OPERATING INSTRUCTIONS EN Translation of the original instructions ACP 15 Dry compact Multi-stage Roots pump Table of contents Table of contents 1 About this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1.1 Applicable documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2.2 Pictographs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2.3 Instructions/Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2.4 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.4 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.1.1 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.1.2 Differences between the pump versions. . . . . . . . . . . . . . . . . . . . 12 4.2 Man/machine interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.1 Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.2 Connection to the pumping line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.2.1 Connection at pump inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.2.2 Connection at pump exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.2.3 Connecting the purge circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.3 Leak test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.4 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.4.1 Customer electrical installation protection. . . . . . . . . . . . . . . . . . . 17 5.4.2 Connection to the mains power supply. . . . . . . . . . . . . . . . . . . . . 18 5.5 Remote connector wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.5.1 Wiring of digital inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.5.2 Setting of the rotation speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.5.3 Wiring of the digital outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.6 RS-485 serial link wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.6.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.6.2 Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.6.3 Command list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 6.1 Prerequisites to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 6.2 Matrix gas/applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.3 Different control modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.3.1 Local mode operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.3.2 Remote mode operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 6.3.3 RS-485 serial link operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 6.3.4 Operation monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.4 Gas ballast operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.5 Purge operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 7.1 Safety and maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 7.1.1 How to contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 7.2 Maintenance frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 7.3 Maintenance on the customer’s site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 7.4 Standard repair exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2 Table of contents 7.4.1 Disconnecting the pump from the installation. . . . . . . . . . . . . . . . 33 7.4.2 Conditioning the pump for shipping. . . . . . . . . . . . . . . . . . . . . . . . 33 8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.1 Shutting down for longer periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.2 Re-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 9 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9.1 Trouble at pump start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9.2 The pump runs incorrectly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 11 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 12 Technical data and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12.3 Facilities characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 12.3.1 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 12.3.2 Nitrogen characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 12.3.3 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 12.4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 12.5 Weight distribution and seismic brackets . . . . . . . . . . . . . . . . . . . . . . . . . 41 ETL Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3 About this manual 1 About this manual 1.1 Validity This operating manual is for customers of Pfeiffer Vacuum. It describes the functioning of the designated product and provides the most important information for safe use of the unit. The description follows applicable EU guidelines. All information provided in this operating manual refers to the current state of the product's development. The documen- tation remains valid as long as the customer does not make any changes to the product. Up-to-date operating instructions can also be downloaded from www.pfeiffer-vacuum.com. This document is a translation of the original French instructions. This manual covers products with the following references: Part number Model Description V5SAXXXXXX ACP 15 Models for standard applications V5VSXXXXXX V5GAXXXXXX ACP 15 G Models for applications with traces of corrosive gases V5VGXXXXXX 1.1.1 Applicable documents Declaration of conformity included with this manual UL/CSA compliant use (ETL mark) included with this manual 1.2 Conventions 1.2.1 Safety instructions The safety instructions in Pfeiffer Vacuum operating instructions are the result of risk evaluations and hazard analyses and are oriented on international certification stan- dards as specified by UL, CSA, ANSI Z-535, SEMI S2, ISO 3864 and DIN 4844. In this document, the following hazard levels and information are considered: DANGER Imminent danger Indicates an imminent hazardous situation that will result in death or serious injury. WARNING Possibly imminent danger Indicates an imminent hazardous situation that can result in death or serious injury. CAUTION Possibly imminent danger Indicates an imminent hazardous situation that can result in minor or moderate injury. NOTICE Command or note Command to perform an action or information about properties, the disregarding of which may result in damage to the product. 