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User`s Manual - Flexcell International Corp.

1. 49 0 221 347 0 Fax 49 0 221 347 1250 documentation leybold com www leybold com GA01201_1002 07 2005 35 EEC Manufacturers Declaration in the sense of the Directive on Machinery 92 37 EG Annex IIb We Leybold Vacuum GmbH herewith declare that operation of the incomplete machine defined below is not permissible until it has been determined that the machine into which this incomplete machine is to be installed meets the regulations of the EEC Directive on Machinery Designation of the Products Rotary vane pump dual stage Types TRIVAC D 4 B without Motor D 8 B without Motor Cat Nos 113 07 113 17 Applied harmonized Standards B EN 1012 2 1996 K ln den K ln den 01 07 2005 a Marcus Eisenhuth Mitglied der Gesch ftsf hrung Leiter Produktentwicklung Konstr ktion Vorvakuum Pumpen Leybold vacuum Leybold Vacuum GmbH Bonner StraBe 498 50968 K ln Tel 49 0 221 347 0 Fax 49 0 221 347 1250 documentation leybold com www leybold com 36 GA01201_1002 07 2005 Leybold Vacuum Declaration of Contamination of Compressors Vacuum Pumps and Components The repair and or servicing of compressors vacuum pumps and components will be carried out only if a correctly completed declaration has been sub mitted Non completion will result in delay The manufacturer can refuse to accept any equipment without a declaration A separate declaration has to be completed for ev
2. Brush and industrial vacuum cleaner We recommend that you service the pump every two years covering the following E Cleaning W Checking the individual components W Exchange of all seals W Functional check This check should be run by the Leybold Service Remarks Refer also to the Operating Instructions Section individual components Condensed water is thus removed from the oil Refill Only after the pump has been switched off Visually normally light and transparent oil change is required when discolorations increase Chemically to DIN 51558 when the neutralisation number exceeds 2 then an oil change will be required Mechanically when dynamic viscosity at 25 C exceeds 240 mPas then an oil change will be required Disposal of waste oil see Section 5 8 1 W Clean inlet screen with a cleaning agent and blow it out with compressed air under a suction hood W Replace the defective inlet screen Use a cleaning agent which complies with the national international specifications Observe the safety regulations when using cleaning agents Already clean before the maintenance interval has elapsed when the noise level increases W Clean internal demister with cleaning agent W Replace the defective internal demister W Dispose of the defective internal demister as Special waste Cleaning agent according to national international specifications Observe the safety regulations when using
3. Leybold Vacuum Italia S p A 8 Via Trasimeno 1 20128 Milano Sales Phone 39 02 27 22 31 Fax 39 02 27 20 96 41 sales leybold it Service Phone 39 02 27 22 31 Fax 39 02 27 20 96 41 service leybold it Field Service Base Z l Le Capanne 1 05021 Acquasparta TR Phone 39 0744 93 03 93 Fax 39 0744 94 42 87 service leybold it Sales 49 221 347 1234 Service 49 221 347 1765 sales leybold com service leybold com S Leybold Vacuum USA Inc S 5700 Mellon Road Export PA 15632 8900 Tel 724 327 5700 Fax 724 325 3577 LV_07900_2005 e mail info leyboldvacuum com Netherlands Leybold Vacuum Nederland B V Computerweg 7 NL 3542 DP Utrecht Sales and Service Phone 31 346 58 39 99 Fax 31 346 58 39 90 sales netherlands leybold com service netherlands leybold com Spain Leybold Vacuum Espa a S A C Huelva 7 E 08940 Cornella de Llobregat Barcelona Sales Phone 34 93 666 46 16 Fax 34 93 666 43 70 sales spain leybold com Service Phone 34 93 666 49 51 Fax 34 93 685 40 10 Sweden Leybold Vacuum Scandinavia AB Box 9084 SE 40092 G teborg Sales and Service Phone 46 31 68 84 70 Fax 46 31 68 39 39 info leybold se Visiting delivery address Datavagen 57B SE 43632 Askim Switzerland Leybold Vacuum Schweiz AG Leutschenbachstrasse 55 CH 8050 Z rich Sales Phone 41 1 308 40 50 Fax 41 1 302 43 73 sales leybold ch Service Phone 41 1 308 40 62
4. Fax 41 1 308 40 60 America USA Leybold Vacuum USA Inc 5700 Mellon Road Export PA 15632 info leyboldvacuum com Sales Eastern amp Central time zones Phone 1 724 327 5700 Fax 1 724 733 1217 Pacific Mountain Alaskan amp Hawaiian time zones Phone 1 480 752 9191 Fax 1 480 752 9494 Service Phone 1 724 327 5700 Fax 1 724 733 3799 Leybold Vacuum GmbH Bonner StraBe 498 Bayenthal 50968 K ln Tel Fax 49 0 221 347 0 49 0 221 347 1250 e mail documentation leybold com Asia PR China Leybold Vacuum Tianjin International Trade Co Ltd Beichen Economic Development Area BEDA o 8 Western Shuangchen Road Tianjin 300400 China Sales and Service Phone 86 22 2697 0808 Fax 86 22 2697 4061 Fax 86 22 2697 2017 leybold leybold com cn Leybold Vacuum Tianjin Equipment Manufacturing Co Ltd Beichen Economic Development Area BEDA No 8 Western Shuangchen Road Tianjin 300400 China Phone 86 22 2697 0808 Fax 86 22 2697 4061 Fax 86 22 2697 2017 leybold leybold com cn Leybold Vacuum Tianjin International Trade Co Ltd Beijing Branch 1 908 Beijing Landmark Towers 8 North Dongsanhuan Road Chaoyang District Beijing 100004 China Sales and Service Phone 86 10 6590 7607 Fax 86 10 6590 7622 Leybold Vacuum Tianjin International Trade Co Ltd Shanghai Branch Add No 33 76 Futedong San Rd Waigaogiao FTZ Shanghai 200131 China S
5. sed inside the pump if these substances exceed the vapour tolerance of the pump E 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 M 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 B The exhaust line should be laid so that it slopes down and away from the pump so as to prevent condensate from back streaming into the pump E The entry of particles and fluids must be avoided under all circumstances E 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 E Corrosion deposits and cracking of oil within the pump are not allowed E 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 In the case of custom pumps with a part number deviating from that stated in the EC Declaration of Conformity please note the information provided in the supplementary sheet Safety information Caution Non compli
6. 5 5 E E l 0 1 1 is 5 4 3 1 0 1 3 10 10 10 10 10 10 10 10 mbar Pressure Fig 5 Pumping speed characteristics of the TRIVAC D 4 B and TRIVAC D 8 B 50 Hz operation Sl units b 4 lt bp _ gt n a ae c TIT Br lt Q e h ha hy his T na Y pr wu m gt by gt Type D a b b Do C h hi ho Ng m n o D 4 B Cat No 140 081 16KF 75 162 147 132 100 265 215 200 230 455 198 99 108 D 8 B Cat No 140 082 16 KF 100 480 Dimensions in mm Fig 6 Dimensional drawing for the TRIVAC rotary vane pumps Dimensions a b to b2 and h1 are approximate Caution Warning 14 GA 01201 1002 07 2005 2 Transportation and Storage Pumps which are filled with operating agents must only be moved while standing upright Otherwise oil may escape Avoid any other orientations during transport Check the pump for the presence of any oil leaks since there exists the danger that someone may slip on spilt oil When lifting the pump you must make use of the crane eyes provi ded on the pump for this purpose also use the recommended type of lifting device Installation Key to Fig 7 Eye for moving the pump Intake port Exhaust port Oil level glass Gas ballast knob Threaded connection M 16 x 1 5 for inert gas ballast Adapter Cover
