LEYBOLD TRIVAC E2 Bedienungsanleitung

Contents

Contents Page

IMPORTANT SAFETY CONSIDERATIONS . . 4

1 Description . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.1 Principle of Operation . . . . . . . . . . . . . . . . . . .6

1.2 Supplied Equipment . . . . . . . . . . . . . . . . . . . .8

1.2.1 Notes on the Oil and how to Order . . . . . . . . .8

1.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . .9

1.4.1 Motor Dependent Data . . . . . . . . . . . . . . . . . .9

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.2 Connection to the System . . . . . . . . . . . . . . .12

2.3 Electrical Connection . . . . . . . . . . . . . . . . . .13

2.3.1 Pumps with AC Motor . . . . . . . . . . . . . . . . . .13

2.3.2 Pumps with Three-Phase Motor . . . . . . . . . .13

2.4 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5.1 Pumping of Non-Condensable Gases

and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5.2 Pumping of Condensable Gases

and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .16

2.5.3 Operating Temperature . . . . . . . . . . . . . . . . .16

2.6 Shut Down / Shelving . . . . . . . . . . . . . . . . . .17

2.6.1 Shut Down through Monitoring

Components . . . . . . . . . . . . . . . . . . . . . . . . .17

2.6.2 Failure of the Control System or

the Mains Power . . . . . . . . . . . . . . . . . . . . .17

Page

3 Checking / Maintenance . . . . . . . . . . . . . . .18

3.1 Checking the Oil Level . . . . . . . . . . . . . . . . .18

3.1.1 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.2 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2.1 Disposal of Used Pump Materials . . . . . . . . .19

3.3 Cleaning the Dirt Trap . . . . . . . . . . . . . . . . . .20

3.4 Removing and Inserting the

Internal Demister . . . . . . . . . . . . . . . . . . . . .20

3.5 Disassembly and Assembly of the

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . .21

3.5.1 Instructions for the TRIVAC D 5 E - D 10 E . .21

3.5.2 Instructions for the TRIVAC D 16 E . . . . . . . .22

3.6 Full Maintenance . . . . . . . . . . . . . . . . . . . . .23

3.7 Leybold Service . . . . . . . . . . . . . . . . . . . . . .23

3.8 Shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4 Maintenance Plan . . . . . . . . . . . . . . . . . . . .24

5 Maintenance Kits and Repair Sets . . . . . . .26

5.1 Ordering Information for the Maintenance Kits

and the Repair Sets . . . . . . . . . . . . . . . . . . .30

5.2 Ordering Information for the Special Tools . . .30

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . .31

EC - Declaration of Conformity . . . . . . . . .32

We reserve the right to modify the design and the

specified data.The illustrations are not binding.

2GA 01.600/10.02 - 07/01

Directions

We strongly recommend that you read

these Operating Instructions with care so as

to ensure optimum operation of the pump

right from the start.

Indicates procedures that must be strictly

observed to prevent hazards to persons.

Indicates procedures that must strictly be

observed to prevent damage to, or destruc-

tion of the pump.

Figures

The references to diagrams, e.g. (1/2) consist of the Fig.

No. and the Item No. in that order.

Leybold-Service

If a pump is returned to LEYBOLD, indicate whether the

pump is free of substances damaging to health or

whether it is contaminated.

If it is contaminated also indicate the nature of the

hazard. LEYBOLD must return any pumps without a

„Declaration of Contamination“ to the sender’s address.

Disposal of Waste Oil

Owners of waste oil are entirely self-responsible for pro-

per disposal of this waste.

Waste oil from vacuum pumps must not be mixed with

other substances or materials.

Waste oil from vacuum pumps (Leybold oils which are

based on mineral oils) which are subject to normal wear

and which are contaminated due to the influence of oxy-

gen in the air, high temperatures or mechanical wear

must be disposed of through the locally available waste

oil disposal system.

Waste oil from vacuum pumps which is contaminated

with other substances must be marked and stored in

such a way that the type of contamination is apparent.

This waste must be disposed of as special waste.

European, national and regional regulations concerning

waste disposal need to be observed.Waste must only be

transported and disposed of by an approved waste dis-

posal vendor.

GA 01.600/10.02 - 07/01

The oil for the TRIVAC E vacuum pumps is

supplied separately.

Caution

Warning

Caution

4GA 01.600/10.02 - 07/01

IMPORTANT SAFETY CONSIDERATIONS

The Leybold TRIVAC E vacuum pump is designed for safe and efficient operation when used properly and in accor-

dance with this manual. It is the responsibility of the user to carefully read and strictly observe all safety precautions

described in this section and throughout the manual. This product must be operated and maintained by trained per-

sonnel only. Consult local, state, and national agencies regarding specific requirements and regulations. Address any

further safety, operation and/or maintenance questions to your nearest Leybold Vacuum office.

