RVP Duo 11atex

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OPERATING INSTRUCTIONS EN

Translation of the Original

DUO 11 ATEX
Rotary vane pump
Dear Customer,
Thank you for choosing a Pfeiffer Vacuum product. Your new rotary vane pump is designed
to support you by its performance, its perfect operation and without interfering your individual
application. The name Pfeiffer Vacuum stands for high-quality vacuum technology, a
comprehensive and complete range of top-quality products and first-class service. With this
expertise, we have acquired a multitude of skills contributing to an efficient and secure
implementation of our product.
Knowing that our product must not interfere with your actual work, we are convinced that our
product offers you the solution that supports you in the effective and trouble-free execution of
your individual application.
Please read these operating instructions before putting your product into operation for the
first time. If you have any questions or suggestions, please feel free to contact info@pfeiffer-
vacuum.de.
Further operating instructions from Pfeiffer Vacuum can be found in the Download Center on
our website.

Disclaimer of liability
These operating instructions describe all models and variants of your product. Note that your
product may not be equipped with all features described in this document. Pfeiffer Vacuum
constantly adapts its products to the latest state of the art without prior notice. Please take
into account that online operating instructions can deviate from the printed operating
instructions supplied with your product.
Furthermore, Pfeiffer Vacuum assumes no responsibility or liability for damage resulting from
the use of the product that contradicts its proper use or is explicitly defined as foreseeable
misuse.

Copyright
This document is the intellectual property of Pfeiffer Vacuum and all contents of this
document are protected by copyright. They may not be copied, altered, reproduced or
published without the prior written permission of Pfeiffer Vacuum.
We reserve the right to make changes to the technical data and information in this document.

2/58
Table of contents

Table of contents
1 About this manual 7
1.1 Validity 7
1.1.1 Applicable documents 7
1.1.2 Variants 7
1.2 Target group 7
1.3 Conventions 7
1.3.1 Instructions in the text 7
1.3.2 Pictographs 8
1.3.3 Stickers on the product 8
1.3.4 Abbreviations 9

2 Safety 10
2.1 General safety information 10
2.2 Safety instructions 10
2.3 Safety precautions 15
2.4 ATEX classification and safety measures 15
2.4.1 Labeling of the vacuum pump 15
2.4.2 Potential hazards 16
2.4.3 Safety measures 17
2.5 Product usage limits 18
2.6 Proper use 18
2.7 Foreseeable improper use 19
2.8 Personnel qualification 19
2.8.1 Ensuring personnel qualification 19
2.8.2 Personnel qualification for maintenance and repair 20
2.8.3 Advanced training with Pfeiffer Vacuum 20

3 Product description 21
3.1 Function 21
3.2 Operating principle 22
3.3 Scope of delivery 22
3.4 Identifying the product 22

4 Transportation and Storage 23


4.1 Transporting the vacuum pump 23
4.2 Storing the vacuum pump 24

5 Installation 25
5.1 Installing the vacuum pump 25
5.2 Connecting the vacuum side 25
5.3 Connecting the exhaust side 26
5.4 Grounding the vacuum pump 27
5.5 Establishing mains connection 28
5.5.1 Choosing the cable bushing 29
5.5.2 Connect three phase motor with 6-pin terminal board 29
5.5.3 Selecting on-site fuse protection 30
5.5.4 Connecting the PTC thermistor tripping unit 30
5.5.5 Checking the direction of rotation 31
5.6 Filling the operating fluid 31

6 Operation 33
6.1 Putting the vacuum pump into operation 33
6.2 Switching on the vacuum pump 33
6.3 Operating the vacuum pump with inert gas 34
6.4 Refilling operating fluid 36
6.5 Switching off the vacuum pump 36

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Table of contents

7 Maintenance 38
7.1 Maintenance instructions 38
7.2 Checklist for inspection and maintenance 39
7.3 Changing the operating fluid 40
7.3.1 Determine degree of aging of P3 operating fluid 41
7.3.2 Draining the operating fluid 41
7.3.3 Rinsing and cleaning the rotary vane vacuum pump 42
7.4 Cleaning the inert gas valve 44

8 Decommissioning 45
8.1 Decommissioning the vacuum pump for longer periods 45
8.2 Recommissioning 45

9 Recycling and disposal 46


9.1 General disposal information 46
9.2 Dispose of rotary vane pump 46

10 Malfunctions 47

11 Service solutions by Pfeiffer Vacuum 49

12 Spare parts 51
12.1 Maintenance kit 1 – maintenance level 1 51
12.2 Maintenance kit 2 – maintenance level 2, cleaning and dismantling 52
12.3 Overhaul kit – Maintenance level 3 52
12.4 Coupling set for versions with magnetic coupling 52
12.5 Set of vanes 52

13 Accessories 53
13.1 Accessory information 53
13.2 Ordering accessories 53

14 Technical data and dimensions 54


14.1 General 54
14.2 Substances in contact with the media 54
14.3 Technical data 55
14.4 Dimensions 55

Declaration of conformity 57

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List of tables

List of tables
Tbl. 1: Stickers on the product 8
Tbl. 2: Abbreviations used in this document 9
Tbl. 3: ATEX designations 16
Tbl. 4: Potential hazards 17
Tbl. 5: Measures and safety equipment 17
Tbl. 6: Permissible ambient and operating conditions 18
Tbl. 7: Current values for fuse layout 30
Tbl. 8: Maintenance intervals 40
Tbl. 9: Troubleshooting for rotary vane pumps 48
Tbl. 10: Spare parts pack Duo 11 ATEX 51
Tbl. 11: Content of maintenance kit 1 51
Tbl. 12: Ordering accessories 53
Tbl. 13: Consumables 53
Tbl. 14: Conversion table: Pressure units 54
Tbl. 15: Conversion table: Units for gas throughput 54
Tbl. 16: Materials that make contact with the process media 54
Tbl. 17: Technical data Duo 11 ATEX 55

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List of figures

List of figures
Fig. 1: Position of the labels on the product 9
Fig. 2: Design, construction 21
Fig. 3: Rotary vane vacuum pump functional principle 22
Fig. 4: Lifting and transporting the vacuum pump 24
Fig. 5: Minimum distances 25
Fig. 6: Vacuum connection with flange connection 26
Fig. 7: Exhaust connection with flange connection 27
Fig. 8: Connecting the grounding cable 28
Fig. 9: Delta connection for low voltage 29
Fig. 10: Star circuit for high voltage 29
Fig. 11: Connection example with PTC thermistor tripping unit 31
Fig. 12: Filling the operating fluid 32
Fig. 13: Gas ballast valve with inert gas connection 35
Fig. 14: Filling the operating fluid 36
Fig. 15: Draining the operating fluid 42
Fig. 16: Removing/fitting the cap 43
Fig. 17: Valve with inert gas connection 44
Fig. 18: Content of maintenance kit 1 – maintenance level 1 51
Fig. 19: Dimension diagram Duo 11 ATEX 56

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About this manual

1 About this manual


IMPORTANT
Read carefully before use.
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. The document shall remain valid
provided that the customer does not make any changes to the product.

1.1.1 Applicable documents

Designation Number
Declaration of conformity A component of these instructions
Operating instructions for the motor Refer to motor terminal box
Declaration of Conformity for the motor Motor supplier
Accessories operating instructions Refer to Accessories

1.1.2 Variants

Pump type Pump version


Duo 11 ATEX Version with magnetic coupling

1.2 Target group


These operating instructions are aimed at all persons performing the following activities on the product:
● Transportation
● Setup (Installation)
● Usage and operation
● Decommissioning
● Maintenance and cleaning
● Storage or disposal
The work described in this document is only permitted to be performed by persons with the appropriate
technical qualifications (expert personnel) or who have received the relevant training from Pfeiffer Vac-
uum.

1.3 Conventions
1.3.1 Instructions in the text
Usage instructions in the document follow a general structure that is complete in itself. The required ac-
tion is indicated by an individual step or multi-part action steps.
Individual action step
A horizontal, solid triangle indicates the only step in an action.
► This is an individual action step.
Sequence of multi-part action steps
The numerical list indicates an action with multiple necessary steps.
1. Step 1
2. Step 2
3. ...

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About this manual

1.3.2 Pictographs
Pictographs used in the document indicate useful information.

Note

Tip

1.3.3 Stickers on the product


This section describes all the stickers on the product along with their meaning.

Rating plate
VACUUM
D-35641 Asslar
The rating plate of the rotary vane pump is located on the front right-
Mod. DUO 11 ATEX
P/N PK D59 905 C hand side next to the sight glass.
S/N 23679713
Oil P3 0.5 l
S(N2) max. 10.5 m3/h
Motor rating plate (not shown)
n max. 3600 1/min
Mass 15.3 kg The motor rating plate is located on the respective motor.
II 3/3G Ex h IIC T4 Gc X
+12 °C ≤ Ta ≤ +40 °C

Made in Germany 2019/02

ACHTUNG! Sticker (yellow)


Vor dem Einfüllen des Öles Drehrichtung der
Pumpe prüfen! Attention! Check the direction of rotation of the rotary vane pump be-
ATTENTION!
Before filling in the oil check direction of
fore filling with operating fluid.
rotation of the pump!
ATTENTION!
Avant remplir l’huile vérifier le sense de rotation
de la pompe!

Vor Inbetriebnahme Pumpe mit Öl Sticker (red)


füllen
Fill the rotary vane pump with operating fluid before commissioning.
Fill the pump with oil before putting
into operation
Remplir la pompe d’huile avant la mise
en route

Arrow indicating direction of rotation


The direction of rotation arrow indicates the required motor rotation di-
rection.

warranty seal Closure seal


The product is sealed ex-factory. Damaging or removing a closure seal
results in loss of the warranty.
Warning hot surface
This sticker warns of injuries caused by high temperatures in case of
touching without protection during operation.

Tbl. 1: Stickers on the product

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About this manual

1 2 3 4 5

7 6

Fig. 1: Position of the labels on the product

1 Rating plate of the rotary vane vacuum pump 5 Motor rating plate
2 Attention! Check the direction of rotation of the rotary vane pump 6 Arrow indicating direction
before filling with operating fluid of rotation
3 Fill rotary vane pump with operating fluid before commissioning 7 Closure seal
4 Hot surface warning sign

1.3.4 Abbreviations

Abbreviation Explanation
BA Operating instructions
DN Nominal diameter (from the French: diamètre nominal)
ISO International Organization for Standardization
abs. Absolute
DIN German Institute for Standardization (Deutsches Institut für Normung)
IN Rated (nominal) current
Imax Maximum current
FKM Fluoropolymer rubber
M version Version with magnetic coupling
PTC Temperature-dependent resistor (Positive Temperature Coefficient)
PE Earthed conductor (protective earth)
OME Oil mist filter (Oil Mist Eliminator)
ODK Oil return flow line (Oil Drain Kit)
WAF width across flats
MM Maintenance manual
Tbl. 2: Abbreviations used in this document

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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.
► Instructions to avoid the danger situation

WARNING
Potential pending danger
Indicates a pending danger that could result in death or serious injury if not observed.
► Instructions to avoid the danger situation

CAUTION
Potential pending danger
Indicates a pending danger that could result in minor injuries if not observed.
► Instructions to avoid the danger situation

NOTICE
Danger of damage to property
Is used to highlight actions that are not associated with personal injury.
► Instructions to avoid damage to property

Notes, tips or examples indicate important information about the product or about this docu-
ment.

