LEYBOLD 11286 3i Bedienungsanleitung

TRIVAC®B

D 40 B / D 65 B

Rotary Vane Vacuum Pump

ATEX Categories 3 i and 3 i/o

with mineral oil

Operating Instructions GA01218_002_C1

Part Nos.

11286 3i

11286J

11296 3i

11296J

11346

11356

140180 3i/3o

140190 3i/3o

160136V

170046 /B

170284 /B

S170722 /B

Page

0 Important Safety Information 5

0.1 Mechanical hazards 5

0.2 Electrical hazards 5

0.3 Thermal hazards 6

0.4 Hazards caused by materials and substances 6

0.5 Danger of ignition 7

0.6 Hazard caused by noise 7

0.7 Risk of damaging the pump 8

TRIVAC B ATEX Categories 3 i and 3 i/o Vacuum Pump 9

Classification and Marking of the Pump 9

Explanation of the Symbols 9

Protective Measures 11

1 Description 13

1.1 Function 15

1.2 Lubricants 17

1.3 Supplied Equipment 18

1.4 Technical Data 19

1.5 Accessories 24

2 Transport and Storage 25

3 Installation 26

3.1 Placement 26

3.2 Conforming Utilization 27

3.2.1 Non-conforming Utilization 28

3.3 Connection to the System 30

3.4 Electrical Connections 31

4 Operation 35

4.1 Media Compatibility 35

4.2 Start-up 35

4.3 Operation 36

4.3.1 Pumping of Non-Condensable Gases and Vapours 36

4.3.2 Pumping of Condensable Gases and Vapours 36

4.3.3 Operating Temperature 37

4.4 Shutdown 37

4.4.1 Controller/Mains Power Failure 38

Contents

2 GA01218_002_C1 - 07/2018 - © Leybold

Translation of the original German installation and operation instructions GA01218_001_C1

5 Maintenance 39

5.1 Maintenance Plan 40

5.2 Leybold Service 41

5.3 Monitoring the Oil Level 42

5.3.1 Checking the Condition of the Oil 42

5.4 Oil Change 43

5.5 Cleaning the Inlet Screen 45

5.6 Removing and Fitting the Internal Demister 45

5.7 Disassembly and Reassembly of the Motor 47

5.7.1 Checking the Coupling 48

5.8 Replacing the Shaft Seal 48

5.9 Removing and Remounting the Pump Module 51

5.9.1 Removing the Pump Module 51

5.9.2 Remounting the Pump Module 52

6 Troubleshooting 53

7 Wearing Parts and Original Spare Parts 55

8 Waste Disposal 55

EC Declaration of Conformity 56

EC Declaration of Incorporation 57

Contents

3GA01218_002_C1 - 07/2018 - © Leybold

Obligation to Provide Information

Before installing and commissioning the TRIVAC B, carefully read these

Operating Instructions and follow the information so as to ensure optimum

and safe working right from the start.

The Leybold TRIVAC B has been designed for safe and efficient operation

when used properly and in accordance with these Operating Instructions. It is

the responsibility of the user to carefully read and strictly observe all safety

precautions described in this section and throughout the Operating

Instructions. The pump must only be operated in the proper condition

and under the conditions described in the Operating Instructions. It

must be operated and maintained by trained personnel only. Consult local,

state, and national agencies regarding specific requirements and regulations.

Address any further safety, operation and/or maintenance questions to our

nearest office.

DANGER indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury.

NOTICE is used to notify users of installation, operation, programming or

maintenance information that is important, but not hazard related.

Figures

The references to figures, e.g. (4/2) consist of the consecutive Fig. No. and

the Item No. in that order.

We reserve the right to alter the design or any data given in these Operating

Instructions. The illustrations are not binding.

Retain the Operating Instructions for further use.

NOTICE

DANGER

WARNING

CAUTION

NOTICE

Safety information

4 GA01218_002_C1 - 07/2018 - © Leybold

0 Important Safety Information

0.1 Mechanical hazards

1 Avoid exposing any part of the human body to the vacuum.

2 Never operate the pump without a connected intake line or without fit-

ting a blank flange.

