Vacuum Solutions
Application Support
Service
LEYBOLD VACUUM
GA 01.600/10.02
TRIVAC® E 2
D 5 E / D 10 E / D 16 E
Dual-Stage Rotary Vane
Vacuum Pump
Operating Instructions
Contents
Contents
Page
IMPORTANT SAFETY CONSIDERATIONS . . 4
1
1.1
1.2
1.2.1
1.3
1.4
1.4.1
Description . . . . . . . . . . . . . . . . .
Principle of Operation . . . . . . . . . .
Supplied Equipment . . . . . . . . . . .
Notes on the Oil and how to Order
Accessories . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . .
Motor Dependent Data . . . . . . . . .
2
2.1
2.2
2.3
2.3.1
2.3.2
2.4
2.5
2.5.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . .12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .12
Connection to the System . . . . . . . . . . . . . . .12
Electrical Connection . . . . . . . . . . . . . . . . . .13
Pumps with AC Motor . . . . . . . . . . . . . . . . . .13
Pumps with Three-Phase Motor . . . . . . . . . .13
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Pumping of Non-Condensable Gases
and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .15
Pumping of Condensable Gases
and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Temperature . . . . . . . . . . . . . . . . .16
Shut Down / Shelving . . . . . . . . . . . . . . . . . .17
Shut Down through Monitoring
Components . . . . . . . . . . . . . . . . . . . . . . . . .17
Failure of the Control System or
the Mains Power . . . . . . . . . . . . . . . . . . . . .17
2.5.2
2.5.3
2.6
2.6.1
2.6.2
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.6
.6
.8
.8
.8
.9
.9
Page
Checking / Maintenance . . . . . . . . . . . . . . .18
Checking the Oil Level . . . . . . . . . . . . . . . . .18
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . .19
Disposal of Used Pump Materials . . . . . . . . .19
Cleaning the Dirt Trap . . . . . . . . . . . . . . . . . .20
Removing and Inserting the
Internal Demister . . . . . . . . . . . . . . . . . . . . .20
3.5
Disassembly and Assembly of the
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . .21
3.5.1 Instructions for the TRIVAC D 5 E - D 10 E . .21
3.5.2 Instructions for the TRIVAC D 16 E . . . . . . . .22
3.6
Full Maintenance . . . . . . . . . . . . . . . . . . . . .23
3.7
Leybold Service . . . . . . . . . . . . . . . . . . . . . .23
3.8
Shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3
3.1
3.1.1
3.2
3.2.1
3.3
3.4
4
Maintenance Plan . . . . . . . . . . . . . . . . . . . .24
5
5.1
5.2
Maintenance Kits and Repair Sets . . . . . . .26
Ordering Information for the Maintenance Kits
and the Repair Sets . . . . . . . . . . . . . . . . . . .30
Ordering Information for the Special Tools . . .30
6
Troubleshooting . . . . . . . . . . . . . . . . . . . . .31
EC - Declaration of Conformity . . . . . . . . .32
We reserve the right to modify the design and the
specified data. The illustrations are not binding.
2
GA 01.600/10.02 - 07/01
Directions
We strongly recommend that you read
these Operating Instructions with care so as
to ensure optimum operation of the pump
right from the start.
Warning Indicates procedures that must be strictly
Leybold-Service
If a pump is returned to LEYBOLD, indicate whether the
pump is free of substances damaging to health or
whether it is contaminated.
If it is contaminated also indicate the nature of the
hazard. LEYBOLD must return any pumps without a
„Declaration of Contamination“ to the sender’s address.
observed to prevent hazards to persons.
Disposal of Waste Oil
Owners of waste oil are entirely self-responsible for proper disposal of this waste.
Caution
Indicates procedures that must strictly be
observed to prevent damage to, or destruction of the pump.
Figures
The references to diagrams, e.g. (1/2) consist of the Fig.
No. and the Item No. in that order.
Waste oil from vacuum pumps must not be mixed with
other substances or materials.
Waste oil from vacuum pumps (Leybold oils which are
based on mineral oils) which are subject to normal wear
and which are contaminated due to the influence of oxygen in the air, high temperatures or mechanical wear
must be disposed of through the locally available waste
oil disposal system.
Waste oil from vacuum pumps which is contaminated
with other substances must be marked and stored in
such a way that the type of contamination is apparent.
This waste must be disposed of as special waste.