2.2 Safety instructions


All safety instructions in this document are based on the results of the risk assessment carried out in
accordance with Machinery Directive 2006/42/EC Annex I and EN ISO 12100 Section 5. Where applica-
ble, all life cycle phases of the product were taken into account.

Risks during transport

DANGER
Risk of explosion from electrostatic charging during transport
There is a risk of fatalities when transporting packaging material (foil) and plastic containers in poten-
tially explosive areas. Ignition can cause very serious injuries, and even fatalities.
► Only unpack the vacuum pump outside of potentially explosive areas.

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. Ignition can
cause very serious injuries.
► Transport, installation and maintenance work may not be performed in potentially explosive at-
mospheres.
► Always shut down the vacuum pump before commencing any work.

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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.
► Secure the danger zone if necessary.
► Pay attention to the center of gravity of the load during transport.
► Ensure even movements and moderate speeds.
► Observe safe handling of the transport devices.
► Avoid sloping attachment aids.
► Never stack products.
► Wear protective equipment, e.g. safety shoes.

Risks during installation

DANGER
Danger to life from electric shock
Touching exposed and voltage-bearing elements generates an electric shock. Incorrect connection of
the mains supply leads to the risk of live housing parts that can be touched. There is a risk to life.
► Before the installation, check that the connection leads are voltage-free.
► Make sure that electrical installations are only carried out by qualified electricians.
► Provide adequate grounding for the device.
► After connection work, carry out an earthed conductor check.

WARNING
Risk of fatalities due to escaping process media
The manufacturer has no influence on the media being supplied with the vacuum pump. Process me-
dia are often toxic, combustible, potentially explosive and/or reactive in other ways. There is a risk of
serious or even fatal injuries if these media are permitted to leak into the atmosphere.
► Refer to the corresponding local guidelines. This information can be obtained from the Depart-
ment of Health and Safety at Work of the user.
► Prevent zone entrainment.
► Connect the pump outlet to the suction system for hazardous media on the system.
► Perform regular inspections to ensure that there are no leaks at the connection between vacuum
pump and suction pipes.

WARNING
Risk of explosion at increased winding temperature in potentially explosive atmospheres
If the winding temperature of the motor is not monitored, the motor winding could potentially become
a source of ignition. There is a risk of explosion, and consequently the risk of sustaining serious inju-
ries.
► Always establish the connections directed into the motor terminal boxes with a corresponding
PTC thermistor tripping unit of an intrinsically safe electric circuit, suitable for the potentially ex-
plosive area.
– Otherwise, the tripping unit must be installed outside of the potentially explosive area.

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.
► Route the exhaust line without shut-off units.
► Observe the permissible pressures and pressure differentials for the product.
► Check the function of the exhaust line on a regular basis.

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Safety

CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

CAUTION
Property damage from intake of solid particles
During commissioning, there is a risk of damage to the suction chamber from dirt from the system or
the pipes.
► Always use the cone sieve included in delivery in the intake flange.
► Ensure that the cone sieve is also installed at all times during installation.

Risks during operation

WARNING
Risk of explosion in the medium to be pumped as a result of increased pressure
With installation on the exhaust side, there is a risk of the exhaust pressure of the vacuum pump ex-
ceeding the atmospheric conditions. The ignition temperature of the medium to be pumped is lowered
in the suction chamber.
If the ignition temperature of the medium to be pumped falls below a temperature of +135 °C, there is
a risk of explosion, and consequently serious injury.
► Ensure that the ignition temperatures of the medium to be pumped is maintained above a tem-
perature of +135 °C at 2000 hPa abs.

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.
► Observe the pertinent regulations for handling toxic process media.
► Safely purge toxic process media via an exhaust line.
► Use appropriate filter equipment to separate toxic process media.

WARNING
Risk of injury from reactive, potentially explosive or otherwise hazardous gas/air mixtures
Uncontrolled gas inlet of air or gases containing oxygen may lead to the formation of potentially ex-
plosive gas/air mixtures in the vacuum system. Ignition can cause very serious injuries.
► Use inert gases only for the supply of ballast gas in order to prevent the formation of a potentially
explosive atmosphere.
► Ensure a closed inert gas system in order to avoid zone entrainment as a result of process gas
entering into the inert gas line.

WARNING
Risk of injury from reactive, potentially explosive or otherwise hazardous gas/air mixtures
Uncontrolled exchange of gases when opening the housing could potentially generate a potentially
explosive mixture of gas and air in the vacuum system or even outside of the vacuum pump. Ignition
can cause very serious injuries.
► Respect segregation of the zones when filling the operating fluid.

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Safety

WARNING
Danger of injury from impermissibly high inert gas pressure
Increased inert gas pressure compromises the operational reliability due to increasing power con-
sumption of the vacuum pump and potentially causes the temperature class threshold to be exceed-
ed. There is a danger of bursting if there is a potentially explosive atmosphere. This leads to injuries
caused by flying fragments, the escaping of high pressure, and damage to the unit.
► Observe the maximum permissible inert gas pressure of 1200 hPa (absolute).
► Dose the inert gas quantity with the dosing screw on the gas ballast valve or on site.

CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

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.
► Route the exhaust line without shut-off units.
► Observe the permissible pressures and pressure differentials for the product.
► Check the function of the exhaust line on a regular basis.

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 in event of 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. Ignition can
cause very serious injuries.
► Transport, installation and maintenance work may not be performed in potentially explosive at-
mospheres.
► Always shut down the vacuum pump before commencing any work.

DANGER
Risk of explosion from electrostatic charging during transport
There is a risk of fatalities when transporting packaging material (foil) and plastic containers in poten-
tially explosive areas. Ignition can cause very serious injuries, and even fatalities.
► Only unpack the vacuum pump outside of potentially explosive areas.

13/58
Safety

WARNING
Health hazard through poisoning from toxic contaminated components or devices
Toxic process media result in contamination of devices or parts of them. During maintenance work,
there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub-
stances causes environmental damage.
► Take suitable safety precautions and prevent health hazards or environmental pollution by toxic
process media.
► Decontaminate affected parts before carrying out maintenance work.
► Wear protective equipment.

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.
► Identify rooms in which magnetic couplings are openly accessible with the symbol: "No access
for people with pacemakers".
► Always keep disassembled couplings away from computers, data carriers, and other electronic
components.

WARNING
Health hazard and risk of environmental damage from toxic contaminated operating fluid
Toxic process media can cause operating fluid contamination. When changing the operating fluid,
there is a health hazard due to contact with poisonous substances. Illegal disposal of toxic substan-
ces causes environmental damage.
► Wear suitable personal protective equipment when handling these media.
► Dispose of the operating fluid according to locally applicable regulations.

CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

CAUTION
Scalding from hot operating fluid
Danger of burns when draining operating fluid if it comes into contact with the skin.
► Wear protective equipment.
► Use a suitable collection vessel.

CAUTION
Danger of burns on hot surfaces
In the event of a fault, the surface temperature of the vacuum pump can increase to above 105 °C.
► Allow the vacuum pump to cool down before carrying out any work.
► Wear personal protective equipment if necessary.

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Safety

2.3 Safety precautions


Duty to provide information on potential dangers
The product holder or user is obliged to make all operating personnel aware of dangers
posed by this product.
Every person who is involved in the installation, operation or maintenance of the product
must read, understand and adhere to the safety-related parts of this document.

Infringement of conformity due to modifications to the product


The Declaration of Conformity from the manufacturer is no longer valid if the operator
changes the original product or installs additional equipment.
● Following the installation into a system, the operator is required to check and re-evalu-
ate the conformity of the overall system in the context of the relevant European Direc-
tives, before commissioning that system.

General safety precautions when handling the product


► Observe all applicable safety and accident prevention regulations.
► Check that all safety measures are observed at regular intervals.
► Do not expose body parts to the vacuum.
► Always ensure a secure connection to the earthed conductor (PE).
► Never disconnect plug connections during operation.
► Observe the above shutdown procedures.
► Keep lines and cables away from hot surfaces (> 70 °C).
► Never fill or operate the unit with cleaning agents or cleaning agent residues.
► Do not carry out your own conversions or modifications on the unit.
► Observe the unit protection class prior to installation or operation in other environments.
► Provide suitable touch protection, if the surface temperature exceeds 70 °C.

2.4 ATEX classification and safety measures


Vacuum pumps of the ATEX series are specially designed and manufactured to comply with the re-
quirements of Directive 2014/34/EU regarding the proper use of equipment and protective systems in
potentially explosive areas. The vacuum pumps are delivered with an ATEX-certified motor and are
designated as follows:
● II 3/3G Ex h IIC T4 Gc X +12 °C ≤ Ta ≤ +40 °C

2.4.1 Labeling of the vacuum pump

Classifica- Description
tion
Device Devices which can be used for applications in potentially explosive atmospheres are
group divided into two groups:
Device group I: Devices for mines susceptible to firedamp (will not be discussed in
any more detail here)
Device group II: Devices for all other potentially explosive areas with the exception of
underground operations in mines and their surface installations which are susceptible
to hazardous firedamp and / or combustible dust.
Device cate- Device group II is divided into three categories which vary in their respective degree
gory of safety.
Devices of Device category 1 are designed to guarantee an extremely high degree
of safety. They must guarantee the necessary degree of safety even if malfunctions
occur only rarely on the device.
Devices of Device category 2 are designed to guarantee a high degree of safety.
They must guarantee the necessary degree of safety even with regular occurrences
of malfunctions or fault conditions which are generally to be expected.
Devices of Device category 3 are designed to guarantee a normal degree of safety.
They guarantee the necessary degree of safety for normal operation.

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Safety

Classifica- Description
tion
Combustible G: Gases or vapors
materials D: Dust (will not be discussed in any more detail here)
Note: The device may only be used in atmospheres susceptible to explosion
due to gases or vapors. Operation in dust-charged, potentially explosive atmos-
pheres is not permitted.
Type of pro- Identification code “Ex h” designated in the standard DIN EN ISO 80079-36 for non-
tection electrical equipment. A protection type established for electrical equipment is not
used.
Explosion Gases and vapors are divided into three Explosion groups based on their particular
groups ignition capability (IIA, IIB and IIC). The ignition power in this regard decreases from
Explosion group IIA to IIC. (The higher Explosion group, e.g. IIC incorporates the re-
spectively lower IIB and IIA).
Temperature Classification of equipment depending on their maximum surface temperature, in ac-
class cordance with assignment as follows:
Temperature class --> Maximum surface temperature/gas temperature:
● T1 --> +450 °C
● T2 --> +300 °C
● T3 --> +200 °C
● T4 --> +135 °C
● T5 --> +100 °C
● T6 --> +85 °C
The temperature class and the actual maximum surface temperature of the equip-
ment includes a safety margin to the minimum ignition temperature of the potentially
explosive atmospheres as stipulated in DIN EN ISO 80079-36.
EPL accord- Equipment protection level
ing to EPL Ga: Equipment with “extremely high” protection level for use in potentially explo-
EN 60079 sive gas atmospheres in which no risk of ignition exists during normal operation, with
foreseeable or infrequent faults/malfunctions.
EPL Gb: Equipment with “high” protection level for use in potentially explosive gas at-
mospheres in which no risk of ignition exists during normal operation, with foreseea-
ble faults/malfunctions.
EPL Gc: Equipment with “extended” protection level for use in potentially explosive
gas atmospheres in which no risk of ignition exists during normal operation.
X Special operating conditions must be observed! Special conditions and notes in the
operating instructions apply.
Ta Permissible ambient temperature for operation of the vacuum pump prescribed on the
rating plate.
Tbl. 3: ATEX designations

2.4.2 Potential hazards


The ignition hazard assessment for the Duo 11 ATEX was performed in accordance with the harmon-
ized standard ISO 80079-36 (Non-electrical equipment for explosive atmospheres - Basic method and
requirements). This assessment includes the identification of hazards described as follows which will
not occur if the system is operated properly with the respective safety measures.