3 Do not operate the pump with any of the covers removed. Serious

injury may result.

4 The location at which the TRIVAC B (including its accessories) is being

operated should be such that angles over 10° from the vertical are

avoided. Select the operating place so that all controls are easily

accessible.

5 The pump when filled with oil must only be moved in its vertical posi-

tion. Spilled oil involves the risk of falling.

6 Make sure that the gas flow from the exhaust port is not blocked or

restricted in any way.

7 If exhaust gases must be collected or contained, do not allow the

exhaust line to become pressurised. The pressure in the oil box must

not exceed 0.5 bar (g). An exhaust line which is too small in diameter

or which is blocked can result in the formation of overpressures within

the pump. Possible consequences can be a damaged or even burst

open pump. Thus the exhaust line must be checked from time to time

to ensure that there are no obstructions.

8 When moving the TRIVAC B always use the allowed means.

0.2 Electrical hazards

1 The electrical connection must only be provided by a trained person.

Please observe the national regulations in the country of use like EN

50110-1 for Europe, for example.

2 Lethal voltages are present at the mains connections. Before starting

with any maintenance and service work, de-energise (lockout/tagout)

the product first.

3 Lay connecting lines so that they cannot be damaged. Protect the

lines against humidity and contact with water. Avoid any heat stress on

the line due to unfavourable laying conditions.

4 Suitably support the connecting lines so that the pumps are not

exposed to any major mechanical stress.

5 After a mains power failure the pump will run up automatically again.

This also applies in the case of an emergency shutdown. In order to

prevent the pump from running up automatically again, the pump must

be integrated within a control arrangement such that it can only be

switched on manually again after the mains power has returned.

6 Provide an adequate ground connection for the pump so as to avoid

any electrostatic charging.

WARNING

Safety information

5GA01218_002_C1 - 07/2018 - © Leybold

0.3 Thermal hazards

1 Under certain ambient conditions the TRIVAC B may attain a tempera-

ture of over 70 °C (158 °F). There then exists the danger of receiving

burns. Note the symbols on the pump pointing to the hazards, and in

the case of a hot pump wear the required protective clothing. All work

on the “pump still warm from operation” should only be done using

protection gloves.

2 Before servicing and maintenance work always leave the pump to cool

down.

3 Note the warning information on the housing surface. If these warning

notices have been removed, covered or obstructed, include corre-

sponding additional warning notices.

0.4 Hazards caused by materials and substances

1 The vacuum line and the exhaust line must be leaktight. Hazardous

process gases may escape or the pumped gases can react with air or

atmospheric humidity. After installation of the pump and after servicing

work on the vacuum system, a leak search will always be necessary.

When pumping hazardous gases we recommend a leak search on a

regular basis. Leaks in the pump cannot be ruled out under all circum-

stances. When pumping hazardous gases, the operator must ensure

that that leaks at the pump will not be a hazard.

2 Since not all application related hazards for vacuum systems can be

described in detail in these Operating Instructions, Leybold has availa-

ble a separate document (Safety Booklet) in which the hazards and

general safety concepts for design, operation and maintenance of

vacuum systems are explained.

When planning to pump hazardous substances with this pump, read

the related chapters in the Safety Booklet and in these Operating

Instructions first. You can download the Safety Booklet from our

homepage.

3 The pump is not suited for oxygen operation.

4 Before commissioning the TRIVAC B, make sure that the media which

are to be pumped are compatible with each other so as to avoid

hazardous situations. All relevant safety standards and regulations

must be observed.

5 When pumping toxic, chemical, radioactive and corrosive gases as

well as pyrophorous substances, the operating company is under the

obligation to comply with the national and international safety regulati-

ons and guidelines. Regarding the suitability of the TRIVAC?B pumps

for special applications in which such gases, respectively substances

shall be pumped, Leybold should be consulted first.

6 If the pump has previously handled hazardous gases, implement the

proper precautionary measures before opening the intake or exhaust

connection. Before opening the pump, purge it for a longer period of

time with an inert gas. If necessary, use gloves, a respirator and/or

protective clothing and work under an exhaust hood. Firmly seal off

CAUTION

DANGER

Safety information

6 GA01218_002_C1 - 07/2018 - © Leybold

the pump. When shipping the contaminated pump for servicing,

please also state the type of hazard. For this you must use a form

which we have prepared for you.