European, national and regional regulations concerning
waste disposal need to be observed. Waste must only be
transported and disposed of by an approved waste disposal vendor.
Caution
GA 01.600/10.02 - 07/01
The oil for the TRIVAC E vacuum pumps is
supplied separately.
3
IMPORTANT SAFETY CONSIDERATIONS
The Leybold TRIVAC E vacuum pump is designed for safe and efficient operation when used properly and in accordance with this manual. It is the responsibility of the user to carefully read and strictly observe all safety precautions
described in this section and throughout the manual. This product must be operated and maintained by trained personnel only. Consult local, state, and national agencies regarding specific requirements and regulations. Address any
further safety, operation and/or maintenance questions to your nearest Leybold Vacuum office.
Warning
Failure to observe the following precautions could result in serious personal injury:
• Before beginning with any maintenance or service work on the TRIVAC E, disconnect the pump from
all power supplies.
• Do not operate the pump with any of the covers removed. Serious injury may result.
• If exhaust gases must be collected or contained, do not allow the exhaust line to become pressurised.
• Make sure that the gas flow from the exhaust port is not blocked or restricted in any way.
• The standard version of the TRIVAC E is not suited for operation in explosion hazard areas. Contact us
before planning to use the pump under such circumstances.
• Before starting up for the first time, the motor circuit (3 phase) must be equipped with a suitable protective motor switch. Please take note of the information in these Operating Instructions or on the electric motor (wiring diagram).
• The TRIVAC E is not suited for pumping of:
- combustible and explosive gases or vapours
- radioactive and toxic substances
- pyrophorous substances.
- oxidations substances.
• Avoid exposing any part of the human body to the vacuum.
• Never operate the TRIVAC E without a connected intake line or blank flange.
• The location at which the TRIVAC E (including its accessories) is operated should be such that angles
over 10° from the vertical are avoided.
• The location of the TRIVAC E should be such that all controls are easily accessible.
• Under certain ambient conditions the TRIVAC E may attain a temperature of over 80 °C (176 °F). There
then exists the danger of receiving burns.
Note the symbols on the pump pointing to the hazards, and in the case of a hot pump wear the required protective clothing.
• Before pumping oxygen (or other highly reactive gases) at concentrations exceeding the concentration
in the atmosphere (> 21 % for oxygen) it will be necessary to use a special pump. Such a pump will
have to be modified and de-greased, and an inert special lubricant (like PFPE) must be used.
4
GA 01.600/10.02 - 07/01
Warning • Before operating the TRIVAC E with atmospheric gas ballast (optional) check first compatibility with the
pumped media so as to avoid hazardous conditions during operation right from the start.
• Before commissioning the TRIVAC E, make sure that the media which are to be pumped are compatible with each other so as to avoid hazardous situations.
All relevant safety standards and regulations must be observed.
• It is recommended to always operate the TRIVAC E with a suitable exhaust line which is properly
connected. It must slope down and away from the pump.
• When moving the TRIVAC E always use the allowed means.
A lifting eye is provided as standard on the pump.
Caution
Failure to observe the following precautions could result in damage to the pump:
• Do not allow the ingestion of small objects (screws, nuts, washers, pieces of wire, etc.)
through the inlet port. Always use the screen which is supplied with every pump.
• Do not use the pump for applications that produce abrasive or adhesive powders or
condensable vapours that can leave adhesive or high viscosity deposits. Please contact Leybold Sales
or Service to select a suitable separator. Also pease contact Leybold Sales or Service when planning
to pump vapours other than water vapour.
• This pump is suited for pumping water vapour within the specified water vapour tolerance limits.
• Avoid vapours that can condense into liquids upon compression inside the pump, if these substances
exceed the vapour tolerance of the pump.
• Before pumping vapours, the TRIVAC E should have attained its operating temperature, and the gas
ballast should be set to position I - III (position 0 = closed, position 3 = max. water vapour tolerance,
30 mbar).
The pump will have attained its operating temperature about 30 minutes after starting the pump. During
this time the pump should be separated from the process, by a valve in the intake line, for example.
• In the case of wet processes we recommend the installation of liquid separators upstream and downstream of the pump as well as the use of the gas ballast.
• The exhaust line should be laid so that it slopes down and away from the pump so as to prevent condensate from backstreaming into the pump.
• The entry of particles and fluids must be avoided under all circumstances.