7. 5 8 1 82 inch see Fig 11 The adapter flange 11 5 is screwed to the motor flange with four additional screws Maintenance Key to Fig 12 Coupling element Hexagon socket screw Spring washer Coupling one half Key Compression disc O ring Bushing Shaft seal Centering disk Hexagon socket screws OOONDARWN NN NN NN S N Fig 12 Exchanging the shaft seal 5 6 Replacing the Shaft Seal Required tools Allen keys 3 mm 5 mm 8 mm flat nose pliers plastic hammer shaft seal driver possibly puller for coupling The TRIVAC 4 8 B has two shaft seals the outer one is subject to greater wear Oil marks under the coupling housing are signs of a damaged outer shaft seal The outer shaft seal 12 9 can be replaced without removing or disassem bling the pump module Shutdown the pump Drain the oil see Section 5 2 or place the pump on its front side Unscrew the four non recessed hex socket screws 11 7 and remove the motor 11 6 together with the intermediate flange 11 8 Remove the gasket 11 1 Remove the coupling element 12 1 Remove the hex socket screw 12 2 and the spring washer 12 3 Pull off the coupling 12 4 Remove the key 12 5 Pull off the compression disc 12 6 and the O ring 12 7 Unscrew the hex socket screws 12 11 and pull off the centering disk 12 10 together with the bushing 12 8 If the centering disk is stuck screw the capscrews
8. Service Pump module is worn out Replace the pump module 5 7 Deviating mains voltage Check the motor voltage and check available mains voltage Oil in the intake line Oil comes from the vacuum system Check the vacuum system or in the vacuum Anti suckback valve is blocked Clean or repair the anti suckback valve Service vessel Sealing surfaces of the anti suckback valve are Clean or repair intake and anti suckback valve Service damaged or dirty Oil level is too high Drain out excess oil 5 1 Oil is turbid Condensation Degas the oil or change the oil and clean the pump 4 2 2 5 2 Precaution open the gas ballast valve or fit separator Pump is excessively Oil level is much too low oil level is no longer visible Add oil 5 1 5 2 noisy Silencing nozzle is clogged Clean the silencing nozzle or replace it Fig 10 Intake pressure is too high Lower the intake pressure 7 Internal demister is clogged Clean or replace demister 5 4 Coupling element is worn Install new coupling element 5 5 5 6 Vanes or bearings are damaged Repair pump Service Pump shuts down after a few minutes with very high motor temperature or with a very high current uptake gt 15 A Relay does not switch off the start up capacitor voltage too low Let the motor cool down for at least 10 minutes Ensure correct power supply voltage 218 242 V Repair information Refer to the stated section in these Operating Instructions 1 Bubble tes
9. When disposing of used oil you must observe the applicable environ mental regulations Due to the design concept TRIVAC B pumps require very little maintenan ce when operated under normal conditions The work required is described in the sections below In addition to this a maintenance plan is provided in Section 5 10 All work must be carried out by suitably trained personnel Maintenance or repairs carried out incorrectly will affect the life and performance of the pump and may cause problems when filing warranty claims LEYBOLD offers practical courses on the maintenance repair and testing of TRIVAC B pumps Further details are available from LEYBOLD on request If the TRIVAC B is used in ambient air which is much contaminated make sure that the air circulation and the gas ballast valve are not adversely affected Please take the spare parts numbers from the enclosed spare parts list In case of special designs and variants please always indicate the speci al variant and serial number Operation Warning Contamination Form Caution Caution Caution GAO1201 1002 07 2005 21 Maintenance 22 GA01201_1002 07 2005 Caution Caution Key to Fig 9 1 Oil fill plug 2 Oil level mark maximum 3 Oil level mark minimum 4 Oil drain plug Fig 9 Oil change 5 1 Checking the Oil Level During operation of the TRIVAC B the oil level must always remain between marks 9 2 and 9 3 on the
10. back in check the gasket and reinstall a new one if necessary Remove the oil fill plug 9 1 and fill in with fresh oil Screw the oil fill plug 9 1 back in If there is the danger that the operating agent may present a hazard in any way due to decomposition of the oil or because of the media which have been pumped you must determine the kind of hazard and ensure that all necessary safety precautions are taken Torque for the oil fill plug 9 1 10 Nm Gasket P N 239 55 165 Torque for the oil drain plug 9 4 10 Nm Gasket P N 239 55 165 We can only guarantee that the pump operates as specified by the technical data if the lubricants recommended by us are used Maintenance Warning Caution Warning e Torques Caution GAO01201 1002 07 2005 23 Maintenance 24 GA01201 1002 07 2005 Caution Caution 5 3 Cleaning the Inlet Screen A wire mesh sieve is located in the intake port of the pump to act as a dirt trap for coarse particles lt should be kept clean to avoid a reduction of the pumping speed For this purpose remove the inlet screen 2 2 from the intake port and rinse it in a suitable vessel with solvent Then thoroughly dry it with compressed air If the inlet screen is defective replace it with a new one The cleaning intervals depend on the application If the pump is exposed to large amounts of abrasive materials a dust filter should be fitted into the intake line 5 4 Removing and Fitt
11. cleaning agents Oil change W First oil change after 100 operating hours W Pump switched off and cold Exchange the oil while the pump is cold So as to avoid releasing adsorbed gases Clean the oil level glass with a cleaning agent and blow it out with compressed air under a suction hood Use cleaning agents only corresponding to the national international specifications Observe the safety regulations when using cleaning agents Quantity of oil see Section 1 4 Oil disposal see Section 5 8 1 Already clean before the maintenance interval has elapsed when the pump or the motor gets too warm Caution switch off the pump and ensure that it cannot run inadvertently disconnect from the mains Maintenance 6 Troubleshooting Fault Possible cause Remedy Repair Pump does not Wiring is malfunctioning Check and repair wiring a start Motor protection switch incorrectly set Set motor protection switch properly 3 3 three phase motors only Operating voltage does not match motor Replace the motor 4 2 Motor is malfunctioning Replace the motor 4 2 Oil temperature is below 12 C Heat the pump and pump oil or use a different oil 4 2 3 5 2 Oil is too thick Change the oil 5 2 Exhaust filter exhaust line is clogged Replace the filter or clean the exhaust line Pump is seized up sign pump is jammed Repair the pump Service Pump does not Measuring technique or gauge is unsuitable Use correct measuri
12. follows in which vents the pump chamber and forces the valve disc 4 6 against its seat This effectively prevents backstreaming of oil The anti suckback valve 2 3 operates independently of the opera ting mode of the pump i e also with gas ballast Key to Fig 3 Accessories Bearings Non return valve Pump chamber of the TRIVAC Oil reservoir Oil pump OakWN i ig 3 Schematic of the lubricating system Key to Fig 4 1 Oil reservoir 5 Valve seat 2 Spring 6 Valve disk 3 Control piston 7 Gas inlet 4 Anti suckback piston Fig 4 Hydropneumatic anti suckback valve 1 2 The equ Pump w 1 center 1 center 2 clampi Supplied Equipment ipment supplied with the TRIVAC B pump includes ith motor including initial filling of N 62 or HE 200 oll ing ring ng ring with dirt trap ng rings DN 25 KF As protection during shipment the connection ports are each blanked off by rubber diaphragms and supporting rings TRIVAC B pumps with single phase AC motor are supplied ready to operate with switch built in thermal motor protection switch A mains cable must be ordered additionally Note E 100 V 120 V NEMA Cat No 200 81 090 E 200 V 240 V NEMA Cat No 200 81 141 E 200 V 240 V EURO Cat No 200 81 091 Description GAO1201 1002 07 2005 11 Description 1 3 Accessories Cat No Seperator AK 4 8 DN 16 KF 188 06 Exhaust filter AF 4 8 DN 16 KF 189 06 Drain t