7 When cleaning a system in which a TRIVAC pump has been integrat-

ed, all parts in contact with the medium need to be compatible with

the cleaning agent so as to prevent a chemical reaction. Residues of

the cleaning agent within the pump must be avoided.

8 Contaminated parts can be detrimental to health and environment.

Before beginning with any work, first find out whether any parts are

contaminated. Adhere to the relevant regulations and take the neces-

sary precautions when handling contaminated parts.

0.5 Danger of ignition

1 Only those pumps which are equipped with an ATEX certified motor

are suited for operation in the explosion hazard areas approved for the

pumps.

2 The standard version of the TRIVAC B is not suited for operation in

explosion hazard areas.

3 The TRIVAC pumps including the accessories are fundamentally not

suited for pumping of combustible and explosive gases or vapours.

The pump including accessories is only suited within the scope of the

ATEX guideline for pumping of explosive gases and vapours. Mixtures

of substances may, regarding the fire and explosion risk be critical or

uncritical. The operating company is under the commitment to analyse

this and rate the hazard potential accordingly so as to therefrom derive

the necessary safety measures which must be introduced.

4 Provided ignitable or pyrophorous substances are present in the

equipment you must:

■ensure that no air can enter into the equipment,

■ensure that the system is leak-tight,

■with an inert gas purge (with dry nitrogen, for example) dilute all ignit-

able gases or vapours which may enter into the pump through the

pump’s inlet and/or with an inert gas purge reduce the concentration

of ignitable gases or vapours in the pump and in the exhaust line to

less than a quarter of the lower explosion limit (LEL) published for the

respective gases.

0.6 Hazard caused by noise

The noise level produced by the pump less than 60 dB(A). Suitable

hearing protection measures must be introduced.

CAUTION

Safety information

7GA01218_002_C1 - 07/2018 - © Leybold

0.7 Risk of damaging the pump

1 Before starting up for the first time, the motor circuit must be equipped

with a suitable protective motor switch. Please take note of the infor-

mation in these Operating Instructions and on the electric motor (wiring

diagram).

2 Do not allow the ingestion of small objects (screws, nuts, washers,

pieces of wire, etc.) through the inlet port. For this reason always use

the inlet screen which is supplied as standard.

3 Do not use the pump for applications that produce abrasive or

adhesive powders or condensable vapours that can leave adhesive or

high viscosity deposits. When planning to pump vapours other than

water vapour please contact our sales or service department for

advice.

4 This pump is suited for pumping water vapour within the specified

water vapour tolerance limits.

5 Avoid vapours that can condense into liquids when being compressed

inside the pump, if these substances exceed the vapour tolerance of

the pump.

6 Before pumping vapours the TRIVAC B should have attained its

operating temperature. This will be the case approximately 30 minutes

after having started the pump. During this warming up phase, the

pump should be separated from the process, by a blocking valve in

the intake line, for example.

7 In the case of wet processes we recommend the installation of liquid

separators upstream and downstream of the pump as well as the use

of the gas ballast.

8 The exhaust line should be laid so that it slopes down and away from

the pump so as to prevent condensate from backstreaming into the

pump.

9 The entry of particles and fluids must be avoided under all

circumstances.

10 Reactive or aggressive substances in the pump chamber may impair

the operating oil or modify it. In addition, such substances may be

incompatible with the materials of the pump (Viton, grey cast iron, alu-

minium, steel, resins, glass etc.).

11 Corrosion, deposits and cracking of oil within the pump are

not allowed.

12 Normal amounts of humidity within the range of the pump’s water

vapour tolerance will not significantly affect pump performance when

the gas ballast is active.

13 When operating the pumps at gas throughput, it is urgently recom-

mended to connect an exhaust filter or use a suitable exhaust line.

Here, the exhaust line must slope down and away from the pump.

14 In the case of custom pumps please note the information provided in

the supplementary sheets.