4 About this manual 1.2.2 Pictographs Prohibition of an action or activity in connection with a source of danger, the disregarding of which may result in serious accidents Warning of a displayed source of danger in connection with operation of the unit or equipment Command to perform an action or task associated with a source of dan- ger, the disregarding of which may result in serious accidents Important information about the product or this document 1.2.3 Instructions/Abbreviations used  or Work instruction: you must perform an operation here. 1.2.4 Labels I/O Pump Start/Stop INLET Pump inlet connection PUMP EXHAUST Pump exhaust connection This label warns the user against possible risk of injury due to any hand contact with hot surfaces. It states that protective gloves should be used before performing any intervention. This label informs the user, that moving parts present inside the pump could cause per- sonal injury, like crushing or cutting. The user must keep all body parts away from moving parts. This label indicates that due to its heavy weight, the product should not be handled manually, but always through appropriate handling devices. This label indicates that some of the internal parts are energized and could cause elec- trical shocks in case of contact. It advises to disconnect the pump before any intervention or to properly lock-out and tag-out the equipment breaker before any intervention on the pump. P0385E4 This label indicates the voltage of the equipment in which the pump is to be connected. Référence AC Rating 110-230V 50/60Hz 15-10A Frequency inverter serial n° This label indicates the location of the holes for seismic bracket installation. SEISMIC TIE DOWN A 329 962 - 5 5 About this manual This label indicates that the power supply must be switched off before connecting and/ or disconnecting the pump. Any person responsible for installation or operation of the product must first refer to the operating manual. This label warns the user against potential risks associated with the use of this product. CAUTION ATTENTION Use suitable power supply cord Utiliser le câble d’alimentation Any person responsible for installation or operation of the product must first refer to the for required voltage adapté pour la tension requise HDoo tn soutr tfoaucech SNuer fpaacse tcohuacuhdeer operating manual. See user’s manual Consulter les documents joints The installer must glue the following labels to the most appropriate and visible place on the pump to warn the operator about potential hazards: 1 Weight Label 1 2 Heavy object label 2 3 Hot surface label 3 4 Hazardous voltage label 4 5 Presence of moving part label 5 6 Seismic down label 7 Mains voltage Label 6 7 7 6 6 6 Safety 2 Safety 2.1 Safety precautions Obligation to inform Any person responsible for installing, using or maintaining the product must first read the security instructions in this operating manual and comply with them. It is the operating customer’s responsibility to protect all operators against the dan- gers associated with the product, with the media pumped and with the entire instal- lation. Installation and use of the accessories The products can be fitted with special accessories. The installation, use and refurbish- ment of the connected accessories are described in detail in the respective manuals. Only use original accessories. Accessory part numbers: see Accessories. WARNING Hazard associated with non-compliant electrical installation Safe operation after installation is the operator’s responsibility. Connect the product to an installation that is compliant with local safety standards. Do not carry out any alterations or modifications to the product on your own initiative. For specific questions, contact your service center. WARNING Electric shock hazard in case of contact When the product's mains switch is set at O, some internal components still have an electrical charge. Make sure that the mains connection is always visible and accessible so that it can be unplugged at any time. Disconnect the power cable from all power sources before starting any work on the product. WARNING Danger due to lack of lock out/tag out (LO/TO) electrical device. In order to properly secure the pump for installation and/or maintenance, it is required to lock out/tag out the pump properly in accordance with OSHA requirement 29 CFR.1910.147. WARNING Other located hazardous energies Electrical circuit and other pressurized circuits as nitrogen are potential hazards: Always lock out these energy sources before working on the product. 