LEYBOLD DRYVAC DV 450 User manual

Part Numbers

112045V07-1 /09-1 /15-1 /19-1

/20-1 /29-1 /30-1

112065V05-1 /07-1 /09-1 /14-1

/14-2 /14-3 /15-1 /16-1 /17-1

/18-1 /19-1 /20-1 /23-1 /30-1

/32-1 /35-1 /36-1 /37-1

112065FP08-1 /18-1 /28-1

112080V05-1 /07-1 /14-1 /15-1

/17-1

DRYVAC

DV 450, DV 650, DV 800

Dry Compressing Vacuum Pumps

Operating Instructions 300314330_002_C7

Contents

2 300314330_002_C7 - 05/2021 - © Leybold

Page

0 Important Safety Information 5

Explanation of Warning Symbols 5

0.1 Mechanical Hazards 7

0.2 Electrical Hazards 9

0.3 Thermal Hazards 10

0.4 Hazards Caused by Materials and Substances 11

0.5 Ignition Risk 13

0.6 Noise Hazard 13

0.7 Dangers in connection with safety-related

measures and precautions 13

0.8 Danger of Pump Damage 14

1 Description 16

1.1 Design 16

1.2 Supplied Equipment 17

1.3 Technical Data 20

1.4 Ordering Information 25

1.4.1 Pumps 25

1.4.2 Accessories 27

2 Transport and Storage 29

3 Installation 32

3.1 Placement 32

3.2 Conforming Use 34

3.2.1 Non-conforming Use 34

3.3 Connecting the Intake and Exhaust Lines 36

3.3.1 Intake Lines 36

3.3.2 Exhaust Lines 37

3.4 Connecting Cooling Water 38

3.4.1 Water Quality 40

3.5 Connecting Purge Gas 41

3.5.1 Gas Ballast Valve 44

3.5.2 Guidelines for Purge Gas Operation, Settings and Monitoring 45

3.6 Electrical Connection 48

3.6.1 Electrical Connection DRYVAC DV 450/650 and 450/650-r 50

3.6.2 Electrical Connection DRYVAC DV 450/650 54

3.6.3 Electrical Connection DRYVAC DV 450/650-r 56

3.6.4 Electrical Connection DRYVAC DV 800 59

3.6.5 Electrical Connection DRYVAC DV 800-r 62

Contents

3300314330_002_C7 - 05/2021 - © Leybold

Original operating instructions.

3.7 Leak Search after Installation 64

3.8 Mounting Accessories 65

3.8.1 Roots Pump Adapter 65

3.8.2 Non-return Valve 66

4 Operation 68

4.1 Media Compatibility 68

4.2 Profibus Interface 68

4.3 Start-up 68

4.4 Operation 69

4.4.1 LED Operator and Keys 70

4.4.2 Frequency Converter Outputs 73

4.4.3 Relay Option Board 75

4.4.4 Option: Changing the Speed of the Pump 76

4.4.5 Warning and Shut-off Thresholds 79

4.4.6 Gas Ballast Operation 80

4.4.7 Pumping of 100% Argon 81

4.5 Shut-off and Venting 81

4.6 Removing from Service 82

5 Maintenance 83

5.1 Leybold Service 83

5.2 Maintenance Intervals 83

5.3 Exchanging the Oil 84

5.4 Checking and Cleaning the Gas Ballast Filter 86

5.5 Replacing the Filter Cartridge in the Purge Gas Pressure Reducer 87

6 Troubleshooting 88

6.1 Pump Malfunctions 88

6.2 Fault and Alarms Displayed at the Frequency Converter 89

7 Wearing Parts 96

8 Waste Disposal 96

EU Declaration of Conformity 97

Certificates 101

Safety Information

4 300314330_002_C7 - 05/2021 - © Leybold

Obligation to Provide Information

Before installing and commissioning the pump, carefully read these

Operating Instructions and follow the information so as to ensure optimum

and safe working right from the start.

The Leybold DRYVAC has been designed for safe and efficient operation

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

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

precautions described in this section and throughout the Operating

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

under the conditions described in the Operating Instructions. It must be oper-

ated and maintained by trained personnel only. Consult local, state, and

national agencies regarding specific requirements and regulations. Address

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

office.

“Trained personnel” for the operation of this pump are

■skilled workers with knowledge in the fields of mechanics, electrical engi-

neering and vacuum technology and

■personnel specially trained for the operation of vacuum pumps.

DANGER indicates an imminently hazardous situation which, if not avoid-

ed, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

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

could result in minor or moderate injury.