13. of condensed vapours We strongly recommend operating the TRIVAC B in this mode for about 30 minutes after completion of the process In cyclic operation the TRIVAC B should not be switched off during the intervals between the individual working phases power consumption is minimal when the pump is operating at ultimate pressure but should con tinue to run with gas ballast valve open and intake port closed if possible via a valve Once all vapours have been pumped off from a process e g during drying the gas ballast valve can be closed to improve the attainable ultimate pressure 4 2 3 Operating Temperature Proper operation of the TRIVAC B is ensured in the ambient temperature range between 12 C to 40 C 55 F to 104 F At operating temperature the surface temperature of the oil case may lie between 40 C and over 70 C 104 F and 156 F depending on the load The surface temperature of the TRIVAC B pumps may rise above 70 C There is the danger of receiving burns Caution Warning Installation GA01201_1002 07 2005 19 Installation 20 GA01201_1002 07 2005 Warning Caution Warning Warning 4 3 Shutdown Under normal circumstances all that you need do is to electrically switch off the TRIVAC B No further actions will be required When pumping condensable media let the pump continue to operate with the gas ballast valve open and the intake line closed before switching o
14. plate Cover plate connection for oil filter OakWN Oo ON Fig 7 Connections and controls 3 Installation 3 1 Placement The standard pump is not suited for installation in the explosion hazard Warning areas When planning such an application please contact us first The TRIVAC B pump can be set up on a flat horizontal surface Rubber feet under the coupling housing ensure that the pump can not slip If you wish firmly install the pump in place insert bolts through bore holes in the rubber feet Max tilt for the pump without further attachment with possibly fitted Caution standard accessories is 10 from the vertical The rubber feet act as vibration absorbers They must therefore not be compressed by screws When installing the TRIVAC B pump make sure that the connections and controls are readily accessible The site chosen should allow adequate air circulation to cool the pump keep front and rear unobstructed The ambient temperature should not exceed 40 C 104 F and not drop below 12 C 55 F see Section 4 2 3 The max amount of heat given off approximately corresponds to the rated motor power GA01201_1002 07 2005 15 Installation 16 GA01201_1002 07 2005 Caution Caution Warning 3 2 Connection to the System Before connecting the TRIVAC B remove the shipping seals from the connection flanges 7 2 and 7 3 Retain the shipping seals in case you need to sto
15. power failure the pump must be integrated in the control system in such a way that the pump can only be switched on again manually This applies equally to emergency cut out arrangements 5 Maintenance Disconnect the electrical connections before disassembling the pump Make absolutely sure that the pump cannot be accidentally started If the pump has pumped harmful substances contrary to what has been stated in Section 3 4 ascertain the nature of hazard and take adequate safety measures Observe all safety regulations Whenever you send a pump to Leybold indicate whether the pump is con taminated or is free of substances which could pose a health hazard If it is contaminated specify exactly which substances are involved You must use the form we have prepared for this purpose we will forward the form on request A copy of the form is printed at the end of these operating instructions Declaration of contamination of vacuum equipment and components Another suitable form is available from the Leybold homepage http www leybold com under the headline Support amp Download Attach the form to the pump or enclose it with the pump Do not put the form in the polyethylen bag together with the pump This statement detailing the contamination is required to satisfy legal requi rements and for the protection of our employees Pumps which are not accompanied by a contamination statement will be returned to the sender
16. pump must only be operated and maintained by trained staff while in the proper state and as described in these Operating Instructions Please also note local and government requirements and regulations Should you have any questions relating to safety operation or maintenance of the equip ment please get in touch with your nearest Leybold Vacuum office The icon indicates procedures that must be strictly observed to prevent hazards to persons This special icon warns about dangers caused by high electric voltages Touching parts at a high voltage can result in immediate death Covers which are marked with this icon must only be removed by trained electricians after having reliably disconnected the electric power source Indicates procedures that must strictly be observed to prevent damage to or destruction of the equipment Emphasises additional application information and other useful information provided within these Operating Instructions Warning Warning Caution Note Notes GAO1201 1002 07 2005 5 Safety information Warning Non compliance with the follo wing precautions can result in severe injury 6 GA01201_1002 07 2005 Warning Important Safety Information Before beginning with any maintenance or service work on the TRIVAC B 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 collec
17. 12 11 into the jack screw holes in the centering disk GA01201_1002 07 2005 27 Maintenance 28 GA01201_1002 07 2005 Caution Caution Caution Pull the bushing out from the centering disc and force the shaft seal 12 9 out of the centering disk We recommend the use of a new shaft seal an O ring and bushing for reassembly Before insertion moisten the new shaft seal slightly with a little vacuum pump oil Using a suitable plastic or aluminium cylinder shaft seal driver and a pla stic hammer force the shaft seal 12 9 carefully and without bending it into the centering disk for position of shaft seal see Fig 12 If you do not have a shaft seal driver place the shaft seal on the opening in centering disk and carefully force it in with light blows of the plastic ham mer The shaft seal must not be bent Carefully push the bushing 12 8 into the shaft seal Push the centering disk 12 10 with the shaft seal and bushing onto the shaft and up against the end plate fasten it with the hex socket screws 12 11 Push the O ring 12 7 and the compression disc 12 6 onto the shaft Insert the key 12 5 Mount the pump half of the coupling 12 4 on the shaft Install the spring washer 12 3 and tighten the hex screw 12 2 Insert the coupling element 12 1 into the coupling and mount the motor see Section 5 5 5 7 Removing and Remounting the Pump Module Required tools Allen keys 3 mm 5 m
18. 2 We recommend that you contact the Leybold Service Maintenance GA01201_1002 07 2005 31 Maintenance 5 10 Maintenance Plan Recommendation No 1 Rotary vane pump TRIVAC D 4B TRIVAC D 8B Operate the pump for at least 0 8 h with gas ballast Check the oil level if required change the oil Check the quality of the oil change the oil if required Clean the inlet screen in the intake port change it as required Clean the internal demister change it as required Check the edges of the teeth on the coupling element for any damages change the coupling element as required Change the oil and clean the oil level glass Check the fan of the pump and motor as well as the cooling fins on the motor for deposits and clean as required Key to maintenance plan VE VP rs 6m a n a Maintenance before switching on the system Maintenance before starting production Daily maintenance Six monthly maintenance Annual maintenance Maintenance every n years 32 GA01201 1002 07 2005 Measurement test quantity Interval Operating auxiliary materials VE VP t 6m a n a x Oil N 62 or special x x and alternative oils see Section 1 3 visually x x chemically x mechanically x Suitable cleaning agent and x compressed air Suitable cleaning agent Oil N 62 or special and alternative oils Suitable cleaning agent and compressed air
