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Leybold Series A Pump Service Manual

1. 50 A For corr series pumps 50 po 75x82x0 2 Gold plated For corr series pumps la pap Vals atap 37368108 34 6x45x10 The valve stop in the Valve stop 373 58 107 63x45x9 Black plastic Figures is made of black plastic loo 1 1 Valvestop 37358106 80x74 8x12 Abay Center bearing 261 51 132 D12x15 Cast iron Center bearing 261 51 131 D15x15 Cast iron D30x30 14x35x4 5 Ferobestos EC 52 52 1 1 52 N D A Intermediate plate 261 51 135 Cast iron HIGH VACUUM STAGE ASSEMBLY Vane 411 55 112 53 3 E Vane anism 14x70x4 5 53 3 Vae ARR IRR 22x45x4 5 Ferobestos EC 53 Ps Vane 41155154 22x90x4 5 53 3 Vae 4m 55116 32 5x75x4 5 Ferobestos EC S S R HE E Included in module see page 57 of parts list D diameter Included in module repair kit see page 57 of parts list Duroplast durable thermoplastic Al aly aluminum alloy 7 uolipy ENUEN Ws OVAL ERR CutsisaN Dimensions D8A D16A pana Beo art name atalog No mm Remarks HIGH VACUUM STAGE ASSEMBLY Cont d Rotor HV stage 321 66 126 D48x35 Cast iron 54 AA tor HV st
2. B 1 amp Sec 3 3 molecular filter to intake tube 1 to prevent reoccurance of problem For D2A D4A DBA amp D16A pump models B 5 amp B 6 only replace oil filter 35 Wrong pump fluid is being Clean pump and charge it with the Sec 4 3 2 used recommended pump fluid Pump ran low on pump fluid Clean pump and charge it with the Sec 4 3 2 recommended pump fluid Pump fluid has broken down Large vacuum leak Repair leak clean pump and change pump Sec 4 3 2 fluid Pump is running continuously Clean pump change pump fluid and run pump Sec 4 3 2 above 112 Torr at lower pressure This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed if the section is ot specified the steps are located in Section 5 t the beginning of Section 5 E 7 UONIPA yenuey Ya OVAL Sy 3 The pump will not achieve ts ultimate pressure RL a Gas ballast valve 17 TABLE 6 1 TROUBLESHOOTING CHART C Probable Cause Valve 17 is open Recommended Corrective Action Close valve 17 unless condensation is a problem l Cap 18 is worn Install rew cap 18 D 1a The O ring 27 on the end of the gas ballast tube 27 is worn Install new O ring 27 B 5 D 1c and E 9 b Vacuum line connection Vacuum line is connected to exhaust p
3. 10167 K 10168 K Module repair kt 10169 K 10170 K A 390 26 117 hen 35 Anti suckback modification kit 720 24 003 120V 60 Hz Anti suckback modification kit 720 24 002 208 240 480V 50 60 Hz Anti suckback modification kit 720 24 005 120V 60 Hz Anti suckback L modification kit 720 24 004 2b8 240 480V 50 60 Hz Anti suckback modification kit 720 24 001 208 240 480V 50 60 Hz Module repair kit 10166 K 10171 K 2 Number Required Per Unit l 5 Pump Model y E s oa oa oea pra osoa BRA anes Lae CO nemara SI oao fT Modue standara The module is made up of all parts listed with 5 la Module corrosive series 10166c__ an beside its catalog number in Table 7 2 car CU Moodle standard si LT l Module corrosive series 10167C Tl Module standard For extreme corrosive service pump modules 2 TTT Module corrosive series 899512 contact the main office gt A TT Module standard la Module corrosive series 898513 1 Module standard 1 Module corrosive series 101700 1 Module standard a Pel Universal gasket set 19102 B2 The gasket set is made up of all parts listed with a Universal gasket set beside its catalog number in Table 7 2 Universal gasket set 19106 B2 The gaskets are Viton they can be used for g standard corrosive and extreme corrosive applications Buna gasket sets are available on request t 1 1017
4. 3 NOTE When Step d 3 is completed the beveled ends of the two long cylindrical pins 65 should extend most of the way through the upper alignment holes in the second stage pump cylinder 46 REQUIRED ACTION For the D2A D4A D8A and D16A pump models while keep ing the assembly vertical pull the second stage cylinder 46 straight up over the long cylindrical pins 65 until it is tight against the center bearing plate 52 see Figure 5 20 For the D30A D60A and D90A pump models only while keeping the assembly vertical push the Step b 3 assembly straight down until it is tight against the second stage cylinder 46 4 Ensure that the cylinders 46 55 and center bearing plate 52 remain tight against each other throughout the module assembly sequence e NOTE If you are reusing the old vanes 53 make sure that each used vane is replaced in its same rotor slot Also make sure that the orientation of each vane is the same as it was betore disassem bly so that each used vane is not turned end for end in its slot NOTE Be sure that the slotted edge of the vanes 53 faces the center of the rotor 54 when inserting the vanes into the rotor NOTE For the D4A D16A D60A and D90A pump models only the high vacuum stage rotor 54 and vanes 53 are longer than the second stage rotor 48 and vanes 49 For these pump models be sure to insert the longer vanes 53 into the high vacuum stage rotor 54 TRIVAC A M
5. FIGURE 7 2 E eer Tr hati E a ae ak ac T
6. ee ee ee eee ee eens 8 3 1 2 Reporting Shipping Shortage ee ee ee ee eee eens 8 3 1 3 Reporting Incorrect Shipment 0 ee ee eee eee ee 9 3 2 Initial Filling With Lubricating Fluid L 9 3 3 Connecting the Pump to the System ee ee eee eee eee ee eee eee 9 3 4 Making the Electrical Connection 0 cc ee ee ee et ee ee eee eee ee eee eens 10 SECTION 4 STARTING OPERATING AND MAINTAINING THE PUMP oo ooo o 10 L Startup inn cis Matias ie E Ree OS OE ee eee E R arene Sat esen ober 10 4 1 1 Checking the Direction of Rotation o o ee eee E Ie a E eet eee os ay Sd 10 4 1 2 Using the Gas Ballast Valve During Pump Warm up 0002 o 10 4 2 Operation onnon Sasa daniel Ghat A Wee Re E fh ade Tie ele EE Deda Te AE ee Ree a 11 4 3 Preventative Maintenance a A A A A A ARO doe 11 4 3 1 Checking the Lubricating Fluid Level ooooo ooo 11 4 3 2 Changing the Lubricating Fluid aaeeea eea 12 4 3 3 Checking the Lubricating Fluid for Contamination oo ooo o e eee 13 4 3 4 Long Term Storage il ars id ete A A A Buds hat ew n ia is Be 13 4 3 5 Checking the Dirt Traps is A A AS Bb A R d Sak BN AA ew E 13 4 3 6 Avoiding Oil Leaks During Shipping and Storage x lt rennarar 13 SECTION 5 DISASSEMBLY CLEANING AND ASSEMBLY INSTRUCTIONS ooo 14 Module Replacement Procedure o o o oooo eee ee ee ee
7. or system is vented to atmospheric pressure after pump shutdown m Module O rings Dirty or damaged O rings 47 are dirty or 47 are allowing venting aa A o For D4A D16A Valve plate 58 is dirty Clean or replace valve plate TABLE 6 1 TROUBLESHOOTING CHA Motor 73 Motor is rotating in wrong direction Interchange line ends Motor malfunction Check rotational lock bearing D 13 4 F 1b Contact motor manufacturer s service center D 13 8 F 1 Install new O rings 47 B 1 thru F 17 damaged of module n Intake tube O ring 5 is allowing venting of module Sealing surface on bottom of tube is scratched Smooth scratches with jeweler s rouge B 1 B 2 amp B 4 B 1 thru B 7 8 D60A and D90A or worn D 11 pump models only vaive plate 58 Vacuum line or vessel contains leak a Vacuum line or evacuated vessel Repair leak or clean O ring if dirty b Anti suck back Valve disk 67 is worn Remove old disk 67 and install new one or valve assembly or dirty clean old disk Valve disk 67 and Clean disk and piston or install new ones piston 68 are stuck in Clean intake tube portion of high vacuum place in high vacuum pump cylinder 55 pump cylinder 55 B 1 thru B 7 C 1 amp D 5 This column contains the
8. results in an oil mist in the exhaust stream and higher pump fluid con sumption operating temperature and ultimate pressure After closing the gas ballast valve the pump normally reaches ultimate pressure as soon as it cools to operating temperature CAUTION PUMPING PROCESS GAS WITH A COLD VANE PUMP CAN RESULT IN VAPORS CONDENSING IN THE PUMP FLUID 1 Operate the pump with the gas ballast valve 17 open see Section 2 3 1 and the intake tube 1 closed for about 12 hour while the pump is warming to operating temperature NOTE If your system has a valve in the vacuum line the intake tube 1 can be closed by shutting the vacuum line valve during the pump warming period NOTE When the pump is cold condensation may occur in spite of the gas ballast valve being open 2 Open the intake tube 1 and or vacuum line valve and allow the pump to operate for a few addi tional minutes with the gas ballast valve 17 open This will remove condensable vapors from the system 10 TRIVAC A Manual Edition L 3 NOTE Most of the vapors have been expelled from the pump when the pressure nears the ultimate total pressure with gas ballast see Table 4 1 NOTE If your process has high levels of condensable vapors it may be necessary to run the vane pump with the gas ballast valve open see Section 2 3 2 When running continuously with the gas ballast valve open we recommend installing an SE smoke eliminator or an AF exhaust filter w
9. the motor will restart itself as soon as it cools down Table 4 1 lists operating and other technical data for each of the TRIVAC dual stage vane pump models 1 NOTE The pump fluid is usually saturated with condensate when the fluid becomes milky white or dark and the pump runs hot and fails to reach its ultimate pressure see Table 4 1 REQUIRED ACTION If during operation the pump fluid becomes saturated with condensate run the pump with the intake tube 1 and or vacuum line valve closed and the gas ballast valve 17 open See Section 2 3 1 until the condensate is vaporized and expelled from the exhaust port 6 2 If condensate in the pump fluid is severe the pump should be flushed out and the pump fluid changed see Section 4 3 2 See Symptom 1 of the Troubleshooting Chart Table 6 1 for other methods of removing condensate from the pump fluid 4 3 PREVENTATIVE MAINTENANCE NOTE See Section 6 Troubleshooting to resolve corrective maintenance problems 4 3 1 Checking the Pump Fluid Level NOTE When the pump is not running the pump fluid level appears lower NOTE It is not unusual for the pump fluid to foam because of the churning action of the disk oil slinger Foaming is more pronounced at high operating pressures If only foam is visible in the oil level glass 15 it means that the pump fluid level is low Occasionally check the pump fluid level when the pump is running near its ultimate pressure see Table 4 1
10. 5 23 Reassembling the Module to the Coupling Housing o ee ee tee eens 42 SECTION 7 SPARE PARTS LIST 7 1 Disassembled Pump D2A Pump Model Shown 0 00 eee ee ee ee eee eens 56 7 2 Exploded Isometric Drawing of a D30A Pump Model rr 73 TRIVAC A Manual Edition L SECTION 1 INTRODUCTION 2 This manual contains important information regarding the safe operation maintenance and repair of your TRIVAC dual stage pump We urge you to read Sections 1 3 and 4 before using your pump Section 6 the troubleshooting chart should be used in conjunction with the rest of the manual should the need occur 1 1 MANUAL KEY This manual covers the following pump models see Section 1 2 in addition to extreme corrosive service pumps Corrosive Dual Speed Standard ta Application and Corrosive enigs Series Application Series D60A2X D60AC2X WARNING statements are used in this manual to prevent injury to personnel CAUTION statements are used to prevent damage to equipment NOTES contain helpful information REQUIRED ACTION is used where necessary to distinguish the action of the step from the WARNINGS CAUTIONS and NOTES Numbers in parentheses refer to position numbers of parts in the parts list see Section 7 These numbers are also used to identify parts on the figures The terms lubricating fluid pump fluid fluid oil and lubricant when used in this manua
11. 70 411 D122x3 Viton pump cylinder the other two go on the high vacuum stage pump cylinder Oil nozzle Rotor with shaft pT ce Position no se ele isd Included in module see page 97 of parts list Included in module repair Kit see page 57 of parts list Included in universal gasket set and module repair kit see page 57 of parts list 41155 112 14x35x4 5 Ferobestos EC 411 55 155 22x45x4 5 Ferobestos EC 481 21 242 Rotor with shaft 481 21 243 D48x186 Cl Stl Rotor with shaft D68x 183 Qe ee Shaft 401 57 294 St Rotor D101 x 75 al Shaft 401 57 296 Sti ERRE ne Ea ae ee ONT 32 5x75x4 5 Ferobestos EC Sti steel Cl cast iron Viton heat resistant synthetic rubber D diameter 41155 116 v9 7 UONIPZ IENUEW Va OVH Number Required per Unit Pump Model Di Part Name Catalog No mensions ak psa T oen oren oon ERR D90A SECOND STAGE ASSEMBLY Cont d 50 1 Valve plate standard 401 64 109 45x35x0 1 Stl 50 Fr Vaive iat standard 401 64116 63x45x0 1 Stainless steal EEE A EEES For strd series pumps For strd series pumps For strd series pumps For corr series pumps 50 Valve plate standard 401 64 114 75x82x0 2 50 Valve plate corrosive 401 64 121 45x35x0 1 Gold plated Valve plate corrosive 401 64 116 63x45x0 1 Stainless steel E
12. D8A and D16A pump models only use snap ring pliers to remove the retainer ring 34 from the gas ballast valve tube 17 then slide the cover 33 off of the tube 17 c For all pump models slide the O ring 27 flat gasket 29 and spring 28 off of the gas ballast valve 17 tube see Figure 5 10B d For the D2A and D4A pump models only use a screwdriver to unscrew and remove the nonreturn valve 23 assembly from inside of the top of the gas ballast valve see Figure 5 10A e For the D2A and D4A pump models only use a small screwdriver to unscrew and remove the strengthening piece 26 spring 25 and flat gasket 24 from the nonreturn valve 23 See Figure 5 10A f For D8A D16A D30A D60A and D90A pump models only use a screwdriver to remove the retaining washer 21 valve 19 and O ring 20 from inside of the top of the gas ballast valve See Figure 5 10A g For the D30A D60A and D90A pump models only remove the retainer ring 30 valve plate washer 32 spring 31 and valve plate 32 from the tube end of the gas ballast valve See Figure 5 10B Remove the two O rings 70 from the air inlet tube 69 See Figure 5 11 Remove the O ring 3 from the dirt trap 2 See Figure 5 11 Remove the O ring 5 from the end of the pump intake tube 1 See Figure 5 11 For D2A D4A D8A and D16A pump models pull the brass piston 68 from the valve disk 67 See Fig 5 11 Z For D30A D60A and
13. D90A pump models unscrew the brass piston 68 from the valve disk 67 See Fig 5 11 Remove the fiat gasket 9 from each of the two plug screws 8 See Figure 5 11 TRIVAC A Manual Edition L VALVE ASSEMBLY VALVE ASSEMBLY CATAII NOTE The tube end of the D8A D16A gas ballast valve is similar to the D2A D4A except the D8A D16A has a cover 33 and retainer ring 34 above the oil filter 35 Figure 5 10B Tube End of Gas Ballast Valve TRIVAC A Manual Edition L 23 D 8 D 9 D 10 D 11 24 NOTE All parts shown are from a D2A pump model except for the D30A D60A D90A coupling ring 36 TA Figure 5 11 Miscellaneous Disassembled Parts Remove the seal 43 from the lever 41 See Figure 5 11 CAUTION BE CAREFUL TO AVOID SCRATCHING THE END PLATE OR INSIDE OF THE BRONZE E BUSHING WHEN REMOVING THE RADIAL SHAFT SEAL SCRATCHES TO THESE SURFACES COULD RESULT IN POOR PUMP PERFORMANCE Remove the radial shaft seal 45 from the rear end plate 60 as follows see Figure 5 12 a Place a thin wooden block on or beside the end plate b CAUTION DO NOT INSERT ANY TYPE OF PRYING DEVICE INTO OR THROUGH THE BRONZE BUSHING Insert the end of a screwdriver between the bronze bushing and the shaft seal 45 Rest the shaft of the screwdriver on the wooden block c Using the wooden block as a fulcrum and the screwdriver as a lever pry the shaft seal 45 out of the end plat
14. disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E 8p TABLE 6 1 TROUBLESHOOTING CHART Continued Recommended Trouble Area Probable Cause Corrective Action l Repair Steps 4 The evacuated vessel b Anti suck back Centrifugal switch 39 Clean assembly 39 41 42 B 1 thru C 6 F 9 or system is vented to valve assembly lever 41 spring 42 F 11 amp F 12 atmospheric pressure cont d assembly is excessively after pump shutdown dirty cont d Air inlet tube 69 is Clean air inlet tube 69 clogged B 1 thru C 7 C 14 F 7 F 9 F 11 8 F 12 Centrifugal switch 39 is Install new centrifugal switch 39 B 1 thru C 5 F 9 malfunctioning F 11 amp F 12 Lever 41 is bent Straighten or install new lever 41 B 1 thru C 6 F 9 F 11 amp F 12 a Intake or exhaust Line contains restriction Clear line B 1 connecting lines b Slap noise heard The silencing hole is the N oil slap when tiny hole in the side of the attaining ultimate gas ballast valve 17 See Symptom 11a 5 The pump is excessively noisy t Use a fine wire to clear any dirt from the silencing hole DO NOT ENLARGE THE HOLE p
15. eee eee ee en E eb eae eee b een K R KN 59 60 Gas Ballast Valve Assembly Includes Oil Filter nen ene een tenes 60 61 COUplIAG ASSEMDIY sirane 5 0 KAR ig A Eee SOS awl ad E Ka Md LAE Aa aS a 61 62 Module Centrifugal Switch and Retainer Ring 0 ccc ccc cc ce ete teeter ee net ee te eneeenes 62 Lover Assembly ouch Ta daha Ry Aaa A A Sealer E REAT ae AUNTIE SEE Ta hace he ee ene bd 62 Second Stage Assembly Includes Center Bearing and Exhaust Valve Plate and Stop 62 63 64 High Vacuum Stage Assembly e ce ce eee nen n ee een eee beeen en ee ene nees 64 65 66 Module Studs and Pins lt a ar H ccc cee ee tee cee tenn e cnet eee nese eens teteuneteeenenua 66 Anti Suck Back Assembly A NN 67 Motors Bi A A AA A A AA 68 69 70 Oil Sight Gauge Assembly es es orio ee KS Rar een nee een a tenn een eee 67 TRIVAC A Manual Edition L 55 7 UOMIPZ ENUEN Va OVAL Figure 7 1 Disassembled Pump D2A Pump Model Shown NOTE The numbers on this figure correspond to the Position No listed for each part in Table 7 2 beginning on page 58 TABLE 7 1 SPARE MODULL_ GAS The repair kit is made up of all parts listed with a or beside its catalog number in Table 7 2 For corrosive application series pumps the catalog No of the kit is the same except the K is replaced b