Potential Occurrence due to Safety measures


hazard
Hot surfa- Heat generated as a re- Operating fluid dissipates the heat which is produced in
ces sult of friction and com- the inside of the rotary vane pump on the components
pression in the pumping cooled by convection. The installation conditions must be
system, and in particular observed.
at increased intake pres-
sure
Hot gases Compression of the re- The gas temperatures were determined during tests car-
quired gases ried out under permissible application conditions. Observe
the information in the operating manual.
Mechanical No mechanical sparks Surfaces on the inside of the rotary vane pump are wetted
sparks will be produced during with operating fluid to cool them.
normal operation with
normal use of the system

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Safety

Potential Occurrence due to Safety measures


hazard
Electrical Electric motor Application of an explosion-proof electric motor. Observe
sparks the labeling (refer to rating plate) of the electric motor and
the operating instructions.
Static elec- Rotary vane pump is not Rotary vane pump is to be integrated in the equipotential
tricity earthed bonding at the installation site. Static charging from insu-
lating coats of paint can be excluded as the rotary vane
pump is not painted.
Chemical Reaction between proc- To be assessed by the user.
reaction ess gas and operating
fluid
Zone en- Leaking rotary vane Rotary vane pump undergoes a final inspection with heli-
trainment pump/system um leak test within the framework of a production control
(leakage rate < 1 × 10-8 Pa m3/s).
Tbl. 4: Potential hazards

2.4.3 Safety measures


The following information must be observed or appropriate measures implemented if reliable operation
of the rotary vane pump is to be guaranteed:

Measures/safety equipment Speci- We


fica- recom-
tion mend
Oil pres- Monitoring of oil pressure with oil pressure switch (optional): X
sure ● Falling below the switch-point will cause a malfunction of the
vacuum safety valve.
● Exceeding the switch-point could indicate an overload of the
magnetic coupling.
Exhaust Monitoring of the exhaust pressure with pressure switch (optional) X
pressure to protect the rotary vane pump against overload.
Operating Monitoring of the operating fluid temperature with temperature sen- X
fluid tem- sor (optional):
perature ● A deviation from the normal value could be indicative of a fault.
Operating Monitoring of the operating fluid level with level switch (optional): X
fluid level ● If the fill level falls below the "Min" mark, opening of the
change-over contact can be used as a signal to switch off the
rotary vane pump.
Motor wind- Connect the temperature sensor in the motor terminal box on the X
ing temper- PTC thermistor tripping unit (see chapter “Connecting the PTC
ature thermistor tripping unit”, page 30) as prescribed in the motor op-
erating instructions.
Tbl. 5: Measures and safety equipment

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Safety

2.5 Product usage limits


Parameter Duo 11 ATEX
Installation location ● Indoors, protected against:
─ dust deposits
─ falling objects
─ fire-fighting water
● Outdoors, protected against:
─ falling objects
─ direct influence of weather such as rain, splash water,
strong drafts and sunlight
─ fire-fighting water
─ lightning strike
Installation altitude max. 1000 m above sea level
At installation heights > 1000 m above sea level, the rated pow-
er of the motor must be reduced or the ambient temperature
limited due to increased heating of the vacuum pump.
Constant intake pressure ≤ 50 hPa
Tank size for pumping out atmos- max. 100 liters
pheric pressure
Cycle operation Operating duration > downtime, cycle > 20 mins
Exhaust pressure of the vacuum ≤ 1500 hPa abs.
pump
Exhaust pressure at OME max. atmospheric pressure
Ambient temperature +12 °C to +40 °C
Relative air humidity ≤ 85 %
Installation surface flatness Horizontal
Intake temperature of medium to ≤ 40 °C
be pumped
Operation with gas ballast Only permissible with inert gas: ≤ 1200 hPa abs.
Tbl. 6: Permissible ambient and operating conditions

WARNING
Risk of explosion in the medium to be pumped as a result of increased pressure
With installation on the exhaust side, there is a risk of the exhaust pressure of the vacuum pump ex-
ceeding the atmospheric conditions. The ignition temperature of the medium to be pumped is lowered
in the suction chamber.
If the ignition temperature of the medium to be pumped falls below a temperature of +135 °C, there is
a risk of explosion, and consequently serious injury.
► Ensure that the ignition temperatures of the medium to be pumped is maintained above a tem-
perature of +135 °C at 2000 hPa abs.

Inspection of media by the user


Testing with ambient air as the medium to be pumped has shown that if the aforementioned ambient
and operating conditions are maintained, the maximum surface and gas temperatures do not exceed a
value of +130 °C.
With the utilization of dry media being pumped, heating of the pump could become more intense. Ap-
propriate measures are to be implemented to prevent this heating, for example reducing the permanent
intake pressure.
1. Check whether the thermal behavior of the media being pumped deviates from the behavior of the
ambient air.
2. Ensure suitable countermeasures wherever the difference to the ignition temperature is reduced.

2.6 Proper use


► Use the vacuum pump for vacuum generation only.
► Adhere to the installation, commissioning, operating, and maintenance instructions.

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Safety

► Use only accessory parts recommended by Pfeiffer Vacuum.


► Use the vacuum pump to convey potentially explosive atmospheres in accordance with the label-
ing.
► Operate the vacuum pump within the application limits of the product (see chapter “Product usage
limits”, page 18) and in compliance with the technical data.
► Observe the corresponding safety measures (see chapter “Safety measures”, page 17).

2.7 Foreseeable improper use


Improper use of the product invalidates all warranty and liability claims. Any use that is counter to the
purpose of the product, whether intentional or unintentional, is regarded as improper use; in particular:
● pumping media which are corrosive to or too aggressive for the vacuum pump materials
● pumping media that introduce an ignition source to the suction chamber
● pumping pyrophoric or corrosive media, or media releasing FKM
● pumping media prone to spontaneous, specific exothermic reactions
● pumping media that contain impurities such as particles, dust, or condensate
● pumping media that can condense or cause adhering deposits to form in the suction chamber
● pumping media with a propensity to sublimation
● pumping pressurized media (> atmospheric pressure)
● pumping fluids
● pumping radioactive media
● using the vacuum pump outside the specified area of application
● using the vacuum pump in systems in which sporadic loads and vibrations or periodic forces act
on the unit
● using the vacuum pump in strong electrical, magnetic, or electromagnetic fields
● using for media being pumped for which the ignition temperature drops below a temperature limit
of T4, at pressures greater than atmospheric pressure
● using pipes to lift the vacuum pump
● using accessories or spare parts not listed in this manual
● using the vacuum pump as a climbing aid
● painting the vacuum pump, motor and accessories
● using operating fluids that have not been approved by Pfeiffer Vacuum
● using mineral-based operating fluids such as P3, with an oxygen concentration > 21 %.
Mineral-based operating fluids are combustible and ignite at high temperatures, and when they
come into contact with pure oxygen. These operating fluids oxidize heavily and thus lose their lu-
bricating capacity.

2.8 Personnel qualification


The work described in this document may only be carried out by persons who have appropriate profes-
sional qualifications and the necessary experience or who have completed the necessary training as
provided by Pfeiffer Vacuum.
Training people
1. Train the technical personnel on the product.
2. Only let personnel to be trained work with and on the product when under the supervision of
trained personnel.
3. Only allow trained technical personnel to work with the product.
4. Before starting work, make sure that the commissioned personnel have read and understood
these operating instructions and all applicable documents, in particular the safety, maintenance
and repair information.

2.8.1 Ensuring personnel qualification


Specialist for mechanical work
Only a trained specialist may carry out mechanical work. Within the meaning of this document, special-
ists are people responsible for construction, mechanical installation, troubleshooting and maintenance
of the product, and who have the following qualifications:
● Qualification in the mechanical field in accordance with nationally applicable regulations
● Knowledge of this documentation

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Safety

Specialist for electrotechnical work


Only a trained electrician may carry out electrical engineering work. Within the meaning of this docu-
ment, electricians are people responsible for electrical installation, commissioning, troubleshooting, and
maintenance of the product, and who have the following qualifications:
● Qualification in the electrical engineering field in accordance with nationally applicable regulations
● Knowledge of this documentation
In addition, these individuals must be familiar with applicable safety regulations and laws, as well as the
other standards, guidelines, and laws referred to in this documentation. The above individuals must
have an explicitly granted operational authorization to commission, program, configure, mark, and earth
devices, systems, and circuits in accordance with safety technology standards.

Trained individuals
Only adequately trained individuals may carry out all works in other transport, storage, operation and
disposal fields. Such training must ensure that individuals are capable of carrying out the required activi-
ties and work steps safely and properly.

2.8.2 Personnel qualification for maintenance and repair

Advanced training courses


Pfeiffer Vacuum offers advanced training courses to maintenance levels 2 and 3.

Adequately trained individuals are:


● Maintenance level 1
─ Customer (trained specialist)
● Maintenance level 2
─ Customer with technical education
─ Pfeiffer Vacuum service technician
● Maintenance level 3
─ Customer with Pfeiffer Vacuum service training
─ Pfeiffer Vacuum service technician

2.8.3 Advanced training with Pfeiffer Vacuum


For optimal and trouble-free use of this product, Pfeiffer Vacuum offers a comprehensive range of
courses and technical trainings.
For more information, please contact Pfeiffer Vacuum technical training.

