ULVAC DAT-100SEP (01) PDF Document

After opening the packaging for your ULVAC DAT-100SEP, you should check the following:

1. Is the product as you requested?

2. Are the accessories and necessary parts included? The standard accessories are:

• User’s manual: x1

• Inlet and outlet caps (fitted to inlet and outlet): x3 (for DAT-100SEP)

3. Is the pump damaged in any way?

4. Are any external screws or inlet and outlet pipes loose? Are any components missing?

If there are any problems with the pump, contact your agent or the sales division of the manufacturer.

The safety icons in the manual for the ULVAC DAT-100SEP warn the operator of possible dangers and damage. The meanings are as follows:

• Danger: Incorrect handling of the equipment is very likely to result in death or serious injury to the operator.

• Warning: Incorrect handling of the equipment may result in death or serious injury to the operator.

• Caution: Incorrect handling of the equipment may result in light or medium injuries to the operator or damage to the equipment.

• Note: Incorrect handling of the equipment may result in damage to the equipment and hinder its correct operation.

• High Temperatures: Some components reach surface temperatures in excess of 60°C during pump operation. Burns may result if these components are touched during operation.

• Electric Shock: To prevent electric shock, always shut-off the primary power supply before working on electrical wiring, or engaging in any electrical work.

Danger

Applications:

1. This pump is not designed to be explosion-proof, and should therefore not be used to discharge explosive gases.

2. Gas may leak from parts of the pump other than the outlet. It should not be used with toxic gases. If used with toxic gas, the interior will be contaminated, requiring caution during maintenance.

Maintenance and Repair:

3. When requesting repairs, always note the gas used with the pump on the Usage Check Sheet. If used with toxic gas, it will be contaminated. Use with some gases will preclude dismantling and repair.

Warning

Installation:

1. Do not use the pump in an explosive atmosphere. This may result in injury and fire.

2. Ensure no inflammable materials (e.g., solvents) are in the vicinity when using the pump.

3. Ensure the motor is freely ventilated to prevent overheating, which may result in fire or burns.

Power Supply:

1. Always remove the power cord from the terminal before checking or repairing the pump to prevent electric shock or accidental starting.

2. Ensure wiring is in accordance with technical standards and regulations to prevent fire.

3. Remove the power cord before connecting any wiring to prevent electric shock.

4. Always ensure the pump is correctly earthed. A dedicated earth leakage breaker is recommended to prevent electric shock.

5. Use the pump only at the rated voltage to avoid motor burnout or fire.

6. Do not damage, modify, pull the power cord, or place objects on it.

7. Ensure the power cord has a cross-section area of 1.0mm2 or more.

8. Switch off the main power supply before disconnecting the power cord.

9. Do not touch the power cord with wet hands.

10. The motor’s thermal protector is not a guaranteed safety device. For safety, fit an overload (over current) protection device and an earth leakage breaker.

11. Applying inverter controlled pressure to the motor will cause serious damage or failure.

Operation:

1. This pump is not explosion-proof. Ensure no inflammable materials or explosive gases are in the vicinity.

2. Do not insert fingers or objects into the motor inlet.

3. Operating the pump with the discharge outlet blocked may cause the pump to rupture and the motor to become overloaded. The internal pressure is limited to 0.03 MPa (gauge pressure).

Maintenance and Repair:

1. The pump should only be dismantled or repaired by a trained technician.

2. Use a dust mask and gloves during repair work to prevent ingestion of microscopic wear particles.

Installation Cautions:

1. Satisfy the following conditions for storage, installation, and operation:

• Ambient temperature of 7-40°C and maximum relative humidity of 85%.

• Elevation of 1000m or less above sea level.

• Level floor of sufficient strength.

• No condensation.

• Dust-free environment.

• Well ventilated.

• Environment free of corrosive or explosive gas.

• Not subject to direct sunlight.

• No danger of fire.

• Free of soot and oil.

• Free of splashing or flooding.

• Kept indoor and ventilated.