16. exhaust pressure prevents the pump fluid from draining completely 3 SEE THE SECTION 4 3 2 WARNING Using an 8 mm allen wrench unscrew and remove the plug screw 8 from one of the oil drain ports and allow the fluid to drain from the pump See Figure 1 1 4 When the flow of fluid slows bian switch the pump ON and OFF to drain the remaining fluid 5 Using an 8 mm allen wrench reinstall the plug screw 8 with flat gasket 9 into the oil drain port 12 TRIVAC A Manual Edition L 4 3 4 4 3 5 4 3 6 6 If the used pump fluid is very dirty flush out the pump as follows a If not already done turn off the pump and refer to Steps 1 through 5 to drain the used pump fluid b CAUTION WHEN FLUSHING OUT THE PUMP FILL IT TO CAPACITY WITH PUMP FLUID SEE TABLE 4 1 FOR THE FLUID CAPACITY OF YOUR PUMP MODEL Disconnect your vacuum line from the intake tube 1 turn the pump on and slowly pour clean pump fluid into the intake tube 1 while the pump is running Allow the pump to run for at feast 10 minutes then turn it off Repeat Steps 1 3 4 and 5 to drain the fluid from the pump If the pump fluid used for flushing is dirty repeat Steps 6b through 6e Reconnect the vacuum line to the intake tube 1 7 SEE THE SECTION 4 3 2 WARNING Unscrew and remove the plug screw 8 from one of the oil fill ports See Figure 1 1 S 8 NOTE The fluid capacity of each dual stage TRIVAC pump model is listed in Table 4 1 Th
17. hand tight onto the threaded studs 2 NOTE If the two remaining cylindrical pins 64 have a beveled end the beveled end should face away from the center of the module REQUIRED ACTION Align the two alignment holes in the front end plate 44 with the two alignment holes in the second stage cylinder 46 Using a rubber hammer drive the remaining two cylindrical pins 64 into the alignment holes until the pins 64 extend about 3 16 inch out of the outside surface of the front end plate 44 see Figure 5 22 k CAUTION NICKS OR TEARS IN THE RADIAL SHAFT SEAL COULD RESULT IN A LUB RICATING FLUID LEAK AND POOR PUMP PERFORMANCE NOTE The side of the seal that has a small circular spring around the ID faces the bronze bushing in the front end plate FRONTEND PLATE Lee TRS B Figure 5 21 Driving the Short Cylindrical Pins that Align the Rear End Plate and the HV Cylinder D2A Pump Model Shown TRIVAC A Manual Edition L 39 5 F FRONT END PLATE 44 RADIAL SHAFT SEA 45 SHAFT SLEE i raas Figure 5 22 Using a Shaft Sleeve to Install the Radial Shaft Seal into the Front End Plate D2A Pump Model Shown Step F 6 k Cont d REQUIRED ACTION Install the radial shaft seal 45 into the front end plate 44 as follows 1 Insert the seal using one of the following methods Method a Insert a shaft sleeve over the shaft see Figure 5 22 slide the seal 45 o
18. pressure and sometimes pump seizure Change the pump fluid frequently to ensure good performance and to extend the life of your pump TRIVAC A Manual Edition L eo eb aap 2 5 ANTI SUCK BACK MECHANISM When the pump is intentionally turned off or if there is a power failure the anti suck back mechanism seals the intake tube 1 and vents the pumping chamber The pump starts easier when the pumping chamber is vented The sealing of the intake tube 1 prevents pump fluid from surging back into the vacuum line and maintains the vacuum in the vessel or system The primary components of the anti suck back mechanism are the centrifugal switch 39 the lever 41 with spring 42 and seal 43 the air inlet tube 69 and the piston 68 with valve disk 67 see Figure 2 1 The centrifugal switch 39 is attached to the shaft When the pump is turned off the shaft rotation slows causing the centrifugal switch 39 to push against the lever 41 As a result the lever 41 opens the air inlet tube 69 see Figure 2 1 Air at atmospheric pressure rushes through the open tube 69 and into the high vacuum stage pump cylinder 55 thus venting the pump This air also forces the brass piston 68 and attached valve disk 67 to seal the pump intake tube 1 When the pump is started again the shaft rotation causes the centrifugal switch 39 to pull away from the lever 41 A spring 42 pushes the lever in the opposite direction c
19. the oil casing 12 a Intake tube 1 or gas ballast valve 17 Install new flat gasket 4 B 1 B 2 amp B 4 or B 5 Oil casing 12 is scratched below tube 1 or valve 17 Install new oil casing 12 B 1 thru B 7 11 The pump will not start a Coupling 37 and or elastic element 36 Coupling and or element is worn or improperly installed Properly instal new coupling and or elastic element If needed replace shaft end plates 44 60 If needed B 1 and or center bearing 52 See Symptoms 1 and 2 thru F 17 Clean hole If necessary replace shaft B 1 thru B 8 and or end plate 60 if needed B 9 thru F 17 B 1 thru B 8 if needed B 9 thru C 7 C 9 C 13 F 9 F 10 F 11 amp F 12 or B 9 thru F 17 Shaft is seized in bushing Lubricating fluid is contaminated Hole in rear end plate 60 bronze bushing is clogged Hole running from bottom edge of front end plate 44 to bronze bushing is clogged Clean hole If necessary replace shaft and or end plate 44 This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E D 13 D 14 and F 12 except set pump on its oil ca
20. the hole in the base of the intake portion of the high vacuum pump cylinder 55 see Figure 5 4 F 8 CAUTION USE CARE WHEN HANDLING THE MODULE TO AVOID BENDING THE LEVER 41 OR CENTRIFUGAL SWITCH 39 This CAUTION also applies to Steps F 9 through F 12 Repeat Steps C 9 C 6 C 5 C 4 and C 3 except assemble rather than disassemble 40 TRIVAC A Manual Edition L F 9 Install the coupling 37 onto the module shaft as follows see Figures 5 3 and 5 4 a Align the slot in the coupling with the key 38 on the shaft b Slide the coupling onto the shaft until it rests against the retainer ring 40 c Screw the coupling setscrew clockwise until it is tight F 10 Grab the coupling 37 and turn the module shaft see Figure 5 3 If the end plates 44 60 pump cylinders 46 55 and center bearing 52 are aligned properly the shaft will turn smoothly If there is any binding adjust the alignment as follows a Loosen the hexagon nuts 63 on the threaded studs 62 see Figure 5 6 NOTE The D16A and D8A pump models have four rather than three nuts and studs b CAUTION BEFORE STRIKING THE REAR END PLATE 60 ENSURE THAT THE DISK 61 see Figure 5 2 IS NOT ASSEMBLED TO THE MODULE Strike the face of the rear end plate 60 a couple of times while cross tightening the hexagonal nuts 63 see Figure 5 6 Tighten these nuts until all are snug c Grab the coupling 37 and turn the module shaft to see if the s
21. the other end faces up then fit an O ring 47 into the O ring groove in the second stage pump cylinder 46 i CAUTION DO NOT CHIP SCRATCH OR BREAK THE EDGES OF THE VANES ot NOTE If you are reusing the old vanes 49 make sure that each used vane is replaced in its same rotor slot Also make sure that the orientation of each vane is the same as it was before disassem bly so that each used vane is not turned end for end in its slot NOTE Be sure that the slotted edge of the vanes 49 faces the center of the rotor 48 when inserting the vanes into the rotor a 38 TRIVAC A Manual Edi Cont d REQUIRED ACTION Use long nose pliers to insert the three vanes 49 into the slots in the second stage rotor 48 see Figure 5 8 j Attach the front end plate 44 to the partially assembled module as follows 1 NOTE The side of the front end plate 44 that has the threaded studs 62 extending out of it faces the second stage cylinder 46 see Figure 5 21 The edge of the front end plate that has a small hole is the bottom edge REQUIRED ACTION While keeping the partially assembled module vertical align the front end plate bushing hole with the shaft and align the threaded studs 62 with their mating holes in the rear end plate 60 Slide the front end plate 44 down over the shaft until the plate 44 fits tight against the second stage cylinder 46 Install the washers and nuts
22. the two upper alignment holes in the HV cylinder 55 until the flat end of each pin extends just out of each upper HV cylinder alignment hole see Figure 5 19 4 Ensure that the center bearing plate 52 and the HV stage cylinder 55 are tight against each other and that they remain tight throughout the module assembly sequence c Place the second stage pump cylinder 46 so that it is lying flat with the top edge the flat portion that has the screw holes exhaust holes and gas ballast hole on the right facing away from you Fit an O ring 47 into the O ring groove on the cylinder 46 surface that is facing up For D30A D60A and D90A pump models the second stage cylinder 46 should be lying flat on an open vice or other open support so that the shaft can be inserted through it in Step d 3 Attach the assembly that you put together in Step b 3 to the second stage pump cylinder as follows see Figure 5 20 1 Take the assembly from Step b 3 and insert its second stage end the end that has the longer section of the shaft down into the second stage pump cylinder 46 2 NOTE When aligned correctly the flat portions of the top of the two pump cylinders 46 55 are in line with each other REQUIRED ACTION Align the beveled end of the two long cylindrical pins 65 the pins which extend out of the alignment holes in the center bearing plate 52 with the two upper alignment holes in the second stage cylinder 46
23. the valve 17 is closed see Figure 1 1 To open the valve turn the cap 18 until a cap hole is aligned with the valve 17 hole to close the valve 17 turn the cap 18 so that the valve 17 hole is covered by the cap 18 When the valve 17 is open air at atmospheric pressure rushes in the cap end hole through the gas ballast valve stem and into the second stage pump cylinder 46 see Figure 2 3 TRIVAC A Manual Edition L 5 2 3 2 LATASA NOTE This photograph is for illustration purposes only When assembled the cap end of the gas ballast valve 17 is attached outside the top of the oil casing 12 see Figure 1 1 and an oil filter 35 and other parts fit around the valve 17 stem see Figure 5 10B Figure 2 3 Gas Ballast Valve and Second Stage Pump Cylinder With Front End Plate Removed Purpose and Function of the Gas Ballast Valve All systems contain moisture Some processes have large quantities of condensable vapors in the process gas When these vapors condense in the pump they degrade the lubricating and sealing qualities of the pump fluid see Section 2 4 resulting in excessive pump wear higher base pressure and sometimes pump seizure The gas ballast valve allows removal of condensable vapors and condensate such as water alcohol gasoline benzene carbon tetrachloride etc from the pump It also enables high levels of water vapors to be pumped without condensation The wa
24. the vessel to be evacuated For high or ultrahigh vacuum 103 to 1011 Torr the rotary vane pump is Used as a backing or roughing pump and is connected in series and or parallel with other types of pumps which are designed to obtain a high vacuum 2 1 DIRECT DRIVE MECHANISM When the motor is switched on the motor shaft turns the pump shaft The motor shaft and pump shaft are con nected directly through a coupling 37 and an elastic element 36 see Figure 5 23 The elastic element 36 absorbs shock and vibration and results in quiet operation of the pump 2 2 PUMPING MECHANISM 2 2 1 High Vacuum Stage Pump Cylinder The pump intake tube 1 fits into the top of the high vacuum stage pump cylinder 55 The shaft and attached rotor 54 are mounted eccentrically in the high vacuum stage housing 52 60 55 Three rectangular vanes 53 fit into slots in the rotor 54 see Figures 2 1 and 2 2 As the shaft and rotor 54 rotate centrifugal force pushes the vanes 53 out against the pump cylinder 55 inner surface see Figure 2 2 The three vanes divide the cylinder into chambers 120 apart 4 TRIVAC A Manual Edition L 2 2 2 ITA314 OES 2 ATA6 20 Figure 2 2 High Vacuum Stage Pump Cylinder With Rear End Plate Removed Figure 2 1 D4A Module One pumping cycle proceeds as follows see Figure 2 2 Gas is drawn through the pump intake tube 1 into an increasingly large vacuum tight chamber Chamber A Th
25. up for pumps with automat ically resetting thermal overloads Most of our single phase motors have automatically resetting thermal overloads Don t run the pump without an exhaust line and an adequate exhaust system if hazardous gases or vapors are expelled from the pump Don t exceed a maximum back pressure of 7 psig Exces sive pressure in the pump could damage the seals blow out the sight glass or rupture the pump housing In addition ex cessive backpressure can result in hazardous process gas or contaminated oil leaking out of the pump Dont install an exhaust line with a smaller ID than the exhaust port or allow restrictions or deposit buildup in the exhaust line If you are purging the oil casing with inert gas limit the inert gas flow to avoid exceeding the 7 psig limit Hazardous process gases can concentrate in the vacuum pump its oil and its filters If the pump has been used on toxic explosive pyrophoric corrosive volatile or other haz ardous substances take the proper safety precautions before opening the pump or filters Proper precautions could include inert gas purging before and after you drain the oil to sweep hazardous gas from the pump or filters gloves or protective clothing to avoid skin contact with toxic or highly corrosive substances specially ventilated work areas fume hoods safety masks breathing apparatus etc Before sending any equipment to our factory or to one of our service centers
26. vacuum stage pump cylinder b F front bushing C center bushing R rear bushing c L length T thickness max maximum min minimum d See Figure 5 7 High Vacuum Stage Vane Dimensions mm Step F 1 a Cont d a 1 If the motor is single phase and it was supplied through Leybold it has been factory wired for correct rotation therefore it isn t necessary to check motor rotation unless you altered the wiring or replaced the motor If the wiring was altered or the motor replaced refer to Step a 2 below a 2 If the motor Is 3 phase or if It wasn t supplied through Leybold or if its wiring was altered check the direction of rotation as follows a Connect the power supply momentarily to jog the motor and then immediately switch it off 30 TRIVAC A Manual Edition L Step a 2 Cont d b Check if the fan on the rear end of the motor is rotating in the correct direc tion Looking from the fan end of the motor the fan and motor shaft should be rotating clockwise see Figure 5 15 c Turn off the motor and disconnect the power supply d If the rotation direction is incorrect reverse it by interchanging the electrical line connection at the motor end then repeat Steps a 2 a through a 2 c above For 3 phase motors correct the direction of rotation by interchanging any two of the three phases b Steps b 1 and b 2 below apply only to D30A D60A and
27. 0A pump models only loosen the setscrew s to remove the centrifugal switch 39 from the shaft rather than from the coupling 37 Using a phillips screwdriver unscrew and remove the two screws that attach the lever to the front end plate When removing the lever 41 hold its opposite end down to avoid losing the spring 42 from the penetration in the front end plate 44 Remove the lever 41 and spring 42 from the plate 44 see Figure 5 4 Using a small screwdriver remove the retainer disk 71 from the slot in the air inlet 69 tube see Figure 5 4 CAUTION FAILURE TO HOLD THE DRIFT PIN or bolt STRAIGHT WHEN DRIVING THE CYLINDRI CAL PINS COULD RESULT IN DAMAGE TO THE MODULE HOUSING Using a hammer and a drift pin or long bolt remove the cylindrical pins as follows see Figure 5 5 a Drive one of the two short cylindrical pins 64 that aligns the rear end plate 60 and the high vacuum stage pump cylinder 55 toward the center bearing 52 until the pin 64 falls out NOTE On some pump models this pin 64 does not have room to fall out In this case con tinue driving it until all three pins fall out of the alignment hole in the front end plate 44 b While keeping the drift pin or bolt inserted through the rear end plate alignment hole drive the long cylindrical pin 65 toward the front end plate 44 Continue driving the cylindrical pins TRIVAC A Manual Edition L C 9 P C 8b CONTINUED un
28. 1 K 390 26 121 h P This kit must be installed before pumping toxic pyrophoric or hazardous gases See the supplemental instructions that come with the kits and with the TRIVAC AC pumps for the part numbers of each item in the kit 89 7 UOMIP3 JENUEW Vu OVAIHL TABLE 7 2 COMPLETE LIST OF PARTS Number Required per Unit Pump Model Dimensions mm KF16 Al aly KF25x71 Al aly KF40x107 Al aly Dirt trap with KF16 Steel centering ring Dirt trap amp centering ring 411 70 206 KF25 Steel Dirt trap with 411 70 121 KF40 Steel centering ring O ring 239 70 176 D18x5 Viton Poringa ro BO 7 De Vi a N N _ One of the O rings goes on the 3 intake centering ring the other 3 2 239 70 516 D42x5 goes on the exhaust centering ring 4 2 NE aea 238 20 147 V D38x44 It 200 One of the flat gaskets fits under 4 2 2 Flatgasket 23820156 D55x63 It 200 the intake tube the other fits 4 J 2 2 f Flatgasket 238 2015844 D75x84 It 200 under the gas ballast valve Em K C EE Exhaustport CE KF25x42 Aaly ESEN ae EXHAUST PORT ASSEMBLY Exhaust port 433 60 113 KF16 Al aly LT Included in universal gasket set and module repair kit KF Leybold quick assembly clamp ring diameter see page 57 of parts list D diameter Al aly aluminum alloy included in the standard module see Page 57 Vito