20/58
Product description

3 Product description
3.1 Function
DuoLine rotary vane vacuum pumps are two-stage, oil-sealed rotary positive displacement pumps for
use in coarse and medium vacuum. The vacuum pumps are equipped with a safety valve that vacuum
seals the vacuum chamber and simultaneously vents the vacuum pump when the pump is at a stand-
still. The rotary vane vacuum pump is available in the standard version with a conventional seal, or as
an M version with non-contact and wear-proof drive with magnetic coupling. The pump housing is her-
metically sealed.
The rotary vane pump Duo 11 ATEX is a vacuum pump designed for special applications in low and
medium vacuum, observing the application limits. A magnetic coupling allows contactless and wear-free
operation of the drive, thus ensuring a hermetically sealed and fully enclosed pump housing. An eccen-
trically mounted rotor in the pump system divides the suction chamber into multiple compartments with
2 radially sliding vanes. The volume of each chamber changes periodically as the rotor rotates. This
provides suction of the gas at the vacuum flange, whereby the gas is then compressed in the suction
chamber via rotation of the rotor and discharged at the exhaust. The gaps between rotor, stator and
vanes are oil-tight to ensure that the pressures are sufficiently reduced to the correct requirements. As
well as providing a sealing function, the operating fluid also serves to dissipate the heat generated by
compression, lubricate the bearing, and discharge impurities from the pumping system. The rotary vane
vacuum pump is fitted with a vacuum safety valve which completely seals the vacuum chambers upon
shutdown of the vacuum pump, while at the same time venting the pump.
12 13 14 1 2 3 4 5 6

11 10 9 8 7
Fig. 2: Design, construction

1 Circlip of vacuum flange 8 Gas ballast valve


2 Centering ring and blank flange 9 Hose connection for inert gas (installed at the factory
with locking screw)
3 Vacuum flange 10 Base plate
4 Circlip of exhaust flange 11 Drain screw for operating fluid
5 Eye bolt 12 Sight glass
6 Cable bushing for mains connection 13 Cap
7 Motor 14 Filling screw for operating fluid

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Product description

3.2 Operating principle


1

6 2

5
4

Fig. 3: Rotary vane vacuum pump functional principle

1 Housing 4 Vane
2 Vacuum flange (inlet) 5 Suction chamber
3 Rotor 6 Exhaust (outlet)

The rotary vane pump is an oil-sealed rotary displacement pump. The pumping system is made up of
the housing, the eccentrically mounted rotor, and the centrifugally- and spring-loaded radially sliding
vanes, which divide the suction chamber into multiple chambers. The volume of each chamber changes
periodically as the rotor rotates. This provides suction of the gas at the vacuum flange, which thereby
continues to be compressed in the suction chamber via rotation of the rotor until the exhaust valve
opens and the gas is discharged against atmospheric pressure.

Gas ballast valve


The gas ballast device is used to blend inert gas with the process gas in the pumping system. An in-
crease in the proportion of inert gas prevents condensation in the suction chamber as the required gas/
vapor mixture is compacted within certain limits and discharged.

Operating fluid, oil


The pump oil, also known as operating fluid, fulfills various tasks in a rotary vane pump:
● lubrication of all moving parts
● filling part of the dead volume under the exhaust valve
● sealing the gap between the intake and exhaust channel, and between the vanes and the working
chamber
● ensuring an optimal temperature balance through heat transfer

3.3 Scope of delivery


● Rotary vane vacuum pump with motor
● Operating fluid
● Cone sieve with centering ring and O-ring for both connection flanges
● Blank flange for both connection flanges
● Stainless steel circlips
● Connecting elements for inert gas (separate package)
● Documentation
● Optional accessories

3.4 Identifying the product


► To ensure clear identification of the product when communicating with Pfeiffer Vacuum, always
keep all of the information on the rating plate to hand.
► Observe the motor-specific data on the motor rating plate attached separately.
► Learn about certifications through test seals on the product or at www.tuvdotcom.com with com-
pany ID no. 000021320.

22/58
Transportation and Storage

4 Transportation and Storage


4.1 Transporting the vacuum pump
DANGER
Risk of explosion from electrostatic charging during transport
There is a risk of fatalities when transporting packaging material (foil) and plastic containers in poten-
tially explosive areas. Ignition can cause very serious injuries, and even fatalities.
► Only unpack the vacuum pump outside of potentially explosive areas.

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. Ignition can
cause very serious injuries.
► Transport, installation and maintenance work may not be performed in potentially explosive at-
mospheres.
► Always shut down the vacuum pump before commencing any work.

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.
► Secure the danger zone if necessary.
► Pay attention to the center of gravity of the load during transport.
► Ensure even movements and moderate speeds.
► Observe safe handling of the transport devices.
► Avoid sloping attachment aids.
► Never stack products.
► Wear protective equipment, e.g. safety shoes.

Preparations for transport


Pfeiffer Vacuum recommends keeping the transport packaging and original protective cov-
er.

General information regarding safe transport


1. Observe the weight specified on packaging.
2. Use a transport aid if necessary (trolley, lift truck).
3. Transport the product in its original packaging.
4. Always place the product on an adequately sized, level surface.
Transporting the vacuum pump in its packaging
1. Use a pallet truck to transport the vacuum pump in its packaging.
2. Note the center of gravity of the load.
3. Observe safe handling of manually operated transport devices.
4. Ensure harmonious movements and moderate speeds.
5. Ensure a flat substrate.
6. Wear protective equipment, e.g. safety shoes.

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Transportation and Storage

1 2

Fig. 4: Lifting and transporting the vacuum pump

1 Circlip with blank flange (2×) 2 Eye bolt

Transporting the vacuum pump without its packaging


One eye bolt is included in the scope of delivery. It is securely bolted to the vacuum pump at the factory.
1. Unpack the vacuum pump.
2. Attach a suitable lifting tool onto the eye bolt.
3. Pay attention to the correct use and fastening of the lifting equipment.
4. Lift the vacuum pump out of the transport packaging vertically.
5. Remove the eye bolt following transport and installation as required.
– Keep the eye bolts for future use.

4.2 Storing the vacuum pump


Storage
Pfeiffer Vacuum recommends storing the products in their original transport packaging.

Procedure
1. Fill the vacuum pump with operating fluid up to the upper edge of the sight glass.
2. Close both connection flanges and all openings on the vacuum pump.
3. Make sure that the gas ballast valve is closed.
4. Store the vacuum pump only in dry, dust-free rooms, within the specified ambient conditions.
5. In rooms with humid or aggressive atmospheres: Hermetically seal the vacuum pump together
with a drying agent in a plastic bag.
6. Change the operating fluid if the storage period is longer than 2 years.

24/58
Installation

5 Installation
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. Ignition can
cause very serious injuries.
► Transport, installation and maintenance work may not be performed in potentially explosive at-
mospheres.
► Always shut down the vacuum pump before commencing any work.

5.1 Installing the vacuum pump

> 40 mm

Fig. 5: Minimum distances

Notes on installing the vacuum pump


1. Place the vacuum pump on a flat, horizontal surface, to safeguard the operating fluid supply.
2. Screw the base plate of the vacuum pump to the mounting surface if necessary.
3. When installing the pump in a closed housing, ensure adequate air circulation.
4. Keep the sight glass and gas ballast valve visible and freely accessible.
5. Keep the voltage and frequency specifications on the motor rating plate visible and freely accessi-
ble.
6. Fill with operating fluid prior to first commissioning.
– Quantity and type according to rating plate.

5.2 Connecting the vacuum side


CAUTION
Property damage from intake of solid particles
During commissioning, there is a risk of damage to the suction chamber from dirt from the system or
the pipes.
► Always use the cone sieve included in delivery in the intake flange.
► Ensure that the cone sieve is also installed at all times during installation.

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Installation

1 2 3 4

Fig. 6: Vacuum connection with flange connection

1 Circlip 3 Intake line


2 Centering ring with cone sieve and O-ring 4 Blank flange

Connecting the vacuum side


1. Remove the blank flange from the vacuum flange.
2. Make sure that the centering ring with cone sieve and the O-ring are in the vacuum flange.
3. Establish the shortest possible connection between the vacuum pump and vacuum chamber;
equivalent to the nominal flange diameter as a minimum.
4. Metal hoses with flange connections must be used exclusively in this regard.
5. Support or suspend the piping to the vacuum pump so that no piping system forces act on the
vacuum pump.
6. Connect both flanges with a circlip (DN 16 ISO-KF).
7. Protect the vacuum pump against contamination using suitable measures.

5.3 Connecting the exhaust side


WARNING
Risk of fatalities due to escaping process media
The manufacturer has no influence on the media being supplied with the vacuum pump. Process me-
dia are often toxic, combustible, potentially explosive and/or reactive in other ways. There is a risk of
serious or even fatal injuries if these media are permitted to leak into the atmosphere.
► Refer to the corresponding local guidelines. This information can be obtained from the Depart-
ment of Health and Safety at Work of the user.
► Prevent zone entrainment.
► Connect the pump outlet to the suction system for hazardous media on the system.
► Perform regular inspections to ensure that there are no leaks at the connection between vacuum
pump and suction pipes.

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.
► Route the exhaust line without shut-off units.
► Observe the permissible pressures and pressure differentials for the product.
► Check the function of the exhaust line on a regular basis.

26/58
Installation

NOTICE
Malfunction and damage to the vacuum pump from inadmissible exhaust line installation
Negative pressure in the exhaust line causes malfunctions and damage to the vacuum pump. Nega-
tive pressure is permitted only in rotary vane vacuum pumps with magnetic coupling.
► When dissipating gases, make sure that the exhaust pressure is at least 250 hPa higher than the
intake pressure.

1 2
5

Fig. 7: Exhaust connection with flange connection

1 Exhaust line 4 O-ring


2 Blank flange 5 Circlip
3 Centering ring with cone sieve

Connecting the exhaust side


1. Remove the blank flange from the exhaust flange.
2. Ensure that the centering ring with cone sieve and the O-ring are fitted in the exhaust flange.
3. Choose a minimum exhaust line cross section equal to the nominal diameter of the connection
flange.
4. Metal hoses with flange connections must be used exclusively in this regard.
5. Connect both flanges with a suitable circlip.
6. Support or suspend the piping to the vacuum pump so that no piping system forces act on the
vacuum pump.
7. Route the piping downwards from the vacuum pump, to prevent condensate return.
8. Route process gases safely.
9. Use a suction device to prevent zone entrainment.

Condensate separator
Pfeiffer Vacuum recommends installing a condensate separator, with condensate drain at
the lowest point of the exhaust line.

5.4 Grounding the vacuum pump


A suitable grounding cable must be connected to eliminate any applicative disruptive influences.

27/58
Installation

Fig. 8: Connecting the grounding cable

Procedure
1. Connect the ground terminal to the base plate of the vacuum pump with the local equipotential
bonding of the potentially explosive area.
2. Route the connection in accordance with locally applicable provisions.
3. In addition to the ground terminal of the vacuum pump, establish a further connection on the mo-
tor housing.
– Refer to the operating instructions of the motor in this regard.

5.5 Establishing mains connection


Depending on the pump type, different motor designs or mains voltages can be used:
● Three phase motor (without switch and mains cable)

DANGER
Danger to life from electric shock
Touching exposed and voltage-bearing elements generates an electric shock. Incorrect connection of
the mains supply leads to the risk of live housing parts that can be touched. There is a risk to life.
► Before the installation, check that the connection leads are voltage-free.
► Make sure that electrical installations are only carried out by qualified electricians.
► Provide adequate grounding for the device.
► After connection work, carry out an earthed conductor check.

CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

28/58
Installation

NOTICE
Risk of damage from excess voltage
Incorrect or excessive mains voltage will destroy the motor.
► Always observe the motor rating plate specifications.
► 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.

5.5.1 Choosing the cable bushing


Selection of the correct cable bushings is entirely the responsibility of the user.

The cable bushings are chosen in accordance with current EU Directive 2014/34/EU
● Select the power supply cable according to the respective application.
● The cable bushings must be suitable for the power supply cable being used.

Procedure
1. Observe the max. permissible tightening torque for the cable gland on the terminal box.
2. Refer to the operating instructions of the respective motor.

5.5.2 Connect three phase motor with 6-pin terminal board

NOTICE
Property damage from high starting torque
The specific load behavior of the vacuum pump requires direct on-line starting at full motor power.
Engine damage occurs if a different starting circuit is used.
► Always start the motor directly.
► Never use a star-delta start-up circuit.