• Reactive or aggressive substances in the pump chamber may impair the operating oil or modify it.
In addition, such substances may be incompatible with the materials of the pump (Viton, grey cast iron,
aluminium, steel, resins, glass etc.).
• Corrosion, deposits and cracking of oil within the pump are not allowed.
Note
This information will help the operator to obtain the best performance from the equipment:
• Normal amounts of humidity within the range of the pump’s vapour tolerance will not significantly affect
pump performance when the gas ballast is active. Preferably use the exhaust flange located on the side
of the motor.
GA 01.600/10.02 - 07/01
5
Description
Key to Fig. 1
1 Intake port
2 Oil drain
3 Oil level indicator
4 Name plate
5 Oil fill
6 Exhaust port
7 Gas ballast valve
8 Mains power connection
7
8
0
6
1
2
3
G
B
5
IN
T
U
O
IN
T
IL U
O O
1
TR
IVA
C
4
3
2
Fig. 1 TRIVAC D 5 E rotary vane pump (other TRIVAC E models are similar)
1 Description
1.1 Principle of Operation
The TRIVAC D 5 - 16 E are dual stage oil sealed rotary
vane vacuum pumps.
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 number in the designation of the pump indicates the
pumping speed of this pump in m3 · h-1.
These pumps are capable of pumping gases and
vapours out of vessels and vacuum systems down into
the fine vacuum pressure range. The standard pumps
are not designed to handle oxygen at concentrations
exceeding the concentration of oxygen in the 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 5 to 16 E is screwed
directly to the bearing piece. The shaft of the pump and
the shaft of the motor are linked by a coupling piece. The
bearings in the inner pump body are force-lubricated 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 volume of each chamber changes periodically with
each turn of the rotor so that the gas at the intake port
(1/1) is sucked in. The gas enters the pump chamber,
and after the admission aperture has been sealed off by
the vane, the gas is compressed and moved on.
The compressed gas is ejected from the pump chamber
through the exhaust valve. Oil which is entrained in the
gas is roughly separated by an internal demister and at
the same time any mechanical contaminations are also
removed from the oil. The gas exits the pump through the
exhaust port.
Oil injected into the pump chamber serves the purpose
of sealing and lubrication. The knocking noise (oil slap)
which normally occurs when the pump approaches its
ultimate pressure is avoided by injecting a small amount
of air into the oil so that a silencing effect is attained.
The connection components, the gas ballast knob and
the oil fill plug are located on the top of the pump.
6
GA 01.600/10.02 - 07/01
Description
Key to Fig. 2
1 Gas ballast valve
2 Gas ballast inlet
3 Tandem valve
(vacuum protection)
4 Intake port
5 Oil feed (oil pump)
6 Rotor
7 Vane (HV)
8 High vacuum stage
(pump chamber)
9 Vane (FV)
10 Forevacuum stage
(pump chamber)
11 Non-return valve
12 Diaphragm valve
13 Exhaust valve
14 Bypass valve
15 Exhaust port
1
0
2
3
2
3
15
1
G
B
4
14
5
13
12
6
7
8
9
10
11
Fig. 2 Sectional view through a TRIVAC D 5 E pump
(other TRIVAC E models are similar)
By opening the gas ballast valve (2/1, optional) it is possible to admit a controlled quantity of air (gas ballast) into
the pump chamber while the compression process is in
progress. The gas ballast will prevent the condensation
of vapours within the pump up to the extent of the vapour
tolerance levels as stated in the specifications for the
pump (these data refer to water vapour).
A special lubrication system with forced lubrication of the
sliding bearings has been developed to enable operation
of the pump at intake pressures up to 1000 mbar.
An oil pump supplies the oil from the oil reservoir into a
high pressure oil system which in turn supplies all bearings. From here the oil enters the pump chamber of the
vacuum pump.
The oil pump is located in bearing piece of the high vacuum stage. Separation of oil and gas in the pump involves
two stages. First an internal demister which is arranged
ahead of the exhaust valve ensures the creation of larger
droplets.
Next these are returned back to the oil reservoir via a
separation panel. This ensures a minimal loss of oil.
GA 01.600/10.02 - 07/01
This and the combination with the large usable oil reservoir, results in long intervals between the oil exchanges,
even at high intake pressures.
The gas ballast valve (GB) is opened or closed by turning it (positions 0, 1, 2, 3).