7 Safety WARNING Risk associated with process gases The user and/or integrator of the product is/are fully responsible for the operational safe- ty conditions of the equipment. The manufacturer has no control over the types of gases this pump is exposed to. Frequently process gases are toxic, flammable, corrosive, ex- plosive and/or otherwise reactive. It is the user and/or the integrator's responsibility to follow the necessary safety requirements. Toxic gases can cause serious injury or death. Operators and users must: Take the appropriate safety recommendations to prevent injury. Consult the respon- sible department for instructions and safety information. Hazardous gases from the pump can cause serious injury or death. Regula- tions require to connect the pump’s exhaust to a facility hazardous gas ex- haust system which incorporates appropriate filters, scrubbers, etc. This system must meet all air and water regulations. Check that the pump is correctly connected to the equipment (see Installation). Contact the service center for further information. The potential risks with an air cooled, dry multi-stage Roots pump involve electricity, the chemical processes, hot surfaces, the pressurized nitrogen device. ● Only qualified personnel trained in safety rules (EMC, electrical safety, chemical pol- lution) may carry out the installation and maintenance described in this manual. Our service centers can provide the necessary training. ● Do not remove the blanking plates sealing the inlet and exhaust ports if the product is not connected to the pumping line. ● Do not operate the product unless the inlet and exhaust are connected to a vacuum and exhaust pumping line. ● Do not expose any part of the human body to the vacuum. ● Comply with all safety and risk prevention instructions in accordance with local safety standards. ● Regularly check compliance with all precautionary measures. ● Do not turn on the product if the covers are not in place. 2.2 Protective equipment In some situations, personal protective equipment must be worn when handling the vac- uum pump and its components. The owner must provide operators with the necessary equipment. This equipment must be checked regularly and used in accordance with the supplier's recommendations. DANGER Health risk relating to contact with toxic materials The vacuum pump, pumping line components, and operating media may be contami- nated with toxic, corrosive, reactive, or radioactive materials, depending on the process. Wear appropriated safety equipment when pump is disconnected for maintenance, or re-installed, and also for oil filling and draining. WARNING Risk of injury due to hot surfaces For the operator's safety, the products are designed to avoid thermal risk. However, spe- cific operating conditions may exist that require extra caution from users due to the high temperatures (external surfaces > 70°C on the exhaust pipe). Let the part cool before working on the product. If necessary wear protective gloves according to directive EN 420. 8 Safety WARNING kg Risk of injury due to falling objects When transporting parts/items by hand, there is a danger of loads slipping and falling down. Carry small and medium-size parts/items with two hands. Carry parts/items > 20 kg with a suitable lifting device. Wear safety shoes with steel toe according to directive EN 347. 2.3 Proper use NOTICE EC conformity The manufacturer's declaration of conformity becomes invalid if the operator modifies the original product or installs additional components. Following installation into a plant and before commissioning, the operator must check the entire system for compliance with the valid EU directives and reassess it accord- ingly. ● The vacuum pump may only be used to generate a vacuum while pumping gases. ● The product may be used in an industrial environment. ● The product may be used in a laboratory environment. ● The G version pump is compatible with traces of corrosive gases. 2.4 Improper use Improper use will cause all claims for liability and warranties to be forfeited. Improper use is defined as usage for purposes deviating from those mentioned above, especially: ● pumping of flammable and explosive mixtures ● pumping of corrosive gases (exception: pumps in G version) ● pumping of liquids ● pumping of dusts ● use of the vacuum pump to generate pressure ● operation in potentially explosive areas ● use of accessories or spare parts, which are not named in this manual The product is not designed to carry people or loads and is not for use as a seat, step- ladder or any other similar purpose. 9 Transport and storage 3 Transport and storage Upon delivery, check that the product has not been damaged during transport. If the product is damaged, contact the carrier and notify the manufacturer. In all situations we recommend: Keeping the product in its original packaging so it stays as clean as it was when dis- patched by us. Only unpack the product once it has arrived at the location where it will be used. Keeping the packaging (recyclable materials) in case the product needs to be trans- ported or stored. Keeping the blanking plates in place on the inlet, exhaust and purge ports while the product is not connected to the pumping line. 3.1 Transport WARNING Risk of injury associated with heavy loads Given the weight of the product, it should be removed from its packaging only by per- sonnel qualified and trained in handling heavy materials. Use the lifting rings and devices provided with the product. The manufacturer cannot be held liable for the consequences of using lifting devices other than those provided. WARNING Risk of tilting Even though compliance with EEC safety rules is guaranteed, all necessary precautions should be taken when moving, installing and operating the product. Do not place the product on an inclined plane. Place it on a flat, hard floor. Do not push the product sideways. To lift the product: Use a lifting device suitable for the product's weight. Use a lifting sling with a single arm that can withstand a load > 23 kg. A wheel kit is available as accessory: fitted over the frame, it facilitates the displacement of the pump over short distanc- es (see 11) and (see 12.4). 10