LEYBOLD TRIVAC B D 40 BCS Bedienungsanleitung

Part Nos.

113 88/89/98/98J/99

1129646

TRIVAC B

D 40 BCS / D 65 BCS

Rotary Vane Vacuum Pump

■with mineral oil

■with PFPE

Operating Instructions GA01301_002_C1

Contents

2 GA01301_002_C1 - 07/2018 - © Leybold

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

1 Description 9

1.1 Function 10

1.2 Lubricants 12

1.3 Supplied Equipment 14

1.4 Technical Data 15

1.5 Accessories 19

1.5.1 TRIVAC - System 19

2 Transport and Storing 21

3 Installation 22

3.1 Placement 22

3.2 Conforming Utilization 23

3.2.1 Pumping of Oxygen 23

3.2.2 TRIVAC D65B 3He for Helium Applications 24

3.3 Connection to the System 25

3.4 Electrical Connections 26

4 Operation 29

4.1 Media Compatibility 29

4.2 Start-up 29

4.3 Operation 30

4.3.1 Pumping of Non-Condensable Gases and Vapours 30

4.3.2 Pumping of Condensable Gases and Vapours 30

4.3.3 Operating Temperature 31

4.4 Shutdown 31

4.4.1 Shutdown through Monitoring Components 32

4.4.2 Controller/Mains Power Failure 32

Contents

3GA01301_002_C1 - 07/2018 - © Leybold

Original installation and operating instructions.

5 Maintenance 33

5.1 Maintenance Plan 34

5.2 Leybold Service 35

5.3 Monitoring the Oil Level 36

5.3.1 Checking the Condition of LVO 100 36

5.3.2 PFPE 37

5.4 Oil Change 37

5.5 Cleaning the Inlet Screen 40

5.6 Removing and Fitting the Internal Demister 40

5.7 Disassembly and Reassembly of the Electric Motor 42

5.8 Replacing the Shaft Seal 43

5.9 Removing and Remounting the Pump Module 46

5.9.1 Removing the Pump Module 46

5.9.2 Remounting the Pump Module 47

6 Troubleshooting 48

7 Wearing Parts and Original Spare Parts 50

8 Waste Disposal 50

EC-Declaration of Conformity 51

Page

Notes

4 GA01301_002_C1 - 07/2018 - © Leybold

Obligation to Provide Information

Before installing and commissioning the TRIVAC BCS, carefully read these

Operating Instructions and follow the information so as to ensure optimum

and safe working right from the start.

The Leybold TRIVAC BCS 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

5GA01301_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 BCS (including its accessories) is

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

are avoided.

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

on. 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 BCS always use the allowed means.

0.2 Electrical hazards

1 The electrical connections must only be provided by a trained electri-

cian as specified, for example, by the regulations EN 50110-1.

Observe local regulations.

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

6 GA01301_002_C1 - 07/2018 - © Leybold

0.3 Thermal hazards

1 Under certain ambient conditions the TRIVAC BCS may attain a

temperature 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 pro-

tection gloves.

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

down.

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 Before pumping oxygen (or other highly reactive gases) at concen-

trations exceeding the concentration in the atmosphere (> 21 % for

oxygen) it will be necessary to use a special pump. Such a pump will

have to be modified and degreased, and an inert special lubricant (like

PFPE) must be used.

4 Before commissioning the TRIVAC BCS, 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 regulati-

ons 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

regulations and guidelines. Regarding the suitability of the TRIVAC BCS

pumps for special applications in which such gases, respectively sub-

stances 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.

CAUTION

DANGER

Safety information

7GA01301_002_C1 - 07/2018 - © Leybold

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 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 pre-

pared for you

7 For the TRIVAC BCS-PFPE:

When handling PFPE you should observe the following:

During thermal decomposition at temperatures over 290 °C toxic and

corrosive gases are released. When handling PFPE keep it way from

open fires. Do not smoke in the work area.