Available as an option is a gas ballast valve having a
knurled screw (see Fig. 13 on page 28). When fully
opening this valve, the resulting gas flow will correspond
to that of valve position 3 in the following Table.
GB position
Explanation
0
no gas ballast
maximum ultimate pressure
1
for cleaning the pump’s oil at a good ultimate pressure and low oil consumption
2
good water vapour tolerance without producing excessive noise
3
maximum water vapour tolerance in
accordance with the technical data on
page 6.
7
Description
When the pump is at standstill (mains power failure, or
when the pump is shut down) the pump chamber is hermetically sealed off by two safety valves (tandem valve
and gas ballast diaphragm valve) which are controlled
through the oil pressure.
This reliably avoids any inadvertent venting of the vacuum chamber and the backstreaming of oil.
1.2 Supplied Equipment
Each TRIVAC D 5 - D 16 E pump is supplied with the
following basic equipment:
• Pump with motor
• Separately included oil filling (see Section 1.2.1)
• Separately included dirt sieve with O-ring
• Operating Instructions
• “Declaration of Contamination” form
The connection ports are provided with foil protectors for
protection during shipping.
The TRIVAC E pumps having an AC motor are supplied
ready for operation, complete with switch, built-in thermal
motor overload protection, mains cord (1.8 m long) and
a mains plug which depends on the country of use.
1.3 Accessories
Cat. No. /Order No.
Exhaust filter AF 10, DN 25 KF . . . . . . . . . . . . .190 51
Exhaust filter AF 16, DN 25 KF . . . . . . . . . . . . .190 52
Replacement filters FE 10 (set of 5) . . . . . . . . . .190 81
Replacement filters FE 16 (set of 5) . . . . . . . . . .190 82
Drain clock for the exhaust filter AF 8/10/16 . . . .190 95
Condensate separator AK 10, DN 25 KF . . . . . .190 61
Condensate separator AK 16, DN 25 KF . . . . . .190 62
Oil drain cock (for D 5 E - D 16 E) . . . . . . . . . . .190 90
Manual oil return via the gas ballast port . . . . . .190 93
(Kit for AF 8-16) ARM
Connection components required to connect the exhaust
filter and the condensate separators in each case:
1 Pipe bend
DN 25 KF
184 37
2 Centering rings with O-ring
DN 25 KF
183 27
2 Clamping rings
DN 25 KF
183 42
The three-phase models do not come with the accessories needed for the electrical connection. However, these
accessories are available upon request.
1.2.1 Notes on the Oil and how to Order
Oil N 62 or HE 200 is used as standard. If any other kind
of special oil is being used, this fact will be indicated by
a sticker on the oil box stating the type of special oil
used.
Not all types of oil have been released for all pumps. You
must only use the kind of oil which has been specified for
the particular pump.
8
GA 01.600/10.02 - 07/01
Description
1.4 Technical Data
D5E
D 10 E
D 16 E
6/7,3
12/14,6
21/23,6
m3·h-1
5,2/6
9,9/11,3
16/19
Ult. partial pressure without gas ballast
mbar
≤ 5 x 10-4
≤ 5 x 10-4
≤ 5 x 10-4
Ult. total pressure without gas ballast**
mbar
≤ 2 x 10-3
≤ 2 x 10-3
≤ 2 x 10-3
Ult. total press. w. gas ballast (stage 2)**
mbar
≤ 3 x 10-2
≤ 3 x 10-2
≤ 3 x 10-2
Stage 1
mbar
10
10
10
Stage 2
mbar
30
20
20
Stage 3
mbar
40
30
30
Nominal pumping speed* 50/60 Hz
m3·h-1
Pumping speed 50/60 Hz
Water vapour tolerance
Connection port
DN
16 KF
25 KF
25 KF
Noise level (50 Hz)
dB (A)
≤ 49
≤ 49
≤ 52
Permissible ambient temperature
°C
Oil filling max./min
l
1,25/0,75
1,25/0,75
1,25/0,75
