LEYBOLD TRIVAC E2 User manual

Part Nos.

140 000

140 001

140 002

140 003

140 004

140 005

140 008

140 009

TRIVAC E 2 / D 2,5 E

Dual-Stage Rotary Vane Vacuum Pump

Operating Instructions GA01602_002_C0

Contents

2 GA01602_002_C0 - 09/2016 - © Leybold

Page

0 Important Safety Information 5

0.1 Mechanical hazards 5

0.2 Electrical hazards 5

0.3 Thermal hazards 6

0.4 Hazards caused by materials and substances 6

0.5 Danger of ignition 7

0.6 Risk of damaging the pump 8

1 Description 9

1.1 Function 10

1.2 Supplied Equipment 12

1.3 Technical Data 13

1.4 Accessories 20

2 Transport and Storing 21

3 Installation 22

3.1 Placement 22

3.2 Normal use 23

3.2.1 Abnormal use 24

3.3 Connection to the System 24

3.4 Electrical Connections 26

4 Operation 26

4.1 Media Compatibility 26

4.2 Start-up 26

4.3 Operation 27

4.3.1 Pumping of Non-Condensable Gases and Vapours 27

4.3.2 Pumping of Condensable Gases and Vapours 27

4.3.3 Operating Temperature 28

4.4 Shutdown 29

4.4.1 Shutdown through Monitoring Components 29

4.4.2 Controller/Mains Power Failure 29

Contents

3GA01602_002_C0 - 09/2016 - © Leybold

Original installation and operating instructions.

5 Maintenance 30

5.1 Maintenance Plan 31

5.2 Leybold Service 32

5.3 Monitoring the Oil Level 32

5.3.1 Checking the Condition of LVO 100 33

5.4 Oil Change 34

5.5 Cleaning the Inlet Screen 35

5.6 Removing and Fitting the Internal Demister 36

5.7 Disassembly and Reassembly of the Electric Motor 37

5.8 Full maintenance 38

6 Troubleshooting 39

7 Wearing Parts and Original Spare Parts 41

7.1 Maintenance Kits and Repair Sets 41

7.2 Ordering Information for the Maintenance Kits

and the Repair Sets 42

7.3 Ordering Information for the Special Tools 42

8 Waste Disposal 46

EC- Declaration of Conformity 47

Page

Notes

4 GA01602_002_C0 - 09/2016 - © Leybold

Obligation to Provide Information

Before installing and commissioning the TRIVAC E, carefully read these

Operating Instructions and follow the information so as to ensure optimum

and safe working right from the start.

The Leybold TRIVAC E has been designed for safe and efficient operation

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

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

precautions described in this section and throughout the Operating

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

and under the conditions described in the Operating Instructions. It

must be operated and maintained by trained personnel only. Consult local,

state, and national agencies regarding specific requirements and regulations.

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

nearest office.

DANGER indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury.

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

could result in death or serious injury.

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

could result in minor or moderate injury.

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

maintenance information that is important, but not hazard related.

Figures

The references to figures, e.g. (4/2) consist of the consecutive Fig. No. and

the Item No. in that order.

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

Instructions. The illustrations are not binding.

Retain the Operating Instructions for further use.

NOTICE

DANGER

WARNING

CAUTION

NOTICE

Safety information

5GA01602_002_C0 - 09/2016 - © Leybold

0 Important Safety Information

0.1 Mechanical hazards

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

2 Never operate the pump without a connected intake line or without fit-

ting a blank flange.

3 Do not operate the pump with any of the covers removed.

Serious injury may result.

4 The location at which the TRIVAC E (including its accessories) is being

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

avoided.

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

on. Spilled oil involves the risk of falling.

6 Make sure that the gas flow from the exhaust port is not blocked or

restricted in any way.

7 If exhaust gases must be collected or contained, do not allow the

exhaust line to become pressurised.The pressure in the oil box must

not exceed 0.5 bar relative to the atmospheric pressure. An exhaust

line which is too small in diameter or which is blocked can result in the

formation of overpressures within the pump. Possible consequences

can be damage or even burst open the pump. Thus the exhaust line

must be checked from time to time to ensure that there are no obst-

ructions.

