Cable replacement: Vacuum pump power supply 03079997-03 Caution!

The vacuum pump must be disconnected from the mains voltage for this work. Remove the cover over the connection box.

Disconnect the cable.

Carefully pull the cable out of the terminal box through the cable grommet.



Clean the inside of the housing.

Thread in the new cable.



Caution:

The vacuum pump can be operated in the 200-230 V as well as in the 380-400V supply.

To prevent the vacuum pump from being accidentally damaged by overvoltage, it must always be delivered in the 380-400V (star) configuration.

Check the bridges in the terminal box and reassemble them according to the connection diagram (3 bridges between U2, V2, and W2).

Note that there must be a plain washer under and above the bridges or cable lugs. Even with star connection, all three bridges and nine plain washers must be installed.



Connecting the new cable to V1, V1, and W1. Caution: Note numbering or colors.

1 (black) to U1

2 (brown) to V1

3 (blue) to W1

Check the protective conductor connection (GN YE) See also reference document 90010850-010202bx4 or the corresponding documents in the Team Center. Please also observe the correct torque. (M4 2.5 Nm)



Mount the cover of the junction box. Note: If the cover over the power connection box is missing, replace it with 03127851-01 "Cover for vacuum pump power connection box". The cover must then be affixed with an ASM nameplate valid for this motor. This is available fromwerner.schuermann@asmpt.de. Note: The cable can have different lengths. The last functional status is 1.4 m long. The cable be shipped with the original cable length as long as the cable is not damaged. Required tools: Allen wrench set, Torx wrench set, socket wrench set, open-end wrench set Cleaning the vacuum pump Clean vacuum pump Clean the housing and the cables of the vacuum pump Vacuum Pump Safety Instructions General Safety Instructions Failure to observe the safety instructions may result in risk to man and machine! Observe the safety instructions in the operating manual of the corresponding machine for all work! Conventions on using safety instructions and presentation means Safety Instructions These instructions contain information that you must observe for your personal safety and to prevent damage to property.The instructions are highlighted by warning triangles and are shown as follows, depending on the degree of danger:



Danger! Risk in the sense of these instructions means that death, serious bodily injury or considerable damage to property will occur if the hazard warnings are not observed.



Warning!



Warning in the sense of these instructions means that death, serious physical injury or considerable damage to property can occur if the warning instructions are not observed.



Caution! Caution in the sense of these instructions means that slight bodily injury or damage to property may occur if the caution instructions are not observed.



Note! A note in the sense of these instructions is important information about the product or the respective part of the instructions to which special attention is to be drawn.

Personnel qualification and training Qualified or adequately trained personnel means that these persons are familiar with the installation, operation, and maintenance of the machine and auxiliary equipment and have appropriate qualifications, such as: Training or instruction or authorization to switch on and off, isolate, ground, or tag circuits and system components in accordance with safety engineering standards. Provide training or instruction in accordance with safety engineering standards in the maintenance and use of appropriate safety equipment. First aid training. Safety instructions for the power supply vacuum pump Danger! Life-threatening voltages! The vacuum pump is supplied with 3 x 400 V~ (or 3 x 204 V~ / 3 x 220 V~ / 3 x 230 V~ / 3 x 380 V~ / 3 x 415 V~) ± 5 %, 50/60 Hz mains voltage.



Observe the safety instructions in the operating manual for all work! Before starting work on the power supply, check that it is not live and observe the waiting times!





Parts of this installation therefore carry life-threatening voltages - even when the main switch is turned off. Improper handling of test equipment and the vacuum pump can therefore lead to death or serious injury as well as considerable damage to property. Only qualified personnel (electrotechnically instructed personnel (EiP) under the supervision of a qualified electrician (EQP)) may carry out measurements and repair work. Observe the applicable accident prevention and DIN regulations (in particular DIN EN 60 204, Part 1) or the regulations of your country. Before starting repair work, switch off the main switch and disconnect the measuring equipment and the vacuum pump from the power supply. Secure the installation against being switched on again. Failure to observe this warning may result in death or serious injury if live parts are touched. Maintenance, installation, or removal of assemblies (vacuum pump)

Switch off the vacuum pump and the measuring equipment at the main switch.

Disconnect the vacuum pump and the measuring equipment from the power supply.

Secure the vacuum pump and the measuring equipment against being switched on again and mark that service work is being performed. Safety instructions for maintenance activities WARNING!



Risk of burns



Never carry out cleaning work with flammable liquids (e.g. alcohol) in the presence of open light or fire.

Never spray lubricants or cleaning agents from spray cans in open light or fire.



CAUTION!



Consumables



Observe the safety data sheets of the consumables!



CAUTION!



Cleaning and lubrication



Do not use solvents for cleaning, only ethyl alcohol!