Motor power 50/60 Hz
W
450/550
450/550
700/850
Speed 50/60 Hz
rpm
1350/1650
1350/1650
1380/1650
Protection
IP
54
54
54
Weight with operating agent***kg
kg
22,1
24,2
30,7
Dimensions (W x H x D)***
mm
156 x 258 x 416
156 x 258 x 435
170 x 258 x 494
* to DIN 28 426 T1
** to DIN 28 4oo and subsequent numbers
10 bis 50 (EURO - Motor) / 10 to 40 (USA/Japan - Motor)
*** Dimensions and weights with Euro motor
1.4.1 Motor Dependent Data
Motors for
Voltage
Frequency Voltage
Power consumption
Nom. current Fuse*
Protection Nom. speed
D5E
(V)
(Hz)
(W)
(A)
IP
Euro
1~
Three-ph. motor
3~
tolerance
220-240/230
50/60
±5%
450/540
2,5/2,4
10
54
1350/1650
50
±5%
550
2,8
6
54
1500
60
±5%
650
6
54
1800
Y 346/415
1,6
Y 346-460
D 10 E
Euro
Voltage
(V)
1~
Three-ph. motor
3~
1,6
Frequency Voltage
(Hz)
tolerance
Power consumption
Protection Nom. speed
IP
(rpm)
±5%
450/540
2,5/2,4
10
54
1350/1650
±5%
550
2,8
6
54
1500
60
±5%
650
6
54
1800
50/60
±5%
490/550
10
54
1350/1650
Y 346/415
motor
1~
208-240
Motors for
Voltage
(V)
3~
(A)
50/60
110-120;
Three-ph. motor
(A)
50
1,6
Y 346-460
1~
Nom. current Fuse*
(W)
220-240/230
Wide voltage-
D 16 E
2,8
∆ 220-240/
∆ 200-266/
Euro
(rpm)
∆ 220-240/
∆ 200-266/
Motors for
(A)
2,8
1,6
6,8/5,6
3,4/2,8
Frequency Voltage
(Hz)
tolerance
Power consumption
Nom. current Fuse*
(W)
(A)
(A)
Protection Nom. speed
IP
(rpm)
220-240
50/60
±5%
700/850
5,3/4,6
10
54
1380/1650
∆ 220-240/
50
±5%
650
4
10
54
1430
60
±5%
750
10
54
1720
Y 346-415
∆ 200-277/
Y 346-480
2,3
3,6
2,1
*The values stated for the fuses are recommended values only
Values for up-front fuses for short circuit protection. Please take note of the information provided by the manufacturers of contactors and motor protection switches.
GA 01.600/10.02 - 07/01
9
Description
A
E
F
DN
DN
J
K
X
B
L
M
G
H
IN
OUT
IN
OIL
OUT
N
C
D
O
P
TRIVAC
View of ”X”
R
Q
Fig. 3 Dimensional drawings for the TRIVAC D 5 - D 16 E rotary vane vacuum pumps
10
GA 01.600/10.02 - 07/01
Description
Table of dimensions for Fig. 3
Description
D5E
D 10 E
D 16 E
1~, EURO
421
440
494
1~, World
-
440
-
3~, World
421
440
479
1~, EURO
231
231
242
1~, World
-
249
-
3~, World
212
212
228
1~, EURO
156
156
170
1~, World
-
156
-
3~, World
156
156
170
1~, EURO
182
183
171
1~, World
-
**
-
E
192
195
231
F
77
80
116
G
143
140
176
H
300
300
300
J
258
258
258
K
253
253
253
L
210
210
210
M
205
205
205
N
140
140
140
O
38
38
38
P
29
29
29
Q
110
110
110
R
105
105
105
DN
16
25
25
A
B
C
D
* Capacitor at both sides of the motor
** Capacitor in the terminal box
all dimensions in mm
10
2
Saugvermögen
Pumping
speed
m 3 . h -1
10
D 16 E
D 10 E
1
D
10
5E
0
8
6
4
2
10
-1
10
-4
2
4 68
10
-3
10
-2
10
-1
10
0
Druck
Pressure
10
1
2
10 mbar 10
3
Fig. 4 Pumping speed characteristics of the TRIVAC D 5 E - D 16 E
GA 01.600/10.02 - 07/01
11
Operation
2 Operation
2.1 Installation
The TRIVAC D 5 E - D 16 E can be placed freely on a flat
and horizontal surface.
The rubber elements under the pump’s base prevent the
pump from slipping. If the pump is to be permanently
attached, this may be done by making use of the holes
in the rubber elements and a threaded bolt or similar.
Caution
The inclination of the pump (without additional fixing means) and with possibly attached standard accessories must not
exceed an angle of 10 ° from the vertical
axis.
The rubber elements act as vibration absorbers. For this reason they must not be compressed by the screws. When installing the
pump you must ensure accessibility of all
connections and controls.