Ports U1 – L2, V1 – L1 and W1 – L3 rotate the motor shaft clockwise when looking at the motor fan.
L2

W2 U1
W2 U2 V2

W1 U2

U1 V1 W1
V2 V1
L3 L1 L2 L1 L3

Fig. 9: Delta connection for low voltage

The 3 phases are connected in series, and their connection points connected to the mains. The voltage
per phase is equal to the mains voltage, while the mains current is √3 times the phase current. The del-
ta connection is marked with the ∆ symbol. The voltage between the incoming mains supply lines is
called mains voltage. The mains current is the current flowing in the incoming supply lines.
L2

U1

U2 W2 U2 V2
W2

W1 V2
U1 V1 W1
V1
L3 L1 L2 L1 L3

Fig. 10: Star circuit for high voltage

29/58
Installation

The ends of the 3 phases are connected in the star point. The terminal voltage is √3 times the phase
voltage, the mains current is equal to the phase current. The star circuit is marked with the Y symbol.

5.5.3 Selecting on-site fuse protection

The magnetic coupling does not offer an overload protection.


The magnetic coupling's torque is so strong that it does not provide any overload protection
for the motor.

Procedure
1. For the protection of the motor in case of malfunction, always provide fuse protection according to
the regulations applicable for the region.
2. Select a fuse with delayed action characteristic in accordance with the following table.

Motor voltage [V] Frequency [Hz] Motor rating [kW] IN [A] Imax [A]
230 50 0.25 1.28 4.3
400 50 0.25 0.74 2.5
265 60 0.30 1.28 4.3
460 60 0.30 0.74 2.5
Tbl. 7: Current values for fuse layout

5.5.4 Connecting the PTC thermistor tripping unit

WARNING
Risk of explosion at increased winding temperature in potentially explosive atmospheres
If the winding temperature of the motor is not monitored, the motor winding could potentially become
a source of ignition. There is a risk of explosion, and consequently the risk of sustaining serious inju-
ries.
► Always establish the connections directed into the motor terminal boxes with a corresponding
PTC thermistor tripping unit of an intrinsically safe electric circuit, suitable for the potentially ex-
plosive area.
– Otherwise, the tripping unit must be installed outside of the potentially explosive area.

30/58
Installation

L1
L2
L3

F1 - F3

K1
2) 2) 1) 1) 1)

A1 A2 T1 T2 Y1 Y2 24 21 22 14 11 12

2)
3) Us S3
AC 220 ... 240 V F4 H1
U V W
M
10 3 11 S1
T1...T3

k1 S2

K1

N
Fig. 11: Connection example with PTC thermistor tripping unit

US Control voltage T1 – T3 PTC resistor sensor


S1 OFF button H1 Tripping indicator
S2 ON button M Motor, 3-phase
S3 RESET button 1) For devices with two relay outputs only
K1 Contactor 2) For MSR type (model) only
F1 – F4 Fuses 3) Only for order no.: P 4768 052 FQ and P 4768 052 FE

Procedure
► For motors equipped with PTC in the stator winding, connect a thermistor tripping unit as protec-
tion against overload.
► Observe the supplied operating instructions for the motor with regard to the construction guide-
lines.
► After shut-down, switch the tripping unit back on manually via the installed RESET button or via
the external RESET S3.
– Switching on mains detected as automatic RESET.

5.5.5 Checking the direction of rotation

Operating fluid leaks out


The direction of rotation must be checked on vacuum pumps with three phase motors. If
the direction of rotation for the vacuum pump is incorrect, there is a risk of operating fluid
escaping at the vacuum flange.
● Check the direction of rotation before refilling operating fluid.

Procedure
1. Switch on the rotary vane pump briefly (2 to 3 seconds.)
– The motor and motor fan must rotate clockwise (see the arrow on the fan cover).
2. If the direction of rotation is incorrect, exchange the 2 phases on the connection cable.
3. Refill the operating fluid.

5.6 Filling the operating fluid


The operating fluid type intended for the vacuum pump and the respective filling quantity are indicated
on the rating plate. Only the operating fluid used during initial installation is permissible.

31/58
Installation

NOTICE
Risk of damage due to the use of non-approved operating fluid
Product-specific performance data are not achieved. All liability and warranty claims against Pfeiffer
Vacuum are also excluded.
► Only use approved operating fluids.
► Only use other application-specific operating fluids after consultation with Pfeiffer Vacuum.

Approved operating fluid


● P3 (standard operating fluid)

1 2

max.
min.

Fig. 12: Filling the operating fluid

1 Filling screw for operating fluid 2 O-ring

Consumable
● Operating fluid of the vacuum pump
Required tools
● Allen key, WAF 6 mm
● Torque wrench
Filling the operating fluid
1. Unscrew the operating fluid filler screw.
2. Refill the operating fluid:
– Initial filling with cold vacuum pump: A maximum of 3/4 of the min./max. range.
3. Screw the operating fluid filler screw back in; take care of the O-ring in the process.
– Tightening torque: max. 3.0 Nm
– The operating fluid screw is a constituent part of the leak-tested pump housing.

32/58
Operation

6 Operation
6.1 Putting the vacuum pump into operation
WARNING
Risk of explosion in the medium to be pumped as a result of increased pressure
With installation on the exhaust side, there is a risk of the exhaust pressure of the vacuum pump ex-
ceeding the atmospheric conditions. The ignition temperature of the medium to be pumped is lowered
in the suction chamber.
If the ignition temperature of the medium to be pumped falls below a temperature of +135 °C, there is
a risk of explosion, and consequently serious injury.
► Ensure that the ignition temperatures of the medium to be pumped is maintained above a tem-
perature of +135 °C at 2000 hPa abs.

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.
► Observe the pertinent regulations for handling toxic process media.
► Safely purge toxic process media via an exhaust line.
► Use appropriate filter equipment to separate toxic process media.

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.
► Route the exhaust line without shut-off units.
► Observe the permissible pressures and pressure differentials for the product.
► Check the function of the exhaust line on a regular basis.

Before switching on
1. Check the operating fluid in the sight glass.
2. Compare the voltage and frequency specifications on the motor rating plate with the available
mains voltage and frequency.
3. Protect the vacuum pump from sucking in contamination using suitable measures.
4. Check the operating fluid at regular intervals.
5. Check the exhaust connection for free passage (max. permissible pressure: 1500 hPa absolute).

6.2 Switching on the vacuum pump


CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

33/58
Operation

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.

Operating Conditions
● The optimal operating condition of the vacuum pump is continuous operation.
● Observe the application limits prescribed by (see chapter “Product usage limits”, page 18).
● The lowest possible ultimate pressures can be achieved with the gas ballast valve closed.
Procedure
You can switch on the vacuum pump in every pressure range, between atmospheric pressure and ulti-
mate pressure.
1. Switch the vacuum pump on at the mains switch, or, in the case of three phase motors, on site via
a protective circuit.
2. Allow the vacuum pump to warm up prior to process start, with the vacuum flange closed, for ap-
proximately 30 minutes.
3. Open the gas ballast valve if condensible vapors are present.
4. Check the operating fluid level with the vacuum pump running and at operating temperature.
– The fill level must move within the marks on the sight glass edge during operation.
– Check the operating fluid fill level daily during continuous operation or after every time the
vacuum pump is switched on.

6.3 Operating the vacuum pump with inert gas


If the process requires the supply of inert gas (optional), a supply line is absolutely essential on the gas
ballast valve to ensure controlled admission. Inert gas thins the process gas and prevents condensation
in the vacuum pump.

WARNING
Risk of injury from reactive, potentially explosive or otherwise hazardous gas/air mixtures
Uncontrolled gas inlet of air or gases containing oxygen may lead to the formation of potentially ex-
plosive gas/air mixtures in the vacuum system. Ignition can cause very serious injuries.
► Use inert gases only for the supply of ballast gas in order to prevent the formation of a potentially
explosive atmosphere.
► Ensure a closed inert gas system in order to avoid zone entrainment as a result of process gas
entering into the inert gas line.

WARNING
Danger of injury from impermissibly high inert gas pressure
Increased inert gas pressure compromises the operational reliability due to increasing power con-
sumption of the vacuum pump and potentially causes the temperature class threshold to be exceed-
ed. There is a danger of bursting if there is a potentially explosive atmosphere. This leads to injuries
caused by flying fragments, the escaping of high pressure, and damage to the unit.
► Observe the maximum permissible inert gas pressure of 1200 hPa (absolute).
► Dose the inert gas quantity with the dosing screw on the gas ballast valve or on site.

NOTICE
Risk of damage from condensation in vacuum pump
During operation without gas ballast, condensation may form as a result of the vapor compatibility of
the vacuum pump being exceeded.
► Pump condensable vapors only when the vacuum pump is warm and the gas ballast valve open.
► Allow the vacuum pump to run on after process end for another 30 minutes with the gas ballast
valve open.
– This cleans the operating fluid and protects the vacuum pump against corrosion.

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Operation

1 2 3 4 5 6 7

Fig. 13: Gas ballast valve with inert gas connection

1 Hose clamp 5 Inert gas hose


2 Hose connection with O-ring 6 Locking screw
3 Valve spindle 7 O-ring
4 Gas ballast valve

Required tools
● Allen key, WAF 2.5
● Open-end wrench, 14 mm WAF
● Calibrated torque wrench (tightening factor ≤ 2.5)
Behavior of process gases with condensable vapors
► Connect a supply line at the gas ballast valve.
– Connecting elements are included in the separate package
► Supply the vacuum pump with inert gas during operation via the gas ballast valve.
Fitting the hose connection

Observe the sequence during installation!


1. Disconnect the gas ballast valve from the rotary vane pump.
2. Fit the G 1/8" hose connection onto the valve body.
3. The hose connection must be fitted before screwing the valve body onto the rotary
vane pump again, in order to prevent shearing of the bolts.

1. Disconnect the gas ballast valve from the rotary vane pump.
2. Unscrew the locking screw on the gas ballast valve.
3. Screw in the hose connection on the gas ballast valve while at the same time ensuring correct
fitting of the O-ring.
– Tightening torque: 3 Nm
4. Fit the gas ballast valve again.
– Tightening torque: 1 Nm
5. At the same time, ensure correct fitting of the O-ring.
6. Connect the hose (DN 5 mm).
7. Fit the hose clamp.
8. Select the type and quantity of the inert gas used according to the process.
9. Consult Pfeiffer Vacuum if necessary.
Adjusting inert gas flow
The gas ballast quantity is regulated with the valve spindle.
1. Set the inert gas pressure to max. 1200 hPa (absolute).
2. Make sure that the inert gas pressure is greater than the respective intake pressure.
3. Set the desired gas quantity using the valve spindle.
– Clockwise rotation to the stop: Valve closed.
– Counter-clockwise rotation to the stop: Valve open.

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Operation

6.4 Refilling operating fluid


WARNING
Risk of injury from reactive, potentially explosive or otherwise hazardous gas/air mixtures
Uncontrolled exchange of gases when opening the housing could potentially generate a potentially
explosive mixture of gas and air in the vacuum system or even outside of the vacuum pump. Ignition
can cause very serious injuries.
► Respect segregation of the zones when filling the operating fluid.

Refill with operating fluid before the minimum fill level is reached.