Alternatively, isopropyl alcohol (isopropanol - IPA) can be used.

It is strictly forbidden to clean assemblies inside the vending machines or modules using compressed air.

Safety instructions on hazardous substances CAUTION!



Observe the safety data sheets! Observe the applicable safety data sheet when handling hazardous substances (e.g. Loctite 241, ethyl alcohol). What to do before starting the work ... (vacuum pump) Task and purpose Before carrying out any form of maintenance, conversion, or service work on the vacuum pump, you must secure it against being switched on again, unless otherwise described, and attach appropriate warning signs for this purpose. It is described explicitly if it is not necessary or possible to switch off the machine. There is no risk of injury to employees if you follow the procedure described below .



NOTE!

Additional safety measures This procedure contains the minimum requirements on the procedure for locking or attaching warning signs to the machine during maintenance and service work. Additional safety measures necessary to complete the job safely may be specified by Occupational Safety, the Safety Officer, the Safety Committee, and the Health Department. Description Always follow the procedure described below when you want to enable, control, or release the energy in the vacuum pump. Notify all affected employees. Switch off the vacuum pump and all additional devices. Perform the normal shutdown procedure: · Switch off the vacuum pump at the main switch. Disconnect the vacuum pump from all power sources: - Disconnect the mains supply. Lock the installations. - Install a lock wherever possible: Secure the main switch Secure the main switch with a padlock. Check vacuum pump (DIN VDE 0701-0702, sound level measurement, vacuum values) Documentation of measurement results Enter the measurement results in Uptime as well in table 03128463S01Vacuum_pump_BECKER_VX_4.25_m.cable_Test_protocol:



\\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe\03128463S01_Vakuumpumpe_BECKER_VX_4.25_m.Kabel_Testprotokoll.xlsx

After completion of thetest according to DIN VDE 0701-007, please enter the results in the Test Report_(Test-Report)_Vacuum Pump_V1.1. \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe\Prüfprotokoll_(Test-Report)_Vakuumpumpe_V1-1_Vorlage.pdf Scan this and place it in the Uptime drive under the following link. \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe Protective conductor test + insulation measurement according to DIN VDE 0701- 0702 Caution: The following measurement may only be carried out by a qualified electrician "EQP".>Before this measurement, a visual inspection of the connection cables and, if necessary, correction of the connection cables must already have been carried out.

The connection box of the vacuum pump must be closed again. Working under openly accessible contacts is not permitted. Guideline R0040: Safety checks for SMD placement systems (r0040) Safety checks (r0040-Anlage_Appendix_01)

Testing of the vacuum pump according to DIN VDE 0701- 0702



Required measuring device: Profitest 204HP-2.0KV

Please familiarize yourself with the measuring device. Corresponding documents can be found in the reference documents in Uptime.

Connect the vacuum pump to the Profitest 204HP-2.0KV using the "Adapter cable, Profitest 204HP-2.0KV - vacuum pump".See figure "Protective conductor test180 mOhm (1)"



Check the Profitest 204HP-2.0KV for function.See figure "Protective conductor test180 mOhm (2)"





Protective conductor test < 180 mOhm

Set the measuring range for the and protective conductor test and perform the test.See figure "Protective conductor test180 mOhm (3)"(Here, the limit value is set to 187 mOhm in the example for the 204HP-2.0KV Profitest)The protective conductor resistance must be less than 180 mOhm.

The limit value for the vacuum pump was defined with connection cable up to max. 3 m length.

Enter the measurement result into the input mask of Uptime.

Insulation measurement > 1 MOhm

Set the measured values for the insulation measurement and perform the test. See figure "Insulation test 1MOhm". (Example of setting the test parameters: nominal voltage 500 V: limit value 1.00 MOhm)

The insulation resistance must be greater than 1 MOhm.

Enter the measurement result into the Uptime input mask and the test record. After completion of thetest according toDIN VDE 0701- 0702,please enter the results in the Prüfprotokoll_Vakuumpumpe_V1.1 \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe\Prüfprotokoll_(Test-Report)_Vakuumpumpe_V1-1_Vorlage.pdf Scan this and place it in the Uptime drive under the following link. \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe

Disconnect the test assembly from the vacuum pump after testing is complete. Protective conductor leakage current measurement < 3.0 mA according to DIN VDE 0701- 0702 Caution: The following measurement may only be carried out by a qualified electrician "EQP". Before this measurement, a visual inspection of the connection cables and, if necessary, correction of the connection cables must already have been carried out. The connection box of the vacuum pump must be closed again. Working under openly accessible contacts is not permitted. Guideline R0040: Safety checks for SMD placement systems (r0040) Safety checks (r0040-Anlage_Appendix_01) Testing of the vacuum pump according to DIN VDE 0701- 0702



