroll wrap and inside the Inlet with clean cloth. ②Wipe out dust on side and bottom of Tip seal groove by using clean cloth and bamboo spatula.

  • Page 15: Maintenance Of Fs(2)

    ⑧Fill ISP exclusive grease [0.1ml (0.2g)] between 2 lips of Shaft seal(1) and G-seal with syringe evenly around whole periphery. G-seal Shaft seal(1) 2 lips 2 lips CAUTION Danger of shorter operating lifetime and Bearing failure. Be sure to use ISP exclusive grease. Mixing with other oil can shorten grease lifetime and damage Bearings.
  • Page 16 ④Turn inner ring of the Ball bearing by hand and check that it turns lightly and smoothly. ⑤If you feel some rumble, replace the Ball bearing according to 4.5.1 and 4.5.6. Ball bearing G-seal Shaft seal(1) ⑥Fill ISP exclusive grease [0.1ml (0.2g)] between 2 lips of Shaft seal(1) and G-seal with syringe evenly around whole periphery.

  • Page 17: Maintenance Of Os

    3.5 Maintenance of OS 3.5.1 Clean OS ①Wipe out dust on wall and bottom of scroll wrap with clean cloth. ②Wipe out dust on side and bottom of Tip seal groove by using clean cloth and bamboo spatula. ③Blow out the whole unit with air. ④Fully wipe out old grease attached to Needle bearings in the center of OS with clean cloth while turning roller until no more comes out.

  • Page 18: Maintenance Of Inlet Flange

    3.6 Maintenance of Inlet flange ①Clean Inlet filter, Inlet adapter, Inlet gasket and inside the Inlet flange. ②Clean the Inlet filter with air blow. 3.7 Maintenance of Outlet flange ①Loosen Nut and remove Outlet flange. ②Remove O-ring inside the exhaust hole of FS(2), and clean the exhaust hole inner diameter and outlet flange by using cloth and brass brush.

  • Page 19: Assembly

    3.8 Assembly Assemble in reverse order of disassembly. 3.8.1 Assemble Body set ①Place 2 blocks (wood which height is over 55mm) on horizontal workbench and FS(1) on the top of them. ②Fit Crank shaft, O-ring and Inner ring vertically to FS(1). Crank shaft Inner ring O-ring...
  • Page 20 ⑤Fit the Inner ring and O-ring into the Crank Hex. wrench (Size 5mm) shaft. ⑥Fit O-ring to FS(2) and assemble to FS(1). Hex. socket head bolt ⑦Tighten the Hex. socket head bolts FS(2) alternately in the diagonal direction. Tightening torque 7.8±0.7Nm (80±7kg･cm) O-ring O-ring...
  • Page 21 ⑨Stand Body set vertically, fit Parallel key, Fan(1) and Washer. Apply slight amount of threadlocker (medium strength) e.g. LOCTITE 242 to Hex. socket head bolts and fully tighten along with Washer. Tightening torque 14.7±0.7Nm (150±7kg･cm) Fan(1) Hex. socket head bolt Washer Hex.

  • Page 22: Operation

    3.8.3 Fit Inlet flange ①Fit Inlet gasket, Inlet adapter, Inlet filter, O-ring and Inlet flange. ②Apply slight amount of threadlocker (medium strength) e.g. LOCTITE 242 to Hex. socket head bolts. Hex. wrench (Size 5mm) Hex. socket head bolt Inlet flange O-ring Inlet filter Inlet adapter...

  • Page 23: Every Two Years Or Every 16000 Hours Maintenance And Inspection

    4. Every two years or every 16000 hours maintenance and inspection WARNING Danger of failure and bodily injury Conduct periodical maintenance and inspection. If not, it can cause insufficient performance, failure of vacuum pump, and bodily injury. Conduct periodical maintenance and inspection Danger of burns Conduct maintenance and inspection only after vacuum pump becomes cool...

  • Page 24: Maintenance Of Fs(1)

    4.4 Maintenance of FS(1) 4.4.1 Remove Ball bearing set ①Remove Hex. socket head bolts which hold Ball bearing set. Bearing washer Hex. socket head bolt Hex. wrench (Size 5mm) FS(1) Ball bearing set ②Insert 2 straight edge screwdriver under outer diameter of Ball bearing set, lift it up and remove it.
  • Page 25 4.4.3 Remove G-seal and Shaft seal(1) ①Insert straight edge screwdriver to G-seal from the scroll side, hit the screwdriver and remove it. Screwdriver (-) FS(1) Scroll side Shaft seal(1) G-seal ②Insert Fixture 1-E to Shaft seal(1) from scroll side, fit Fixture 5 to FS(1) from the opposite side, and screw M10 Hex.
  • Page 26 4.4.4 Remove Miniature ball bearing of Pin crank set ①Remove two screws located aside of Pin crank set on FS(1) with cross head screw driver and remove Pin crank set. ②Hold side of Pin crank wide 12mm by thin spanner and remove screw with fixes Miniature ball bearings (small), and remove Miniature ball bearings (small).
  • Page 27 4.4.6 Fit Shaft seal(1) ①Apply slight amount of threadlocker (medium strength) e.g. LOCTITE 242 to outer periphery of new Shaft seal(1). ②Insert Fixture 15-E and Shaft seal(1) to Fixture 1-E and fit it to FS(1) from the fin side. ③Fit fixture 2-2 and 5 in this order to FS(1) from scroll side, and screw M10 Hex. socket head bolt along with Hex.
  • Page 28 4.4.7 Fit G-seal ①Insert new G-seal to Fixture 1-E and fit it to FS(1) from fin side. ②Fit Fixture 2-2 and 5 in this order to FS(1) from scroll side, and screw M10 Hex. head bolt along with Hex. nut and Washer. ③Fix Hex.
  • Page 29 4.4.8 Fit Ball bearing ①Wipe out dust and grease attached to Bearing case. ②Fit Fixture 17 to Bearing case from flange side. (Pay attention to direction.) ③Fix Fixture 9B to Bearing case from opposite side and insert new Ball bearing horizontally.