Warning Failure to observe the following precautions could result in serious personal injury:

• Before beginning with any maintenance or service work on the TRIVAC E, disconnect the pump from

all power supplies.

• Do not operate the pump with any of the covers removed. Serious injury may result.

• If exhaust gases must be collected or contained, do not allow the exhaust line to become pressurised.

• Make sure that the gas flow from the exhaust port is not blocked or restricted in any way.

• The standard version of the TRIVAC E is not suited for operation in explosion hazard areas. Contact us

before planning to use the pump under such circumstances.

• Before starting up for the first time, the motor circuit (3 phase) must be equipped with a suitable pro-

tective motor switch. Please take note of the information in these Operating Instructions or on the elec-

tric motor (wiring diagram).

• The TRIVAC E is not suited for pumping of:

- combustible and explosive gases or vapours

- radioactive and toxic substances

- pyrophorous substances.

- oxidations substances.

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

• Never operate the TRIVAC E without a connected intake line or blank flange.

• The location at which the TRIVAC E (including its accessories) is operated should be such that angles

over 10° from the vertical are avoided.

• The location of the TRIVAC E should be such that all controls are easily accessible.

• Under certain ambient conditions theTRIVAC E may attain a temperature of over 80 °C (176 °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 requi-

red protective clothing.

• Before pumping oxygen (or other highly reactive gases) at concentrations 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 de-greased, and an inert special lubricant (like PFPE) must be used.

GA 01.600/10.02 - 07/01

• Before operating theTRIVAC E with atmospheric gas ballast (optional) check first compatibility with the

pumped media so as to avoid hazardous conditions during operation right from the start.

• Before commissioning the TRIVAC E, make sure that the media which are to be pumped are compa-

tible with each other so as to avoid hazardous situations.

All relevant safety standards and regulations must be observed.

• It is recommended to always operate the TRIVAC E with a suitable exhaust line which is properly

connected. It must slope down and away from the pump.

• When moving the TRIVAC E always use the allowed means.

A lifting eye is provided as standard on the pump.

Failure to observe the following precautions could result in damage to the pump:

• Do not allow the ingestion of small objects (screws, nuts, washers, pieces of wire, etc.)

through the inlet port. Always use the screen which is supplied with every pump.

• Do not use the pump for applications that produce abrasive or adhesive powders or

condensable vapours that can leave adhesive or high viscosity deposits. Please contact Leybold Sales

or Service to select a suitable separator. Also pease contact Leybold Sales or Service when planning

to pump vapours other than water vapour.

• This pump is suited for pumping water vapour within the specified water vapour tolerance limits.

• Avoid vapours that can condense into liquids upon compression inside the pump, if these substances

exceed the vapour tolerance of the pump.

• Before pumping vapours, the TRIVAC E should have attained its operating temperature, and the gas

ballast should be set to position I - III (position 0 = closed, position 3 = max. water vapour tolerance,

30 mbar).

The pump will have attained its operating temperature about 30 minutes after starting the pump.During

this time the pump should be separated from the process, by a valve in the intake line, for example.

• In the case of wet processes we recommend the installation of liquid separators upstream and down-

stream of the pump as well as the use of the gas ballast.

• The exhaust line should be laid so that it slopes down and away from the pump so as to prevent con-

densate from backstreaming into the pump.

• The entry of particles and fluids must be avoided under all circumstances.

• 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,

aluminium, steel, resins, glass etc.).

• Corrosion, deposits and cracking of oil within the pump are not allowed.

This information will help the operator to obtain the best performance from the equipment:

• Normal amounts of humidity within the range of the pump’s vapour tolerance will not significantly affect

pump performance when the gas ballast is active.Preferably use the exhaust flange located on the side

of the motor.

Caution

Note

Warning

Description

6GA 01.600/10.02 - 07/01

1 Description

The TRIVAC D 5 - 16 E are dual stage oil sealed rotary

vane vacuum pumps.

The number in the designation of the pump indicates the

pumping speed of this pump in m3· h-1.

These pumps are capable of pumping gases and

vapours out of vessels and vacuum systems down into

the fine vacuum pressure range. The standard pumps

are not designed to handle oxygen at concentrations

exceeding the concentration of oxygen in the atmosphe-

re. Moreover, these pumps are not suited for pumping of

hazardous gases or extremely aggressive or corrosive

media.

The drive motor of the TRIVAC D 5 to 16 E is screwed

directly to the bearing piece. The shaft of the pump and

the shaft of the motor are linked by a coupling piece.The

bearings in the inner pump body are force-lubricated sli-

ding bearings.