1 2

max.
min.

Fig. 14: Filling the operating fluid

1 Filling screw for operating fluid 2 O-ring

Consumable
● Operating fluid
Required tools
● Allen key, WAF 6 mm
● Calibrated torque wrench (tightening factor ≤ 2.5)
Filling the operating fluid
1. Switch off the vacuum pump.
2. Unscrew the operating fluid filler screw.
3. Refill with operating fluid up to the “max.” mark before the minimum fill level is reached.
4. Screw the operating fluid filler screw back in, taking care of the O-ring.
– Tightening torque: 3.0 Nm

6.5 Switching off the vacuum pump


NOTICE
Contamination from operating fluid backflow
After the vacuum pump is switched off, there is a risk that the connected vacuum system can become
contaminated by backflow. The safety valve on the vacuum pump is not suitable for longer-term seal-
ing.
► Install an additional shut-off valve in the intake line.
► Shut off the intake line immediately after switching off the vacuum pump.

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Operation

NOTICE
Contamination of the vacuum chamber from operating fluid backflow
After the vacuum pump is switched off, there is a risk that the connected vacuum system can become
contaminated by backflow.
► Vent the vacuum chamber, regardless of its size, within 30 seconds.
► Shut off the intake line with an additional shut-off valve, after the vacuum pump is switched off
during longer venting operations.

Pfeiffer Vacuum rotary vane pumps have an integral vacuum safety valve on the intake side. The vac-
uum safety valve automatically closes from a differential pressure of ≥250 hPa between the exhaust
and intake sides, when the vacuum pump is switched off, and vents the vacuum pump.
Procedure
1. If required, switch the vacuum pump off in each pressure range.
2. Switch the mains switch off or securely disconnect the drive motor from the mains.
3. Install an additional shut-off valve in the intake line to ensure that the vacuum is maintained in the
vacuum chamber.

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Maintenance

7 Maintenance
7.1 Maintenance instructions
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. Ignition can
cause very serious injuries.
► Transport, installation and maintenance work may not be performed in potentially explosive at-
mospheres.
► Always shut down the vacuum pump before commencing any work.

WARNING
Health hazard through poisoning from toxic contaminated components or devices
Toxic process media result in contamination of devices or parts of them. During maintenance work,
there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub-
stances causes environmental damage.
► Take suitable safety precautions and prevent health hazards or environmental pollution by toxic
process media.
► Decontaminate affected parts before carrying out maintenance work.
► Wear protective equipment.

CAUTION
Risk of injury from entrapment of body parts
During installation and maintenance, the motor may start up uncontrolled. There is a risk of minor in-
jury to fingers and hands (e.g. hematoma), from direct contact with the vacuum flange.
► Maintain sufficient distance to the vacuum flange during all work.
► Safely connect the motor to the mains during installation.
► Safely disconnect the motor from the mains prior to maintenance.
► Secure the motor against re-start.

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.
– Persons who have undergone training from Pfeiffer Vacuum and have subsequently taken
part in refresher courses at intervals of no more than every two years.
– Persons who have been awarded official certification in accordance with Article 14 (6) Betr-
SichV (Ordinance on Industrial Safety and Health).
► We recommend taking advantage of our service training offering.

The following safety information is applicable to the dismantling of drive systems.

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.
► Identify rooms in which magnetic couplings are openly accessible with the symbol: "No access
for people with pacemakers".
► Always keep disassembled couplings away from computers, data carriers, and other electronic
components.

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Maintenance

The following section describes the tasks for cleaning and maintaining the vacuum pump. More ad-
vanced works are described in the service instructions.
Prerequisites
● Vacuum pump is switched off.
● Vacuum pump is vented to atmospheric pressure on the suction side.
● Vacuum pump is cool.
Preparing maintenance
1. Safely disconnect the drive motor from the mains.
2. Secure the motor against switching back on.
3. For maintenance work, only dismantle the vacuum pump to the extend needed.
4. Dispose of used operating fluid according to applicable regulations in each case.
5. When using synthetic operating fluid, please observe the associated application instructions.
6. Only use alcohol or similar media to clean the pump parts.
7. Always perform a leak test after carrying out maintenance and inspection work.

7.2 Checklist for inspection and maintenance


You can carry out maintenance work at Level 1 yourself.
We recommend that maintenance work at Levels 2 and 3 (inspection) be carried out by Pfeiffer Vac-
uum Service. 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.

Notes on maintenance intervals


Depending on the process, the required maintenance intervals may be shorter than the ref-
erence values specified in the table.
● Consult with Pfeiffer Vacuum Service about shorter maintenance intervals for extreme
loads or for specific processes.

Action Inspec- Mainte- Mainte- Mainte- Required


tion nance nance nance material
described in document level 1 level 2 level 3
BA
BA MM MM
Interval daily ≤ yearly ≤ 2 years ≤ 4 years
Inspection
Visual and acoustic pump check ■
Check operating fluid:
● Check fill level
● Check color (contamination)
● Check vacuum pump for leaks
Inspect the OME filter (refer to the ■
operating instructions)
Maintenance level 1 – operating fluid replacement
Clean the outside of the vacuum ■ Operating
pump: fluid1)
● Pump housing Mainte-
● Clean motor fan cap nance kit 1
Changing the operating fluid
Additional activities: ■
● Remove cap
● Clean inside cap and sight
glass, and clean the outside of
the pumping system (without
cleaning agent)
● Remove and clean gas ballast
valve, replace wearing parts

1) Operating fluid is required for all maintenance activities, and must be ordered separately in each case.

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Maintenance

Action Inspec- Mainte- Mainte- Mainte- Required


tion nance nance nance material
described in document level 1 level 2 level 3
BA
BA MM MM
Interval daily ≤ yearly ≤ 2 years ≤ 4 years
Replace the filter in the OME ■
(where present) as prescribed in as re-
the operating instructions quired
Maintenance level 2 – dismantling and cleaning
Dismantle and clean vacuum ■ Mainte-
pump, replace seals and the follow- nance kit 2
ing wear parts:
● Wear parts, vacuum safety
valve (hydraulic piston)
● Wear parts for exhaust valve
(valve flap, valve buffer)
● Wear parts for gas ballast
valve (valve flap)
● Vane springs
Maintenance level 3 – overhaul
Dismantle and clean vacuum ■ Overhaul kit
pump, replace seals and all wear
parts:
● Vane
● Valves, springs, and sight
glass
● Silencer nozzle
● Check the coupling and re-
place as necessary
Tbl. 8: Maintenance intervals

7.3 Changing the operating fluid


Pfeiffer Vacuum recommends determining the precise service life of the operating
fluid in the first operating year.
The service life may deviate from the reference value specified depending on thermic and
chemical loads, and the accumulation of suspended particles and condensate in the oper-
ating fluid.

The usable life of operating fluid is dependent on the area of application of the rotary vane vacuum
pumps.
Instructions for when operating fluid should be changed
● The vacuum pump does not reach the specified ultimate pressure.
● Operating fluid is perceptibly polluted, milky, or cloudy when viewed through the sight glass.
● It is possible to detect thermal aging of the operating fluid from its color identification number (ap-
plies to mineral oils only).

Safety data sheets


You can obtain the safety data sheets for operating fluids from Pfeiffer Vacuum on request,
or from the Pfeiffer Vacuum Download Center.

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Maintenance

7.3.1 Determine degree of aging of P3 operating fluid

WARNING
Health hazard and risk of environmental damage from toxic contaminated operating fluid
Toxic process media can cause operating fluid contamination. When changing the operating fluid,
there is a health hazard due to contact with poisonous substances. Illegal disposal of toxic substan-
ces causes environmental damage.
► Wear suitable personal protective equipment when handling these media.
► Dispose of the operating fluid according to locally applicable regulations.

You can determine the degree of aging of P3 operating fluid in clean processes using the color chart (in
accordance with DIN 51578). The supplementary sheet with the document number PK0219 can be ob-
tained from the Pfeiffer Vacuum Download Center.
Prerequisites
● Vacuum pump switched off
● Vacuum pump is vented to atmospheric pressure on the suction side
● Vacuum pump cooled
Required aids
● Test tube
● Pipette with flexible hose
● Allen key, WAF 8
● Calibrated torque wrench (tightening factor ≤ 2.5)
Determine degree of aging of P3 operating fluid
1. Unscrew the filler screw.
– Be careful with the O-ring.
2. Use the pipette to extract a sample of the operating fluid from the filling port.
3. Pour the sample into a test tube.
4. Check the sample in bright light.
5. If it is a reddish-brown color at the latest (corresponding with color identification number 5),
change the operating fluid.
6. Screw in the filler screw.
– Be careful with the O-ring.
– Tightening torque: 3 Nm

7.3.2 Draining the operating fluid

WARNING
Health hazard and risk of environmental damage from toxic contaminated operating fluid
Toxic process media can cause operating fluid contamination. When changing the operating fluid,
there is a health hazard due to contact with poisonous substances. Illegal disposal of toxic substan-
ces causes environmental damage.
► Wear suitable personal protective equipment when handling these media.
► Dispose of the operating fluid according to locally applicable regulations.

CAUTION
Scalding from hot operating fluid
Danger of burns when draining operating fluid if it comes into contact with the skin.
► Wear protective equipment.
► Use a suitable collection vessel.

41/58
Maintenance

1 2 3 4

Fig. 15: Draining the operating fluid

1 Filling screw for operating fluid 3 O-ring


2 O-ring 4 Drain screw for operating fluid

Consumable
● Operating fluid
Required tools
● Allen key, 5 mm
● Allen key, 6 mm
● Calibrated torque wrench (tightening factor ≤ 2.5)
Draining the operating fluid
1. Shut down the vacuum pump and allow it to cool if necessary.
2. Vent the vacuum pump to atmospheric pressure via the intake side.
3. Unscrew in the operating fluid filler screw, watching out for the O-ring at the same time.
4. Place a collection receptacle below the drain hole.
5. Unscrew in the operating fluid drain screw.
6. Drain the operating fluid in a warm state, if possible.
7. Screw the filler and drain screws back in.
8. Switch on the vacuum pump with the vacuum flange open for max. 5 seconds.
9. Tilt the vacuum pump slightly to completely empty it and drain the remaining operating fluid.
10. In the event of heavy contamination, change the operating fluid several times (flushing).
11. Screw in the drain screw, watching out for the O-ring in the process.
– Drain screw tightening torque: 3.0 Nm
12. Fill with new operating fluid and check the fill level.
13. Screw in the filler screw while at the same time ensuring correct fitting of the O-ring.
– Filler screw tightening torque: 3.0 Nm

7.3.3 Rinsing and cleaning the rotary vane vacuum pump

Cleaning by changing the operating fluid


Pfeiffer Vacuum recommends, in cases of heavy contamination with process residues,
cleaning the inside of the vacuum pump with several operating fluid changes.

42/58
Maintenance

Required tools
● Allen key, 5 mm
● Allen key, 6 mm
● Calibrated torque wrench (tightening factor ≤ 2.5)
Change operating fluid for cleaning
1. Operate the vacuum pump with the gas ballast open, until it is warm.
2. Perform an operating fluid change.
3. Check the pollution level and repeat the changing of the operating fluid if necessary.
4. Replace the corresponding filter elements wherever the accessory is installed.