29. 11 amp F 12 Lever 41 is bent Straighten or install new lever 41 B 1 thru C 6 F 9 F 11 amp F 12 front end plate 44 d Friction occurs Module is not aligned lA Spring 42 is not sitting properly in its hole in the Reinstall the spring 42 in its hole B 1 thru C 6 F 9 F 11 8 F 12 properly Room is too cold The minimum ambient temp erature for easy startup is 50 F Taji Align module B 1 thru B 10 F 10 amp F 12 Start pump at atmospheric pressure before connecting it to your vacuum system Heat oil casing 12 Drain pump fluid heat it and refill pump with warm fluid This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E cg 9 ENUEN Y OVAIHL 12 The pump will not _ achieve its rated pumping speed See Section 1 of the Leybold Heraeus Catalog for pumping speed curves TABLE 6 1 TROUBLESHOOTING CHART Continued a Lubricating fluid b Vacuum line valve c Dirt trap 2 on intake tube 1 d Exhaust or vacuum line Exhaust or vacuum line con
30. 2 Flat gasket 239 25 227 D18x10x1 Flat gasket Flat gasket Retainer ring 231 04 104 Spring gas ballast 221 62 140 239 25 226 239 25 225 D30x16x1 Viton Coupling complete 570 42 130 Retainer ring 23103106 191 gt 40164 117 D14 8x0 2 341 01 109 D48x5 Steel D58x90 COUPLING ASSEMBLY S l Elastic element 701 00 147 41x15 701 00 196 D80x21 Vulkollan 570 42 134 Coupling complete D58x61 D30x18x1 DiIBS1 Steel D15x11 5 Stl fiber Stl fiber t Coupling complete 57042 132 570 42 133 Coupling complete Included in module see page 57 of parts list Included in module repair kit see page 57 of parts list Included in universal gasket set and module repair kit see page 57 of parts list Sti steel Vulkollan vulcanized rubber Buna N synthetic rubber Viton heat resistant synthetic rubber D diameter See Fig 5 10B See Fig 5 10B ee Fig 5 10B ot shown in Figs ot shown in Figs See Fig 5 10B See position 28 Includes pump side and motor side coupling and Pos No 36 See Fig 5 3 cg 7 UONIPZ JENUEN Ya OVAIYL Number Required per Unit Pump Model Part Name Catalog No
31. 5 3 and 5 4 b Check if the anti suck back mechanism will close the air inlet tube 69 as follows 1 Push the split halves of the centrifugal switch 39 until they are tight against the cou pling 37 See Figure 5 3 2 While keeping the split halves of the switch 39 against the coupling 37 check if the lever seal 43 is sealing the opening in the air inlet tube 69 see Figure 5 4 3 If the lever seal 43 is not properly sealing the tube 69 see Symptom 3h of the troubleshooting chart Table 6 1 for recommended corrective action c Make sure that the air inlet tube 69 is pushed back into the module until it is seated firmly When the air inlet tube 69 is installed properly the retainer disk 71 fits against the front end plate 44 see Figure 5 4 F 12 It is easiest to guide the module into alignment with the coupling housing 11 when the coupling housing motor assembly is in the vertical position see Figure 5 23 Proceed as follows a Set the coupling housing motor assembly back onto its motor end and secure the assembly in this vertical position b Place the main housing seal 13 onto the coupling housing flange see Figure 5 2 c Keeping the module vertical guide the module end that has the coupling 37 down into the coupling housing 11 The prongs on the module coupling 37 fit into the mating slots in the elastic element 36 the elastic element is located on the motor shaft in the coupling ho
32. 8 11 142 SS Stainless Steel 242x270x1 Al aly Al aly It KF Leybold quick assembly clamp ring diameter D Diameter Stl steel Viton heat resistant synthetic rubber C Al aly cast aluminum alloy Al aly aluminum aHoy Westit asbestos neoprene with silicone bead It asbestos gasket fiber Buna N synthetic rubber Al Aluminum 09 VONPA TENUEN Va OVAIHL Number Required per Unit D2A Daa D8A D16A D30A D90 A Part Name Catalog No mm Material Remarks PUMP HOUSING ASSY Contd 14 1 Handle 283 02 106 100x86x28 Black plastic ee el H 1 Handie Ss 283 02 107 106x120x32 Black plastic Pa af __ oittevet giass_ 82040124 M50x1 5 Glass Viton_ Includes flat gasket pt Ct ft 1 1 Oitevergiass 52040125 meox2 Glass Viton_ Item 15A Pa fa Flat gasket TE 48x56x23 viton 7 Cp AA rat gasket CG vron Pa a a 4 Aubberto 279 0008 oze owman CA a ae Support 72000068 635x38 st Not shown in Figs 4 4 Vibrationpad 99274005 Buwas _ _________ AO SST ESAS E NS A AAA SEDA MESES FE 7 HE E AL ASSEMBLY This assembly includes 1 1 Gas ballast valve assy 720 00 077 Position Numbers 17 thru Le 1 1 Gasballastvalveassy 72000078 27 and 30 31 amp 32 1 1 Gas ballast valve assy 72000080 ____ pa
33. B 9 F 11 amp F 12 Loosen the coupling setscrew pull the coupling 37 away from the centrifugal switch 39 or retainer ring 40 until the switch 39 has enough space to function properly and then tighten the coupling setscrew This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E ov 7UOMp3 TENUEW Va OVAL TABLE 6 1 TROUBLESHOOTING CHART Continued Trouble Area Probable Cause S baa Repair Steps 3 The pump will not h Anti suck back Centrifugal switch 39 is achieve its ultimate assembly cont d malfunctioning pressure cont d Centrifugal switch 39 lever 41 spring 42 assembly is excessively dirty Install new centrifugal switch 39 Clean assembly 39 41 42 B 1 thru C 5 F 9 F 11 amp F 12 B 1 thru C 6 F 9 F 11 2 F 12 Lever sea 43 is worn Level 41 is bent Reverse seal 43 or install new seal Straighten lever 41 or install new lever B 1 thru B 7 amp D 7 B 1 thru C 6 F 9 F 11 amp F 12 The spring 42 is not sitting properly in its hole in the front end plate 44 The O ring 70 on HV pump cylinder end of the air inlet tube 69 is worn i Radial shaft seal Worn seal 45 is allo
34. Cont d Retaining bracket 491 60 109 40x8x4 Steel Rear end piate 96155190 D15x18 Castiron Rear end plate 351 55 132 D40x28 MODULE STUDS 201 52 104 D6x107 Steel AND PINS Threaded stud threaded stud 20152 109 Dex133 Steel See Fig 5 13 See Fig 5 13 See Fig 5 13 SN separ are sy Hexagon nut D6 Steel ee a EN 3 Hexagon nut Dex a a a a a ylindricat pin 03 505 oezo St a a E a E 64 _ 2 2 Gylinarical pin 2403590 Dexo Steel For front end plate r ERC EIA Cylindrical pin 24103590 D amp x40_ Stel 7 SEC a ea aee j o A oo Included in module see page 57 of parts list D Diameter 9 7 UONIPZ enue Vi OVAIHL D8 gt Number Required per Unit Pump Model NININ NTR TNS miojo i N pe mom eere ete at D90A mm oO E GA ASSEMBLY R eT ann E T E e O T E T E II Spring ever fT See position 42 Ci teo ses position 48 7 AA norte 900 95 960 Soas ass Wo shown in Figures Valvedisk 4noso136 D20 St Viton ____ S en ce ee E CTs DE AA ot isk E 50197 bas St Viton PTT Piston 32106130 forex Bras f _______ AA non ETT ora es E le e ET Piston azmos11 owwzzm Bras gt o AA ar inter sar vera 277 ee A A intra aa aia oaa sea 2 Oring O os vwo Retaineraik 23105 107 os sea SY Retainer
35. D90A pump models with three phase motors 1 If the pump has a new motor supplied by Leybold a rotational lock bearing has been correctly installed at the factory to prevent the motor from rotating in the wrong direction In this case check the wiring of the motor as follows CAUTION FAILURE TO IMMEDIATELY TURN OFF THE MOTOR IF THE MO TOR FAN DOES NOT ROTATE COULD RESULT IN DAMAGE TO THE MOTOR AND THE PUMP f a Connect the power supply and turn the motor on b Check if the fan on the rear end of the motor see Figure 5 15 rotates c Turn off the motor and disconnect the power supply d If the fan did not rotate correct the motor wiring by interchanging any two of the three phases then repeat Steps b 1 a through b 1 c 2 If the motor was not supplied through Leybold or the pump has an old Leybold supplied motor grab the motor shaft or motor fan and attempt to turn it clock wise and then counterclockwise then proceed as follows CORRECTLY INSTALLED LOCK BEARING Looking from the fan end of the motor if the fan or shaft will turn clockwise and will not turn counterclockwise the pump has a correctly installed rotational lock bearing In this case do Steps b 1 a through b 1 d to check the wiring LOCK BEARING INSTALLED BACKWARDS Looking from the fan end of the motor if the fan or shaft will turn counterclockwise and will not turn clockwise the rotational lock bearing is installed backwards In this
36. F 17 5 A REQUIRED MATERIALS AND TOOLS 5 A 1 Required Materials CAUTION DO NOT DISASSEMBLE THE MODULE UNLESS YOU HAVE THE CORRECT MODULE REPAIR KIT OR GASKET SET The repair kit contains a gasket set a valve plate 50 and vanes 49 53 The kit for the D2A D4A DBA and D16A pump models also contains an oil filter 35 The catalog number for a gasket set or repair kit for each dual stage pump mode is listed in the parts list See Table 7 1 Correct gasket set or module repair kit Container for catching pump fluid A MMB oe Standard cleaning solvent such as acetone Do not use a hydrocarbon solvent if your pump will be filled with any PFPE pump fluidT Grade 400 sandpaper Correct pump fluidt as follows CAUTION UNDER CERTAIN CIRCUMSTANCES THE PUMP FLUID RECOMMENDED BY THE FACTORY MAY BE DIFFERENT THAN THAT LISTED BELOW IN THESE INSTANCES USE THE FACTORY RECOMMENDED ue Pump Application Pump Fluidt Standard Series HE 175 Extreme Corrosive Service HE 1600 PFPE Corrosive Application Series HE 200 or HE 400 High Temperature Applications HE 600 Replacement parts as needed see Section 7 for parts list 5 A 2 Required Tools NOTE All required tools and all nuts bolts screws and threaded holes are metric except for the wrenches required for the U S standard bolts or screws securing the motor to the coupling housing adapter flange 72 and the screws and bolts used in the motor The module is the unit made up prim
37. F MOTOR D2A COUPLING 37 aa WITH FAN a D30A D60A COUPLING AND COUPLING RING Figure 5 15 Coupling Housing and Motor D2A Pump Model Shown 26 TRIVAC A Manual Edition L STEP D 15 CONTINUED S if necessary for cleaning remove and disassemble the oil level glass assembly 15 as follows a Use one of the following three methods to remove the oil level glass assembly from the coupling housing 11 Method 1 Unscrew the assembly using an adjustable spanner which has the correct pin loca tions to match the two holes in the assembly or Method 2 Place the nose ends of a large pair of snap ring pliers into the two holes in the assem bly 15 insert a screwdriver or small bar between the nose ends of the snap ring pliers use the screwdriver or bar to force the pliers and the assembly to turn counterclockwise unscrew the assembly from the coupling housing see Figure 5 16 or Method 3 Place a sturdy pin drift pin or drill bit into each of the two holes in the assembly 15 cross the pins to form an X insert a screwdriver or small bar through the oil level glass assembly side of the X use the screwdriver or bar to force the pins and the assembly to turn counterclockwise unscrew the assembly 15 from the coupling housing 11 b Disassemble the oil level glass assembly 15 as follows 1 Using long nose pliers unscrew the target piece from the assembly 2 Push the glass and
38. ILURE TO REMOVE THE SHIPPING WEDGE OR EXHAUST PORT COVER BEFORE STARTING THE PUMP COULD RESULT IN DAMAGE TO THE PUMP Remove and discard the protective cover from the pump intake tube 1 and exhaust port 6 and the metal shipping disc from the exhaust port see Figure 7 2 the foldout Also remove and dis card the red plastic shipping wedge from underneath the coupling housing 11 A Day Glo orange tag attached to the pump contains instructions for removing the shipping wedge CAUTION ENSURE THAT THE VACUUM LINE IS CONNECTED TO THE INTAKE TUBE 1 AND NOT TO THE EXHAUST PORT 6 see Figure 1 1 CONNECTING THE VACUUM LINE TO THE EXHAUST PORT 6 COULD RESULT IN DAMAGE TO THE PUMP OR TO YOUR SYSTEM NOTE ideally the inside diameter 1D of the vacuum line should be the same size or larger than the 1D of the intake tube 1 If the vacuum line is too narrow it will reduce the pumping speed w REQUIRED ACTION Using the KF clamp ring and the centering ring with dirt trap 2 and O ring 3 connect the pump intake tube 1 to the vacuum line KF is a registered trademark of Leybold _ TRIVAC A Manual Edition 9 i Don t install an exhaust line with a smaller ID than the exhaust port or have restrictions valves in the exhaust line during operation Such restrictions reduce the pumping speed sould damage the oil seals or cause a dangerous overpressure in the pump Using the KF clamp ring and the cent
39. ING THE PUMP WARNING DO NOT BEGIN DISASSEMBLING THE PUMP UNTIL THE MOTOR SWITCH IS TURNED TO THE OFF POSITION AND THE POWER IS DISCONNECTED NOTE While disassembling the pump note the location of the O rings gaskets and seals so that the new parts can be placed in the correct locations during reassembly Remove the KF clamp ring from the intake tube 1 and exhaust port 6 to disconnect the pump from your system Remove the dirt trap with O ring 2 and 3 from the intake tube 1 and the centering ring 7 from the exhaust port 6 c Using an 8 mm allen wrench remove the oil fill and oil drain plug screws 8 and flat gaskets 9 and allow the lubricating fluid to drain from the pump into a proper container see Figure 5 1 lt Remove the intake tube 1 from the oil casing 12 as follows l a Unscrew and remove the screws and washers that attach the intake tube to the oil casing see Figure 5 1 b CAUTION WHEN USING A SCREWDRIVER USE CARE TO AVOID NICKING OR SCRAP ING THE ALUMINUM CASING A NICK OR SCRATCH MAY CAUSE AN EXHAUST GAS LEAK OR A LUBRICATING FLUID LEAK Pull the intake tube 1 up from the oil casing 12 If additional force is required move the intake tube 1 from side to side or use a screwdriver to pry the tube from the casing c Using care to avoid nicking or scraping the casing or flange clean the used flat gasket 4 from the oil casing and or intake tube flange Repeat Steps B 4a through B 4c e
40. LEYBOLD VACUUM PRODUCTS INC LEYBOLD Measuring and Analytical Technology Vacuum Process Engineering Vacuum Technology Part Number 722 78 001 M Edition L y lt a A nload d our nn ida TRIVAC A PLEASE NOTE We do sell the related Dual Stage products within this literature but we are not connected in any way with the manufacture of your product We provide this literature for the products we sell and service They y O a ane u m are intended to provide users with the manufactures instructions to operate 7 the equipment in a safe manner Manufactured in the United States LIMITED WARRANTY Seller warrants to the original purchaser that the equipment to be delivered pursuant to this Agreement will be as described herein and will be free from defects in material or workmanship Minor deviations which do not affect the performance of the equipment shall not be deemed to constitute either a failure to conform to the specifications or a defect in material or workmanship This warranty shall extend for a period of twelve 12 months from the initial date of shipment Should any failure of conformity to this warranty appear within twelve 12 months from the initial date of shipment Seller shall upon immediate notification of such alleged failure and substantiation that the equipment has been operated and maintained in accordance with Seller s recommendations and standard industry practices correct such defec
41. Loza vaa oaa orea oaoa 887 1 COUPLING ASSEMBLY Cont d 38 Key coupling 221 16 065 38 AAC ATE se De mea CENTRIFUGAL SWITCH AND RETAINER RING Centrifugal switch 500 36 128 D70x27 Centrifugal switch 500 36 147 231 03 101 i 231 03 104 The 2 additional rings fit onto the shaft on both sides of the second stage rotor LEVER ASSEMBLY Lever 281 53 130 73x36 Steel D9x11 SECOND STAGE ASSEMBLY Front end plate 301 51 138 D12x18 Cl Brz Front end plate 301 51 140 One of the seals fits 239 53 142 D15x32x7 into the front end Radial shaft seal 239 53 110 L D22x40x7 plate the other fits i into the rear end plate Included in module see Page 57 of parts list Stl steel D diameter Included in universal gasket set and module repair kit Cl cast iron Brs brass see page 57 of parts list Viton heat resistant synthetic rubber Brz bronze 7 uonp ENUEN Va OVAL Number Required per Unit Pump Model ee pza vaa osa prea pana 686A SECOND STAGE ASSEMBLY Cont d l Second stage 231 58 117 D54 8x35 pump cylinder i i cl Second stage 231 58 124 D79x45 Cl pump cylinder eae ed Second stage 231 58 122 D118 5x75 cl pump cylinder 239 70 409 gt Two of these O rings Viton Viton go on the second stage 239 70 156 D86x2 239
42. O rings gaskets seals and all pump parts are clean before reassembly F 1 CAUTION IF THE PUMP ROTATES IN THE WRONG DIRECTION FOR TOO LONG PUMP FLUID IS EJECTED OUT OF THE INTAKE TUBE 1 AND THE VALVE DISK 67 OR THE MOTOR MAY BE DAMAGED Ensure that the direction of rotation of the motor is correct as follows a Steps a 1 and a 2 are for the D30A pump models with single phase motors and for all D2A D4A D8A and D16A pump models See plate on motor for motor specifications TRIVAC A Manual Edition L 29 sugges TABLE 5 1 ROTOR BEARING SHAFT AND VANE CRITICAL DIMENSIONS de y Minimum Rotor sa 34 970 34 970 44 960 44 960 74 921 74 921 Length mm HV 34 970 69 970 44 960 89 960 74 921 149 890 Maxim m 12027 027 12 ao 22 22033 Bushing Babies 12 027 12 027 22 070 mm 12 027 12 027 22 033 Minimum Shaft Diameter at Points of Wear mm 11 992 11 992 14 992 21 991 21 991 Second Stage Leases 991 NR 991 44 Pee 44 991 74 990 74 ET Vane in 34 980 34980 44980 44 980 74 971 74971 Dimensions 4 47 4 47 a 47 mm min 4 445 4 445 Mil 4 445 4 440 4 440 34 991 69 990 44 991 89 988 74 990 149 986 34 980 69 977 44 980 89 973 74 971 149 961 4 47 aar aar gt 407 7 4 445 4445 4 445 4 440 4 Maximum Inside l Diameter of Pump i l Cylinders mm 54 830 54 830 78 630 78 630 118 535 118 535 a S second stage pump cylinder HV high