The oil level glass for viewing the minimum/maximum oil

level and the oil drain plug as well as the name plate are

located on the front of the pump.

The connection components, the gas ballast knob and

the oil fill plug are located on the top of the pump.

1.1 Principle of Operation

The rotor (2/6) which is eccentrically arranged in the

pump housing (pump chamber) has two radially sliding

vanes (2/7 and 2/9) which divide the pump chamber of

the pump into several chambers.

The volume of each chamber changes periodically with

each turn of the rotor so that the gas at the intake port

(1/1) is sucked in. The gas enters the pump chamber,

and after the admission aperture has been sealed off by

the vane, the gas is compressed and moved on.

The compressed gas is ejected from the pump chamber

through the exhaust valve. Oil which is entrained in the

gas is roughly separated by an internal demister and at

the same time any mechanical contaminations are also

removed from the oil.The gas exits the pump through the

exhaust port.

Oil injected into the pump chamber serves the purpose

of sealing and lubrication. The knocking noise (oil slap)

which normally occurs when the pump approaches its

ultimate pressure is avoided by injecting a small amount

of air into the oil so that a silencing effect is attained.

TRIVAC

OUT

OIL

Key to Fig. 1

1 Intake port

2 Oil drain

3 Oil level indicator

4 Name plate

5 Oil fill

6 Exhaust port

7 Gas ballast valve

8 Mains power connection

Fig. 1 TRIVAC D 5 E rotary vane pump (other TRIVAC E models are similar)

Description

GA 01.600/10.02 - 07/01

By opening the gas ballast valve (2/1, optional) it is pos-

sible to admit a controlled quantity of air (gas ballast) into

the pump chamber while the compression process is in

progress. The gas ballast will prevent the condensation

of vapours within the pump up to the extent of the vapour

tolerance levels as stated in the specifications for the

pump (these data refer to water vapour).

A special lubrication system with forced lubrication of the

sliding bearings has been developed to enable operation

of the pump at intake pressures up to 1000 mbar.

An oil pump supplies the oil from the oil reservoir into a

high pressure oil system which in turn supplies all bea-

rings. From here the oil enters the pump chamber of the

vacuum pump.

The oil pump is located in bearing piece of the high vacu-

um stage.Separation of oil and gas in the pump involves

two stages. First an internal demister which is arranged

ahead of the exhaust valve ensures the creation of larger

droplets.

Next these are returned back to the oil reservoir via a

separation panel.This ensures a minimal loss of oil.

This and the combination with the large usable oil reser-

voir, results in long intervals between the oil exchanges,

even at high intake pressures.

The gas ballast valve (GB) is opened or closed by tur-

ning it (positions 0, 1, 2, 3).

Available as an option is a gas ballast valve having a

knurled screw (see Fig. 13 on page 28). When fully

opening this valve, the resulting gas flow will correspond

to that of valve position 3 in the following Table.

GB position Explanation

0no gas ballast

maximum ultimate pressure

1for cleaning the pump’s oil at a good ulti-

mate pressure and low oil consumption

2good water vapour tolerance -

without producing excessive noise

3maximum water vapour tolerance in

accordance with the technical data on

page 6.

Key to Fig. 2

1 Gas ballast valve

2 Gas ballast inlet

3 Tandem valve

(vacuum protection)

4 Intake port

5 Oil feed (oil pump)

6 Rotor

7 Vane (HV)

8 High vacuum stage

(pump chamber)

9 Vane (FV)

10 Forevacuum stage

(pump chamber)

11 Non-return valve

12 Diaphragm valve

13 Exhaust valve

14 Bypass valve

15 Exhaust port

Fig. 2 Sectional view through a TRIVAC D 5 E pump

(other TRIVAC E models are similar)

123

Description

8GA 01.600/10.02 - 07/01

When the pump is at standstill (mains power failure, or

when the pump is shut down) the pump chamber is her-

metically sealed off by two safety valves (tandem valve

and gas ballast diaphragm valve) which are controlled

through the oil pressure.

This reliably avoids any inadvertent venting of the vacu-

um chamber and the backstreaming of oil.

1.2 Supplied Equipment

Each TRIVAC D 5 - D 16 E pump is supplied with the

following basic equipment:

• Pump with motor

• Separately included oil filling (see Section 1.2.1)

• Separately included dirt sieve with O-ring

• Operating Instructions

• “Declaration of Contamination” form

The connection ports are provided with foil protectors for

protection during shipping.

The TRIVAC E pumps having an AC motor are supplied

ready for operation, complete with switch, built-in thermal

motor overload protection, mains cord (1.8 m long) and

a mains plug which depends on the country of use.

The three-phase models do not come with the accesso-

ries needed for the electrical connection.However, these

accessories are available upon request.