Protective conductor leakage current measurement < 3.0 mA Required measuring device: Benning CM9 leakage current clamp meter Please familiarize yourself with the measuring instrument. Corresponding documents can be found in the reference documentsin Uptime: For the measurement, use "Cable: External vacuum pump supply" 03154362-01. This must be adjusted for the measurement. (approx. 10 cm the cable sheath is removed.) The black current-carrying cables are insulated with insulating tape. Only the protective conductor (GN YE) is made accessible for measurement with the current clamp. Caution:

Check the "Leakage current measurement cable" before the test to see whether it is damaged. Connect the vacuum pump to the main switch box using the "Leakage current measurement cable". Grasp the protective conductor with the leakage current clamp and place it safely on the floor. Connect the main switch box to mains voltage. Switch on the vacuum pump at the main switch. The leakage current must not exceed 3 mA. Enter the measurement result into the Uptime input mask.

After completion of thetest according toDIN VDE 0701- 0702,please enter the results in the test report_Vacuum_pump_V1.1. \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe\Prüfprotokoll_(Test-Report)_Vakuumpumpe_V1-1_Vorlage.pdf Scan this and place it in the Uptime drive under the following link. \\mchsv102\uptime\Links_+_TeamCenter_JT_3D-Daten\03_Placement_Machines\Vakuumpumpe

After the measurement has been completed, the vacuum pump must be switched off at the main switch and disconnected from mains voltage. Remove the "Leakage current measurement cable". This may only be used for leakage current measurement. Sound level measurement Sound level measurement:Place the vacuum pump on the floor. Position the sound level meter 1 m away from the vacuum pump (connection box) at a height of 1.6 m above the vacuum pump as shown in the picture.

Caution:The sound level measurement must be carried out with the vacuum pump installation kit mounted. Sound level measurement and vacuum measurement can be performed in parallel.



Note:Make a comparison measurement of the environment. This should not be louder than 30 dB otherwise the measurement result will be distorted. Connect the vacuum pump to the "Main switch box". Connect the "Main Switch Box" to the mains. Switch on the vacuum pump at the main switch. Measure the volume of the vacuum pump, it should notbelouder than 70dB. Enter the measurement result into the Uptime input mask. After completion of the measurement, the vacuum pump must be switched off at the main switch and the main switch box must be disconnected from the voltage mains. Equipment needed (tools): Sound level meter Testo 815(calibrated)03154099-02 Vacuum pump EL.CA ext. main switch box 03090043-01Open-end wrench A/F36 03038435-01Double nipple detachable G3/4 Ms 03092492-01Thread seal Loctite 55 150m 03086345-03Installation kit, vacuum pump Vacuum measurement Vacuum measurementInfiltrated air 2xCP20P heads > 540 mbar Note:Sound level measurement and vacuum measurement can be performed in parallel.Wrap the thread of the "Double nipple, detachable" with "Thread Sealing Cord Loctite 55 150m" and screw it into the free front opening of the vacuum pump.Tighten them with the "Open-end wrench A/F36". Next, screw the "Vacuum pump installation kit" onto the "Double nipple, detachable" and tighten the screws. Caution:The "Vacuum pump installation kit" is configured for vacuum measurement in such a way that it simulates the infiltrated air of two CP20P heads in the machine. 4 open PUN4 hoses are used for this purpose. Do not change this setup under any circumstances, and do not change the length of the hoses. A vacuum > 540 mbar must be present at the gage with this setup if the vacuum pump is in order. Connect the "Compressed Air Tester" to one of the four open PUN4 hoses. Connect the vacuum pump to the "Main switch box". Connect the "Main Switch Box" to the mains. Switch on the vacuum pump at the main switch. Carry out the measurement. Enter the measurement result into the Uptime input mask. After completion of the measurement, the vacuum pump must be switched off at the main switch and the main switch box must be disconnected from the voltage mains. If a vacuum of < 540 mbar is measured during this measurement, then check the slider width, length and thickness, the evenness of the vacuum sidewall, all seals, and the blow-off valve for function with the vacuum pump de-energized.

Possible causes of failure for insufficient vacuum:

slide too worn. (compare the height, width, thickness of the sliders with the replacement sliders)

Are the sliders possibly damaged?

Is the sealing plate on the side of the sliders worn?

Is the seal on the sealing plate damaged or does it not seal correctly with the pump housing?

Is the overpressure valve damaged or incorrectly adjusted?

Are all seals or Loctite sealing threads present?

Are the seals damaged?



Equipment needed (tools):00313523-01Compressed air tester with measuring cable03154099-02 Ext. vacuum pump EL.CA main switch box 03090043-01Open-end wrench A/F36 03038435-01Double nipple detachable G3/4 Ms 03092492-01Thread seal Loctite 55 150m 03086345-03Installation kit, vacuum pump