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Related Manuals for Pfeiffer Vacuum OKTA 4000 ATEX
Summary of Contents for Pfeiffer Vacuum OKTA 4000 ATEX
- Page 1 OPERATING INSTRUCTIONS Translation of the Original OKTA 4000 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 information Safety instructions Safety precautions ATEX classification and safety measures 2.4.1 Labeling of the vacuum pump... - Page 4 Shutting down for longer periods Recommissioning Recycling and disposal General disposal information Dispose of Okta roots pumps Malfunctions Service solutions by Pfeiffer Vacuum Spare parts 12.1 Ordering spare parts packs Accessories 13.1 Accessory information 13.2 Ordering accessories Technical data and dimensions 14.1 General...
- Page 5 Overflow valve maintenance intervals Tbl. 17: Troubleshooting Tbl. 18: Accessories Tbl. 19: Consumables Tbl. 20: Conversion table: Pressure units Tbl. 21: Conversion table: Units for gas throughput Tbl. 22: Technical data Okta 4000 ATEX with lubricant P3 and H1 5/62...
- Page 6 List of figures List of figures Fig. 1: Position of the stickers on the product Fig. 2: Okta 4000 ATEX design Fig. 3: Okta ATEX | Overflow valve active Fig. 4: Okta ATEX | overflow valve blocked Fig. 5: Transporting the vacuum pump using a belt Fig.
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Page 7: About This Manual
Keep the manual for future consultation. 1.1 Validity This operating instructions is a customer document of Pfeiffer Vacuum. The operating instructions de- scribe the functions of the named product and provide the most important information for the safe use of the device. The description is written in accordance with the valid directives. The information in this op- erating instructions refers to the product's current development status. -
Page 8: Pictographs
This section describes all the stickers on the product along with their meanings. Rating plate (example) The rating plate is located on the front side above the D-35641 Asslar sight glass Mod.: Okta 4000 ATEX Motor rating plate (not shown) Mod.-No.: PP W73 ... Ser. -No.: 1234567895 max. 3600 1/min Oil: P3 7,0 l S(N): max. -
Page 9: Abbreviations
About this manual Warning hot surface This sticker warns of injuries caused by high tempera- tures as a result of contact without protection during op- eration. Magnetic field warning This sticker warns of injuries to people with pacemak- ers. Tbl. 2: Stickers on the product Fig. -
Page 10: Trademark Proof
About this manual Abbreviation Explanation Width Across Flats Permissible ambient temperature Tbl. 3: Abbreviations used 1.4 Trademark proof ● Loctite ® is a trademark of HENKEL IP & HOLDING GMBH. 10/62... -
Page 11: Safety
Safety 2 Safety 2.1 General safety information The following 4 risk levels and 1 information level are taken into account in this document. DANGER Immediately pending danger Indicates an immediately pending danger that will result in death or serious injury if not observed. ►... - 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 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.
- Page 14 Safety CAUTION Danger of burns on hot surfaces Depending on the operating and ambient conditions, the surface temperature of the vacuum pump can increase to above 70 °C. ► Provide suitable touch protection. Risks during maintenance, decommissioning and malfunctions DANGER Risk of explosion when carrying out installation and maintenance work in potentially explo- sive areas There is a risk of explosion if unsuitable tools are used in potentially explosive areas.
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Page 15: Safety Precautions
Safety 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. ►... -
Page 16: Labeling Of The Vacuum Pump
Safety potentially explosive areas. The vacuum pumps are delivered with an ATEX-certified motor and are designated as follows: Standard temperature range ● Ԑx II 2/2G Ex h IIB T3 Gb X +5 °C ≤ Ta ≤ +40 °C Extended temperature range (with lubricant H1) ●... -
Page 17: Potential Hazards
Safety Classification Description Special operating conditions must be observed! Special conditions and notes in the operating instructions apply. Permissible ambient temperature for operation of the vacuum pump prescribed on the rating plate. Tbl. 4: ATEX designations 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). -
Page 18: Limits Of Use Of The Product
Safety Place Measures/safety equipment Category 2 Category 3 Speci- Speci- fica- rec- fica- rec- tion tion mend mend Magnetic First switch on the roots pump when the back- coupling ing pump can accept the required amount of You must observe the volume flow ratio of ≤... -
Page 19: Proper Use
● Use of the vacuum pump as a climbing aid ● Overcoating the vacuum pump whereby the permissible layer thicknesses in accordance with DIN EN ISO 80079-36 are exceeded ● Use of operating lubricant other than that specified by Pfeiffer Vacuum 19/62... - Page 20 Safety ● Use of the vacuum pump outside the temperature range stated on the rating plate ● 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.