Touch the inner sections of the pumps only while wearing clean gloves,

and use clean tools;

work in clean and dry rooms;

after having removed the pump from its packaging, start it up immedi-

ately;

as cleaning agents solvents based on hydrofluorether compounds may

be used.

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

explosion hazard areas.

2 The TRIVAC pumps including the accessories are fundamentally not

suited for pumping of combustible and explosive gases or 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 the-

refrom derive the necessary safety measures which must be intro-

duced.

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 nitrogen, for example) dilute all ignitable

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 ignita-

ble 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

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

hearing protection measures must be introduced.

DANGER

CAUTION

Safety information

8 GA01301_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 BCS 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

Description

9GA01301_002_C1 - 07/2018 - © Leybold

1 Description

TRIVAC BCS pumps are oil-sealed rotary vane pumps. The TRIVAC D 40

BCS and D 65 BCS are dual-stage pumps. The number in the type

designation (40 or 65) indicates the pumping speed in m3 · h-1.

The TRIVAC BCS-PFPE have been prepared especially for operation with

perfluoropolyther.

TRIVAC BCS pumps can pump gases and vapours, and evacuate vessels

or vacuum systems in the fine vacuum range.

They have been designed particularly for use in connection with corrosive

or aggressive media. Moreover, the pump has been prepared for the instal-

lation of an electric monitoring facility. Leybold have developed for the

TRIVAC BCS a range of accessories which considerably extend the range

of applications for this kind of pump. These accessories which in connec-

tion with the TRIVAC BCS vacuum pump make up the TRIVAC system, are

described briefly in Chapter 1.5.

Via an intermediate flange the drive motor of the TRIVAC is mounted to the

coupling housing. The pump and motor shafts are directly connected by a

flexible coupling. The bearing points of the pump module are force lubrica-

ted sliding bearings.

All controls as well as the oil-level glass and the nameplate are arranged on

the front. All connections are to be found at the sides of the pump. The oil-

level glass is provided with prisms for better observation of the oil level.

The pump module consists of assembly parts which are pin-fitted so as to

allow easy disassembly and reassembly. The pump module can be easily

removed without special tools.

Fig. 1 TRIVAC BCS pump with accessories

Description

10 GA01301_002_C1 - 07/2018 - © Leybold

1.1 Function

The rotor (2/7), mounted eccentrically in the pump housing (2/6), has two

radially sliding vanes (2/5) which divide the pump chamber into several com-

partments. The volume of each compartment changes periodically with the

rotation of the rotor.

As a result, gas is sucked in at the intake port (2/1). The gas passes through

the dirt trap sieve (2/2), flows past the open anti-suckback valve (2/3) and

then enters the pump chamber. In the pump chamber, the gas is passed on

and compressed, after the inlet aperture is closed by the vane.

The oil injected into the pump chamber is used for sealing and lubricating.

The slap noise of the oil in the pump which usually occurs when attaining the

ultimate pressure is prevented by admitting a very small amount of air into the

pump chamber.

The compressed gas in the pump chamber is ejected through the exhaust

valve (2/10). The oil entrained in the gas is coarsely trapped in the internal

demister (2/11); there the oil is also freed of mechanical impurities. The

TRIVAC BCS-PFPE pumps do not have an internal demister. The gas leaves

the TRIVAC BCS-PFPE through the exhaust port.

During compression, a controlled amount of air – the so-called gas ballast –

can be allowed to enter the pump chamber by opening the gas ballast valve.

The gas ballast stops condensation of vapours in the pump chamber up to

the limit of the water vapour tolerance as specified in the technical data for

the pump.

Fig. 2 Sectional drawing of the TRIVAC BCS

1 Intake port

2 Dirt trap

3 Anti-suckback valve

4 Intake channel

5 Vanes

6 Pump chamber

7 Rotor

8 Cover plate, connection for inert gas

ballast

9 Exhaust channel

10 Exhaust valve

11 Internal demister

12 Spring buckles

13 Cover plate, connection for oil filter

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