43. SOLINE NAPTHA FUEL OIL VARSOL AND STODDARD SOLVENTS CAUTION DO NOT IMMERSE THE NEW ROTATIONAL LOCK BEAR ING IN SOLVENT GREASE MUST REMAIN IN THE INSIDE OF THIS BEARING Wipe all grease from the bearing well in the fan end plate from the fan end of the shaft and from the ID and OD of the new rotational lock bearing Reinstall the rotor and shaft in the motor housing S NOTE When installed properly the fan end of the shaft the one with the bearing removed will face you CAUTION It is essential that the rotational lock bearing is placed on the shaft in a way which allows the Inner Bearing Sleeve to rotate clockwise Except for the D60A D90A s with Marathon motors the side of the bearing that has the bearing s name and number stamped in it should face toward the center of the motor Occasionally the name and number are stamped on the wrong side of this bearing To double check hold the OD of the rotational lock bearing so that the side with the stamped name and number faces the rotor While holding the OD tight rotate the ID If the ID rotates only in the clockwise direction the rotational lock bearing is positioned correctly 33 Step F 1 b 2 Cont d m CAUTION FAILURE TO EVENLY DRIVE THE ROTATIONAL LOCK F 2 F 3 34 BEARING DOWN THE SHAFT COULD RESULT IN GALLING OF THE BEARING ID REQUIRED ACTION Apply Loctite 609 to the area of the shaft where the bearing will fit and to the ID of the new rotat
44. age 32166125 54 321 66 123 D68x45 54 S 321 66 122 068x90 54 Rotor 32166119 D10095 Castiron O 54 Rotor HV stage 321 66 120 D101x150 Castin i s CsY T Pump cylinder 231 65 117 D54 8x35 Cast iron 1 Pump cylinder 231 65 116 D54 8x70 Cast iron HV stage l L Pump cylinder 231 65 121 D79x45 Cast iron HV stage x 1 Pump cylinder 231 65 122 Y D79x90 Cast iron Pump cylinder 231 65 118 D118 5x75 Cast iron S eee ea la Pump cylinder 231 65 107 D118 5x 150 Cast iron DE Re ee ee E DOES AN sf 1 1 Oilnmozle 39225107 05 Bras The oil nozzle is located 56 O en IEA o a o in the second stage pump 56 l Oil nozzle 39225124 15 Bras cylinder TON SE eed E EA Radial shaftseal OA See position C 5 _1 aa ad See Fig 5 9 57 TS Key rotor 221 16 156 5x5x28 Stl See Fig 5 9 57 2 Key rotor 221 16 188 6x6x50 Stl See Fig 5 9 58 i Valve plate 400 50 135 16x16x5 Sti Viton See Fig 5 13 58 2 Valve plate 400 50 138 25x25x5 Sti Viton Included in module see page 57 of parts list included in universal gasket set and module repair kit see page 57 of parts list Both rotors are the same part number on the D30A pump model D diameter Stl steel X Viton heat resistant synthetic rubber HV high vacuum 99 y S gt S 2 D m S S pl Number Required per Unit S Part N K D90A z HIGH VACUUM STAGE ASSEMBLY
45. and the gas ballast valve 17 is closed The minimum pump fluid level is reached when the fluid surface is visible at the lower rim of the oil level glass 15 or at the L mark on the oil sight gauge 72 See Figure 1 1 If the pump fluid level is low use Section 4 3 2 Steps 7 8 and 9 to add the appropriate amount of the correct fluid The maximum pump fluid level is reached when the fluid surface is at the top rim of the oil level glass 15 or at the H mark on the oil sight gauge 72 If the pump fluid level is too high use Section 4 3 2 Steps 1 3 and 5 to drain some fluid Recheck the oil level while the pump is running to ensure that the fluid level is correct TRIVAC A Manual Edition L 11 TABLE 4 1 TECHNICAL DATA L rump Model Fae ee Cit 6 8 Ultimate partial pressure tT Torr 3x 107 4 3x 1077 13x 1074 13x 1074 3x 107 4 3x 107 3x107 5 O 60A D90 Ultimate pressure with gas ballast Torr 3x 107 3 3x 107 3 3x107 3 3x107 3 5x 107 3 Water vapor tolerance Torr E ela eae a poh e Tat E S AE 13 7 16 8 16 8 OE C al Sound pressure level max at three feet with gas ballast closed dB A Sound pressure level ave at three feet with gas ballast open dB A Maximum ambient temperature 104 F 40 o t The ultimate pressure of pumps filled with perfluoropolyether fluid is 9 x 10 4 Torr except for 50 Hz D60A pump models The ultimate pressure o
46. anual Edition L 37 VANES 49 53 Figure 5 20 Pulling the Second Stage Pump Cylinder Tight Against the Center Bearing D2A Pump Model Shown TARI Step F 6 e Cont d REQUIRED ACTION Repeat Step C 11 except assemble rather than disassemble to insert the three vanes 53 into the slots in the high vacuum stage rotor 54 f While keeping the partially assembled module vertical fit an O ring 47 into the O ring groove on the HV cylinder 55 surface that is facing up see Figure 5 20 g Attach the rear end plate 60 to the partially assembled module as follows 1 NOTE Be sure to attach the rear end plate 60 to the HV stage end of the module The HV pump cylinder 55 is the one with the intake tube portion NOTE The side of the rear end plate 60 that has the bronze bushing faces out REQUIRED ACTION While keeping the partially assembled module vertical align the rear end plate bushing hole with the shaft Slide the rear end plate 60 down over the shaft until the machined surface of the rear end plate fits tight against the HV stage cylinder 55 2 Align the two alignment holes in the rear end plate 60 with the two alignment holes in the HV cylinder 55 then use a rubber hammer to drive two short cylindrical pins 64 until the pin ends are slightly recessed in their alignment holes in the rear end plate 60 see Figure 5 21 h Turn the partially assembled module over so that
47. arily of the shaft rotors vanes coupling centrifugal switch end plates pump cylinders and center bearing Figure 5 3 shows a module tThe terms lubricating fluid pump fluid fluid and lubricant when used in this manual refer to the proper vacuum pump fluid The pump s identification plate lists the type of vacuum pump fluid that we initially added to the pump when it was new 14 TRIVAC A Manual Edition L WARNING ALL TOOLS MUST BE DEGREASED BEFORE USE ON PUMPS FILLED WITH PERFLUORO POLYETHER FLUID Metric allen wrench set Medium screwdriver Phillips head screwdriver Small screwdriver Small diagonal cutting pliers Snap ring pliers Hammer Drift pin or long brass bolt Metric box or ratchet wrench set Rubber hammer or lead or brass faced hammer Long nose pliers Puller optional Thin wooden block to be used as fulcrum For D30A D60A and D90A pump models U S standard allen and socket wrench set For all other pump models U S standard box or open end wrench set Adjustable spanner or large pair of snap ring pliers or two drill bits drift pins or other sturdy pins Cleaning brush Vernier calipers or micrometers Paint brush Shaft sleeve or cellophane tape Seal driver optional REMOVING THE MODULE FROM THE PUMP WARNING IF THE PUMP HAS BEEN USED ON CORROSIVE OR VOLATILE CHEMICALS OBSERVE PROPER SAFETY PRECAUTIONS TO PROTECT PERSONNEL BEFORE OPEN
48. ation or buildup from the three vane slots in each rotor 48 54 See Figure 5 9 E 6 Visually inspect the air inlet tube 69 to ensure that it is clear of debris see Figure 5 11 28 TRIVAC A Manual Edition L E 7 Thoroughly clean the coupling housing 11 making certain that no dirt has accumulated in the crevices of the housing see Figure 5 15 E 8 Carefully inspect all parts for excessive wear Give particular attention to the following a The ends of each rotor 48 54 may be wearing against the inside surface of the front 44 and rear 60 end plates or against the center bearing 52 Inspect these surfaces for gouges and wear see Figure 5 8 If you observe scoring or wear proceed as follows 1 Replace the plate that is scored 2 Check the rotors for burrs If burrs are found sand or file them smooth 3 Using calipers or micrometers measure the length of each rotor Dimension A of Figure 5 9 If the length dimension of either rotor is less than the dimen sion listed for your pump model in Table 5 1 on the following page replace that rotor b The shaft rides in bronze bushings in the front 44 and rear 60 end plates and in the center bearing 52 plate see Figures 5 6 5 8 and 5 9 Inspect the inside surface of these three bronze bushings for gouging or wear If you observe deep gouging replace the gouged shaft or the plate containing the gouged bushing If you observe minor scratches or wea
49. ausing the seal 43 attached to the lever to close the air inlet tube 69 The suction of the pump draws the valve disk 67 and attached piston 68 away from the opening in the intake tube 1 allowing the pump to further evacuate the vessel or system On AC pump models the anti suckback mechanism is modified to avoid exposing the pumping module to atmospheric air and to avoid the possibility of hazardous process gas escaping from the pump during shutdown The centrifugal switch and lever assembly are removed and a solenoid valve with tubing is added so that the module is vented with gas from the oil casing during shutdown SECTION 3 PREPARING AND INSTALLING THE PUMP 3 1 RECEIVING NOTE The Leybold packing list is attached to the outside of one of the shipping containers 3 1 1 Reporting Shipping Damage Leybold makes every effort to ensure that your order is packed properly However rough or careless handling in transit occasionally results in shipping damage In such cases the carrier is responsible for the damages Unpack the pump and check for shipping damage as follows 1 Inspect the outside of the shipping container for shipping damage If you will be making a damage claim save the shipping container and packing materials 2 Unpack the pump 3 Carefully inspect the pump for damage 4 If you find any damage proceed as follows a Save the shipping container packing material and parts for inspection b Notify the ca
50. b DS0A DSOA amp DIVA TR Nm it fb F 15 Fill the pump with the proper pump fluid see Section 5 A 1 as follows see Figure 1 1 a Using an 8 mm allen wrench screw a plug screw 8 with flat gasket 9 into each oil drain port b Pour the required amount of pump fluid into the exhaust port 6 or into one of the oil fill gt The required amount of pump fluid for each pump model is listed in Table 4 1 c Using an 8 mm allen wrench screw a plug screw 8 with flat gasket 9 into each oil fill p F 16 NOTE The O ring on the centering rings must be clean to avoid leaks Use the KF clamp rings to connect the intake tube 1 and exhaust port 6 of the pump to your sys F 17 Change the pump fluid after a 100 hour break in period of pump operation see Section 4 3 2 TRIVAC A SECTION 6 TROUBLESHOOTING ING BEFORE REPAIRING THE PUMP BE SURE TO READ ALL WARNINGS AND CAUTIONS IN SECTION D AT THE BEGINNING OF SECTION 5 B The design of the TRIVAC rotary vane pumps allows for easy repair Most corrective maintenance problems can be d quickly by using Table 6 1 or repairs beyond the scope of this manual contact your nearest Leybold Sales Office for the location of tarest service center de 6 1 contains the instructions for troubleshooting your pump if a malfunction occurs To use the table first the symptom then locate the trouble area and perform the recommended corrective action If disass
51. case do Steps b 2 a through b 2 s which follow to disassemble the motor and install the lock bearing correctly NO LOCK BEARING OR MALFUNCTIONING LOCK BEARING If the fan or shaft will rotate in both directions we recommend installing a rotational lock bearing See Steps b 2 a through b 2 s If you have insufficient time to order and install a rotational lock bearing now do Steps a 2 a through a 2 d to ensure correct rotation of the motor then order and install a rotational lock bearing as soon as possible Proceed as follows to install a rotational lock bearing see Figure 5 17 Note that the ro tational lock bearing is installed on the fan end of the motor for all pump models except for D60A D90A pump models with Marathon motors The lock bearing on D60A D90A s with Marathon motors is installed on the shaft end NOTE Catalog numbers for the required parts and materials are listed in Table 5 2 NOTE If the motor is attached to the pump remove the motor before proceeding with Steps a through s a Unscrew and remove the screws that attach the fan cover to the end of the motor Remove the fan cover TRIVAC A Manual Edition L 31 5 F Step F 1b 2 Cont d b For D30A pump models use an allen wrench to loosen the setscrews that secure the fan to the shaft Remove the fan For D60A and D90A pump models loosen the screw that secures the fan to the shaft Remove the fan then use diagonal cut
52. ction 5 is a detailed step by step procedure for disassembling cleaning and assembling the TRIVAC dual stage vane pumps It is to be used in conjunction with the troubleshooting chart Table 6 1 for pump repair MODULE REPLACEMENT PROCEDURE NOTE The correct replacement module for your pump is listed in the parts list see Section 7 NOTE If your pump has the anti suckback solenoid valve modification see the supplement P N 722 78 031 that came with the pump for special instructions on replacing the pumping module if you prefer to replace the module rather than repair it proceed as follows 1 Use the Section 5 B instructions for disassembly 2 Do Steps F 12 F 13 and F 14 except B 8 3 Add the proper pump fluid see Section 5 A 1 as follows see Figure 1 1 a Using an 8 mm allen wrench screw a plug screw 8 with flat gasket 9 into each oil drain port b Pour pump fluid into the exhaust port 6 or an oil fill port until the fluid level is halfway up the oil level glass 15 or oil sight gauge 72 c NOTE The pump may run noisily until the pump fluid has time to flow into the module Run the pump for Ya to 1 minute and then turn it off d Add additional pump fluid as necessary to bring the pump fluid level halfway up the oil level glass 15 or between the L and the H marks on the oil sight qauge 72 e Using an 8 mm allen wrench screw a plug screw 8 with flat gasket 9 into each oil fill port 4 Do Steps F 16 and
53. d Se eee Tad WEG Ie ee PE A ad dad Ce wa 43 LIST OF FIGURES Figure Title Page SECTION 1 INTRODUCTION Sketch 1 1 Pump Identification Plate 0 ccc cece ete ee ee teen cane eee uneneetuveuaeene 3 1 1 Location of the Identification Plate the Oil Fill Ports and the Oil Drain Ports 00 cece ee eeees 4 SECTION 2 PRINCIPLES OF OPERATION Sketch 2 1 Cross Section of the Gas Ballast Valve on the D8A AC through D9DA AC Extreme Corrosive Service PUMPS x s 6 gt gt e x K RRR RKR UKR 7 2 1 DAA NIGGA anette dd Sood ta deat Ha ak R le Ba Rds eis dl ela RT aries K 5 2 2 High Vacuum Stage Pump Cylinder with Rear End Plate Removed oo o eee eee 5 2 3 Gas Ballast Valve and Second Stage Pump Cylinder with Front End Plate Removed aaan aasan 6 SECTION 5 DISASSEMBLY CLEANING AND ASSEMBLY INSTRUCTIONS 5 1 Assembled Pump D16A Pump Model Shown cee eee ee aa 16 5 2 Module Attached to Coupling Housing D2A Pump Model Shown 0 000 eee ee eee 17 5 3 Module Side View D2A Pump Model Shown 0 0 0 0 00 0 0000 pe ee eee ee ene eee eas 18 5 4 Front End of Module Minus Coupling and Centrifugal Switch D2A Pump Model Shown 19 5 5 Removing the Cylindrical Pins from the Module D2A Pump Model Shown loa eee eee 20 5 6 Rear End of Module Minus the Disk O2A Pump Model Shown o oo oo 20 5 7 High Vacuum Stage Pump Cylinder D2A Pump Model Shown o oo cee eee ee 21 5 8 S
54. d backwards or is malfunctioning If the lock bearing is installed correctly repeat Steps b 1 a through b 1 d to check the wiring of the motor NOTE When reassembling the valve plate 50 to the second stage pump cylinder 46 ensure that the bent tabs that cover the exhaust holes are facing down If the tabs are not bent it does not matter which side is facing down Repeat Steps D 15 through D 11 D 9 and D 7 through D 2 except assemble rather than disassemble CAUTION NICKS OR TEARS IN THE RADIAL SHAFT SEAL COULD RESULT IN A LUBRICATING FLUID LEAK AND POOR PUMP PERFORMANCE CAUTION FAILURE TO RECESS THE RADIAL SHAFT SEAL 45 IN ITS SLOT IN THE REAR END PLATE 60 WILL RESULT IN THE VANES 53 RUBBING AGAINST THE SEAL 45 DURING PUMP OPERATION NOTE The side of the seal that has a small circular spring around the 1D faces the bronze bushing in the rear end plate 60 REQUIRED ACTION Use one of the following methods to install a new radial shaft seal 45 in the rear end plate 60 see Figure 5 12 Method 1 Insert the new seal into its slot in the rear end plate Vang a hammer and a seal driver see Figure 5 22 recess the seal in the slot or Method 2 Insert the new seal into its slot in the rear end plate Place the used seal over the new seal Use a hammer to tap the used seal until it indents the new seal in its slot in the rear end plate Remove and discard the used seal TRIVAC A Manual Ed
55. e Unscrew and remove the threaded studs 62 from the front end plate 44 See Figure 5 12 NOTE The D8A and D16A pump models have four threaded studs rather than three NOTE For use during reassembly the ends of the threaded studs 62 that have the shorter threaded set screw into the front end plate 44 see Figure 5 8 During reassembly the threaded studs should be screwed they are tight in the front end plate Repeat Step D 8 except remove the shaft seal 45 from the front end plate 44 For the D4A D16A D60A and D90A pump models only use an allen wrench to remove the two screws 1 attach the retaining bracket 59 to the high vacuum pump cylinder 55 Remove the retaining bracket and valve plate 58 from the pump cylinder see Figure 5 13 NOTE The D2A D8A and D30A pump models do not have retaining brackets 59 and valve plates TRIVAC A Manual Edition i TITAS i Figure 5 12 Removing the Radial Shaft Seal From the End Plates D2A Pump Model Shown NOTE The D60A and D90A pump model has two retaining brackets 59 and two valve plates 58 that must be removed NOTE For use during reassembly the thicker viton section of the valve plate 58 faces up NOTE When removing the valve stop 51 observe the orientation of the valve stop valve plate 50 and pump cylinder 46 It is important that these parts are placed in this same orientation during reassembly see Figure 5 14 Unscr