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Page 21: Product Description
Operation with a backing pump connected upstream enables compressing against atmospheric pressure. Roots pumps from the ATEX series are equipped with a magnetic coupling and a thermometer. Fig. 2: Okta 4000 ATEX design 1 Blank flange (mounted on the vacuum flange) Thermometer 2 Eye bolts... -
Page 22: Design With Blocked Overflow Valve
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: ●... -
Page 23: Scope Of Delivery
Product description 3.3 Scope of delivery ● Roots pump with motor / motor provided by the customer ● Connection flanges produced in accordance with PN 16 ● Seal for the connection flange ● Protective cover for the connection flange ● Screw kit for the connection flange ●... -
Page 24: Transportation And Storage
● Fill the gear and bearing chambers with lubricant only once the final installation posi- tion is reached. Preparations for transport 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 25: Storing Vacuum Pump
Neither the suction chamber nor the pistons in the 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. -
Page 26: 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 27: Filling With Lubricant
– Reference surface is the vacuum flange. 3. Evenly screw the 4 feet of the vacuum pump onto the base without distorting the pump housing. 4. Use adjustment elements from the Pfeiffer Vacuum range of accessories for roots pumps mount the feet horizontally. -
Page 28: Connecting Vacuum Side
Installation max. min. max. min. Fig. 7: 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 29: Connecting The Fore-Vacuum Side
Installation Fig. 8: 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 30: 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 31: 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 = 85 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 32: Connecting 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 33: Checking The Direction Of Rotation
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 store the shut-down Pfeiffer Vacuum recommends connecting motors with PTC in the stator winding to a PTC resistor tripping device for protection against overload. 33/62... -
Page 34: 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 35: 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 36: Switching On Vacuum Pump
Operation 6.3 Switching on 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 37: Checking The Power Input
≤ 0.08) ● S = Rated volume flow rate of the roots pump [m Example for Okta 4000 ATEX with e.g. 50 hPa intake pressure and 8 % sealing gas content = (4860 × 50 × 0.08)/1013 = 19.2 Nm At discharge pressures >... -
Page 38: Vibration Monitoring
Due to the different set-up and process conditions, Pfeiffer Vacuum will not specify any binding, generally-applicable limit values. The alarm, warning and shutdown limits for the oscillation variables specified in the guidelines and standards are not adequate assessment criteria. -
Page 39: Monitor The Operating Condition
● 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. 39/62... -
Page 40: Monitoring The Motor Condition
Operation Bearing Bearing damage frequency Okta 4000 ATEX Fixed bearing Cage rotation frequency (0.42 × n) Hz Rollover frequency of an irregularity on the outer ring (5.81 × n) Hz Rollover frequency of an irregularity on the inner ring (8.19 × n) Hz Rolling element rotation frequency (2.43 ×... - Page 41 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. ► Make sure that the sealing gas pressure inside the pump does not exceed 1200 hPa. ►...
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Page 42: 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 43: Checklist For Inspection And Maintenance
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 44 ● Changing lubricant ■ OI: Operating instructions, SI: Service 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...
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Page 45: Changing 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 46 Maintenance Fig. 15: Draining lubricant 1 Filler screws O-rings 2 O-rings Collection receptacle 3 Drain screws Draining lubricant The change interval of the lubricant depends on the vacuum pump application and is highly dependent on the operating conditions. 1. Place the collection receptacle underneath. 2.
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Page 47: Cleaning The Suction Chamber
Maintenance Procedure 1. Unscrew the filler screws. 2. Fill the lubricant on both sides according to the sight glass. – Fill levels for the first fill: approx. 5 mm above the sight glass middle. 3. Seal the filler screws. – Tightening torque: 32 Nm 4. - Page 48 Maintenance Fig. 17: 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 49: 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 50: Recycling And Disposal
– Fluoroelastomers (FKM) – Potentially contaminated components that come into contact with media 9.2 Dispose of Okta roots pumps Pfeiffer Vacuum roots pumps from the Okta series contain materials that you must recycle. 1. Fully drain the lubricant. 2. Dismantle the motor. -
Page 51: 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 52: 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 53: Service Solutions By Pfeiffer Vacuum
We are always focused on perfecting our core competence – servicing of vacuum components. Once you have purchased a product from Pfeiffer Vacuum, our service is far from over. This is often exactly where service begins. Obviously, in proven Pfeiffer Vacuum quality. - Page 54 Service solutions by Pfeiffer Vacuum 5. Prepare the product for transport in accordance with the provisions in the contamination declaration. a) Neutralize the product with nitrogen or dry air. b) Seal all openings with blind flanges, so that they are airtight.
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Page 55: Spare Parts
Spare parts 12 Spare parts 12.1 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. 55/62... -
Page 56: Accessories
Accessories 13 Accessories View the line of accessories for Pfeiffer Vacuum roots pumps online at pfeiffer-vacuum.de. 13.1 Accessory information Sealing gas device The use of sealing gas at the bearing points protects the lubricant from contamination by the ingress of process media and flushing fluid into the bearing and oil chambers. -
Page 57: Technical Data And Dimensions
Technical data and dimensions 14 Technical data and dimensions 14.1 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 58: Dimensions
-10 – 40 °C -10 – 40 °C Operating fluid Operating fluid amount 6.8 l 6.8 l Weight: with motor 700 kg 700 kg Tbl. 22: Technical data Okta 4000 ATEX with lubricant P3 and H1 14.3 Dimensions Dimensions in mm 58/62... - Page 59 DN 250 PN 16 Dichtrille/sealing groove Innen-/inner Ø Außen-/outer Ø Tiefe/depth 3,4 mm DN 150 PN 16 8x M20 240 (8x M20) Ø 12 x M24 ATEX-Thermometer / ATEX thermometer Fig. 18: Okta 4000 ATEX 59/62...
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Page 60: 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 Dr. Adrian Wirth, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Asslar, Germany. Signature: Pfeiffer Vacuum GmbH Berliner Straße 43... -
Page 61: 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 Dr. Adrian Wirth, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Asslar, Germany. Signature: Pfeiffer Vacuum GmbH Berliner Straße 43... - Page 62 Notizen / Notes:...
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