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

maintenance information that is important, but not hazard related.

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

Instructions. The illustrations are not binding.

Retain the Operating Instructions for further use.

NOTICE

DANGER

WARNING

CAUTION

NOTICE

Safety Information

5300314330_002_C7 - 05/2021 - © Leybold

0 Important Safety Information

Explanation of Warning Symbols

Toxic gases

Danger of explosion

Fire danger

Reactive or corrosive

media

Contaminated parts

The pump must be leaktight.

When the pump has been used to

pump hazardous gases before,

introduce appropriate safety pre-

cautions before opening it. Before

opening the pump, purge it for a

longer period of time with an inert

gas. If necessary, wear suitable

personal protection equipment like

gloves, breathing protection and

protection clothing, for example.

Hazardous Voltage

Disconnect power before opening

Contact causes electrical shock

High Leakage Current

Earth connection essential before connecting supply

Electrical Hazards

Danger of residual voltage for up to 5 min after disconnecting power

supply. Connect and disconnect the mains plug only in deenergized

condition

Hot Surface

Do not touch.

Allow this area to cool before servicing

Burn hazard

Hot Surface inside. Do not touch, wear protective equipment.

Safety Information

6 300314330_002_C7 - 05/2021 - © Leybold

Purge gas

Check compatibility with applications

Overpressure in the discharge line

Components can be thrown in all directions.

The pressure in the discharge line must not exceed atmospheric

pressure by 200 mbar max.

The discharge line must not be blocked or restricted.

Pumps with wheels

must only be placed and moved on levelled horizontal surfaces!

Vacuum

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

Machinery starts automatically

Connect the pump so that it not will restart automatically after a mains

power failure, once the power returns.

Overhead load

Transport the pump only at the four crane eyes or secured

with a forklift.

Safety Information

7300314330_002_C7 - 05/2021 - © Leybold

0.1 Mechanical Hazards

1 In order to avoid the destruction of systems and injury to operating

personnel we urgently recommend to observe the information and

installation information provided in these Operating Instructions.

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

3 Do not operate the pump with an opened intake port. There exists the

risk of suffering injury.

4 The pump is intended for generating a vacuum only. If an

overpressure can occur in the pump and the system then they must

be pro-tected against such an overpressure by an overpressure safety

valve, for example.

5 The maximum permissible discharge pressure for the DRYVAC is 1.2

bar abs.

Always operate the pump with a connected exhaust line. The exhaust

line must be designed for the specific kind of application and shall be

connected to a central exhaust gas system.

Make sure that the gas flow at the discharge is not blocked or restrict-

ed in any way, even when the pumped out gases need to be collected

or contained.

No shutoff devices are required in the discharge line for pump opera-

tion. If shutoff devices are installed, open them before starting the

pump.

In the case of processes involving much condensate, we recommend

the installation of a condensate separator in the discharge line.

6 When using purge gas, protect the purge gas supply so that in the

event of a malfunction or power interruption no overpressure can

occur within the pump system.

7 We recommend to design the discharge line in consideration of a pos-

sible overpressure of 10 bar. In the event of a malfunction, such a

pressure can occur briefly, e.g. when the exhaust is shut suddenly.

8 For transporting the pump use only suitable transport means.

When selecting the lifting and transport means take note of the total

weight before transporting the pump.

As standard, the pump has been equipped with four crane eyes.

When transporting the pump with a forklift or similar, ensure that the

pump has been secured on the forks or on a suitable pallet.

The lifting eye of the screw pump must never be used to lift any pump

combinations (Roots pump + backing pump).

WARNING

Safety Information

8 300314330_002_C7 - 05/2021 - © Leybold

9 Select the location where the pump is installed so that all controls can

be easily accessed. Place the pump only on a floor which is level. It

can topple when it is tilted by more than 10° with respect to the ver-

ti-cal axis.

For pumps on castors only

Because of the fitted castors, the pump must only be placed on a level

floor capable of supporting the pump’s weight, as otherwise there

exists the risk of the pump rolling away. Moreover, the pump may only

be moved on a level floor! Moving the pump along sloping paths or

ramps is prohibited! The pump must only be transported with a forklift

or a crane! At the installation location, screw down the adjustable feet.

10 Before beginning with any maintenance and servicing work always

ensure that no gas can flow backwards through the pump since

then the rotors might turn against the normal direction of rotation. For

this reason vent the vacuum chamber to the discharge pressure level

or ensure through suitable valves that the vacuum chamber and the

lines are reliably separated from the pump. When connecting several

pump systems, pressure differences between inlet and discharge can

give rise to uncontrolled turning of the pump’s shafts.