19. OPERATING INSTRUCTIONS GA01201_1002 TRIVAC B D4B D8B Rotary Vane Vacuum Pump Cat No 113 08 17 140 081 082 Leybold vacuum Contents Section Page Important Safety Informati0N oooocoooconnoo o 6 1 Description eieae ona eel e a eta wend car 8 1 1 FUNCION s A eet edes ect 9 1 2 Supplied Equipment scooter E Ae S CRUEL 11 1 8 INCCESSONES dui gets ad eA A EQ DRE ad a 12 1 4 Technical Data scd RE a Bowie RE ES RU RE es 13 1 4 1 Motor Related Data a elect ae athe bits dis tet 13 2 Transportation es oe ie deeds 14 3 Installation ici reed Ree i ae are P n 15 3 1 Placement api di eee trace free t P EHE CARE PBVPEEN es 15 3 2 Connection to the System liliis es 16 3 3 Electrical Confiectioris cla eL PX e eee ee cen PARTE 17 3 4 Areas of Application uuo a eee des dae PCR ee vd 17 4 Operation aiii A ee 18 4 1 SID tb la lb ra dal o po al pida 18 4 2 ODGratlon sect add eaten ada a Mata eae e 18 4 2 1 Pumping of Non Condensable Gases 0 iile 18 4 2 2 Pumping of Condensable Gases and Vapours 00200 0b eee 19 4 2 3 Operating Temperature 6 eee 19 4 3 SHUI E EE 20 4 3 1 Shutdown through Monitoring Components isses 20 4 3 2 Failure of the Control System or the Mains Power liliis 20 2 GA01201 1002 07 2005 Section 5 1 5 1 1 5 2 5 3 5 4 5 5 5 6 5 7 5 7 1 5 7 2 5 8 5 8 1 5 9 5 10 Page Maintenance 2 e eee eee eee hh eee eee 21 C
20. ales and Service Phone 86 21 5064 4666 Fax 86 21 5064 4668 leybold_sh leybold com cn Leybold Vacuum Tianjin Guangzhou Branch Add G F 301 Building 110 Dongguangzhuang Rd Tianhe District Guangzhou 510610 China Sales Phone 86 20 8723 7873 Phone 86 20 8723 7597 Fax 86 20 8723 7875 leybold_gz leybold com cn India Leybold Vacuum India Pvt Ltd A 215 Road No 30 MIDC Wagle Industrial Estate Thane W 400 604 Maharashtra India Sales and Service Phone 91 22 2581 2929 Fax 91 22 2581 2626 ivt2004 yahoo com Japan Leybold Vacuum Japan Co Ltd Head Office Tobu A K Bldg 4th Floor 23 8 Shin Yokohama 3 chome Kohoku ku Yokohama shi Kanagawa ken 222 0033 Sales Phone 81 45 4713330 Fax 81 45 4713323 Leybold Vacuum Japan Co Ltd Osaka Branch Office MURATA Bldg 7F 2 7 53 Nihi Miyahara Yodogawa ku Osaka shi 532 0004 Sales Phone 81 6 6393 5211 Fax 81 6 6393 5215 Leybold Vacuum Japan Co Ltd Tsukuba Technical S C Tsukuba Minami Daiichi Kogyo Danchi 21 Kasumi no Sato Ami machi Inashiki gun Ibaraki ken 300 0315 Service Phone 81 298 89 2841 Fax 81 298 89 2838 Korea Leybold Vacuum Korea Ltd 761 4 Yulkeum ri SungHwan eup Cheonan City Choongchung Namdo 330 807 Korea Sales Phone 82 41 580 4420 Fax 82 41 588 3737 Service Phone 82 41 580 4415 Fax 82 41 588 3737 Singapore Leybold Vacuum Singapore Pte Ltd No 1 I
21. ales koeln leybold com Leybold Vacuum GmbH Service Center Emil Hoffmann StraBe 43 D 50996 Cologne Suerth Phone 49 221 347 1439 Fax 49 221 347 1945 service leybold com Leybold Vacuum GmbH Mobile after sales service Emil Hoffmann StraBe 43 D 50996 Cologne Suerth Phone 49 221 347 1765 Fax 49 221 347 1944 kundendienst leybold com Leybold Vacuum Dresden GmbH Zur Wetterwarte 50 Haus 304 D 01109 Dresden Service Phone 49 351 88 55 00 Fax 49 351 88 55 041 info leybold dresden de www leybold dresden de Europe Belgium Leybold Vacuum Nederland B V Belgisch bijkantoor Leuvensesteenweg 542 9A B 1930 Zaventem Sales Phone 32 2 711 00 83 Fax 32 2 720 83 38 sales belgium leybold com Service Phone 32 2 711 00 82 Fax 32 2 720 83 38 service belgium leybold com France Leybold Vacuum France S A 7 Avenue du Qu bec Z A de Courtaboeuf B P 42 F 91942 Courtaboeuf Cedex Sales and Service Phone 33 1 69 82 48 00 Fax 33 1 69 07 57 38 sales france leybold com Leybold Vacuum France S A Valence Factory 640 Rue A Berg s B P 107 F 26501 Bourg l s Valence Cedex Phone 33 4 75 82 33 00 Fax 33 4 75 82 92 69 marketing valence leybold fr Great Britain Leybold Vacuum UK Ltd Waterside Way Plough Lane GB London SW17 OHB Sales Phone 44 20 8971 7000 Fax 44 20 8971 7001 sales leybold com Service Phone 44 20 8971 7030 Fax 44 20 8971 7003 service leybold com Italy
22. an inert special lubricant like PFPE must be used Hazardous substances may escape from the pump and the oil Take ade quate safety precautions For example wear gloves face protection or breathing protection Observe all safety regulations For proper operation of the pump it is essential that the pump has an ade quate supply of the correct and clean oil at all times The oil must be changed when it looks dirty or if it appears chemically or mechanically worn out see Section 5 1 1 The oil should be changed after the first 100 operating hours and then at least every 2 000 to 3 000 operating hours or after one year At high intake pressures and intake temperatures and or when pumping contaminated gases the oil will have to be changed much more frequently Further oil changes should be made before and after long term storage of the pump If the oil becomes contaminated too quickly install a dust filter and or oil fil ter see Section 1 3 Contact us for more information in this matter Only change the oil after the pump has been switched off and while the pump is still warm Required tool Allen key 8 mm Remove the oil drain plug 9 4 and let the used oil drain into a suitable con tainer When the flow of oil slows down screw the oil drain plug back in briefly switch on the pump max 10 s and then switch it off again Remove the oil drain plug once more and drain out the remaining oil Screw the oil drain plug
23. ance with the follo wing precautions can cause damage to the pump This information serves the purpose of making optimum use of the pump Caution GAO1201 1002 07 2005 7 Description Key to Fig 1 1 Oil filter OF 4 25 2 Exhaust filter AF 4 8 3 Condensate trap AK 4 8 Fig 1 TRIVAC B with accessories 8 GA01201 1002 07 2005 1 Description TRIVAC B pumps are oil sealed rotary vane pumps The TRIVAC D 4 B and D 8 B are dual stage pumps The number in the type designation 4 or 8 indicates the pumping speed in m h1 TRIVAC B pumps are capable of pumping gases and vapours and evacua ting vessels or vacuum systems down into with the medium vacuum range The standard versions of the pump are not suited for pumping of oxygen exceeding the concentration as found in the atmosphere and are also not Suited for pumping of hazardous gases or extremely aggressive or corrosi ve media The drive motor of the TRIVAC B is directly flanged to the pump at the cou pling housing The pump and motor shafts are directly connected by a fle xible coupling The bearing points of the pump module are force lubricated sliding bearings All controls as well as the oil level glass and the namepla te 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 f
24. aration of Contamination to the sender s address Disposal of Waste Oil Owners of waste oil are entirely self responsible for proper 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 oxygen 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 sub stances must be marked and stored in such a way that the type of conta mination 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 disposal vendor The references to diagrams e g 1 2 consist of the Fig No and the Item No in that order We reserve the right to modify the design and the specified data The illu strations are not binding The vacuum pumps from the TRIVAC B system from Leybold ensure when properly used and when observing the information provided in these Operating Instructions safe and reliable operation Please read all safety related notes provided in this section and the remaining part of the Operating Instructions with care and ensure compliance The