56. e cor rect pump fluid is listed in Section 5 A 1 am Oo aa Pour the pump fluid into the oil fill port 9 Using an 8 mm allen wrench reinstall the plug screw 8 with flat gasket 9 into the oil fill port 10 If the negative pressure exhaust system was disconnected in Step 2 reconnect it Checking the Pump Fluid for Contamination Occasionally check the pump fluid for contamination by looking through the oil level glass 15 on the side of the pump If the fluid in the oil level glass 15 has an unusual color is very dark or appears dirty or turbid refer to _ Section 4 3 2 to change the fluid For anti corrosive fluid flakes in the fluid indicate that its corrosive resistance is spent and thus the fluid should be changed The oil sight tube 72 on the end of the oil casing does not give an accurate indication of the condition of the pump fluid see Figure 5 1 NOTE See Section 4 2 for identifying and eliminating condensate from the pump fluid NOTE See Symptom 2 of the Troubleshooting chart Table 6 1 for other methods of eliminating contamination from the pump fluid NOTE The frequency of pump fluid change can vary from several months to every day depending on the opera ting conditions of the pump The frequency must be adjusted to the operating conditions If the pump fluid becomes contaminated quickly use an OF 3000 or OF 1000 Oil Filtering System to protect the pump and to ex tend the period between pump fluid cha
57. e eee ee eee 14 5 A Required Materials and Tools ee ee ee eee eee eee ees 14 SA T Required Materialss oc oo cds Seas atin ON aid a R doles Se Le dues ak ees oe Ge ea ew eas a ele 14 5 A 2 Required Tools can 5 3 55 tye ea we tan E a os ee a re a AS nO UR ane Biases 14 5 B Removing the Module from the Pump 2 0 0c ee eee ee ee eee eee ee 15 B C Disassembling the Module o oooomroro oro e NT 5 D Disassembling the Remaining Parts e e e lt ro roer ne o i Loro 22 5 E Cleaning and Inspecting the Disassembled Pump e lt e e roo 28 5 E 1 Special Requirements for Extreme Corrosive Service Pumps pr 28 5 E 2 Instructions for Cleaning and Inspecting all Pump Models oo oooooooooo omo oo os 28 5 F Reassembling the Pump is rei RC ooo 29 SECTION 6 TROUBLESHOOTING lt lt x ee ee ee eee eee ete ee ee eee 43 SECTION 7 PARTS LIST ooooooo ee ees A la 55 TRIVAC A Manual Edition L 1 LIST OF TABLES Table Title Page SECTION 4 STARTING OPERATING AND MAINTAINING THE PUMP 4 1 Technical Data ia a A a RTA E d ai o a 12 SECTION 5 DISASSEMBLY CLEANING AND ASSEMBLY INSTRUCTIONS 5 1 Rotor Bearing Shaft and Vane Critical Dimensions o 30 5 2 Parts Required for Installing Rotational Lock Bearing ooo 32 SECTION 6 TROUBLESHOOTING 6 1 Troubleshooting Chart sce da YS hae Saee
58. e high vacuum stage rotor 54 from the sha NOTE Two threaded metric pulling holes are located in the outside end of the high vacuum rotor 54 for with a puller see Figure 5 7 NOTE The second stage rotor 48 and the shaft are permanently attached to each other on the D2A D4A D8 and D16A pump models Figure 5 9 TRIVAC A Manual Edition HV STAGI a PUMP CYLINDER 55 HV STAGE ROTOR 54 17A 4 27 Figure 5 7 High Vacuum HV Stage Pump G l Cylinder D2A Pump Model Shown ATARI S Figure 5 8 Second Stage Pump Cylinder D2A Pump Model Shown TRIVAC A Manual Edition L 21 5 D DISASSEMBLING THE REMAINING PARTS D 1 D 2 D 3 D 4 D 5 D 6 22 Disassemble the gas ballast valve as follows SECOND STAGE 7 ROTOR X las HIGH VACUUM GE T ITABA19A Figure 5 9 High Vacuum Stage Rotor Removed From the Shaft D2A Pump Model Shown WARNING D8A AC THROUGH D90A AC EXTREME CORROSIVE SERVICE PUMPS HAVE AN ADAPTER EPOX IED TO THE TOP OF THE GAS BALLAST VALVE SEE SKETCH 2 1 DO NOT REMOVE THIS ADAPTER OR DO STEP f FOR THESE PUMP MODELS THE GAS BALLAST VALVE IS INTENTIONALLY PLUGGED ON D2A AND D4A EXTREME CORROSIVE SERVICE PUMPS THEREFORE DO NOT DO STEPS a d e AND f FO PUMPS WITH INTENTIONALLY PLUGGED GAS BALLAST VALVES 2 a For all pump models pull the cap 18 off of the gas ballast valve 17 See Figure 5 10A b For the
59. e rotation increases the size of the chamber until it is sealed off by a second vane Chamber B Further rotation diminishes the chamber size and compresses the gas Chamber C The gas is then forced out through an opening in the center bearing plate 52 and into the second stage pump cylinder 46 see Figure 2 1 With each cycle the pump removes a portion of the original gas contained in the vessel or system being evacuated until the ultimate pressure of the pump is reached The ultimate pressure is measured with the pump intake tube closed off It is the lowest pressure attainable for a particular pump The ultimate partial pressure for dual stage vane pumps is 3 x 107 Torr as measured with a LN cold trapped ionization gauge Ultimate pressure measured with thermocouple gauges will be approximately 1 to 1 decade higher Second Stage Pump Cylinder The second stage of the pump is similar to the high vacuum stage in construction and operation It accepts gas from the high vacuum stage further compresses it and then forces it out through the exhaust valve 50 51 see Figures 2 1 and 2 3 2 3 GAS BALLAST MECHANISM 2 3 1 Opening and Closing the Valve There are two holes in the side of the gas ballast valve cap 18 on standard pump models When one of these holes is aligned with the hole in the gas ballast valve 17 the valve is open see Figure 2 3 When the side of the cap 18 is covering the hole in the gas ballast valve 17
60. econd Stage Pump Cylinder D2A Pump Model Shown cc eee eee eee eee 21 5 9 High Vacuum Stage Rotor Removed from the Shaft D2A Pump Model Shown aaaea eaaa 22 5 10A Cap End of Gas Ballast Valve naa a 23 5 10B Tube End of Gas Ballast Valve ee ee eee ee eee 23 5 11 Miscellaneous Disassembled Parts ee eee eee nes 24 5 12 Removing the Radial Shaft Seal from the End Plates D2A Pump Model Shown sananen eenaa 25 5 13 D4A Module Showing Retaining Bracket and Valve Plate 2 ce ee ee eee 25 5 14 Removing the Valve Stop and Plate D2A Pump Model Shown 0 2 00 0 ee ees 26 5 15 Coupling Housing and Motor D2A Pump Model Shown 0 0 0 0 0 ee tees 26 5 16 Removing the Oil Level Glass from the Coupling Housing D2A Pump Model Shown 27 5 17 Disassembled Motor D3DA Motor Shown 0 0 ee eee eee R 32 5 18 Rotors Shaft Center Bearing Plate Assembly D2A Pump Model SHOWN esd aris ek Baia eae 35 5 19 Driving the Long Cylindrical Pins that Align the HV Stage Cylinder and the Center Bearing D2A Pump Model Shown 0 RRR eT Ed R ee De ee a REE RT EE 0 36 5 20 Pulling the Second Stage Cylinder Tight Against the Center Bearing D2A Pump Model Shown 38 5 21 Driving the Short Cylindrical Pins that Align the Rear End Plate and the HV Stage Cylinder D2A Pump Model Show 39 5 22 Using a Shaft Sleeve to Install the Radial Shaft Seal into the Front End Plate D2A Pump Model Shown 40
61. embly of a is necessary to perform the corrective action refer to the steps listed in the Repair Steps column of Table e Table recommends cleaning use the general cleaning instructions in Section 5 E in addition to any specific ps recommended CONTENTS Page lubricating fluid is milky white or dark and the pump fails to reach its ultimate pressure and runs hot Condensation in Lubricating Fluid ce eee teen tnt eee are 44 The lubricating fluid has an unusual color is very dark dirty turbid or contains flakes Contamination of the Lubricating Fluid 0 0 0 cee eee eens 44 The pump will not achieve its ultimate pressure igus ia aaah Gedy R a RENIE RT 45 46 47 The evacuated vessel or system is vented to atmosphere pressure after pump shutdown ATA 47 48 The pump is excessively noisy x e e e x e e eee eee ene eet as 48 Excessive smoke or oil mist in exhaust stream 2 ee een tee ee eae 49 Lubricating fluid is ejected out of the intake tube 0 cc eee teens 49 Excessive lubricating fluid is consumed ee ene eee eens 49 50 Lubricating fluid is leaking from the top of the oil casing 0 teens 50 Exhaust gas is leaking from the top of the oil casing e eet 50 The pump will not Start cai eels ee ee Sass Ca a Ri we tare ee an ge iia oh ae a 50 51 The pump will not achieve its rated pumping speed 0 0 ee teen ene 52 Lubricating fluid or oil is found in the vacuum line or in the ves
62. ention to cleaning the following areas E 1 Inspect all O ring grooves for burrs and dirt Sand and or clean as necessary E 2 CAUTION FAILURE TO REMOVE BURRS AND SCRATCHES FROM THE SHAFT COULD RESULT IN DAMAGE TO THE RADIAL SHAFT SEALS 45 Inspect the coupling key 38 and the shaft for burrs or scratches Sand smooth if necessary see Figure 5 4 E 3 Ensure that all dirt accumulation is cleaned from all passages including the following The hole on the bottom edge of the front end plate 44 this hole extends al the way to the bronze bushing w The small hole in or just above the rear end plate 60 and front end plate 44 bronze bushing see Figures 5 6 and 5 8 P The oil nozzle 56 hole in the second stage pump cylinder 46 remove the oil nozzle screw and clean the screw and the hole see Figure 5 14 then screw the oil nozzle 56 into its hole in the cylinder 46 2 l NOTE The D30A D60A and D90A pump models have two oil nozzles that must be cleaned d For D30A D60A and D90A pump models only clean the brass air nozzle screw 66 located inside of the intake tube portion of the high vacuum pump cylinder 55 e The tiny silencing hole in the side of the gas ballast valve 17 stem just below the bolting flange use fine wire to clear any dirt from the hole DO NOT ENLARGE THE HOLE E 4 Using a brush thoroughly clean the center bearing 52 See Figure 5 9 E 5 Clean all dirt accumul
63. ep precisely Steps F 6a through F 6j REQUIRED ACTION Assemble the module as follows Place the high vacuum HV stage cylinder 55 so that it is lying flat with the intake tube portion the top on the right facing away from you see Figure 5 19 Fit an O ring 47 into the O ring groove on the cylinder 55 surface that is facing up Attach the assembly that you put together in Step F 5 to the HV stage pump cylinder 55 as follows Figure 5 19 Driving the Long Cylindrical Pins that Align the HV Cylinder and the Center Bearing D2A Pump Model Shown 36 TRIVAC A Manual Edition L b Cont d 1 Take the Step F 5 assembly and insert its HV stage end the end that has two pulling holes on the outside end of the rotor down into the HV stage cylinder 55 until the center bearing plate 52 rests against the HV stage cylinder 55 see Figure 5 19 2 Align the two alignment holes in the center bearing plate 52 with the two upper align ment holes on the HV stage cylinder 55 See Figure 5 19 3 NOTE When driving the two long cylindrical pins 65 into the alignment holes the flat end nonbeveled end of the pins 65 should face the HV cylinder 55 The HV cylinder is the one with the intake tube portion REQUIRED ACTION Using a rubber hammer hit the beveled end of the pins to drive the two long cylindrical pins 65 down through the two alignment holes in the center bearing plate 52 then through
64. ering ring with an O ring 7 make one of the following connections to the exhaust port 6 a If practicable install the exhaust line at a slightly descending angle to prevent condensate from flowing back into the pump and contaminating the pump fluid Attach a drain valve at the lowest point in the exhaust line to drain off any condensates then run the exhaust line up to its emission outlet This arrangement also prevents particulates from dropping back into the pump from the exhaust line b If the exhaust line must be installed in the ascending position and the process gas contains high levels of condensable vapors connect an AK condensate trap to the exhaust port AK traps serve to collect the condensates from saturated vapors See Section 1 of our catalog for additional information on condensate traps c If no exhaust line is connected and your pump will be running above 1 Torr inlet pressure connect an AF or SE series exhaust filter to the exhaust port 6 to remove pump fluid va pors and smoke See Section 1 of our catalog for additional information on exhaust filters 5 If the exhaust line is attached to a negative pressure exhaust system adjust the negative pressure so that pump fluid will not be drawn from the pump MAKING THE ELECTRICAL CONNECTION When making the electrical connections for your motor ensure that everything is grounded properly Six foot linecords are supplied on all standard single phase 6 0 HZ motors t
65. es the invalidity or lack of application shall not impair or affect the other provisions and the application of those provisions which can be given effect without the invalid or unenforceable provision or application With this intention the provisions of this agreement are declared to be severable Pump Model Displacement liters minute Ultimate partial pressure o Torr Ultimate pressure with gas ballast Torr 3x 10 3 jo fe 7 Oil Capacity quee Adal spinners ibs perfluoropolyether 13 gt 16 8 16 8 cae Ce De 20 so Sound pressure level aor at three feet with gas ballast closed dB A Sound pressure level TE at three feet with gas ballast open dB A 57 Intake tube and exhaust port diameter mm KF 16 KF 16 KF 25 KF 40 Maximum ambient temperature 104 F 40 C TRIVAC A Manual Edition L Death or serious injury can result from the improper use or application of this pump If the pump will be exposed to toxic explosive pyrophoric highly corrosive or other hazardous process gases including greater than atmos pheric concentrations of oxygen contact Leybold for specific recommendations Ground the motor properly during installation Disconnect the power before beginning installation maintenance or repair work or before interchanging the input leads when cor recting the direction of rotation Disconnecting the power also avoids an unexpected start
66. ew and remove the four screws that attach the valve stop 51 to the top of the second stage pump cylinder 46 Remove the valve stop 51 and thin metal valve plate 50 from the pump cylinder 46 See Figure 5 14 NOTE The valve stops 51 on the larger pumps are cast aluminum On most of the smaller pumps the valve stops are a black plastic ITAA140 Figure 5 13 D4A Module Showing Retaining Bracket and Valve Plate TRIVAC A Manual Edition L 25 VALVE STOP 00 ee 1 T TT SECOND STAGE PUMP CYLINDER 46 OIL NOZZLE 56 TMS NOTE The valve plate 50 on the D30A D60A D90A pump models has four tabs rather than two Figure 5 14 Removing the Valve Stop and Plate D2A Pump Model Shown D 13 Using a U S standard wrench unscrew and remove the four nuts and washers that attach the motor 73 to the coupling housing 11 Remove the motor from the coupling housing see Figure 5 15 D 14 For the D2A D4A D8A and D16A pump models only pull the elastic element 36 off of the coupling 37 mounted on the motor shaft see Figure 5 15 For the D30A D60A and D90A pump models only pull the coupling ring 36 off of the coupling 37 mounted on the motor shaft see Figures 5 11 5 3 and 5 15 D 15 CAUTION DO NOT USE CHANNEL LOCK PLIERS TO REMOVE THE OIL LEVEL GLASS ASSEMBLY FROM THE COUPLING HOUSING USING CHANNEL LOCKS COULD RESULT IN DAMAGE TO THE OIL LEVEL GLASS ASSEMBLY REAR OR FAN END O
67. f D60A pumps with perfluoropolyether fluid and with 50 Hz motors is 3 x 1073 Torr The ultimate partial pressure is measured with an LN trapped ionization gauge The ultimate pressure with gas ballast is measured with a Kammerer Type McLeod Compression Gauge Both of these pressures can be as much as a decade higher when is measured with a thermal conductivity gauge KF Leybold quick assembly clamp ring diameter 4 3 2 Changing the Pump Fluid WARNING IF THE PUMP HAS BEEN USED ON CORROSIVE TOXIC OR VOLATILE CHEMICALS OBSERVE PROPER SAFETY PRECAUTIONS BEFORE REMOVING THE PLUG SCREW 8 CAUTION HYDROCARBON PUMP FLUID SHOULD BE CHANGED AT THE FOLLOWING TIMES a AFTER A 100 HOUR BREAK IN PERIOD OF PUMP OPERATION b WHEN THE PUMP FLUID IS CONTAMINATED see Section 4 3 3 c WHEN CONDENSATION IN THE PUMP FLUID IS SEVERE see Section 4 2 AND d BEFORE AND AFTER THE PUMP IS STORED FOR A LENGTHY PERIOD see Section 4 3 4 PERFLUOROPOLYETHER FLUID SHOULD BE RECONDITIONED WHEN IT BECOMES CONTAMINATED NOTE Always change the pump fluid while the pump is warm to prevent condensables from remaining in the pump Turn the pump off and change the fluid as follows 1 Ensure that the pump is turned off then place an appropriate container under one of the oil drain ports to catch the used pump fluid 2 If a negative pressure exhaust system is attached to the exhaust line of the pump disconnect it NOTE A negative
68. gaskets out of the assembly 5 E CLEANING AND INSPECTING THE DISASSEMBLED PUMP CAUTION THE SECTION 5 E INSTRUCTIONS ARE FOR CLEANING PUMP PARTS DO NOT USE THESE INSTRUCTIONS FOR CLEANING THE MOTOR It is not necessary to clean parts that will not be reused A new valve disk 67 and elastic element 36 and all new seals gaskets and O rings should be used for all pumps Use Freon TF or acetone to clean all surfaces thoroughly For final rinse use solvents such as alcohol or Freon TF MTAA Figure 5 16 Removing the Oil Level Glass 15 From the Coupling Housing D2A Pump Model Shown TRIVAC A Manual Edition L 27 5 E 1 Special Requirements for Extreme Corrosive Service Pumps WARNING STEPS 1 THROUGH 4 BELOW MUST BE FOLLOWED FOR EXTREME CORROSIVE SERVICE PUMPS 1 NOTE New vanes 49 53 and a new oil filter 35 are required for extreme corrosive service pumps therefore it is not necessary to do Step E 8c REQUIRED ACTION Refer to Steps E 1 through E 8b 2 to clean and inspect all metal parts 2 Degrease all tools that will be used for handling degreased extreme corrosive service pump parts Ensure that the working surface is free of any hydrocarbon substance 3 Degrease and rinse all metal pump parts in a nonhydrocarbon solvent 4 Wet all seals and all internal pump parts with the recommended perfluoropolyether pump fluid 5 E 2 Instructions for Cleaning and Inspecting All Pump Models Give particular att