8 When moving the TRIVAC E always use the lifting means provided.

0.2 Electrical hazards

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

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

Observe local regulations.

2 Lethal voltages are present at the mains connections. Before starting

with any maintenance and service work, de-energise (lockout/tagout)

the product first.

3 Lay connecting lines so that they cannot be damaged. Protect the

lines against humidity and contact with water. Avoid any heat stress on

the line due to unfavourable laying conditions.

4 Suitably support the connecting lines so that the pumps are not

exposed to any major mechanical stress.

5 After a mains power failure the pump will run up automatically again.

This also applies in the case of an emergency shutdown. In order to

prevent the pump from running up automatically again, the pump must

be integrated within a control arrangement such that it can only be

switched on manually again after the mains power has returned.

6 Provide an adequate ground connection for the pump so as to avoid

any electrostatic charging.

WARNING

Safety information

6 GA01602_002_C0 - 09/2016 - © Leybold

0.3 Thermal hazards

1 Under certain ambient conditions the TRIVAC E may attain a

temperature of over 70 °C (158 °F). There then exists the danger of

receiving burns.

Note the symbols on the pump pointing to the hazards, and in the

case of a hot pump wear the required protective clothing. All work on

the “pump still warm from operation” should only be done using pro-

tection gloves.

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

down.

3 Note the warning information on the housing surface. If these warning

notices have been removed, covered or obstructed, include corre-

sponding additional warning notices.

0.4 Hazards caused by materials and substances

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

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

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

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

(like PFPE) must be used

2 Before commissioning the TRIVAC E, make sure that the media which

are to be pumped are compatible with each other so as to avoid

hazardous situations. All relevant safety standards and regulations

must be observed.

3 When pumping toxic, chemical, radioactive and corrosive gases as

well as pyrophorous substances, the user is under the obligation to

comply with the national and international safety regulations and

guidelines. Regarding the suitability of the TRIVAC E pumps for special

applications in which such gases shall be pumped, Leybold should be

consulted first.

4 If the pump has previously handled hazardous gases, implement the

proper precautionary measures before opening the intake or exhaust

connection.

Before opening the pump, purge it for a longer period of time with an

inert gas.

If necessary, use gloves, a respirator and/or protective clothing and

work under an exhaust hood. Firmly seal off the pump.

When shipping the contaminated pump for servicing, please also state

the type of hazard. For this you must use a form which we have pre-

pared for you.

5 Contaminated parts can be detrimental to health and environment.

Before beginning with any work, first find out whether any parts are

contaminated. Adhere to the relevant regulations and take the neces-

sary precautions when handling contaminated parts.

CAUTION

DANGER

Safety information

7GA01602_002_C0 - 09/2016 - © Leybold

0.5 Danger of ignition

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

explosion hazard areas.

2 The TRIVAC pumps including the accessories are fundamentally not

suited for pumping of combustible and explosive gases or vapours.

Mixtures of substances may, regarding the fire and explosion risk be

critical or uncritical. The operating company is under the commitment

to analyse this and rate the hazard potential accordingly so as to the-

refrom derive the necessary safety measures which must be intro-

duced.

Provided ignitable or pyrophorous substances are present in the

equipment you must:

nensure that no air can enter into the equipment,

nensure that the system is leak-tight,

nwith an inert gas purge (a nitrogen purge, for example) dilute all igni-

table gases or vapours which may enter into the pump through the

pump’s inlet and/or with an inert gas purge reduce the concentration

of ignitable gases or vapours in the pump and in the exhaust line to

less than a quarter of the lower explosion limit (LEL) published for the

respective gases.

CAUTION

Safety information

8 GA01602_002_C0 - 09/2016 - © Leybold

0.6 Risk of damaging the pump

1 Before starting up for the first time, the motor circuit must be equipped

with a suitable protective motor switch. Please take note of the infor-

mation in these Operating Instructions and on the electric motor (wiring

diagram).

2 Do not allow the ingestion of small objects (screws, nuts, washers,

pieces of wire, etc.) through the inlet port. For this reason always use

the inlet screen which is supplied as standard.