25. coupling element 13 5 onto one coupling half Push the entire pump module new or repaired onto the tie rods Screw on the hex nuts 13 1 and carefully cross tighten them torque 7 5 Nm Mount the oil case together with the gasket see Section 5 4 Fill in oil Caution Maintenance GA01201_1002 07 2005 29 Maintenance Contamination Form Warning Warning 30 GA01201_1002 07 2005 5 8 Service by Leybold Whenever you send a pump to Leybold indicate whether the pump is con taminated or is free of substances which could pose a health hazard If it is contaminated specify exactly which substances are involved You must use the form we have prepared for this purpose we will forward the form on request A copy of the form is printed at the end of these operating instructions Declaration of contamination of vacuum equipment and components Another suitable form is available from the Leybold homepage http www leybold com under the headline Support amp Download Attach the form to the pump or enclose it with the pump This statement detailing the contamination is required to satisfy legal requi rements and for the protection of our employees Pumps which are not accompanied by a contamination statement will be returned to the sender The pump must be packed in such a way that it will not be damaged during shipping and so that any contaminants are not released from the packa
26. en 52 and 62 dB A Introduce suitable hearing protection Before pumping oxygen or other highly reactive gases at concen trations exceeding the concentration in the atmosphere 21 96 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 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 M lt is recommended to always operate the TRIVAC B with a suitable exhaust line which is properly connected It must slope down and away from the pump E When moving the TRIVAC B always use the allowed means only The pump is equipped as standard with a handle E 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 E 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 B This pump is suited for pumping water vapour within the specified water vapour tolerance limits E Avoid vapours that can condense into liquids when being compres
27. erature C 12 40 Motor rating W 370 Nominal speed min 1500 Type of protection IP 54 Weight kg 18 7 21 2 Connections intake and exhaust side DN 16 KF 1 To DIN 28 400 and subsequent numbers Lenght weight motor rating nominal speed and noise levels for the pumps with AC motor 230 V 50 Hz only Note We can only guarantee that the pump will meet its specifications when using the type of lubricant which has been specified by us 1 4 1 Motor Related Data D4B D8B Cat No l W kg Cat No W kg Motor connections Motor Rated Speed P N mm mm voltage frequency power current motor 113 07 223 10 6 113 17 248 12 8 ohne Motor 140081 455 19 1 140 082 480 21 1 1 100 V 120 V 50 Hz 60 Hz 570 W 660 W 7 7 5 6 A 1420 1690 10000 2292 200 V 240 V 50 Hz 60 Hz 4 0 2 8 A a mains cable must be ordered additionally W 100 V 120 V NEMA Cat No 200 81 090 W 200 V 240 V NEMA Cat No 200 81 141 W 200 V 240 V EURO Cat No 200 81 091 GAO01201 1002 07 2005 13 Transportation and Storage 10 10 10 10 10 1 10 Tor 750 2 T T T Ultimate partial pressure without gas ballast 10 350 Ultimate total pressure without gas ballast mm D8B cm os Ultimate total pressure with gas ballast D4B 10 j 10 45 vo N D D Q D 0 amp 10 0
28. ermediate flange Hex socket screw OMONOAKRWP Fig 11 Disassembly and reassembly of the electric motor GA01201_1002 07 2005 25 Maintenance 26 GA01201_1002 07 2005 Warning Caution 5 5 Disassembly and Reassembly of the Electric Motor Before starting work always disconnect the motor from the mains Pull the mains plug Required tools Allan keys size 2 5 size 3 size 5 and size 6 Possibly a puller for the cou pling Place the pump on its front side Unscrew the four non recessed hex socket screws 11 7 Remove the intermediate flange 11 8 together with the electric motor 11 6 Remove the gasket 11 1 Remove the handle 11 2 Loosen the threaded pin 11 4 and pull the coupling 11 3 with the blade wheel off the motor shaft Unscrew the hex socket screws 11 9 Remove the electric motor 11 6 and the adapter flange 11 5 in the case of the USA motors Clean all parts and check that they are in perfect condition if not replace them with new parts Reassemble in the reverse order In the case of 60 Hz motors USA versions with adapter flange the cou pling must not be pushed on to the shaft right up to the stop On the other hand if it is not pushed on far enough the pump module may be damaged during operation Push the coupling on in such a way that the distance between the front end of the coupling 11 3 and front side of the adapter flange 11 5 amounts to 41 3 0 8 mm 1
29. ery single component This declaration may be completed and signed only by authorised and qualified staff Customer Dep Institute Reason for returning amp applicable please mark A repair U chargeable L1 warranty Address A replacement U chargeable 1 warranty A DKD calibration L Factory calibration Person to contact Returning of goods because of following reason Phone Fax Order number of customer A rent loan A for credit O against exchange A exchange already received arranged A Description of the equipment machine or component Ancillary equipment Type Part number Serial number Type of oil used B Condition of the equipment Has the equipment been used Drained Product service fluid All openings sealed airtight Purged If yes which cleaning agent and which method of cleaning lt 0 Z JA 050 Po C Description of processed substances Please fill in absolutely 1 What substances have come into contact with the equipment Yes No Contamination No Yes O m 0C a M a a corrosive a a a microbiological a a a a explosive a a radioactive a M other harmful substances a Trade name and or chemical term of service fluids and substances processed properties of the substances According to safety data sheet e g toxic inflammable corrosive radioactive Trade name Che
30. ff see Section 4 2 2 When pumping aggressive or corrosive media let the pump continue to operate even during long non working intervals e g overnight with the intake line closed and the gas ballast valve open This avoids corrosion during idle periods If the TRIVAC B is to be shutdown for an extended period after pumping aggressive or corrosive media or if the pump has to be stored proceed as follows When having pumped harmful substances take adequate safety precau tions Our technical sales department is available for further advice in these mat ters Drain the oil see Section 5 2 Add clean oil until the oil level is at the min mark see Section 5 2 and let the pump operate for some time Then drain the oil and add clean oil until the oil level is at the max mark see Section 5 2 Seal the connection ports Special conservation or anti corrosion oils aren t necessary Please also take note of the information given in Section 5 9 Storing the Pump 4 3 1 Shutdown through Monitoring Components When the pump has been switched off due to overheating sensed by the motor coil protector or other monitoring components at the pump e g thermal sensor the pump must only be started manually after the pump has cooled down to the ambient temperature and after having removed the cause first 4 3 2 Controller Mains Power Failure In order to prevent the pump from running up unexpectedly after a mains
31. ge 5 8 1 Waste Disposal of Used Pump Materials The corresponding environmental and safety regulations apply This applies equally to used filters and filter elements oil filter exhaust filter and dust filter In the case of hazardous substances determine the kind of hazard first and observe the applicable safety regulations If the potential hazard still persists the pump must be decontaminated before starting with any maintenance work For professional decontamination we recommend our Leybold service Never exchange the oil or the filters while the pump is still warm Let the pump cool down to uncritical temperatures first You must wear suitable protective clothing 5 9 Storing the Pump Before putting a pump into operation once more it should be stored in a Caution dry place preferably at room temperature 20 C Before the pump is shelved it must be properly disconnected from the vacuum system pur ged with dry nitrogen and the oil should be changed too The inlets and outlets of the pump must be sealed with the shipping seals which are provided upon delivery The gas ballast switch must be set to the 0 position and if the pump is to be shelved for a longer period of time it should be sealed in a PE bag containing some desiccant silica gel When a pump is put into operation after it has been shelved for over one year standard maintenance should be run on the pump and the oil should also be exchanged see Section 5