69. haft turns smoothly see Figure 5 3 Many times the act of turning the shaft will bring the module into alignment d Continue repeating Steps F 10a through F 10c until the shaft turns smoothly and there is no bind ing It is sometimes necessary to loosen or tighten each hexagon nut several times to eliminate all binding Many times it is necessary to tighten two of the nuts 63 and loosen the other nut s a bit However all nuts should be tightened to roughly the same torque e Test the breakaway torque of the shaft It must be less than 15 in Ibs If you cannot eliminate the binding there must be an obstruction inside of the module In this case disassemble and inspect the module eliminate the obstruction and then reassemble the module ensuring that all parts are installed properly h F 11 NOTE When the pump is not running the air inlet tube 69 should be open When the pump is running the centrifugal switch 39 should pull away from the lever 41 causing the lever seal 43 to close the air inlet tube 69 see Figures 5 3 and 5 4 Ensure that the anti suck back mechanism is operating correctly as follows a Check to see if there is a gap between the lever seal 43 and the end of the air inlet tube 69 If there is not a gap while the pump is at rest it means that the lever 41 is bent the spring 42 is out of position or the centrifugal switch 39 is malfunctioning Remedy the problem before proceeding see Figures
70. hat are purchased through Leybold Most of our single phase motors also have automatically resetting thermal overloads If the motor doesn t have a linecord you must provide the correct thermal overloads to protect the motor For 3 phase motors use the schematic diagram on the motor nameplate or in the junction box to make the electrical connection For TRIVAC AC pump models with 3 phase motors wire the solenoid valve for high or low voltage according to the instructions on the solenoid valve nameplate Attach the solenoid valve leads to any two of the three input line voltage wires 3 4 SECTION 4 STARTING OPERATING AND MAINTAINING THE PUMP 4 1 START UP Before starting the pump remove the shipping wedge an orange cardboard tag on the pump has instructions for removing the wedge The AC pump models don t have a wedge or a tag The motor manufacturer guarantees a maximum of six starts per hour at maximum power To avoid exceed ing six starts per hour run the pump continuously and regulate the vacuum in your system with a valve 4 1 1 Check the Direction of Rotation Refer to Section 5 Step F 1 to check the direction of motor rotation Looking from the motor end of the pump the motor fan should rotate clockwise If the fan doesn t rotate in the correct direction turn the pump off immediately to avoid damaging the motor or the pump 4 1 2 Using the Gas Ballast Valve During Pump Warm up NOTE Opening the gas ballast valve 17
71. ie 25105106 f oe swe Included in module see page 57 of parts list Included in module repair kit and universal gasket set see page 57 of parts list OIL SIGHT 720 00 113 5 11 32 x5 8 GAUGE 720 00 114 5 11 32 x5 8 ASSEMBLIES 72000115 613 16 x5 8 A mounting bolt with 2 2 2 Mounting bolt 720 00 129 5 16 24 UNF 2A 2 flat gaskets 72B is available under Part No 720 00 118 725 90001 Jo 725 91 001 OOo O these 4 seals is Flat gasket 725 90 000 ae available under Part 72591000 wees A seal kit containing Sight tube 722 11 003 Sight tube 722 11 004 D Diameter C al aly cast aluminum alloy M motor side adapter flange P pump side adapter flange Viton heat resistant synthetic rubber Al aluminum 89 JT UONIPZ TENUEN Yu OVAL Number Required per Unit Fume ede Part Name Motor Motor Ea CA EEES E D6OA Specifications Part No 1 3 hp TEFC 1 ph _722 60 066 115 208 230V 60 Hz 1725 rpm 115 208 230V 50 Hz 1500 rpm Wired for 115V i Motor l 1 3hp TEFC 3ph 722 60 067 200 230 460V 60 Hz 1725 rpm HHHH a 200 220 380V 50Hz 1500 rpm 1 hp TEFC 1 ph 115 208 230V wired for 115V 50 60 Hz 1500 1725 rpm This motor has an automatic resetting thermal overload hp horsepower l l kw kilowatt V voltage VAC voltage alternating current ph phase Hz hertz TEFC to
72. ified the steps are located in Section 5 SECTION 7 PARTS LIST e 7 1 contains information for ordering modules gasket sets and repair kits Table 7 2 is a complete list of spare parts Figures 7 1 and 7 2 to help identify the part that you need The numbers called out in the figures correspond to the Maion number listed for each part in the first column of Table 7 2 For example the first column on Page 58 lists 1 O the intake tube One Figure 7 1 the number 1 is pointing to the photograph of the intake tube The second series of six columns indicates which pump model uses the part and how many each pump requires For exem ple in Table 7 2 the number 1 under the D2A column for Position No 1 indicates that one intake tube Part No 433 60 118 is required for the D2A pump model Be sure to specify the model and Serial Number of your pump when ordering spare CONTENTS Page Disassembled Pump D2A Pump Model Shown Figure 7 1 2 0 e ee ee tenn o 56 A AS A a AAA e arr a 57 Universal Gasket Set cu cias ri AA ete ow aut 57 Module Repair 1 2 dane oh hdl A a Midi ade ees 57 Anti Suckback Modification KIL cee ete een en ene eens 57 Intake Tube ASSOMDIY co it lye Blige NAT tye RTA TAE athlete A ARR el tele hacen She ara ae Se ek deta Nl N ES 58 Exhaust Port ASSEDI y vcd id Goan ae pine be Gap ete arena ahaa dw beatae aed 58 59 Pump Housing Assembly 0 cc ccc cee ete R
73. ional lock bearing Using a hammer and a pipe that has an ID greater than the shaft OD gently tap the rotational lock bear ing down over the shaft until it bottoms out Wipe off any excess Loctite n CAUTION It takes about 5 minutes for loctite 609 to begin setting For D30A pump models Steps 0 and p should be completed before the Loc tite has time to set in case the end plate must be removed Apply Loctite 609 to the OD of the new rotational lock bearing and to the ID of the mating bearing well in the end plate o Repeat Steps f c and b except assemble rather than disassemble p For D30A pump models only spin the fan to check if the motor rotates freely If there is a lot of friction immediately remove the fan and the fan end plate before the Loctite has time to set then remove and discard one of the spacer rings and reassemble the motor a Using the four screws attach the fan cover to the motor r Spin the shaft to check if the fan contacts the fan cover or fan end plate If it does remove the fan cover and adjust the position of the fan on the shaft then reassemble s NOTE Allow the motor to sit for at least 1 hours prior to testing This will allow the locktite time to cure and firmly bind the surfaces REQUIRED ACTIONS Use the instructions at the beginning of Step b 2 to determine if the rotational lock bearing is installed correctly and to correct the problem if the lock bearing is installe
74. ith a return line Close see Section 2 3 1 the gas ballast valve 17 after all vapors have been pumped out of the system or when there is only a small accumulation of vapor with a large excess of permanent gases 4 2 OPERATION WARNING Don t pump toxic pyrophoric or hazardous gases unless your pump has the anti suckback solenoid valve modification see Pages 8 and 57 When pumping these hazardous gases we recommend a negative pressure exhaust system and inert gas purging of the oil casing and gas ballast valve In addition a pump specially prepared for perfluoropolyether vacuum oil is required for pumping highly reactive or extremely corrosive gas Contact the factory for recommendations CAUTION Pumping corrosive gases with a standard pump can result in premature failure Contact the factory for pump modifications for your particular process CAUTION RUNNING THE PUMP AT GREATER THAN 1 TORR INLET PRESSURE RESULTS IN AN OIL MIST IN THE EXHAUST STREAM INSTALL AN EXHAUST FILTER SEE SECTION 3 3 AND CHECK THE PUMP FLUID LEVEL FREQUENTLY SEE SECTION 4 3 1 WHEN OPERATING THE PUMP ABOVE 1 TORR CAUTION DO NOT RUN THE PUMP CONTINUOUSLY AT GREATER THAN 300 TORR INLET PRESSURE FOR THE D2A D8A AND D30A PUMP MODELS OR GREATER THAN 187 TORR FOR THE D4A D16A D60A AND D90A PUMP MODELS The 115 230 V 50 60 Hz single phase motors have an automatically resetting thermal overload If this overload shuts off the pump and the ON OFF switch is left ON
75. ition L F 4 Assemble the gas ballast valve 20 as follows a For D8A D16A D30A D60A and D90A pump models only reassemble the insides of the cap end of the gas ballast valve 17 as follows see Figure 5 10A 1 Fit the O ring 20 around the inner rim of the valve plate 19 The O ring goes onto the side of the valve plate that has the metal valve 2 Insert the valve plate 19 O ring 20 assembly into the top of the gas ballast valve 17 The side of the valve plate that has the metal valve faces down 3 Push the retaining washer 21 into the top of the gas ballast valve until it is tight against the valve plate 19 b For D30A D60A and D90A pump models only insert the parts into the inside of the tube end of the gas ballast valve in the following order see Figure 5 10B First Valve plate 32 that has three slots Second Spring 31 Third Valve plate 32 washer Fourth Retainer ring 30 Fit the retainer ring into the groove in the inside of the gas ballast valve tube c Repeat Steps D 1e through D 1a except assemble rather than disassemble F 5 Assemble the high vacuum stage rotor 54 and the center bearing 52 to the shaft as follows see Figures 5 9 and 5 18 a NOTE The second stage rotor 48 is permanently attached to the shaft on the D2A D4A D8A and D16A pump models NOTE If the center bearing plate 52 does not have the small hole it can face either direction Coat the bron
76. l 45 is worn Inert gas pressure in purge line of modified pumps is too high Reduce inert gas presure to below 3 psig for an oil casing purge amp below 2 psig for an inert gas connection to the gas ballast valve This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E os pS yenuey NA OVAL TABLE 6 1 TROUBLESHOOTING CHART Continued Symptoms Trouble Area Probable Cause Recommended Repair Steps Corrective Action 8 Excessive lubricating c Gas ballast valve 17 Valve 17 is open Close valve 17 or use AF exhaust filter with oil return Sec 2 3 1 fluid is consumed line Also see symptoms d Lubricating fluid Motor is rotating in wrong Interchange the line ends 6 and 9 cont d is ejected out of direction intake tube 1 Check rotational lock bearing Flat gasket 4 is worn Instali new flat gasket 4 B 5 Oil casing 12 is scratched below valve 17 flange Flat gasket 4 is worn 9 Lubricating fluid is leaking from the top of the oil casing 12 Gas ballast valve 17 Install new oil casing 12 B 1 thru B 7 10 Exhaust gas is leaking from the top of
77. l casing see Figure 5 2 Remove the oil casing by sliding it straight back away from the main flange of the coupling hous ing NOTE If resistance is encountered strike the front corner of the oil casing 12 with a rubber hammer to release the oil casing 12 from the coupling housing 11 B 8 WARNING THE DISK ON THE MODULE END HAS A SHARP EDGE FAILURE TO USE CARE WHEN REMOVING AND HANDLING THE DISK MAY RESULT IN INJURY Using a phillips head screwdriver remove the disk 61 from the shaft see Figure 5 2 B 9 WARNING PUMP FLUIDS ARE EXCELLENT LUBRICANTS AND AS SUCH ARE VERY SLIPPERY BE CAREFUL WHEN HANDLING THE MODULE SINCE IT CONTAINS LUBRICATING FLUID WHICH COULD SPILL CAUSING A HAZARD 16 TRIVAC A Manual Edition L STEP B 9 CONTINUED Remove the module as follows a Unscrew and remove the lower screws and washers that attach the module to the coupling housing 11 see Figure 5 2 b WARNING ESPECIALLY FOR THE HEAVIER PUMPS D30A AND D60A BE SURE TO SUPPORT THE MODULE WHEN REMOVING THE SCREWS OTHERWISE THE MODULE MAY FALL RESULTING IN DAMAGE OR INJURY While supporting the module unscrew and remove the remaining upper screws and washers c Pull the module straight back and away from the coupling housing 11 B 10 Clean the large flat seal 13 from the coupling housing 11 and or front end plate 44 see Figure 5 2 NOTE A replacement gasket is supplied with the gasket set and module re
78. l refer to the proper vacuum pump fluid 1 2 MODEL AND CATALOG NUMBERS To understand many of the instructions in this manual you need to know the model number of your pump The plate attached to the end of the pump see Figure 1 1 lists the model catalog and serial numbers in addition to the catalog number of the standard oil for the pump Always supply us with the pump s serial and catalog numbers when returning it to one of our service centers Also report the serial number of the pumping system where applicable TRIVAC LEYBOLD MODEL NO CATALOG NO SERIAL NO THIS PUMP FILLED WITH LEYBOLD VACUUM PRODUCTS INC 5700 Mellon Road Export PA 15632 MADE IN U S A 1TA 1 Sketch 1 1 Identification Plate TRIVAC is a registered trademark of Leybold TRIVAC A Manual Edition L EXHAUST PORT 6 OIL FILL PORT De De i S WITH PLUG SCREW 8 ee INTAKE TUBE 1 OIL FILL PORT a NE WITH PLUG SCREW 8 FAN OR REAR END OF MOTOR 12 IDENTIFICATION PLATE OIL SIGHT GAUGE 72 OILDRAIN PORTS 7 WITH PLUG SCREW 8 ITARA Figure 1 1 Location ot a Identification Plate the Oil Fill Ports and the Oil Drain Ports 030A Pump V Model Shown SECTION 2 PRINCIPLES OF OPERATION Vacuum pumps are used to reduce the pressure in an enclosed vessel or system For rough and medium vacuums 760 to 10 3 Torr the intake tube 1 of the rotary vane pump is connected to
79. n heat resistant synthetic rubber 1t 200 asbestos gasket fiber 6S 7 UONIPZ enueW Va OVAIEL Number Required per Unit Pump Model D60A D2A D4A DBA D16A paoa D60A Part Name EXHAUST PORT ASSY Catalog No Dimensions mm Material Cont d 7 1 1 Centering ring KF16 SS Viton with O ring 7 1 1 Centering ring 88347 KF25 SS Viton with O ring 7 1 1 Centering ring 88348 KF40 SS Viton with O ring PUMP HOUSING ASSEMBLY Plug screw 201 27 105 7 Flat gasket Eye bolt 239 55 165 7 D22x15 1x2 201 13101 Coupling housing Coupling housing M8 DIN 908 Isometric Straight See Figure 7 2 720 00 001 228x140x185 720 00 003 Coupling housing Coupling housing Oil casing Oil casing Oil casing 720 00 019 265x172 5x216 5 149x242x272 5 720 00 021 720 00 005 720 00 007 720 00 009 164x242x272 5 127 5x135x162 162 5x135x162 158x172 5x192 5 Oil casing 720 00 011 200 5x172 5x192 Oil casing Oil casing Seal Included in universal gasket set and module repair kit see page 57 of parts list Included in the standard module see Page 57 Seal 720 00 015 246 5x242x279 5 C Al aly C Al aly 720 00 017 238 11 123 x 321 5x242x279 5 172x190x1 238 11 126 23
80. n Section 5 ve beginning of Section B E B 1 amp Sec 3 3 B 1 amp Sec 3 3 Steps 3 amp 4 See Symptom 11a B 1 thru B 7 D 12 If needed D 13 thru F 17 B 1 thru B 10 F 10 amp F 12 B 1 thru B 7 amp E 3c Clean inside of module and change lubricating fluid B 1 thru F 17 Contact motor manufacturer s service center D 13 amp F 1 7 UIP TENUEW Va OVAL TABLE 6 1 TROUBLESHOOTING CHART Continued Recommended Symptoms Trouble Area Probable Cause Corrective Action Repair Steps 13 Lubricating fluid or a Vapors are back Lubricating fluid is See Symptoms 1 4 2 oil is found in the streaming into contaminated vacuum line or in the the vacuum line vessel or system Vapor pressure of Replace used fluid with HE 200 lubricating fluid being evacuated Also lubricating fluid is 7 Install an RST FA or adsorption trap in the inlet B 1 amp Sec 3 3 line see Symptom 7 insufficient Pump fluid suckback during See Symptom 4b A shutdown Parnes The pump is running hot greater than 95 C or 200 F Install SECUVAC valve or venting device See Symptoms 1 2 3a through 3i 11b 11d 12e 12i 12j and 12k This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not spec
81. nection P Trouble Area Probable Cause Fluid is dirty Vacuum line valve is partially closed Trap 2 is obstructed with dirt Recommended Corrective Action Run pump for 1 hour while it warms to operating temperature See Symptoms 1 and 2 Open vacuum line valve Repair Steps Clean dirt trap 2 Exhaust or intake filter accessory is dirty Clean or install new filtering element B 1 and B 2 Exhaust or intake line diameter is too small b Coupling 37 and or elastic element 36 Coupling and or element is worn or improperly installed Install larger diameter connection line Properly install new element and or coupling Exhaust holes in second stage pump cylinder 46 or opening in center bearing 52 Anti suck back assembly i Friction between the rotors 48 54 or vanes 49 53 and the module housing 44 46 52 55 60 See Symptom 3h Module is not aligned properly Oil nozzle 56 is clogged j Inside of module housing 44 46 52 55 60 Holes or opening is blocked Clean holes or opening See Symptom 3h Align module Clean nozzle 56 Dirt buildup is restraining rotation speed This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed sectionis not specified the stepis are located i
82. new filter B 5 amp B 6 d Pump pressure Pump is running Modify system to run at lower pressure or Sec 4 2 CAUTION 3 continuously at greater use larger pump model Sec 2 Negative pressure is too high Adjust negative pressure exhaust system than 112 Torr e Gas ballast Valve 17 is open valve 17 Close valve 17 or install SE smoke eliminator or AF exhaust filter with oil return line E Interchange the line ends Check rotational lock bearing D 9 amp F 1b a Oil filter 35 Filter is clogged Clean filter or install new filter B 5 amp B 6 b Oil leak Flat gasket 9 on plug Install new flat gasket 9 B 3 D 6 amp F 15 screw 8 is worn Main seal 13 between oil Replace seal 13 B 1 thru B 10 casing 12 and coupling F 12 F 14 thru housing 11 is worn F 16 B 1 thru C 6 D 10 F 6k F 9 F 11 amp F 12 B 1 thru C 1 C 9 C 10 D 8 F 3 F 6g F 10 amp F 12 Sec 3 3 7 Lubricating fluid is ejected out of the intake tube 1 Also see Symptom 13 Motor 73 Motor is rotating in wrong direction 8 Excessive lubricating fluid is consumed Also see symptoms 6 and 9 Install new seal and check if the exhaust line is too narrow or if an exhaust filter or screen is clogged Front end plate radial shaft seal 45 is worn Rear end plate radial Install new seal shaft sea