2.2 Connection to the
System
Before connecting the pump, the shipping seals on the
connection flanges (6/1 and 6/2) must be removed.
If residues of adhesives are present on the connecting
flanges you must remove these using a suitable solvent
like alcohol, for example.
Insert the dirt sieve (6/8) with the O-ring.
The intake and exhaust lines are fitted with standard
small flanges. The connection flanges must be clean and
undamaged.
The intake line and the exhaust line must be connected
using corrugated pipes or vacuum hoses so that no
mechanical forces can be transferred to the pump.
The intake line must be clean. Any deposits in the intake
line will tend to degas and impair the attainable vacuum
pressures.
Select a place for the pump which ensures a sufficient air
circulation for cooling the pump (keep front and rear
sides unobstructed).
The cross section of the intake and exhaust line must at
least be of the same diameter as that of the pump
connections.
The ambient temperature around the pump should not
exceed 50 °C (in the case of USA and Japan motors
40 °C) and not drop below 10 °C (see Section 2.5.3).
An intake line which is too small in diameter will throttle
the pumping speed.
If required the crane eye or the handle may be removed.
Caution
The oil filling has been included separately.
Before operating the pump you must fill in
the correct quantity of oil (see Section 3.2).
An exhaust line which is too small in diameter can result
in the formation of overpressures within the pump. Possible consequences are damaged shaft seals and possibly also an oil leak.
The pressure in the oil box must not exceed 1.5 bar
(abs.)
When pumping vapours we strongly recommend the
installation of a condensate separator on the suction
side and also on the exhaust side.
The exhaust line must be laid so that it slopes down and
away from pump (lower than the pump) to prevent any
condensate from flowing back into the pump. If a sloping
line can not be installed, a separator must be fitted.
When the oil mist is to be removed from the exhaust gas
flow we recommend the installation of an exhaust filter.
When pumping inert gases the pump’s gas ballast inlet
can directly be connected to the system by an adaptor
(for this the gas ballast knob must be removed).
Intake and exhaust port are of the screwed type and can
be replaced by direct connection to the system.
12
GA 01.600/10.02 - 07/01
Operation
2.3 Electrical Connection
Warning During all electrical work ensure that the
power supply lines have reliably been switched off and protected against being switched on inadvertently.
In order to prevent the pump from running
up unexpectedly after a power failure, the
pump must be connected to the system
controller in such a way that the pump may
only be re-started manually. This applies
equally after the pump has been switched
off through an emergency switch.
The electrical connections may only be
made by an electrician as defined by VDE
0105 in accordance with the VDE 0100 guidelines.
The pumps are supplied with either an AC motor or a
three-phase motor.
2.3.1 Pumps with AC Motor
The pump may be directly connected via its mains cable
and its plug to the mains.
In the case of 230 V mains, 6 A slow blow or 10 A fast
blow fusing is required as a minimum.
A check on the direction of rotation is not required since
this is fixed.
2.3.2 Pumps with Three-Phase Motor
The TRIVAC E pumps equipped with a three-phase
motor are delivered without the components required for
their electrical connection.
You must connect the pump using an appropriately rated
cable (we recommend: AWG 18 for the 5 to 10 type
models and AWG 16 for the 16 type modes) and a suitably rated motor protection switch. The value set on the
motor protection switch must correspond to the current
rating stated on the name plate of the motor.
Shown in Fig. 5 is the way in which the pump having a
three-phase motor (50/60 Hz) may be connected in Star
or Delta fashion. Please also take note of the information
given on the name plate of the motor.
Caution
After having connected the motor and each
time after having made a change to the
wiring you must check the direction of rotation.
For this switch the motor on briefly and
determine whether or not a suitable plate (a
blank flange, for example) held in front of
the intake is sucked towards the pump’s
body. If this is not the case you must interchange two of the mains phases.
Note the direction indicating arrow on the
fan cowl.
The thermal motor overload protector protects the motor
in case it is overloaded.
The mains voltage must comply with the voltage stated
on the name plate.
Warning When the thermal motor overload protection system has switched the motor off, the
motor will automatically cut in again when
the temperature has dropped below the
maximum permissible operating temperature.