32. hecking the Oll Level x 1 cds ERR it al aye danas 22 Checking the Condition of N 62 or HE 200 Oil oo oooooooooo 22 Oil Change il iis Ba wd cene be Phd en ase eee aed 23 Cleaning thenlebScreen usc esi ne ht eee ay heehee edie ba 24 Removing and Fitting the Internal Demister 0 0 0 00 eee ee eee 24 Disassembly and Reassembly of the Electric Motor 0 000 26 Replacing th ShaftSeal a ici eh Get ee Pee ie PUN pea 27 Removing and Remounting the Pump Module 0 0005 28 Removing the Pump Module ge RR eed d ec 29 Remounting the Pump Module iisie en 29 ServICeDy E8ybold uiuo Ra Sidon bacon ANI gos RU RUANDA 30 Waste Disposal of Used Pump Materials liliis 30 Storing the Pump e epe Rv umet rt ese ne bre Eds 31 Maintenance Pla x quete dee er Rr eer ea ed eoe IHESU 32 Troubleshooting bie nlcIiRI Leere eie je ex EL a 33 Spare Parts eer epO e a 34 EEC Declaration of Conformity leeren 35 EEC Manufacturer s Declaration ooooooooommmmmomm omm 36 Declaration of Contamination 00 00 e eee eee o 37 Contents GA01201_1002 07 2005 3 Notes 4 GA01201_1002 07 2005 Figures Leybold Service If a pump is returned to Leybold indicate whether the pump is free of sub stances 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 Decl
33. ined its operating temperature 4 2 1 Pumping of Non Condensable Gases and Vapours If the process contains mainly permanent gases the TRIVAC B may be operated without gas ballast position O provided that the saturation vapour pressure at operating temperature is not exceeded during com pression If the composition of the gases to be pumped is not known and if conden sation in the pump cannot be ruled out run the pump with the gas ballast valve open in accordance with Section 4 2 2 4 2 2 Pumping of Condensable Gases and Vapours With the gas ballast valve open position I and at operating temperature TRIVAC B pumps can pump pure water vapour up to the water vapour tole rance specified by the technical data If the vapour pressure increases above the permissible level the water vapour will condense in the oil of the pump When pumping vapours ensure that the gas ballast valve is open and that the pump has been warmed up for approximately 30 minutes with the intake line closed Vapour phases may only be pumped up to the permissible limit after the pump has attained its operating temperature During pumping vapours may dissolve in the oil This changes the oil properties and thus there is a risk of corrosion in the pump Therefore don t switch off the pump immediately after completion of the process Instead allow the pump to continue operating with the gas ballast valve open and the intake line closed until the oil is free
34. ing the Internal Demister Required tools Allen keys SW 5 and SW 8 Required spare parts Allen keys 5 mm and 8 mm The internal demister is spring mounted in a frame When it is clogged it rises periodically to reduce the pressure difference created The resultant noise at high intake pressures indicates that the internal demi ster is dirty Periodically clean or replace the internal demister the maintenance interval depends on the application Use a suitable solvent for cleaning Shutdown the pump and drain the oil see Section 5 2 Pull the handle upward Remove the four recessed screws 10 5 on the oil case 10 1 Don t remove the non recessed screws they hold the motor flange in place Pull the oil case forward off the pump Remove the gasket 10 7 Press the spring buckles 10 2 sideways away from the frame 10 4 Lift off the frame 10 4 and remove the internal demister 10 8 Clean all parts and check that they are in perfect condition if not replace them with new parts Reassemble in the reverse order Torque for the screws 10 5 is 5 Nm Maintenance Key to Fig 10 Oil case Spring buckles Demister Frame for demister Hex socket screws 4 pcs Slencing nozzle Gasket NO0OIRAO0NnN Fig 10 Removal and fitting of the internal demister Key to Fig 11 1 Gasket Handle Coupling Threaded pin Only for USA motors adapter flange Electric motor Hex socket screws Int
35. itted so as to allow easy disassembly and reassembly The pump module can be easily removed without special tools Description Key to Fig 2 1 Intake port 13 2 2 Inlet screen E 3 Anti suckback valve QS 7 4 Intake channel SS NN A 5 Vane 12 e 3 6 Pump chamber 7 Rotor SS 8 Cover plate connection for inert gas ballast 4 4 4 9 Exhaust channel 10 Exhaust valve 11 Internal demister Ki 12 Spring buckles 10 A PS B 13 Cover plate connection for oil filter pl VMI Fig 2 Sectional drawing of the TRIVAC B 1 1 Function The rotor 2 7 mounted eccentrically in the pump chamber 2 6 has two Operating Principle radially sliding vanes 2 5 which divide the pump chamber into several compartments 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 inlet screen 2 2 flows past the open anti suckback valve 2 3 and then enters the pump chamber 2 6 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 exhau
36. m 8 mm box wrench 10 mm possibly pliers 5 7 1 Removing the Pump Module Drain the oil and remove the oil case see Section 5 4 Unscrew the hex nuts 13 1 Pull the entire pump module 13 2 forward off the tie rods 13 6 When doing so ensure that the individual pin fitted parts are not loose ned Further disassembly of the pump module should only be carried out by a trained service engineer Remove the gasket 13 4 Remove the coupling element 13 5 After removing the protective shipping materials handle the new pump module with care Before installing a new pump module remove the four tie rods from the new module and insert them in the old one for protection during shipment Key to Fig 13 1 Hex nuts 2 Pump module 3 Washer 4 Gasket 5 Coupling element 6 Tie rods Fig 18 Removing and Remounting the Pump Module 5 7 2 Remounting the Pump Module When installing a new pump module it is also advisable to use a new gas ket 13 4 Check the coupling element 13 5 for damage if necessary install a new one Use the tie rods supplied with the new pump module only if the old ones are damaged To do so unscrew the old tie rods with lock nuts and screw in the new ones With the aid of the lock nuts tighten the tie rods Then remove the lock nuts Before mounting the pump module make sure that sealing disc 13 3 fits correctly in its bore ush the gasket 13 4 onto the tie rods 13 6 push the
37. mical name Residues a O Yes OQ No b O Yes OQ No C O Yes OQ No d O Yes OQ No Yes No 2 Are these substances harmful a a 3 Dangerous decomposition products when thermally loaded a a Which without written evidence of decontamination Components contaminated by microbiological explosive or radioactive products will not be accepted D Legally binding declaration we hereby declare that the information supplied on this form is accurate and sufficient to judge any contamination level Name of authorised person block letters Date Signature of authorised person Leybold Vacuum K ln Company stamp GA01201_1002 07 2005 37 Sales and Service Net Worldwide Germany Leybold Vacuum GmbH Bonner Strasse 498 D 50968 Cologne Phone 49 221 347 1234 Fax 49 221 347 1245 sales leybold com Leybold Vacuum GmbH Sales Area North East Branch office Berlin Buschkrugallee 33 1 Obergeschoss D 12359 Berlin Phone 49 30 435 609 O Fax 49 30 435 609 10 sales berlin leybold com Leybold Vacuum GmbH Sales Area South Southwest Branch office Munic Karl Hammerschmidt Strasse 38 D 85609 Aschheim Dornach Phone 49 89 357 33 90 Fax 49 89 357 33 933 sales muenchen leybold com service muenchen leybold com Leybold Vacuum GmbH Sales Area West Branch office Cologne Emil Hoffmann StraBe 43 D 50996 Cologne Suerth Phone 49 221 347 1270 Fax 49 221 347 1291 s