11 During operation, the cooling water circuit must not be shut off. A

cooling water discharge which has been blocked can cause the for-

mation of gas bubbles and result in excessively high pressures.

12 Lay electric feed and cooling water lines so that there is no risk of trip-

ping over these.

13 When changing the oil remove any escaped oil as otherwise there is

the risk of slipping.

14 Before doing installation work on the pump system make sure that no

vacuum is present in the pump and that all media connections have

been depressurised.

15 Before disassembling any cooling water lines, leave the pump to cool

down, shut off the feed line.

Safety Information

9300314330_002_C7 - 05/2021 - © Leybold

0.2 Electrical Hazards

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

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

50110-1 for Europe, for example.

2 Potentially lethal voltages are present at the mains connections. Before

beginning with any maintenance or service work on the pump, discon-

nect the pump from all power supplies (lockout/tagout). In addition,

there is the danger of residual voltage for up to 5 min after disconnec-

tion.

3 Install a device for a safe disconnection from the power supply.

4 High electric voltages! When touching parts at high electric voltages,

there is the risk of suffering severe injuries by an electric shock! Covers

marked with this symbol must only be opened by trained electricians

after having reliably deenergised (lockout/tagout) the equipment.

5 Note the information on the IP type of protection.

6 Always operate the pump with a properly connected protective earth

conductor and make sure that the motor casing is closed

7 Observe the manufacturer’s information and operating instructions for

the respective frequency converter.

8 The pump must only be operated at the frequency specified for the

motor. Use only the Leybold frequency converter.

9 For pumps with external frequency converter: after having connected

the motor and each time after having made changes to the wiring,

check the motor’s direction of rotation.

A wrong direction of rotation can cause a pressure buildup on the

intake side. Moreover, the pump may suffer severe damage.

10 Install a suitable motor protection for the electric motor before starting

up for the first time. Note the information in these Operating

Instructions and on the nameplate.

11 Before starting, check to ensure that the junction box is undamaged,

run a visual inspection on the seals.

12 Install add-on parts (pressure switches, for example) without any

mechanical tensions and protect these against being damaged by

impacts, for example.

13 Lay the connecting lines so that these cannot be damaged. Protect

the lines against humidity and contact with water. Avoid thermally

stressing the lines by unfavourable laying. Comply with the required

standards when designing and laying the electrical connections.

14 Provide strain relief for the connecting lines so that the plugs and the

line connectors are not subjected to excessively high mechanical

stresses.

15 Lay electric feed lines so that there is no risk of tripping over these.

DANGER

Safety Information

10 300314330_002_C7 - 05/2021 - © Leybold

16 For models with external frequency converter only:

Consider the following precautions for the output circuit wiring.

Do not connect any other load than a 3 phase motor to the frequency

converters output.

Never connect a power source to the frequency converters output.

Never short or ground the output terminals.

Do not use phase correction capacitors.

17 The pump must be integrated in the system control arrangement so

that it can not run-up automatically after it has been shut down due to

overtemperature. This applies equally to emergency shut-down

arrangements. After having determined the fault cause, the pump

should be switched on manually again.

18 We recommend the use of the external display (accessory) to operat-

ing the frequency converter. Attach the external display appropriately if

it used permanently.

19 Work on the frequency converter within the motor casing must always

be left to suitably instructed personnel only.

0.3 Thermal Hazards

1 Under certain ambient conditions parts of the pump may attain tem-

peratures over 80° C. There then exists the risk of suffering burns.

Note the danger symbols on the pump and in the case of a hot pump

wear the required protection equipment.

If there is the risk of touching hot surfaces inadvertently, install corre-

sponding protection. When working on a pump which is still warm

from operation, always wear protective gloves.

2 Handle the pump only while vented and after having let it cool down.

3 Before disassembling any cooling water lines, leave the pump to cool

down, shut off the feed line.

4 When uninstalling the cooling water lines, take note of splashing water.

Heated water can cause burns.

5 Never remove the oil-fill or oil-drain plugs while the pump is running.

There exists the risk of suffering burns. Always wear protective gloves

and protective goggles also for protection against the oil.

6 Operating the pump with less than the specified amount of cooling

water will result in excessively high surface temperatures. Moreover,

there exists the risk of suffering burns.

7 DRYVACs without cooling water unit:

(Industrial versions) For these DRYVAC pumps do not connect the

cooling water using self-sealing quick locks or shut off the feed and

discharge lines with valves.

CAUTION

This manual suits for next models

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