1 2 3 4

Fig. 16: Removing/fitting the cap

1 Allen head screw (2×) 4 Pumping system


2 Cap 5 stand
3 O-ring

Remove the cap


1. Drain the operating fluid.
2. Unscrew both Allen head screws from the cap.
3. Remove the cap from the stand in axial direction.
– Take care with the O-ring between cap and stand.
4. Collect any leaking operating fluid.
5. Dispose of operating fluid according to applicable regulations.
Cleaning the pumping system and cap
1. Clean the pumping system from the outside without cleaning agent.
2. Clean the cap from the inside without cleaning agent.
Install cap
1. Insert the O-ring in the groove in the cap.
2. Install cap on stand.
3. Tighten both Allen head screws.
– Tightening torque: 6.0 Nm.
4. Screw in the operating fluid drain screw.
– Be careful with the O-ring.
– Tightening torque: 3.0 Nm
5. Fill with operating fluid and check the fill level (see chapter “Filling the operating fluid”, page 31).
6. Screw in the operating fluid filler screw.
– Be careful with the O-ring.
– Tightening torque: 3.0 Nm

43/58
Maintenance

7.4 Cleaning the inert gas valve

1
2

convex
ballig/
3
4
10 5
6

11 10 7

8
9

Fig. 17: Valve with inert gas connection

1 Circlip 7 Screw (2×)


2 Spindle 8 O-ring
3 O-ring (2x) 9 Hose connection
4 O-ring 10 Screw cap
5 Valve housing 11 O-ring
6 Valve flap

Required tools
● Allen key, WAF 2.5 mm, WAF 5 mm
● Open-end wrench, 14 mm WAF
● Circlip pliers J1
● Calibrated torque wrench (tightening factor ≤ 2.5)
Dismantling the valve
1. Dismantle the hose from the inert gas supply line.
2. Disconnect the valve housing from the vacuum pump.
– Be careful with the O-ring.
3. Unscrew the hose connection the from valve housing.
4. Unscrew the screw cap from the valve housing.
5. Remove the valve flap.
6. Dismantle the circlip using the circlip pliers.
7. Screw the spindle out of the valve housing.
– Be careful with the O-rings.
8. Clean the parts - especially the bores in the valve housing.
9. Replace the parts according to the spare parts pack.
Assembling the valve
1. Determine the curve of the valve flap and place the valve flap in the screw cap with the curved
side facing downwards.
2. Screw the screw cap and the valve housing hand tight.
3. Observe the assembly sequence.
4. First fit the G 1/8" hose connection on the valve housing.
– Tightening torque: 3.0 Nm.
5. Slide the O-ring over the screw cap up to the stop.
6. This must be performed before screwing the valve housing onto the vacuum pump in order to
avoid shearing the Allen head screws.
7. Tighten the screws.
– Tightening torque: 1.0 Nm.
8. Fit the spindle in the valve housing.
9. Insert the circlip.

44/58
Decommissioning

8 Decommissioning
8.1 Decommissioning the vacuum pump for longer periods
Before shutting down the vacuum pump, observe the following instructions to adequately protect the in-
terior of the vacuum pump (pumping system) against corrosion:
Prerequisites
● Vacuum pump is switched off.
● Vacuum pump is vented to atmospheric pressure on the suction side.
● Vacuum pump is cool.
Procedure
1. Remove the vacuum pump from the vacuum system if necessary.
2. Change the operating fluid.
3. Start the vacuum pump and take it up to operating temperature in order to wet the inside of the
pumping system with fresh operating fluid.
4. Switch off the vacuum pump.
5. Fill the vacuum pump to above the “max.” mark with operating fluid, up to the upper edge of the
sight glass.
6. Seal the vacuum and exhaust flanges with blank flanges and circlips.
7. Seal additional openings of the vacuum pump as required.
8. Close the gas ballast valve.
9. Store the vacuum pump in a dry, dust-free room outside of the potentially explosive area observ-
ing the ambient conditions stipulated.
10. In rooms with humid or aggressive atmospheres: Hermetically seal the vacuum pump together
with a drying agent in a plastic bag.
11. Please note, the vacuum pump may not be stored in the vicinity of machines, traffic routes, etc.,
as strong vibrations may damage the bearing.
12. For longer storage periods (> 2 years), Pfeiffer Vacuum recommends changing the operating fluid
again prior to recommissioning.

8.2 Recommissioning
DANGER
Risk of explosion from electrostatic charging during transport
There is a risk of fatalities when transporting packaging material (foil) and plastic containers in poten-
tially explosive areas. Ignition can cause very serious injuries, and even fatalities.
► Only unpack the vacuum pump outside of potentially explosive areas.

NOTICE
Risk of damage to vacuum pump as a result of operating fluid aging
The operating fluid usability is limited (max. 2 years). Prior to recommissioning, following a shutdown
of 2 years or more, carry out the following work.
► Change the operating fluid.
► Replace all elastomer parts.
► Observe the maintenance instructions – consult Pfeiffer Vacuum if necessary.

Ejection of operating fluid


Operating fluid ejection at the exhaust connection after overfilling.
● Drain operating fluid to the normal level prior to recommissioning.

45/58
Recycling and disposal

9 Recycling and disposal


WARNING
Health hazard through poisoning from toxic contaminated components or devices
Toxic process media result in contamination of devices or parts of them. During maintenance work,
there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub-
stances causes environmental damage.
► Take suitable safety precautions and prevent health hazards or environmental pollution by toxic
process media.
► Decontaminate affected parts before carrying out maintenance work.
► Wear protective equipment.

Environmental protection
You must dispose of the product and its components in accordance with all applicable reg-
ulations for protecting people, the environment and nature.
● Help to reduce the wastage of natural resources.
● Prevent contamination.

Environmental protection
The product and its components must be disposed of in accordance with the applica-
ble regulations relating to environmental protection and human health, with a view to
reducing natural resource wastage and preventing pollution.

9.1 General disposal information


Pfeiffer Vacuum products contain materials that you must recycle.
► Dispose of our products according to the following:
– Iron
– Aluminium
– Copper
– Synthetic
– Electronic components
– Oil and fat, solvent-free
► Observe the special precautionary measures when disposing of:
– Fluoroelastomers (FKM)
– Potentially contaminated components that come into contact with media

9.2 Dispose of rotary vane pump


Pfeiffer Vacuum rotary vane pumps contain materials that you must recycle.
1. Fully drain the lubricant.
2. Dismantle the motor.
3. Decontaminate the components that come into contact with process gases.
4. Separate the components into recyclable materials.
5. Recycle the non-contaminated components.
6. Dispose of the product or components in a safe manner according to locally applicable regula-
tions.

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Malfunctions

10 Malfunctions
CAUTION
Danger of burns on hot surfaces
In the event of a fault, the surface temperature of the vacuum pump can increase to above 105 °C.
► Allow the vacuum pump to cool down before carrying out any work.
► 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:
– Pfeiffer Vacuum employees with corresponding qualifications.
– Persons who have undergone training from Pfeiffer Vacuum and have subsequently taken
part in refresher courses at intervals of no more than every two years.
– Persons who have been awarded official certification in accordance with Article 14 (6) Betr-
SichV (Ordinance on Industrial Safety and Health).
► We recommend taking advantage of our service training offering.

Should malfunctions occur, you can find information about potential causes and how to fix them here:

Problem Possible causes Remedy


Vacuum pump will not start ● No mains voltage or ● Check the mains voltage and
up voltage does not corre- mains fuse.
spond to the motor data ● If necessary, check the motor
switch.
● Pump temperature too ● Check the mains voltage and
low mains fuse.
● If necessary, check the motor
switch.
● Thermal protection ● Determine and eliminate the cause.
switch has triggered ● Allow the vacuum pump to cool
down as required.
● Pumping system conta- ● Clean the vacuum pump.
minated ● If necessary, contact Pfeiffer Vac-
uum Service.
● Pumping system dam- ● Clean and maintain the vacuum
aged pump.
● If necessary, contact Pfeiffer Vac-
uum Service.
● Motor faulty ● Replace the motor.
Vacuum pump switches off ● Thermal protection ● Determine and eliminate the cause
after a while after being switch of the motor has of overheating.
started triggered ● Allow the motor to cool down as re-
quired.
● Mains fuse triggered ● Bring vacuum pump to permissible
due to overload (e.g. ambient temperature range.
cold start)
● Exhaust pressure too ● Ensure unobstructed outlet opening
high of exhaust line and exhaust side
accessories.

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Malfunctions

Problem Possible causes Remedy


Vacuum pump does not ● Measurement result dis- ● Check the measurement instru-
reach the specified ulti- torted ment.
mate pressure ● If necessary, check the ultimate
pressure without the vacuum sys-
tem connected.
● Vacuum pump or con- ● Clean the vacuum pump.
nected accessory conta- ● Check the components for contami-
minated nation as required.
● Operating fluid contami- ● Operate the vacuum pump with in-
nated ert gas over a longer period.
● Replace the operating fluid as re-
quired.
● Operating fluid level too ● Top up the operating fluid.
low
● Leak in system ● Locate and eliminate the leak.
● Vacuum pump is dam- ● Contact Pfeiffer Vacuum Service.
aged
Pumping speed of vacuum ● The intake line is not ● Make sure that connections are
pump too low suitably dimensioned short and cross sections adequate-
ly dimensioned.
● Exhaust pressure too ● Check exhaust line outlet opening
high and exhaust side accessories.
Loss of operating fluid ● Casing seal is leaking ● Check and replace the seal.
● Loss of operating fluid ● Install an OME.
from normal operating
conditions – without oil
mist filter (OME)
● Loss of operating fluid ● Clean the OME and ODK, or re-
from normal operating place the filter.
conditions – with oil mist
filter (OME)
Unusual noises during op- ● Noise reduction is con- ● Remove the cap.
eration taminated ● Clean the silencer nozzle.
● If necessary, contact Pfeiffer Vac-
uum Service.
● Pumping system is con- ● Clean and maintain the vacuum
taminated or damaged pump.
● If necessary, contact Pfeiffer Vac-
uum Service.
● Motor bearing is faulty ● Change the motor.
● If necessary, contact Pfeiffer Vac-
uum Service.
Tbl. 9: Troubleshooting for rotary vane pumps

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Service solutions by Pfeiffer Vacuum

11 Service solutions by Pfeiffer Vacuum


We offer first-class service
High vacuum component service life, in combination with low downtime, are clear expectations that you
place on us. We meet your needs with efficient products and outstanding service.
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.
Our professional sales and service employees are available to provide you with reliable assistance,
worldwide. Pfeiffer Vacuum offers an entire range of services, from original replacement parts to service
contracts.

Make use of Pfeiffer Vacuum service


Whether preventive, on-site service carried out by our field service, fast replacement with mint condition
replacement products, or repair carried out in a Service Center near you – you have various options for
maintaining your equipment availability. You can find more detailed information and addresses on our
homepage, in the Pfeiffer Vacuum Service section.