83. nges Long Term Storage 2 weeks or longer Use the Section 4 3 2 instructions to flush out the pump and change the pump fluid before and after the pump is stored for a lengthy period After changing the fluid run the pump for about 20 minutes with the intake sealed off and the gas ballast valve open see Section 2 3 to ensure that all the internal parts are coated with clean pump fluid Cover the intake and exhaust of the pump to prevent dirt dust and condensation from entering during storage Checking the Dirt Trap Occasionally check the wire mesh dirt trap 2 that rests on the pump intake tube 1 A buildup of contaminants on the dirt trap reduces the pumping speed Avoiding Oil Leaks During Shipping and Storage Tightly sealing the pump s inlet and exhaust ports for shipping or storage can cause oil leaks To avoid oil leaks during shipping and storage use a flexible membrane or a rigid cover with a pin hole on the pump s inlet and exhaust ports The flexiole membrane or pin hole accommodate the pressure differences that occur during air shipments and during temperature changes As further precautions against oil leaks during shipping we insert a wedge up under the coupling housing to hold the anti suckback lever and seal in the closed position We also drain the oil from the smaller pumps in case they are turned upside down TRIVAC A Manual Edition L 13 SECTION 5 DISASSEMBLY CLEANING AND ASSEMBLY INSTRUCTIONS Se
84. notify us of any toxic or other harmful products that may be in the pump its oil or its filters You will also need to supply us with the pump s serial and catalog numbers from the ID plate on the end of the oil casing see Figure 1 1 ninna 2 CONTENTS Section Title Page E SECTION 1 INTRODUCTION Si Ace oe Beaten Weave OR A 3 L 31 Manual Key o ici A HRK eh Bet ieee Sag A wa edo a es A 3 1 2 Model and Catalog Numbers iw ee eee ee eee eee ete eee eee 3 SECTION 2 PRINCIPLES OF OPERATION 0 ccc ee ee ee ee eee eee ee eee eens 4 2 1 Direct Drive Mechanism io aT a ecco aes ei kd ie ee He blak De He ee OE RS a 4 2 2 Pumping Mechanism ee ee eee ee ete ee eee eee eee eee ees 4 2 2 1 High Vacuum Stage Pump Cylinder 2 0 ee ee eee eee 4 2 2 2 Second Stage Pump Cylinder sE R a 9 N d ee ee ee eee eee eee eee 5 2 3 Gas Ballast Mechanism ee eee ee T REEE ee eee eee eee eens 5 2 3 1 Opening and Closing the Valve 2 te ee ee ee eee 5 2 3 2 Purpose andi Function 20 3 3 ai a RO ee Saw ees nd Leen gba da teehee tenes 6 2 4 Lubricating Fluid 2 6 56 eek alas dee a PS SA Ce Bae BUG Ou ew ae 7 2 5 Anti Suck Back Mechanism S eiei ce ee E e eee eee ee eee 8 SECTION 3 PREPARING AND INSTALLING THE PUMP 00 0 cece ee eee eee 8 Sl Receiving gt skein SET ted ea bate E SE dN BOs teh AA Ri al Steen ISA N 8 3 1 1 Reporting Shipping Damage 0 1
85. or the intake tube 1 and a centering ring with O ring 7 is supplied for the exaust port 6 Leybold also has a complete line of components fittings and adapters to connect your pump to any system See our catalog for a list of these components See Table 4 1 for the intake and exhaust flange dimensions of your pump model All connections must be vacuum tight for your pump to achieve its ultimate pressure The O ring on the centering tings must be clean to avoid leaks Your pump will perform better and last longer if it is protected by the correct inlet filter and or oil filtering sys tem See our catalog or contact your nearest sales office for the recommended filter for your application Any accessories such as coaxial traps dust separators exhaust filters or inlet filters should be connected after Step 2 below Use the manual that comes with each accessory for installing maintaining and operating the ac cessory see the Leyboid catalog for additional information on accessories CAUTION IF YOU ARE PURGING THE GAS BALLAST VALVE DO NOT EXCEED AN INERT GAS PRESSURE OF 2 psig IF YOU ARE PURGING THE OIL CASE OR EXHAUST LINE WITH INERT GAS DO NOT RAISE THE PRESSURE IN THE OIL CASING ABOVE 3 psig EXCEEDING THESE PRESSURES WILL DEGRADE THE PUMP S PERFORMANCE Connect the pump to your system as follows 1 Set the pump on a horizontal surface It need not be permanently mounted on the surface See Figure 1 1 2 CAUTION FA
86. ort 6 Connect vacuum line to intake tube 1 Sec 3 3 Steps 3 amp 4 c Exhaust connec tion line Line diameter is smaller than exhause port 6 diameter Install larger diameter connection line Sec 3 3 Step 4 d Vacuum line or evacuated vessel Vacuum line or vessel contains leak Repair leak or clean O ring if dirty e Dirt trap 2 on intake tube 1 Trap 2 is obstructed with dirt Clean dirt trap 2 B 1 and B 2 f Lubricating fluid Fluid is contaminated resulting in poor sealing qualities and excessive wear on seals See Symptoms land 2 Wrong lubricating fluid is being used Flush out pump and add correct lubricating fluid Sec 4 3 2 L g Module contains insufficient lubricating fluid Pump fluid level is too low Add lubricating fluid to pump Sec 4 3 1 Oil nozzle 56 is clogged Clean oil nozzle 56 and change lubricating fluid B 1 thru B 7 E 3c amp Sec 4 3 2 Pump is running continuously at 187 or more Torr Slowly pour some lubricating fluid into intake tube 1 and run pump at lower pressure B 1 and Sec 4 2 CAUTION h Anti suck back assembly Also See Symptom 5g L The coupling 37 is too tight against the retainer ring 40 or the centrifugal switch 39 B 1 thru
87. pa fo Gas ballast vale stem f 39008 Al aly St n ee ft TT Gas ballast valve stem 5x85x67__ Aray St Pf rat gasket H H H I See Position No 18 BUE ACA nt CA A A CA EE ee HE wot 1 0 1 1 cam 4975105 osoxw0o Bunn a AA O Tame assembly 35020158 031 76 Thermoplastic See Fig 510 ao PA oras T names Viton Seerig 510A a 1 4 1 1 Retaining washer 22149207 0195x3608 steel SeeFig 510A ee eS ee es ee ee EE Cre e a a Pp tt Tt 1 1 Stitfeningdisk 22204107 D40x0 5 Bronze 23 ta fas tt Nonreturnvaive 35020126 oi6x28 Steel as a tt fT at gasket 2897319344 19x6x1 viton H Pp as tt tt Spring EE 4242 laos o fsea H 26 1 1 T Strengthening piece 451 74 425 4 6x7x0 1 Steel l Pt H H HH T THH Mexe Steel Not shown Included in universal gasket set and module repair kit Buna N synthetic rubber see page 57 of parts list Stl steel Al aly aluminum alloy Must be purchased as gas ballast assembly D diameter i Viton heat resistant synthetic rubber 7 UONp3 ENUEN Va OVAL Number Required per Unit Pump Model R N t talog No D90A GAS BALLAST VALVE ASSEMBLY Cont d 239 70 148 239 70 147 Dimensions mm D16x2 5 221 62 144 D14 5x12x1 25 Steel Spring filter 221 62 143 D20x35 Spring filter 221 62 142 D25 2x38 D5x
88. pair kit 5 C DISASSEMBLING THE MODULE CAUTION USE CARE WHEN HANDLING THE MODULE TO AVOID BENDING THE LEVER 41 OR CEN TRIFUGAL SWITCH 39 see Figures 5 3 and 5 4 C 1 Using a large pair of long nose pliers pull the valve disk 67 and attached brass piston 68 out of the intake portion of the high vacuum pump cylinder 55 see Figures 5 3 and 11 COUPLING HOUSING 11 TAA Figure 5 2 Module Attached to Coupling Housing D2A Pump Model Shown TRIVAC A Manual Edition L 17 5 B B C is erasers T C 3 c4 C 5 18 D30A D60A COUPLING 37 ALIGNMENT HOLES l DZA MODULE ang Figure 5 3 Module Side View D2A Pump Model Shown CAUTION IF A PULLER IS USED TO REMOVE THE COUPLING 37 BE CAREFUL TO AVOID DAMAG ING THE CENTRIFUGAL SWITCH 39 Using a small screwdriver loosen the setscrew that secures the coupling 37 to the shaft Pull the coupling off of the shaft see Figure 5 3 Using small diagonal cutting pliers pull the coupling key 38 from the slot in the shaft see Figure 5 4 Using snap ring pliers remove the retainer ring 40 from the shaft see Figure 5 4 NOTE For use during reassembly the centrifugal switch end with the split halves faces the coupling 37 For the D2A D4A D8A and D16A models only loosen the one or two setscrews that secure the centrifugal switch 39 to the coupling 37 see Figure 5 3 For the D30A D60A and D9
89. r proceed as follows 1 Using calipers or micrometers measure the inside diameter 1D of the bronze bushing If the ID is greater than the dimension listed for your pump in Table 5 1 replace the end plate or center bearing plate containing the worn bushing 2 Using calipers measure the outside diameter OD of the shaft at each area of wear If the shaft OD at any point of wear is less than the dimension listed for your pump model in Table 5 1 replace the shaft c Three rectangular vanes 49 53 fit into slots in each rotor 48 54 See Figures 5 7 and 5 8 Using calipers or micrometers measure the length and thickness dimension of each vane If either dimension is greater than the maximum or less than the minimum dimen sion listed for your pump model in Table 5 1 replace that vane If a vane dimension is greater than the maximum it is the result of swelling due to chemical attack E 9 Using a paint brush cover all the pump parts with a light coat of the proper pump fluid see Section 5 A 1 5 F REASSEMBLING THE PUMP New seals gaskets and O rings and a new valve disk 67 and elastic element 36 should be used when re assembling the pump Use a new valve plate 50 only if wear is visible on the old valve plate For extreme corrosive service pumps new vanes 49 53 and a new oil filter 35 are also used Wet the O rings gaskets and seals with a film of the proper pump fluid before installing Make certain that all
90. ressure stem just below the bolting flange c Coupling 37 and or elastic element 36 d Disk 61 Straighten disk or install new disk B 1 thru B 8 Coupling and or element Install new element and or coupling is worn mechanism e Module Module contains insuffi See Symptom 3g See Symptom 3 cient lubricating fluid 39 f Module bushing Lubricating holes in end _ Clear holes so pump fluid can lubricate the O plates are clogged shaft bushing gt y g Shipping wedge The shipping wedge Remove shipping wedge NOTE Running Sec 3 3 Step 9 was not removed the pump with the shipping wedge installed 2 Symptom 5 can result in damage to the anti suckback 4b gt mi This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are the s ot specified the steps are located in Section 5 ginning of Section 5 E 7 UONIPZ jenuey Va OVAIHL 6t TABLE 6 1 TROUBLES JT Recommended Symptoms Trouble Area l Probable Cause Corrective Action 6 Excessive smoke or a Fluid level in sight Pump is filled with Drain excess lubricating fluid oil mist in exhaust glass 15 is high lubricating fluid beyond stream its capacity b Negative pressure exhaust system only if one is Sec 3 3 Step 5 connected c Oil filter 35 Filter is clogged Clean filter or install
91. rrier that made the delivery within 15 days of delivery in accordance with Interstate Commerce regulations File a claim with the carrier Contact the Leybold Order Services Department to make arrangements for replacing the damaged part ao 3 1 2 Reporting Shipping Shortage If you did not receive all the goods that you ordered do the following 1 Check the number of pieces listed in the upper right section of the packing list If the number of pieces listed is greater than the number of shipping containers received contact the carrier concerning the missing piece 2 Check the packing list to see if the missing item is back ordered 3 Carefully check the packing material and container to ensure that you did not overlook the missing item 4 If you cannot find the item contact our Order Services Department 8 TRIVAC A Manual Edition L maa 3 2 3 3 Reporting Incorrect Shipment If the item received is not the item ordered contact our Order Services Department INITIAL FILLING WITH PUMP FLUID The larger pump models are shipped filled with pump fluid the smaller pump models are shipped with the pump fluid in a separate container Ensure that the oil is in the middle to upper third of the sight glass before starting the pump see Figure 1 1 CONNECTING THE PUMP TO THE SYSTEM KF clamp rings are supplied for the intake and exhaust ports of the pump A centering nos with dirt trap is supplied f
92. s fluid seal is necessary for achieving the ultimate pressure of the pump The pump fluid also transfers heat from the pumping element to the oil casing 12 Other important qualities of the pump fluid include the following lt must have a low vapor pressure at the high temperature generated by gas compression and vane friction It must be oxidation resistant 1t must have a low water absorption rate It must resist cracking under the mechanical stress of gas compression and vane pressure Based on operational testing we have approved the following vacuum pump fluids for use in TRIVAC A pumps Standard Applications HE 175 hydrocarbon Corrosive Applications HE 200 or HE 400 hydrocarbon Extreme Corrosive Applications HE 1600 perfluoropolyether High Temperature Applications HE 600 synthetic diester hydrocarbon If you use a nonapproved pump fluid we can t guarantee that our pumps will meet their operating specifications ultimate pressure pumping speed operating temperature etc However the warranty is voided only if the non approved fluid adversely affects the operation or reliability of the pump The pump s identification plate see Page 3 indicates which pump fluid was initially used in the pump Section 2 3 2 mentions the detrimental effects of condensate on the pump fluid Contaminants also destroy many of the essential qualities of the fluid resulting in pump wear slower pumping speed higher ultimate
93. sel or system being evacuated 53 The pump is running hot greater than 95 C or 200 F cee eee eens 53 TRIVAC A Manual Edition L l 43 vy TABLE 6 1 TROUBLESHOOTING CHART Sympt P f Recommended gc Kn dung Ra 1 The lubricating fluid Gas ballast valve 17 Run pump with intake tube 1 closed off and gas Sec 4 2 is closed ballast valve 17 open until vapors are expelled is milky white or dark Gas ballast valve 17 Clean gas ballast valve 17 B 5 D 1 amp F 4 is clogged and the pump fails to reach its ultimate pressure and runs hot Install new spring 25 flat gasket 24 and B 5 D 1 amp F 4 nonreturn valve 23 or valve 19 or vaive plate 32 as necessary Run pump with gas ballast valve 17 open until Sec 4 1 2 pump is warm l Insulate oil casing 12 E Condensation in lubricating fluid Pump temperature is low Vapor in gas being pumped Add condensate trap to intake tube 1 and or B 1 amp Sec 3 3 exceeds pump tolerance exhaust port 6 Change lubricating fluid Sec 4 3 2 Add OF 3000 or OF 1000 to purify fluid and prevent reoccurrence of problem Add AS dust separator IF or FS inlet filter adsorption trap AK condensate trap or MF 2 The lubricating fluid has an unusual color is very dark dirty turbid or contains flakes Contamination of the pump fluid Process is dirty
94. sing 12 end and lower the motor into alignment If the module coupling is worn do B 1 thru C 2 F 9 amp F 12 7 uowip jenuef Va OVAL LS Symptoms 11 The pump will not start contd Trouble Area c Module is not vented between the rotors 48 54 or vanes 49 53 and the module housing 44 46 52 55 60 e Pump fluid is too thick L Air inlet tube 69 is TABLE 6 1 TROUBLESHOOTING CHART Continued Probable Cause Valve disk 67 and piston 68 are stuck in place in high vacuum pump cylinder 55 For D30A D60A and D90A pump models only small hole in high vacuum pump cylinder 55 just belowpiston 68 is clogged Recommended Corrective Action Repair Steps B 1 thru B 7 C 1 8 D 5 Clean disk and piston or install new ones Clean intake tube portion of high vacuum pump cylinder 55 Clean this small hole B 1 thru B 7 C 1 E 3d if needed C 2 thru C 7 C 14 F 7 F 9 F 11 8 F 12 Centrifugal switch 39 lever 41 spring 42 assembly is excessively dirty Clean assembly 39 41 42 B 1 thru C 6 F 9 F 11 amp F 12 clogged Centrifugal switch 39 is malfunctioning Clean air inlet tube 69 B 1 thru C 7 C 14 F 7 F 9 F 11 amp F 12 Install new centrifugal switch 39 B 1 thru C 5 F 9 F
95. sing long nose pliers remove the three vanes 53 from the high vacuum rotor 54 See Figure 5 7 EEE TRIVAC A Manual Edition L 19 B C C 18 Using small diagonal cutting pliers pull the high vacuum stage rotor key 57 from the slot in the shaft s C 19 Slide the center bearing 52 off of the shaft see Figure 5 9 20 BRONZE BUSHING 1744 23 Figure 5 5 Removing the Cylindrical Pins From the Figure 5 6 Rear End of Module Minus the Disk Module D2A Pump Model Shown D2A Pump Model Shown C 12 Remove the high vacuum stage pump cylinder 55 to expose the high vacuum rotor 54 and the center bearin 52 Remove the O rings 47 from both sides of this pump cylinder see Figure 5 7 C 13 Remove the front end plate 44 from the motor side of the shaft see Figure 5 8 C 14 Pull the air inlet tube 69 from the front end plate 44 or high vacuum stage pump cylinder 55 See Figures 5 3 and 5 8 C 15 Remove the second stage pump cylinder 46 to expose the second stage rotor 48 Remove the O rings 47 from both sides of this cylinder see Figure 5 8 C 16 Repeat Step C 11 except remove the vanes 49 from the second stage rotor 48 See Figure 5 8 C 17 CAUTION BE CAREFUL TO AVOID SCRATCHING THE END OF THE ROTOR OR THE CENTER BEAR ING SCRATCHES TO THESE SURFACES RESULT IN POOR PUMP PERFORMANCE REQUIRED ACTION Using a puller or a prying device remove th