3 Do not use the pump for applications that produce abrasive or

adhesive powders or condensable vapours that can leave adhesive or

high viscosity deposits. When planning to pump vapours other than

water vapour please contact our sales or service department for

advice.

4 This pump is suited for pumping water vapour within the specified

water vapour tolerance limits.

5 Avoid vapours that can condense into liquids when being compressed

inside the pump, if these substances exceed the vapour tolerance of

the pump.

6 Before pumping vapours the TRIVAC E should have attained its

operating temperature. This will be the case approximately 30 minutes

after having started the pump. During this warming up phase, the

pump should be separated from the process, by a blocking valve in

the intake line, for example.

7 In the case of wet processes we recommend the installation of liquid

separators upstream and downstream of the pump as well as the use

of the gas ballast.

8 The exhaust line should be laid so that it slopes down and away from

the pump so as to prevent condensate from backstreaming into the

pump.

9 The entry of particles and fluids must be avoided under all

circumstances.

10 Reactive or aggressive substances in the pump chamber may impair

the operating oil or modify it. In addition, such substances may be

incompatible with the materials of the pump (Viton, grey cast iron, alu-

minium, steel, resins, glass etc.).

11 Normal amounts of humidity within the range of the pump’s water

vapour tolerance will not significantly affect pump performance when

the gas ballast is active.

12 When operating the pumps at gas throughput, it is urgently recom-

mended to connect an exhaust filter or use a suitable exhaust line.

Here, the exhaust line must slope down and away from the pump.

13 In the case of custom pumps (with part numbers deviating from those

stated in the EC Declaration of Conformity) please note the information

provided in the supplementary sheets.

NOTICE

Description

9GA01602_002_C0 - 09/2016 - © Leybold

Fig. 1 TRIVAC D 2,5 E rotary vane pump

TRIVAC

OUT

OIL

1 Intake port

2 Oil drain

3 Oil level indicator

4 Name plate

5 Oil fill

6 Exhaust port

7 Gas ballast valve

8 Mains power connection

1 Description

The TRIVAC D 2,5 E are dual stage oil sealed rotary vane vacuum pumps.

The number in the designation of the pump indicates the pumping speed

of this pump in m3· h-1.

These pumps are capable of pumping gases and vapours out of vessels

and vacuum systems down into the fine vacuum pressure range. The stan-

dard pumps are not designed to handle oxygen at concentrations excee-

ding the concentration of oxygen in the atmosphere. Moreover, these

pumps are not suited for pumping of hazardous gases or extremely

aggressive or corrosive media.

The drive motor of the TRIVAC D 2,5 E is screwed directly to the bearing

piece. The shaft of the pump and the shaft of the motor are linked by a

coupling piece. The bearings in the inner pump body are force-lubricated

sliding bearings.

The oil level glass for viewing the minimum/maximum oil level and the oil

drain plug as well as the name plate are located on the front of the pump.

The connection components, the gas ballast knob and the oil fill plug are

located on the top of the pump.

Description

10 GA01602_002_C0 - 09/2016 - © Leybold

1.1 Function

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

chamber) has two radially sliding vanes (2/7 and 2/9) which divide the pump

chamber of the pump into several chambers.

The volume of each chamber changes periodically with each turn of the rotor

so that the gas at the intake port (2/4) is sucked in. The gas enters the pump

chamber, and after the admission aperture has been sealed off by the vane,

the gas is compressed and moved on.

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

valve. Oil which is entrained in the gas is roughly separated by an internal

demister and at the same time any mechanical contaminations are also

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

Oil injected into the pump chamber serves the purpose of sealing and lubri-

cation. The knocking noise (oil slap) which normally occurs when the pump

approaches its ultimate pressure is avoided by injecting a small amount of air

into the oil so that a silencing effect is attained.

1 Gas ballast valve

2 Gas ballast inlet

3 Tandem valve

(vacuum protection)

4 Intake port

5 Oil feed (oil pump)

6 Rotor

7 Vane (HV)

8 High vacuum stage

(pump chamber)

9 Vane (FV)

10 Forevacuum stage

(pump chamber)

11 Non-return valve

12 Diaphragm valve

13 Exhaust valve

14 Bypass valve

15 Exhaust port

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

123

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