NOTICE

Safety information

8 GA01218_002_C1 - 07/2018 - © Leybold

TRIVAC B ATEX Categories 3 i and 3 i/o Vacuum Pump

Operating Instructions for Operation in Explosion Hazard Areas

The vacuum pumps from the line TRIVAC B Category 3 have been designed

and manufactured especially for the purpose of fulfilling the requirements of

Equipment Group II, Category 3 of the “ATEX Directive” (Directive 2014/34/

EU) for conforming utilisation of equipment and protection systems in explo-

sion hazard areas”.

Classification and Marking of the Pump

In the case of the standard TRIVAC B the inside, i.e. the process gas side of

the pump fulfils the basic safety requirements of the EU Directive 2014/34/

EU. The pump is supplied with an electric motor which is not ATEX certified

and has for this reason been marked as follows:

II (i) 3G IIC T4 (50 Hz) T3 (60 Hz) (12°C <Ta< 40°C) X

This pump is not suited for being installed in explosion hazard areas.

Pumps where the inside and the outside of the pump fulfil the basic safety

requirements of the Directive, are supplied with an ATEX certified motor and

have been marked as follows:

II (i) 3G IIC T4 (50 Hz) (12°C <Ta< 40°C) X

II (o) 3G IIC T3 (50 Hz) (12°C <Ta< 40°C) X

Explanation of the Symbols

II Equipment Group II applies to all equipment for use in areas which can be

endangered by an explosive atmosphere except in underground mining

operations and their related above ground systems which can be endan-

gered by mine gas and/or combustible dust.

(i)/(o) Specifies the category/conditions according to which the inside (i) (i.e.

sections of the equipment in contact with the process gas flow) and the

outside (o) of the equipment are classified provided these differ.

3Category 3 comprises equipment which is designed such that it can be

operated in agreement with the characteristic quantities (operating parame-

ters) specified by the manufacturer and which ensure a normal level of pro-

tection. Equipment belonging to this category is intended for use in areas

where it needs not to be expected that an explosive atmosphere occurs

due to gases, vapours, mists or raised dust but, in case such an atmos-

phere should occur in spite of this then according to all probability only

rarely and briefly. Equipment belonging to this category ensures during nor-

mal operation the required degree of safety.

GFor areas with an explosive atmosphere caused by gases, vapours or

mists in the air.

Category 3 inside

Category 3 inside 3 outside

ATEX

9GA01218_002_C1 - 07/2018 - © Leybold

The pump is not suited for utilisation in dusty areas.

IIA, IIB or IIC Gas Groups: these are subdivisions for equipment belonging

to Group II which is employed in connection with some protection types.

This subdivision is based on the concept of the maximum permitted gap

and the minimum ignition current of the explosive mixture. Refer to Annex

A of the European Standard EN 50014. (EN 50014 electrical apparatus for

potentially explosive atmospheres — General requirements.

Equipment marked with IIB is suited for applications which require equip-

ment with the marking IIA. Correspondingly equipment marked with IIC is

suited for applications which require equipment belonging to Exploding

Group IIA or IIB.

T3, T4 Temperature classification: classification of operating means depend-

ing on their maximum surface temperature, in agreement with the following

table:

Temperature classification Maximum surface

temperature (°C)

T1 450

T2 300

T3 200

T4 135

T5 100

T6 85

Pumps belonging to temperature class T4 (with 50 Hz electric motors)

must only be operated with gases or vapours which exhibit an ignition tem-

perature of over 135° C.

Pumps belonging to temperature class T3 (with 60 Hz electric motors)

must only be operated with gases or vapours which exhibit an ignition tem-

perature of over 200° C.

The temperature classification and the actual maximum surface tempera-

ture of the equipment includes a safety margin with respect to the mini-

mum ignition temperature of the potentially explosive atmosphere as

demanded by EN 13463-1.

50 Hz, 60 Hz Frequency of the electric motor – at a higher frequency the

pump will run faster and produce a higher surface temperature.

Ta Permissible ambient temperature for operating the pump

12 °C < Ta < 40 °C.

XSpecial operating conditions need to be complied with! The special condi-

tions and notes provided in the Operating Instructions apply.

NOTICE

ATEX

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