38. nections must only be provided by a trained electrician or must be supervised by a trained electrician working in accordance with the cur rently valid IEC International EN European or national guidelines Observe all safety regulations TRIVAC B pumps are available with a single phase motor With a single phase AC motor the pumps may be connected directly to the mains via the mains cord and the mains plug Fusing must always be done in accordance with the national and local regulations for single phase mains in Germany 16 amps for example The direction of rotation need not be checked as it is fixed The motor is protected against overloading by a thermal overload switch with automatic resetting If the thermal overload protector shuts off the pump the motor will restart Warning itself as soon as it cools That s why the mains plug should be dis connected from the mains before starting with any work on the pump 3 4 Areas of Application Before pumping oxygen or other highly reactive gases at concentrations Warning exceeding the concentration in the atmosphere 21 96 for oxygen it will be necessary to use a special pump Such a pump will have to be modi fied and degreased and an inert special lubricant like PFPE must be used The TRIVAC B is not suited for pumping of m ignitable and explosive gases or vapours m oxidants m pyrophorous gases The pumps are not suited for pumping of liquids or media which car
39. ng technique and gauge reach ultimate Measure the pressure directly at the pump s intake port pressure External leak Repair the pump Service Anti suckback valve is malfunctioning Repair the valve Service Exhaust valve is malfunctioning Repair the valve Service Oil is unsuitable Change the oil degas it if necessary 5 2 Vacuum lines are dirty Clean the vacuum lines Pump is too small Check the process data replace the pump if necessary Pumping speed is Inlet screen in the intake port is clogged Clean the inlet screen 5 3 too low Precaution install a dust filter in the intake line Exhaust filter is clogged Install new filter element Connecting lines are too narrow or too long Use adequately wide and short connecting lines 3 2 After switching off System has a leak Check the system 7 the pump under Anti suckback valve is malfunctioning Repair the valve Service vacuum pressure in the system rises too fast Pump gets hotter Cooling air supply is obstructed Set pump up correctly 3 1 than usually Ambient temperature is too high Set pump up correctly 3 1 4 2 3 observed Process gas is too hot Change the process Oil level is too low Add oil 5 1 Oil is unsuitable Change the oil 5 2 Oil cycle is obstructed Clean or repair the oil lines and channels Service Exhaust filter exhaust line is obstructed Replace the exhaust filter clean the exhaust line Exhaust valve is malfunctioning Repair the valve
40. nternational Business Park B1 20B The Synergy Singapore 609917 Sales and Service Phone 65 66652910 Fax 65 65668202 vacuum leyboldvac com sg Taiwan Leybold Vacuum Taiwan Ltd No 416 1 Sec 3 Chung Hsin Rd Chu Tung Hsin Chu Taiwan R O C Sales and Service Phone 886 3 5833988 Fax 886 3 5833999 Leybold Vacuum www leybold com
41. oil level glass The amount of oil must be checked and topped up as required Fill in oil only after the pump has been switched off 5 1 1 Checking the Condition of N 62 or HE 200 Oil The ageing process for the standard operating fluid N 62 respectively HE 200 see Section 1 2 will depend very much on the area of application for the pump a Visual check Normally the oil is clear and transparent If the oil darkens it should be changed b Chemical check The neutralisation number of N 62 oil is determined according to DIN 51558 If it exceeds 2 the oil should be changed c Viscosity check If the viscosity of N 62 at 25 C exceeds a level of 240 mPas 20 96 higher than the viscosity of fresh oil an oil change is recommended If gases or liquids dissolved in the oil result in a deterioration of the ultima te pressure the oil can be degassed by allowing the pump to run for approx 30 min with the intake port closed and the gas ballast valve open When wanting to check the oil switch off the pump first and drain out from the warm pump the required amount of oil through the oil drain 9 4 into a beaker or similar Please note the safety information given in Section 5 2 5 2 Oil Change Before pumping oxygen or other highly reactive gases at concentrations exceeding the concentration in the atmosphere 21 96 for oxygen it will be necessary to use a special pump Such a pump will have to be modified and degreased and
42. rap The exhaust gases from the vacuum pump must be safely led away and subjected to post treatment as required In order to reduce the emission of oil vapours we recommend the installation of an additional exhaust fil ter Leybold accessory Depending on the type of application or the kind of pumped media the corresponding regulations and information sheets must be observed The pumps may be operated with an inert gas ballast via a connection which is provided for this purpose The cover plate 7 8 can be removed to gain access to this M 16 x 1 5 threaded port 7 6 Matching connectors are available see Section 1 3 In inlet pressure for the gas ballast should be about 1000 mbar absolute and sufficient quantities of gas must be available about Ta of the pumping speed Never operate the pump with a sealed exhaust line There is the danger of injury Before starting any work on the pump the personnel must be informed about possible dangers first All safety regulations must be observed 3 3 Electrical Connections Before wiring the motor or altering the wiring ensure that mains supply Warning for the pump is off and that it can not be applied inadvertently In order to prevent the pump from running up unexpectedly after a mains power failure the pump must be integrated in the control system in such a way that the pump can only be switched on again manually This applies equally to emergency cut out arrangements The con
43. rap for Seperator exhaust filter oil drain of the pump vacuum tight 190 90 oil tight 190 91 Exhaust filter with lubricant return AR 4 8 DN 16 KF 189 20 Dust filter FS 2 4 186 05 Fine vacuum adsorption trap FA 2 4 with zeolithe 187 05 adsorption trap with aluminium oxide 854 14 adsorption trap with cryo insert 854 17 Cold trap TK 4 8 188 20 Oil filter OF 4 25 101 91 Chemical filter CF 4 25 101 96 Adapter f r gas ballast port M 16x 1 5 DN 16 KF 168 40 M 16 x 1 5 3 3 inch NPT 99 175 011 Oil N 62 11 177 01 5l 177 02 201 177 03 order from Leybold Cologne Oil HE 200 1 at 98 198 006 12 qt case 98 198 049 1 gal 98 198 007 5 gal 98 198 008 order from LHVP Export Pa USA The oil grades N 62 and HE 200 are interchangeable Special oils upon request Caution Only use the kind of oil specified by Leybold Alternative types of oil are specified upon request 12 GA01201 1002 07 2005 Description 1 4 Technical Data TRIVAC D4B TRIVAC D8B two stage two stage Nominal pumping speed ms h1 4 8 9 7 Pumping speed 1 ms h1 4 2 8 5 Ultimate partial pressure without gas ballast mbar 104 Ultimate total pressure without gas ballast 1 mbar 2 103 Ultimate total pressure with gas ballast 1 mbar 5 103 Water vapor tolerance mbar 30 25 Water vapor capacity gm ht 93 157 Oil filling min max 0 3 0 8 0 3 0 9 Noise level to DIN 45 635 dB A 50 52 without with gas ballast Admissible ambient temp