1.2.1 Notes on the Oil and how to Order

Oil N 62 or HE 200 is used as standard.If any other kind

of special oil is being used, this fact will be indicated by

a sticker on the oil box stating the type of special oil

used.

Not all types of oil have been released for all pumps.You

must only use the kind of oil which has been specified for

the particular pump.

1.3 Accessories

Cat. No. /Order No.

Exhaust filter AF 10, DN 25 KF . . . . . . . . . . . . .190 51

Exhaust filter AF 16, DN 25 KF . . . . . . . . . . . . .190 52

Replacement filters FE 10 (set of 5) . . . . . . . . . .190 81

Replacement filters FE 16 (set of 5) . . . . . . . . . .190 82

Drain clock for the exhaust filter AF 8/10/16 . . . .190 95

Condensate separator AK 10, DN 25 KF . . . . . .190 61

Condensate separator AK 16, DN 25 KF . . . . . .190 62

Oil drain cock (for D 5 E - D 16 E) . . . . . . . . . . .190 90

Manual oil return via the gas ballast port . . . . . .190 93

(Kit for AF 8-16) ARM

Connection components required to connect the exhaust

filter and the condensate separators in each case:

1 Pipe bend DN 25 KF 184 37

2 Centering rings with O-ring DN 25 KF 183 27

2 Clamping rings DN 25 KF 183 42

Description

GA 01.600/10.02 - 07/01

1.4 Technical Data

Nominal pumping speed* 50/60 Hz m3·h-1 6/7,3 12/14,6 21/23,6

Pumping speed 50/60 Hz m3·h-1 5,2/6 9,9/11,3 16/19

Ult.partial pressure without gas ballast mbar ≤5 x 10-4 ≤5 x 10-4 ≤5 x 10-4

Ult.total pressure without gas ballast** mbar ≤2 x 10-3 ≤2 x 10-3 ≤2 x 10-3

Ult.total press.w.gas ballast (stage 2)** mbar ≤3 x 10-2 ≤3 x 10-2 ≤3 x 10-2

Water vapour tolerance

Stage 1 mbar 10 10 10

Stage 2 mbar 30 20 20

Stage 3 mbar 40 30 30

Connection portDN 16 KF 25 KF 25 KF

Noise level (50 Hz) dB (A) ≤49 ≤49 ≤52

Permissible ambient temperature °C10 bis 50 (EURO - Motor) / 10 to 40 (USA/Japan - Motor)

Oil filling max./min l1,25/0,75 1,25/0,75 1,25/0,75

Motor power 50/60 Hz W450/550 450/550 700/850

Speed 50/60 Hz rpm 1350/1650 1350/1650 1380/1650

Protection IP 54 54 54

Weight with operating agent***kg kg 22,1 24,2 30,7

Dimensions (W x H x D)*** mm 156 x 258 x 416 156 x 258 x 435 170 x 258 x 494

* to DIN 28 426 T1 ** to DIN 28 4oo and subsequent numbers *** Dimensions and weights with Euro motor

D 5 E D 10 E D 16 E

1.4.1 Motor Dependent Data

Euro 1~ 220-240/230 50/60 ±5 % 450/540 2,5/2,4 10 54 1350/1650

Three-ph.motor ∆220-240/ 50 ±5 % 550 2,8 654 1500

3~ Y 346/415 1,6

∆200-266/ 60 ±5 % 650 2,8 654 1800

Y 346-460 1,6

Euro 1~ 220-240/230 50/60 ±5 % 450/540 2,5/2,4 10 54 1350/1650

Three-ph.motor ∆220-240/ 50 ±5 % 550 2,8 654 1500

3~ Y 346/415 1,6

∆200-266/ 60 ±5 % 650 2,8 654 1800

Y 346-460 1,6

Wide voltage- 110-120; 50/60 ±5 % 490/550 6,8/5,6 10 54 1350/1650

motor 1~ 208-240 3,4/2,8

Euro 1~ 220-240 50/60 ±5 % 700/850 5,3/4,6 10 54 1380/1650

Three-ph.motor ∆220-240/ 50 ±5 % 650 410 54 1430

3~ Y 346-415 2,3

∆200-277/ 60 ±5 % 750 3,6 10 54 1720

Y 346-480 2,1

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 5 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 10 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 16 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

*The values stated for the fuses are recommended values only

Values for up-front fuses for short circuit protection.Please take note of the information provided by the manufacturers of contactors and motor protection switches.

Description

10 GA 01.600/10.02 - 07/01

OUT

OIL

NCD

TRIVAC

Fig. 3 Dimensional drawings for the TRIVAC D 5 - D 16 E rotary vane vacuum pumps

View of ”X”

Andere Handbücher für TRIVAC E2

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