96. smoke eliminator or an AF exhaust filter with an oil return line After closing the gas ballast valve the pump normally reaches ultimate pressure as soon as it cools to operating temperature TRIVAC A Manual Edition L NOTE On extreme corrosive service pumps the gas ballast valve 17 is sealed to prevent gases in the air from reacting with secondary gases or vapors in the pump These pumps have a port on the valve 17 for installing a dry nitrogen gas line see Sketch 2 1 the port is Vg inch NPT for the D2A and D4A models and V4 inch NPT for all other TRIVAC A models The maximum nitrogen pressure is 2 psig delivered to the pump PIPE PLUG ADAPTER WITH NPT PORT EPOXY SEAL This isn t a standard modification it is SEALED WITH EPOXY made primarily to extreme corrosive service pumps GAS BALLAST VALVE 17 RETAINING WASHER 21 1TA 1 2 Sketch 2 1 Cross Section of the Gas Ballast Valve on the D8A AC Extreme Corrosive Service Pumps 2 4 PUMP FLUID The pump fluid partially fills the oil casing 12 It is injected from the oil casing 12 into the module through one or two oil nozzles 56 located in the second stage pump cylinder 46 see Figure 5 8 Pump fluid consump tion is minimal during normal operation but increases when operating at high pressures or with the gas ballast valve open In addition to lubricating the moving parts the pump fluid seals the clearances in the pumping module Thi
97. tally enclosed fan cooled rpm revolutions per minute pl 7 UONIPZ enue Va OVAL 69 Number Required per Unit Pump Model This motor has a rotational lock bearing t This motor has an automatic resetting thermal overload Motor Specifications 1 hp 1 ph TEFC 208 230V wired for 208V 50 60 Hz 1500 1725 rpm 1 hp TEFC 3 ph 208 230 460V 60 Hz 1725 rpm 200 220 380V 50 Hz 1500 rpm 1 1 2 hp TEFC 3 ph 208 230 460V 60Hz 1725 rpm 200 220 380V 50 Hz 1500 rpm hp horsepower kw kilowatt V voltage VAC voltage alternating current ph phase Hz hertz TEFC totally enclosed fan cooled rpm revolutions per minute Motor Part No 722 60 005T 722 60 070 OL 71 00002 TENUEN Va OVAIHL Number Required per Unit Pump Model Part Name Motor Motor paA osa D16A D30A D60A D90A Specifications Part No tt 3 hp TEFC 3 ph tt A rotational lock bearing has been installed on all hp horsepower V voltage VAC voltage alternating current Hz hertz TEFC totally enclosed fan cooled 73 Motor 2hp 3ph TEFC 722 60 074 200 230 460V 1200 rpm 60Hz 200 220 380V 1000 rpm 50Hz 200 220 380V 50 Hz 1500 rpm motors listed on this page kw kilowatt ph phase rpm revolutions per minute oc G C t RN Ste eta G OF A D30A PUMP MOD P PLODED ISOMETRIC DRAW VE
98. ter vapor tolerance for your pump is listed in Table 4 1 If the partial pressure of water vapor in the gas being pumped exceeds the tolerance of your pump the vapor will condense We recommend installing an AK condensate trap on the pump when pumping saturated vapors see Section 1 of our catalog for more information on condensate traps L When the gas ballast valve 17 is open it admits a controlled amount of air into the second stage pump cylinder 46 just before the exhaust holes see Figure 2 3 The open gas ballast valve prevents vapors from condensing by reducing the partial pressure of the condensable vapors and by increasing the operating temperature of the pump The gas ballast valve is not fully effective until the pump is warm to the touch When using the gas ballast valve to remove condensate from the pump fluid it is best to seal off the intake tube 1 Sealing off the intake tube 1 prevents additional vapors from entering the pump while the condensate is being vaporized and the vapor is being ejected See Sections 4 1 2 and 4 2 for instructions for using the gas ballast valve during start up and operation In addition to increasing the operating temperature running the pump with the gas ballast valve open also results in higher ultimate pressure see Table 4 1 higher pump fluid consumption and a pump fluid mist in the exhaust stream If you run the pump with the gas ballast valve open continuously we recommend an SE
99. til the long pin 65 forces the other short pin the one that aligns the front end plate 44 and the second stage pump cylinder to fall out and then the long pin also falls out of the front end plate alignment hole see Figure 5 5 c Repeat Steps C 8a and C 8b for the two short and one long cylindrical pins on the other side of the module 1TA 4 20 Figure 5 4 Front End of Module Minus Coupling and Centrifugal Switch D2A Pump Model Shown Unscrew and remove the hexagon nuts 63 and washers from the ends of the threaded studs 62 which tie the module segments together see Figure 5 6 NOTE The D8A and D16A pump models have four rather than three threaded studs and hexagon nuts Remove the rear end plate 60 from the module see Figure 5 6 NOTE If necessary lightly tap the back edge of the plate with a rubber hammer to free the plate from the module This note also applies to Steps C 12 C 13 and C 15 CAUTION DO NOT SCRATCH THE INSIDE SURFACE OF THE PUMP CYLINDER OR THE END OF THE ROTOR SCRATCHES ON THESE SURFACES RESULT IN POOR ULTIMATE PRESSURE CAUTION DO NOT CHIP SCRATCH OR BREAK THE EDGES OF THE VANES DURING DISASSEMBLY IF THEY ARE TO BE REUSED NOTE f you plan to reuse the vanes be sure to mark the orientation and location of each vane so that during reassembly each used vane is replaced in its same rotor slot and so that each used vane is not turned end for end in its slot REQUIRED ACTION U
100. ting pliers to remove the key from the shaft NOTE For use during reassembly the fan must be positioned on the shaft so that it does not contact the fan end plate or the fan cover TABLE 5 2 Parts Required for Installing the Rotational Lock Bearing Pum ee Rotational Lock Bearing KK17 99 104 0045 D30A 2 Spring Washer N 34 002 Lotes ssid Loctite 601 Rotational Lock Bearing KK35 for 7 D60A D90A 1 Rotational Lock Bearing KK30 for 721 12 004 GE Motors Spring Washers K 6206 for GE Motors 99 164 002 2 LL Lotte 601 or 609 IE For D60A and D90A pumps that have Marathon motors the rotational lock bearing goes onto the shaft end of the motor not on the fan end Figure 5 17 Disassembled Motor D30A Motor Shown 32 TRIVAC A Manual Edition L Step F 1b 2 Cont d c e f g h i k TRIVAC A Manual Edition L Unscrew and remove the four hex head bolts that attach the fan end plate to the motor Use a hammer to tap the edge of the fan end plate to remove it from the motor NOTE If the motor has a malfunctioning rotational lock bearing it will be necessary to use a torch to heat the center of the fan end plate and the shaft The heat should help loosen the Loctite 609 which bonds the OD of the rotational lock bearing to the fan end plate bearing well The lock bearing is press fit and bonded to the shaft with Loctite Additional heat may be required
101. to separate the lock bearing from the shaft Except for D60A D90A s with Marathon motors remove and discard the three spring washers that fit between the fan end plate and the bearing Remove the shaft and attached rotor from the motor housing NOTE It may be necessary to tap the other end of the shaft to free the shaft from the other end plate For D30A pump models only remove and save for reassembly the two spacer rings that fit into the fan end plate bearing well Remove and discard the spacer ring that fits against the bearing on the other end of the shaft Grease the two new spring washers see Table 5 2 and place them together so that the IDs are tight against each other and so that there is a gap between the ODs Figure 5 17 shows ungreased spring washers placed together as de scribed above Except for the D60A D90A s with Marathon motors reach through the motor housing to place the two new greased spring washers into the bearing well in the other end plate Except for the D60A D90A s with Marathon motors use a puller to remove and discard the fan end bearing from the shaft NOTE The fan end bearing is the smaller bearing CAUTION IF ALL GREASE IS NOT REMOVED FROM THE MATING SURFACES THE LOCTITE WILL NOT FORM A PERMANENT BOND AND THE ROTATIONAL LOCK BEARING WILL NOT WORK THE BEST SOLVENT FOR THIS PURPOSE IS TRICHLOROETHANE THE FOLLOW ING SOLVENTS SHOULD NOT BE USED SINCE THEY LEAVE A FILM ON THE SURFACE KEROSENE GA
102. ts by suitable repair or replacement at its own expense Seller s liability under this warranty shall cease if any major repairs to or any replacement or modification of the equipment is made by any person other than Seller s personnel or persons working under the supervision of Seller s personnel unless authorized by Seller in writing Further the warranty shall cease unless the Buyer has operated the equipment in strict compliance with operating instructions and manuals if any provided for the equipment and unless Buyer operates the equipment in normal use and with proper maintenance If the equipment contains components from another manufacturer and are subject to the manufacturer s warranty then Seller s liability shall be limited to the extent of the warranty which Seller received from the manufacturer or supplier of the equipment component parts Seller s liability shall be no greater than the liability of the manufacturer or supplier as determined by a final judgment by the Buyer against the manufacturer or supplier of such components Seller will cooperate with Buyer in such legal action but at Buyer s expense THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL REPRESENTATIONS AND WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY EXCEPT THE WARRANTY OF TITLE THIS WARRANTY CONSTITUTES THE EXCLUSIVE REMEDY and shall not be deemed to have failed of its essential p
103. urpose so long as Seller is willing and able to correct defects covered by the warranty in the manner prescribed The sole purpose of the exclusive remedy shall be to provide Buyer with free repair and or replacement in the manner and for the time period provided herein The entire agreement between the parties is embodied in this writing which constitutes the final expression of the parties and it is the complete and exclusive statement of the terms of the agreement No other warranties are given beyond those set out in this writing LIMITATION OF LIABILITY SELLER SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR DIRECT OR INDIRECT SPECIAL DAMAGES INCIDENTAL OR CONSEQUENTIAL such as but not limited to loss of profits damage to or loss of other property downtime costs of the equipment delay expenses overhead or capital costs claims of Buyer s customers or activities dependent upon the equipment Except to the extent provided in the LIMITED WARRANTY Seller shall not be liable for any claim or loss arising out of or related to this agreement or the equipment provided pursuant thereto whether such claim allegedly arises or is based on contract warranty tort including negligence strict liability in tort or otherwise Liability shall not in any event exceed the cost of the equipment upon which such liability is based SEVERABILITY if any portion or clause of this agreement is held invalid or unenforceable as to any person or under any circumstanc
104. using 11 Look through the opening in the bottom of the coupling housing 11 to align the mating prongs and slots properly see Figure 5 23 d Use the screws and washers to attach the module to the coupling housing 11 see Figure 5 2 e Return the assembly to the horizontal position TRIVAC A Manual Edition L 41 5 F 42 OIL LEVEL GLASS ASSEMBLY 15 E R RUBBER FOOT 16 MOTOR 73 1TA 3 31 NOTE This view is looking toward the opening in the bottom of the coupling housing 11 The coupling housing motor assembly is resting on its motor end The assembly is vertical NOTE See Figure 5 15 for a photograph of the D30A D60A D90A coupling 37 and coupling ring 36 Figure 5 23 Reassembling the Module to the Coupling Housing D4A Pump Model Shown F 13 CAUTION DO NOT SCRATCH NICK OR TEAR THE VALVE DISK 67 WHEN INSERTING IT INTO THE PUMP CYLINDER Using a large pair of long nose pliers insert the valve disk 67 and attached brass piston 68 into the intake por tion of the high vacuum pump cylinder 55 see Figures 5 3 and 11 F 14 Repeat Steps B 8 B 7 B 6 B 5 B 4 and B 2 except assemble rather than disassemble CAUTION OVERTIGHTENING THE OIL CASING ONTO THE COUPLING HOUSING COULD DAMAGE THE FLAT GASKET 13 AND CAUSE AN OIL LEAK Use the following torque when tightening the oil casing onto the coupling housing D2A amp D4A 4 Nm 3 0 ft 1b D8A amp D16A 7 Nm 5 2 ft l
105. ver the shaft sleeve and insert the seal into its slot in the front end plate remove the shaft sleeve from the shaft or Method b Place cellophane tape over the shaft to prevent the seal from being cut or nicked carefully slide the seal 45 over the shaft and insert the seal into its slot in the front end plate remove the tape from the shaft 2 Recess the seal 45 using one of the following methods Method a Slide a seal driver over the shaft using a hammer strike the seal driver to indent the seal into its slot in the front end plate remove the seal driver from the shaft see Figure 5 22 or Method b Slide the used seal over the shaft until it is against the new seal using a hammer tap evenly around the used sea to indent the new seal into its slot in the front end plate remove and discard the used seal F 7 NOTE The end of the air inlet tube with the beveled tip and circumferential slots is the outside end see Figure 5 4 i l Install the air inlet tube 69 into the module as follows see Figure 5 4 a Push the air inlet tube through the hole in the top of the front end plate 44 When installed _ Properly two of the three circumferential slots in the end of the air inlet tube should extend out of the outside surface of the front end plate 44 b Insert the retainer disk 71 into the second slot from the beveled tip of the air inlet tube 69 NOTE The other end of the air inlet tube 69 fits into
106. wing 45 is worn venting of module Reinstall the spring 42 in its hole Install new O ring 70 B 1 thru C 6 F 9 F 11 amp F 12 B 1 thru C 7 C 14 D 2 E 9 F 7 F 9 F 11 amp F 12 Install new seal 45 Inspect the shaft where it rides in the seal for wear Install new shaft if necessary See worn seal in Symptom 8b If replacing shaft do B 1 thru F 17 j Vane 49 53 is Dirt has accumulated in stuck in rotor rotor slot 48 54 slot Vanes are installed with chamfered edge out Clean rotor slots and change lubricating fluid B 1 thru F 17 Clean vane slots and install vane with chamfered B 1 thru F 17 edge facing center of rotor Vanes 49 53 One or more of these parts rotors 48 54 contain gouging or wear pump cylinders 46 55 shaft inside surface of plates 52 60 44 or bronze bushing in plates 60 44 52 Replace worn part with new part B 1 thru F 17 This column contains the disassembly steps required to perform the corrective action Some critical assembly steps are also listed If the section is not specified the steps are located in Section 5 Use the general cleaning instructions at the beginning of Section 5 E 7 uolipy ENUEN Ya OVAIHL Recommended Symptoms Trouble Area Probable Cause Corrective Action 3 The pump will not achieve its ultimate pressure cont d 4 The evacuated vessel
107. xcept this time remove the gas ballast valve assembly 17 from the oil casing 12 emove the oil filter 35 from the gas ballast hole in the oil casing 12 see Figure 5 10B NOTE For the D30A D60A and D90A pump models the oil separator 35 may cling to the gas ballast valve when the valve is removed in Step B 5 In this case pull the oil separator off of the gas ballast valve stem a WARNING PUMP FLUIDS ARE EXCELLENT LUBRICANTS AND AS SUCH ARE VERY SLIPPERY BE CAREFUL WHEN HANDLING THE OIL CASING SINCE IT CONTAINS LUBRICATING FLUID WHICH COULD SPILL CAUSING A HAZARD gt A Manual Edition L 15 A EXHAUST PORT 6 INTAKE TUBE 1 8 9 SCREWS ATTACHING 12 TO 11 1TA22 Figure 5 1 Assembled Pump D16A Pump Model Shown Remove the oil casing 12 as follows a Unscrew and remove the lower screws or nuts and washers that attach the oil casing 12 to the coupling housing 11 see Figure 5 1 b WARNING ESPECIALLY FOR THE HEAVIER PUMPS D30A AND D60A BE SURE TO SUPPORT THE OIL CASING WHILE REMOVING THE SCREWS OR NUTS OTHERWISE THE CASING MAY FALL RESULTING IN DAMAGE OR INJURY While supporting the oil casing unscrew and remove the upper screws or nuts and washers c NOTE If you plan to reuse the large flat seal 13 that fits between the oil casing and the cou pling housing carefully peel the seal 13 from the oil casing flange before removing the oi
108. ze bushing with the proper pump fluid and slide the center bearing 52 onto the shaft so that the side of the center bearing 52 with the small hole faces away from the second stage rotor 48 see Figure 5 9 b Insert the rotor key 57 into its slot in the shaft Tap the key 57 down into its slot c NOTE The end of the high vacuum stage rotor 54 with the two pulling holes is the outside end Align the slot in the ID of the high vacuum stage rotor 54 with the rotor key 57 in the shaft Slide the rotor 54 onto the shaft The rotor 54 must slide freely on the shaft CENTER BEARING AS PLATE x 52 SECOND STAGE HIGH VACUUM ROTOR STAGE ROTOR 48 54 1TA 7 13 Figure 5 18 Rotors Shaft Center Bearing Plate Assembly D2A Pump Model Shown TRIVAC A Manual Edition L 35 CAUTION FAILURE TO ENSURE THAT THE O RINGS 47 REMAIN IN THEIR GROOVES DURING MODULE ASSEMBLY WILL RESULT IN DAMAGE TO THE O RINGS AND POOR PUMP PERFORMANCE NOTE The module assembly sequence Steps F 6a through F 6j is designed to keep the loose O ring facing up so that it does not fall out of its O ring groove CAUTION WHEN ASSEMBLING THE MODULE DO NOT SCRATCH THE ENDS OF THE ROTORS OR THE INSIDE SURFACES OF THE PUMP CYLINDERS OR END PLATES SCRATCHES TO THESE SUR FACES COULD RESULT IN POOR PUMP PERFORMANCE NOTE To ensure that each part is oriented correctly refer to Figure 5 3 and follow each st

Leybold Series A Pump Service Manual

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