  • Page 30: Maintenance Of Fs(2)

    Screw Pin crank Miniature ball bearing (Small) (Pay attention to direction of shield) ③Fit Pin crank set to FS(1) and tighten by screw with slight amount of threadlocker (medium strength) e.g. LOCTITE 242. Important ・Use threadlocker (medium strength) e.g. LOCTITE 242. ・Apply slight amount of threadlocker to thread section.
  • Page 31 4.5.2 Remove G-seal and Shaft seal(1) ①Insert straight edge screwdriver to G-seal from the scroll side, hit the screwdriver and remove it. Screwdriver (-) FS(2) Scroll side Shaft seal(1) G-seal ②Insert Fixture 1-E to Shaft seal(1) from scroll side, fit Fixture 9B and 12 to FS(2) from the opposite side, and screw M10 Hex.
  • Page 32 4.5.3 Clean FS(2) Clean FS(2) in the same way as 3.4.1. 4.5.4 Fit Shaft seal(1) ①Apply slight amount of threadlocker (medium strength) e.g. LOCTITE 242 to outer periphery of new Shaft seal(1). ②Insert Fixture 15-E and Shaft seal(1) to Fixture 1-E and fit it to FS(2) from the fin side.
  • Page 33 4.5.5 Fit G-seal ①Insert new G-seal to Fixture 1-E and fit it to FS(2) from fin side. ②Fit Fixture 2-2 and 5 in this order to FS(2) from scroll side, and screw M10 Hex. head bolt along with Hex. nut and Washer. ③Fix Hex.

  • Page 34: Maintenance Of Os

    4.5.6 Fit Ball bearing ①Fit new O-rings in the two grooves on FS(2). ②Insert new Ball bearing to Fixture 21-E and fit it to FS(2) from fin side. ③Fit Fixture 22-E to FS(2) from scroll side, and screw M10 Hex. head bolt along with Hex.
  • Page 35 4.6.2 Remove Needle bearing ①Insert Fixture 8 to Needle bearing of OS. ②Fit Fixture 10, 11, 9B and 12 in this order from opposite and screw M12 Hex. socket head bolt along with Hex. nut and Washer. ③Fix Hex. socket head bolt with Hex. wrench and turn Hex. nut to remove Needle bearing (a set of 2 bearings).
  • Page 36 M12 Hex. socket head bolt Hex. nut Washer Fixture 12 Fixture 11 Fixture 10 Needle Bearing Needle bearing Fixture 13 Important ・Pay attention to direction of Fixtures. ・Needle bearing consists of 2pcs. Do not combine with other set of bearing. ・Pay attention not to damage scroll top, bottom and side surface of OS.

  • Page 37: Maintenance Of Inlet Flange

    M12 Hex. socket head bolt Hex. nut G-seal Washer Fixture 12 Pay attention to direction Fixture 11 Fixture 10 Needle bearing G-seal Fixture 14 Fixture 13 Minus OS surface Important ・Check direction of Fixtures and G-seal. Side of G-seal where you can see spring faces Bearing. ・Check that the top of G-seal is lower than OS surface.

  • Page 38: Maintenance Of Air Flush Port

    O-ring Exhaust valve Outlet flange Exhaust guide Outlet flange Exhaust valve Exhaust spring Exhaust spring C-type snap ring C-type snap ring Exhaust guide Important Exhaust valve should be at center. 4.9 Maintenance of Air flush port ①Remove Air flush kit from pump with spanner. ②Apply slight amount of threadlocker (medium strength) e.g.

  • Page 39: Fit New Tip Seal

    4.10 Fit new Tip seal ①Place white soft back-up part facing downwards and black hard sliding material facing upwards and push into the groove by hand so that protruded portion of black sliding material is minimal. ②First insert Tip seal in accordance with the shape at the center on FS(2) side of OS and insert gradually further towards outside.
  • Page 40 Important ・When you have replaced Tip seal, do break-in operation so as to smooth Tip seal surface. ・Be sure to take off Exhaust valve during break-in operation. ・During break-in, open Inlet valve 2~3 times hourly so as to emit worm powder. ・This pump is common for 50Hz/60Hz.

  • Page 41: Inspect Pump Performance

    4.13 Inspect pump performance ①Operate pump and measure currents. Specification Current after break-in Model (when Inlet is close) 1-phase 200V 1.8~2.0A ISP-250E 3-phase 200V 1.3~1.5A ②Check that there is no abnormal noise and vibration. Inspect pump performance ③Inspect the ultimate pressure and leak tightness. Unlimited pressure: ≦1.6Pa Leak tightness: ≦1.0 ×...

  • Page 42: Parts List

    6. Parts list Parts name Quantity Parts name Quantity FS(1) Bolt Screw FS(2) Bolt Cover plate(2) Plug Fan cover Washer Fan(2) Exhaust valve set Parallel key Bearing washer Washer Crank shaft Rubber plate Inlet flange Fan spacer Outlet flange Inlet adapter Cover plate(1) Inner ring Fan(1)

  • Page 43: Extended Drawing

    7. Extended drawing -42-...
  • Page 44 3176,Shinyoshida-cho, Kohoku-Ku, Yokohama 223-8501, Japan Tel +81 (0) 45-591-1112 Manual No.V207-00 Fax +81 (0) 45-591-1539 Code No.08822780 http://www.anest-iwata.co.jp/...

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