You can obtain advice on the optimal solution for you, from your Pfeiffer Vacuum representa-
tive.
For fast and smooth service process handling, we recommend the following:
1. Download the up-to-date form templates.
─ Explanations of service requests
─ Service requests
─ Contamination declaration
a) Remove and store all accessories (all external parts, such as valves, pro-
tective screens, etc.).
b) If necessary, drain operating fluid/lubricant.
c) If necessary, drain coolant.
ANFORDERUNG SERVICE
2. Complete the service request and contamination declaration.
ERKLÄRUNG KONTAMINIERUNG

3. Send the forms by email, fax, or post to your local Service Center.

4. You will receive an acknowledgment from Pfeiffer Vacuum.

Submission of contaminated products


No microbiological, explosive, or radiologically contaminated products will be accepted. Where products
are contaminated, or the contamination declaration is missing, Pfeiffer Vacuum will contact you before
starting service work. Depending on the product and degree of pollution, additional decontamination
costs may be incurred.

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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.
c) Shrink-wrap the product in suitable protective foil.
d) Package the product in suitable, stable transport containers only.
e) Maintain applicable transport conditions.

6. Attach the contamination declaration to the outside of the packag-


ing.
ERKLÄRUNG KONTAMINIERUNG

7. Now send your product to your local Service Center.

8. You will receive an acknowledgment/quotation, from Pfeiffer Vac-


uum.

Our sales and delivery conditions and repair and maintenance conditions for vacuum devices and com-
ponents apply to all service orders.

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Spare parts

12 Spare parts
Observe the following instructions when ordering spare parts:
Procedure
► Where possible, have the vacuum pump part number to hand, along with other details from the
rating plate if necessary.
► Install original spare parts only.

Spare parts pack Order no.


Maintenance kit 1 – maintenance level 1 PK E01 050 -CT
Maintenance kit 2 – maintenance level 2, cleaning and dismantling PK E01 049 -T
Set of vanes PK E08 033 -T
Overhaul kit – maintenance level 3 PK E02 080 -T
Coupling set PK E06 015 -T
Tbl. 10: Spare parts pack Duo 11 ATEX

12.1 Maintenance kit 1 – maintenance level 1


Order no.: PK E01 050 CT
Maintenance kit 1 contains:
● Filler and drain screw seals for one operating fluid change
● Cap seal for cleaning oil chamber
● Seals and consumables for cleaning gas ballast valve
1 2

6
5
3 4

7 7

Fig. 18: Content of maintenance kit 1 – maintenance level 1

Item no. Designation Size Scope of delivery


1 O-ring, FPM 10 × 2.5 1
2 O-ring, FPM 123 × 2.5 1
3 O-ring, FPM 16.5 × 1.5 1
4 Valve flap 1
5 O-ring, FPM 6 × 2.2 1
6 O-ring, FPM 11 × 1.5 2
7 O-ring, FPM 8×2 2
Tbl. 11: Content of maintenance kit 1

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Spare parts

12.2 Maintenance kit 2 – maintenance level 2, cleaning and dismantling


Maintenance kit 2 contains all relevant wear parts, that have to be replaced after dismantling and
cleaning the vacuum pump:
● Set of seals
● Wear parts of the gas ballast valve
● Valves and vane springs

12.3 Overhaul kit – Maintenance level 3


The overhaul kit contains all the wear parts of the vacuum pump, which must be replaced after the vac-
uum pump has been dismantled and cleaned:
● Set of seals
● Wear parts of the pumping system (including vane and springs)
● Wear parts of the vacuum safety valve
● Wear parts of the gas ballast valve

12.4 Coupling set for versions with magnetic coupling


The coupling set contains:
● Both coupling halves
● Containment shell with O-ring

12.5 Set of vanes


The set of vanes contains:
● Vane
● Vane springs

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Accessories

13 Accessories
View the range of accessories for rotary vane pumps on our website.

13.1 Accessory information


OME 16 ATEX with operating fluid return line
The oil mist filter prevents the oil mist from escaping and channels separated operating fluid back into
the rotary vane pump.

Operation monitoring
The operation monitoring monitors the oil pressure and emits a signal in the event of a drop in pressure
or if the rotary vane pump shuts down.

Exhaust pressure monitoring


The pressure switch monitors the exhaust pressure of the rotary vane pump.

Operating fluid level monitoring


The level switch monitors the operating fluid fill level of the rotary vane pump.

Operating fluid temperature monitoring


The temperature sensor monitors the temperature of the operating fluid.

13.2 Ordering accessories


Accessories for Duo 11 ATEX Order no.
OME 16 ATEX, Oil Mist Separator PK Z40 200
Oil Return Unit ODK from OME 16 ATEX to Duo 11 ATEX PK 006 081 -T
Operations Monitoring Unit 1, sensor for Oil level PK 007 100 -T
Operations Monitoring Unit 2, Sensor for Oil Level and Oil Temperature PK 007 101 -T
Operations Monitoring Unit 3, Sensor for Oil Level, Oil Temperature and Exhaust PK 007 102 -T
Pressure
Operations Monitoring Unit 4, Sensor for Oil Pressure PK 007 103 -T
PTC Resistor Tripping Device 220 – 240 V AC P 4768 052 FQ
PTC Resistor Tripping Device 24 V AC/DC P 4768 052 FE
Tbl. 12: Ordering accessories

Consumables Order no.


P3, mineral oil, 0.5 l PK 001 136 -T
P3, mineral oil, 1 l PK 001 106 -T
Tbl. 13: Consumables

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Technical data and dimensions

14 Technical data and dimensions


14.1 General
Basis for the technical data of Pfeiffer Vacuum rotary vane pumps:
● Specifications according to PNEUROP committee PN5
● ISO 21360-1: 2016: “Vacuum technology - Standard methods for measuring vacuum-pump per-
formance - Part 1: General description”
● Leak test to ascertain the integral leakage rate according to EN 1779: 1999 technique A1; with
20 % helium concentration, 10 s measurement duration
● Sound pressure level according to ISO 3744, class 2

mbar bar Pa hPa kPa Torr | mm Hg


mbar 1 1 · 10-3 100 1 0.1 0.75
bar 1000 1 1 · 10 5 1000 100 750
Pa 0.01 1 · 10 -5 1 0.01 1 · 10 -3
7.5 · 10-3
hPa 1 1 · 10 -3 100 1 0.1 0.75
kPa 10 0.01 1000 10 1 7.5
Torr | mm Hg 1.33 1.33 · 10-3 133.32 1.33 0.133 1
2
1 Pa = 1 N/m
Tbl. 14: Conversion table: Pressure units

mbar l/s Pa m3/s sccm Torr l/s atm cm3/s


mbar l/s 1 0.1 59.2 0.75 0.987
Pa m /s3 10 1 592 7.5 9.87
sccm 1.69 · 10-2 1.69 · 10-3 1 1.27 · 10-2 1.67 · 10-2
Torr l/s 1.33 0.133 78.9 1 1.32
atm cm3/s 1.01 0.101 59.8 0.76 1

Tbl. 15: Conversion table: Units for gas throughput

14.2 Substances in contact with the media


Pump parts Substances in contact with the media
Housing Aluminium
Inlet/exhaust flange Stainless steel
Sight glass Synthetic
Stator/stator flange Cast iron
Rotor Cast iron (nodular graphite cast iron)
Magnetic coupling Steel, nickel-coated magnets
Containment shell Synthetic
Vane Artificial resin compound, polymer
Exhaust valve Stainless steel
Vacuum safety valve Aluminum, steel, synthetic, FKM
Gas ballast valve Aluminum, stainless steel, steel, FKM
Screws Galvanized steel, stainless steel
Seals FKM (alternative seals upon request)
Tbl. 16: Materials that make contact with the process media

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Technical data and dimensions

14.3 Technical data


Classification Duo 11 ATEX
ATEX-certification II 3/3G Ex h IIC T4 Gc X
Part number PK D59 905
Connection flange (in) DN 16 ISO-KF
Connection flange (out) DN 16 ISO-KF
Pumping speed at 50 Hz 9 m³/h
Pumping speed at 60 Hz 10.5 m³/h
Final pressure with gas ballast 3 · 10-2 hPa
Final pressure without gas ballast 3 · 10-3 hPa
Continuous inlet pressure, max. 50 hPa
Continuous gas temperature, max. 40 °C
Exhaust pressure, max. 1500 hPa
Exhaust pressure, min. 250 hPa
Gas ballast Yes
Gas ballast pressure ≤ 1200 hPa
Water vapor capacity 50 Hz 65 g/h
Water vapor capacity 60 Hz 84 g/h
Water vapor tolerance at 50 Hz 10 hPa
Water vapor tolerance at 60 Hz 11 hPa
Emission sound pressure level without gas ballast at 50 Hz 54 dB(A)
Cooling method, standard Air
Motor version 3-ph motor
Input voltage 50 Hz 230 / 400 V
Input voltage 60 Hz 265 / 460 V
Input voltage: tolerance ±5 %
Rated power 50 Hz 0.25 kW
Rated power 60 Hz 0.3 kW
Rotation speed at 50 Hz 3000 rpm
Rotation speed at 60 Hz 3600 rpm
Protection category IP66
Motor protection PTC
Mains cable included No
Switch No
Magnetic coupling Yes
Leak rate ≤ 1 · 10-8 Pa m³/s
Leak rate safety valve ≤ 1 · 10-5 Pa m³/s
Operating fluid amount 0.5 l
Operating fluid P3
Ambient temperature 12 – 40 °C
Shipping and storage temperature -10 – 40 °C
Weight 15.3 kg
Tbl. 17: Technical data Duo 11 ATEX

14.4 Dimensions
Dimensions in [mm]

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Technical data and dimensions

438+2
(33.5) 61 50.5
221±1 DN 16 ISO-KF
185±1
(7.2)

216.5+2

172.5±1
3

33.5 88
±1
148 70 95
190 145±1

Fig. 19: Dimension diagram Duo 11 ATEX

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Declaration of conformity
Declaration for product(s) of the type:

Rotary vane pump


Duo 11 ATEX
Article no.: PK D59 905 C
II 3/3G Ex h IIC T4 Gc X +12 °C ≤ Ta ≤ +40 °C

We hereby declare that the listed product satisfies all relevant provisions of the following
European Directives.
● Machinery 2006/42/EC (Annex II, no. 1 A)
● Electromagnetic compatibility 2014/30/EU
● Explosion protection 2014/34/EU according to article 13 (1) c)
● Restriction of the use of certain hazardous substances 2011/65/EU
● Restriction of the use of certain hazardous substances, delegated directive
2015/863/EU

Harmonized standards and applied national standards and specifications:


EN ISO 12100: 2011 ISO 80079-37: 2016-12
EN 1012-2: 2011-12 EN 1127-1: 2019
EN ISO 13857: 2008 EN 61000-6-1: 2007
ISO 21360-1: 2016 EN 61000-6-2: 2006
ISO 21360-2: 2012 EN 61000-6-3: 2007 + A1: 2011
EN 61010-1: 2010 EN 61000-6-4: 2007 + A1: 2011
ISO 80079-36: 2016-12 EN ISO 2151: 2: 2008

The authorized representative for the compilation of technical documents is Mr. Wolf-
gang Bremer, Pfeiffer Vacuum GmbH, Berliner Straße 43, 35614 Asslar, Germany.

Signature:
Pfeiffer Vacuum GmbH
Berliner Straße 43
35614 Asslar
Germany
(Daniel Sälzer) Aßlar, 2020-03-25
Managing Director
Notizen / Notes:
E - Date 2006 - P/N:PD0079BEN
*PD0079*

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