• Use anti-vibration rubber between the base and the vacuum pump; do not mount directly to the base.

2. To prevent back injury, always use both hands to lift the pump.

3. Microscopic wear particles are discharged from the outlet. If necessary, connect a pipe from the discharge outlet to the outside of the building.

Operational Cautions:

1. Do not use in applications involving organ transplants, or contact with body fluids or living tissue.

2. Touching rotating components (motor, main shaft, cooling fan) during operation may result in injury.

3. The overload protector operates when the pump is excessively hot. Touching it may result in burns.

4. Touching the motor during or immediately after operation may result in burns.

5. Do not insert fingers or objects into the inlet or outlet during operation.

6. If steam is generated, install a trap to ensure condensate does not enter the pump.

7. Do not stop and restart the equipment repeatedly. Ensure the motor has stopped completely before restarting to prevent damage.

Prohibitions:

1. This pump is for vacuum operation only and must not be pressurized.

2. Do not re-sell, repair, or modify this pump without the approval of the manufacturer.

3. Ensure the gas entering the pump does not contain rubbish, dust, or water (except steam).

4. Do not operate the pump for long periods at near-atmospheric pressure.

Specifications:

Environmental Conditions for Installation, Storage, and Operation:

1. Ambient temperature of 7-40°C and maximum relative humidity of 85% during operation.

2. Equal to or less than 1000m above sea level.

3. Other conditions:

• Level floor of sufficient strength.

• No condensation.

• Dust-free environment.

• Well ventilated.

• Environment free of corrosive or explosive gas.

• Not subject to direct sunlight.

• No danger of fire.

• Free of soot and oil.

• Free of splashing or flooding.

• Keep it indoor ventilated.

• When installing, use anti-vibration rubber to isolate the pump from the base.

Electric Wiring:

1. The wire diameter of the power cord must be φ1.0mm or more.

2. It is recommended to equip a protection device such as an earth leakage breaker or motor breaker on the electric wiring to prevent motor burnout from overcurrent.

3. The attaching screw for the earth terminal must have an earth mark indicated.

4. The electric wire connected to the earth must be a green colored insulating coating wire (with or without yellow stripes) and its wire diameter must be φ1.0mm or more.

Notice: Before operating wire connection, be sure to unplug the power plug.

1. Remove the rubber caps from the inlet and outlet.

2. Switch off the main power supply before connecting the power cord from the pump. Ensure the power plug is sufficient for the rated voltage and current.

3. Turn the switch ON and check that gas is being drawn into the inlet.

4. When this check is complete, turn the power switch OFF to stop the pump.

Piping:

1. Install piping carefully to prevent leaks.

2. Piping connected to the inlet should be at least 10 mm inside diameter.

3. Maximum back pressure is 0.03 MPa (gauge pressure).

4. Select an exhaust pipe that has the same or larger inner diameter as the inlet pipe.

5. When evacuating a vessel, ensure that a shut-off valve is placed between the pump inlet pipe and the vessel.

Storage:

Turn the power off, remove the terminal from the outlet, place the rubber caps over the inlet and outlet, and store the pump in an area of low humidity.

1. When the thermal protection relay operates, switch the power OFF, remove the power cord from the outlet, and contact the manufacturer. Note that the pump will be very hot and should not be touched.

2. The pump operates automatically when the temperature drops. Shut off the power supply and determine the cause of the relay operation.

3. Once the cause of the fault has been removed, wait until the motor cools and then restart operation.

The protector specifications are as follows:

Cold weather can increase the viscosity of bearing grease and harden diaphragms, making the pump difficult to start. Follow this procedure in such conditions:

1. If the pump does not start, try to keep it within the operating temperature range for a little while and then turn the power on again.

2. With the inlet open to the atmosphere, run the pump for a few minutes to warm it up.

3. Commence normal operation once the pump has warmed.

Maintenance Checks (at least once every three days):

1. Check for abnormal noises.

2. Check for abnormal heating of the pump.

3. Check that gas is discharged normally.

If a problem is found, refer to the troubleshooting list.