44. re the pump in the future The pump is shipped with intake and exhaust flanges mounted for hori zontal connection of the connecting lines You can easily convert the ports for vertical connection by removing the four capscrews rotating the flanges as required and reinstalling the capscrews Connect the intake and exhaust lines with a centering ring and a clamping ring each Use the centering ring with dirt trap for the intake port Connect the intake and exhaust line using anti vibration bellows without placing any strain on the pump The intake line must be clean Deposits in the intake line may outgas and adversely affect the vacuum The connecting flanges must be clean and undamaged The maximum throughput of the pump is equivalent to the pumping speed of the pump see Section 1 4 The cross section of the intake and exhaust lines should be at least the same size as the connection ports of the pump If the intake line is too narrow it reduces the pumping speed If the exhaust line is too narrow overpressures may occur in the pump this might damage the shaft seals and cause oil leaks The maximum pressure in the oil case must not exceed 1 5 bar absolute When pumping vapours it is advisable to install condensate traps on the intake and exhaust sides Install the exhaust line with a downward slope lower than the pump so as to prevent condensate from flowing back into the pump If this is not possible insert a condensate t
45. ry Caution large quantities of dust Corresponding protection devices need to be provided The standard pump is not suited for pumping of hazardous gases or Warning vapours Our technical sales department is available for further advice in these matters Installation GAO1201 1002 07 2005 17 Installation 18 GA01201_1002 07 2005 Warning 4 Operation 4 1 Start up Each time before starting up check the oil level On initial start up after prolonged idle periods or after an oil change the specified ultimate pressure cannot be attained until the oil is degassed This can be done by running the pump for approx 30 min with the intake line closed and the gas ballast valve 7 5 open Before starting the pump ensure that the pump and the fitted accesso ries meet the requirements of your application and that safe operation can be guaranteed Avoid exposure of any part of the body to the vacuum There is the dan ger of injury Never operate the pump with an open intake port Vacuum connections as well as oil fill and oil drain openings must never be ope ned during operation The safety regulations which apply to the application in each case must be observed This applies to installation operation and during mainten ance service as well as waste disposal and transportation 4 2 Operation TRIVAC B pumps can pump condensable gases and vapours provided that the gas ballast valve 7 5 is open and the pump has atta
46. s descri bed above First small droplets are coalesced into large drops in the inter nal demister 2 11 fitted above the exhaust valve 2 10 Then the large drops fall into the oil reservoir as the exhaust gas is diverted by the inner walls of the oil case Thus a low loss of oil is obtained This and the large usable oil reservoir ensure long intervals between oil changes even at high intake pressures The vacuum is maintained by the TRIVAC B by an integrated hydropneu matic anti suckback valve 2 3 which is controlled via the oil pressure During operation of the TRIVAC B the control piston 4 3 remains sealed against a spring 4 2 by the oil pressure The valve disc 4 6 of the anti suckback valve is held at the lower position by its own weight valve open When the pump stops because it has been switched off or because of a failure the oil pressure drops and the spring 4 2 presses the control piston 4 3 up Thus a connection is provided between the oil case or the oil reservoir 4 1 and the piston 4 4 of the anti suckback valve Due to the pressure difference between the oil case and the intake port the oil presses the piston 4 4 up and the valve plate 4 6 against the valve seat 4 5 The quantity of oil in the oil reservoir 4 1 prevents the entry of air into the inta ke port 2 1 at the beginning of this process After the oil has flowed out from the reservoir and when the valve plate rests on the valve seat air
47. st Oil filter 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 gas leaves the TRIVAC B through the exhaust port During compression a controlled amount of air the so called gas ballast Operating with gas ballast can be allowed to enter the pump chamber by opening the gas ballast valve position The gas ballast stops condensation of vapours in the pump chamber up to the limit of water vapour tolerance as specified in the technical data for the pump GA01201_1002 07 2005 9 Description Lubrication system Seperation of oil and gas Anti suckback valve 10 GA01201_1002 07 2005 The gas ballast valve is opened position I and closed position O by tur ning the gas ballast knob 7 5 on the front To enable the TRIVAC B to be used at intake pressures as high as 1 000 mbar a special lubricating system was developed featuring force lubricati on of the sliding bearings An oil pump 3 6 pumps the oil from the oil reservoir 3 5 into a pressure lubrication system which supplies oil to all bearing points 3 2 From there the oil enters the pump chamber area 2 6 of the vacuum pump The oil pump is fitted in the front end plate on the coupling side of the pump module The oil suction line is placed low resulting in a large usable oil reservoir The oil is separated from the gas in the TRIVAC B in two steps a
48. t The warm pump with degassed oil is running without gas ballast and the intake is blanked off The exhaust line is led into a vessel with water If an evenly spaced line of bubbles appears then the pump has an external leak GAO01201 1002 07 2005 33 Troubleshooting 7 Spare Parts The spare parts for your vacuum pump are listed in the spare parts list enclosed with the product 34 GA01201_1002 07 2005 EEC Declaration of Conformity We LEYBOLD Vacuum GmbH here with declare that the products defined below meet the basic requirements regarding safety and health of the relevant EC directives by design type and versions which are brought into cir culation by us In case of any product changes made without our approval this declaration will be void Designation of the products Rotary vane vacuum pump dual stage Types TRIVACD 4 D8B Cat No 140 081 140 082 The products conform to the following directives E EC Directive on Machinery 98 37 EG W EC Directive on Low Voltages 73 23 93 68 EG W EC EMC Directive 89 336 EG 91 263 EG 92 31 EWG 93 68 EG Applied harmonised standards B EN 1012 2 1996 B EN 60204 1 1997 W EN 60034 1 A1 A2 A11 2002 Cologne 01 07 2005 Cologne 01 07 2005 Marcus Eisenhuth Wolfgang Giebrnganns Member of the Management Board Head of Desi Head of Product Development Forevacuum Pump Design Leybold Vacuum Leybold Vacuum GmbH Bonner StraBe 498 D 50968 Cologne Tel
49. ted 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 B is not suited for operation in explosion hazard areas For this purpose there are special TRIVAC B Atex Pumps Contact us before planning to use the pump under such circumstances Before starting up for the first time the motor circuit must be equipped with a suitable protective motor switch Please take note of the information in these Operating Instructions or on the electric motor wiring diagram The TRIVAC B is not suited for pumping of m combustile and explosive gases and vapours m radioactive and toxic substances m pyrophorous substances Avoid exposing any part of the human body to the vacuum Never operate the TRIVAC B without a connected intake line or blank flange at the intake port 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 The location of the TRIVAC B should be such that all controls are easily accessible Under certain ambient conditions the TRIVAC B 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 The noise level of the TRIVAC B is betwe

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