Regular Inspections (after the first 6000 hours):

Inspect consumables and replace/clean as needed. The following table lists the consumables and their average life. Note that life varies with conditions of use and is extended by running the pump at minimal load (inlet closed).

Bearings should be replaced by the manufacturer’s service division.

Replace or clean components if performance is reduced or the following symptoms become apparent after 6,000 hours of operation.

The following tools are required for replacing consumables:

1. Torque wrench – bit size 5 mm (13.0 Nm), bit size 4 mm (5.0 Nm)

2. Phillips head (+) screwdriver – No.2

3. Torque screwdriver – No.2 (0.8 Nm, 2.0 Nm, 5.0 Nm)

4. Wrench – width across flat 19 mm

5. Rag

6. Solvent for wiping (such as ethanol that has no effect on rubber)

7. Dust mask (for nose and mouth), gloves, protective eyewear

8. Loctite 242

Important Safety Precautions:

• The pump becomes very hot. After stopping, leave it for 30 minutes to cool before starting work.

• Always wear a dust mask and gloves. Fine particles from mechanical wear can become airborne.

• Always use gloves to prevent injury.

• First, unplug the pump’s power cable from the main power supply.

Part Removal:

1. Remove Connecting Tube: Use a wrench to remove the joint end of the connecting tube that joins the primary and secondary sides of the pump.

2. Remove Diaphragm: Remove the four hex socket bolts (M6x22) to detach the pump head. Then, remove the four small flat head screws (M5x12) and the push plate to access and remove the diaphragm.

3. Remove Air Release Valve, Filter, and Gasket: With the pump head removed, unscrew the five small pan head screws (w/M4x12 SW) to remove the pump head cover. This exposes the pump head gasket and the filter for removal. Then, remove the small pan head screws (M3x5) to detach the air release valve holder and the air release valve.

4. Remove Base: Remove the four hex socket bolts (M5x30) to detach the base. The base is removed for adjusting the connecting rod position during assembly.

Attaching Parts & Assembly:

5. Attach Diaphragm: Place the new diaphragm onto the connecting rod. Adjust it so there is an even space on the left and right sides.

6. Attach Push Plate: Place the push plate on top of the diaphragm. Apply Loctite 242 to 3-4 threads of the small flat head screws (M5x12). Tighten the screws in a cross pattern (1-3-2-4) over three passes, partially tightening each time. Finally, use a torque screwdriver to tighten to 5.0 Nm. Tighten each screw twice.

7. Attach Air Release Valve: Check the correct orientation for the valve and valve holder (it differs between primary and secondary sides). Apply Loctite 242 to 2-3 threads of the pan head screws (M3x4). Tighten them using a torque screwdriver to 0.8 Nm.

8. Attach Filter: Insert the new filter(s). For the DAT-100SEP, the primary side has two filters and the secondary side has one. Ensure they are inserted all the way in.

9. Attach Pump Head Gasket: Attach the gasket, ensuring the correct orientation.

10. Attach Pump Head Cover: The thick part of the center fin should be on the bottom. Use a torque screwdriver to tighten the five small pan head screws (w/M4x12S) to 2.0 Nm. Tighten in a star pattern (1-3-5-2-4) over two passes.

11. Position for Pump Head: Before attaching the pump head, rotate the eccentric shaft so it is on top.

12. Attach Pump Head: Adjust the pump head for even spacing around the diaphragm. Use a torque wrench with a 5 mm bit to tighten the four hex socket bolts (M6x22) to 13.0 Nm. Tighten in a cross pattern over two passes. Repeat steps 7 through 12 for the opposing pump head.

13. Attach Base: After both pump heads are attached, tighten the base using a torque wrench with a 4 mm bit and the hex socket bolts (M5x30) to 5.0 Nm. Tighten in a cross pattern.

14. Attach Connecting Tube: Re-attach the connecting tube to complete the procedure.