GA 01.600/10.02 - 07/01
13
Operation
Delta circuit
Star circuit
Fig. 5 Wiring diagram for the TRIVAC E pumps with three-phase motor
2.3.2.1 Current Drawn by the Three-Phase Motors of the TRIVAC D 5 E - D 16 E
Voltage ranges for
the three-phase
motors
Max. current consumption
at an intake pressure of
about 300 mbar
Min. current
consumption at
ultimate pressure
Setting for the
motor protection
switch (motor data)
TRIVAC D 5 / 10 E
D
50 Hz
60 Hz
200 V - 240 V
200 V - 266 V
2.2 A - 2.6 A
2.5 A - 2.3 A
1.6 A - 2.5 A
1.4 A - 1.9 A
2.8 A
2.8 A
Y
50 Hz
60 Hz
346 V - 415 V
346 V - 460 V
1.2 A - 1.5 A
1.4 A - 1.35 A
0.9 A - 1.4 A
0.8 A - 1.2 A
1.6 A
1.6 A
TRIVAC D 16 E
D
50 Hz
60 Hz
200 V - 240 V
200 V - 277 V
3 A - 3.8 A
3.3 A - 3.5 A
2 A - 3.3 A
1.8 A - 3.1 A
4A
3.6 A
Y
50 Hz
60 Hz
346 V - 415 V
346 V - 480 V
1.8 A - 2.1 A
1.95 A - 2 A
1 A - 1.5 A
0.95 A - 1.45 A
2.3 A
2.1 A
14
GA 01.600/10.02 - 07/01
Operation
10
9
8
0
7
1
2
3
G
B
IN
U
O
T
6
5
IN
T
IL U
O O
Key to Fig. 6
1 Intake port
2 Exhaust port
3 Oil drain
4 Oil level indicator
5 Name plate
6 Oil fill
7 Gas ballast valve
8 Dirt sieve
9 O-ring
10 ON/OFF switch
11 Mains connection
TR
IVA
C
11
4
1
3
2
Fig. 6 Connections and controls
2.4 Start Up
2.5 Operation
Caution
These pumps are capable of pumping gases and
vapours. Vapours can only be pumped provided the gas
ballast valve (optional) is open and provided the pump
has attained its operating temperature.
Check the oil level each time before switching on the pump (see Section 3.2).
After having connected the motor and each
time after having made a change to the
wiring you must check the direction of rotation (see Section 2.3.2).
The pump is started up by operating the ON/OFF switch
(6/10 - does not apply in the case of pumps with a threephase motor). The ON/OFF switch may be operated at
all pressures.
During initial start up and after a longer period during
which the pump has not been used, the pump may not
immediately attain the specified ultimate pressure
because the oil has to be degassed first.
For this you should let the pump run for about 30 minutes with the intake line closed and the gas ballast valve
(6/7) open (position 2 of the gas ballast valve).
GA 01.600/10.02 - 07/01
The maximum vapour tolerance is attained when the gas
ballast valve (6/7) is set to position 3.
2.5.1 Pumping of Non-Condensable Gases
and Vapours
In the presence of excess quantities of permanent gases
the pump may be operated without gas ballast, provided
the saturation vapour pressure at the operating temperature is not exceeded during compression.
If the composition of the gases which are to be pumped
is not known and if the possibility of condensation within
the pump can not be excluded, we recommend operation of the pump with the gas ballast valve open (in accordance with Section 2.5.2).
15
Operation
2.5.2 Pumping of Condensable Gases
and Vapours
With the gas ballast valve (option) open and when the
pump is running at its operating temperature, pure water
vapour can be pumped up to the extent stated in the
technical data for the pump (position 3 of the gas ballast
valve). When the vapour pressure increases above the
permissible level, the vapour will condense in the oil of
the pump.
When pumping vapours make sure that the gas ballast
valve is open and that the pump has been running for at
least 30 minutes with the intake line closed and with gas
ballast.
Caution
It will be possible to pump vapours up to the
permissible limit only after the pump has
reached its operating temperature.
During the pumping process vapours may
dissolve in the oil of the pump. This impairs
the properties of the oil and there is the risk
of corrosion within the pump. For this reason the pump must not be switched off
immediately after termination of the process. The pump must remain on with the
gas ballast valve open and the intake line
sealed until all vapours which were dissolved in the oil have been removed.
We strongly recommend that the TRIVAC
D 5 E - D 16 E pumps be left running for
about 30 minutes after termination of the
process.
2.5.3 Operating Temperature
Proper operation of the TRIVAC D 5 E - D 16 E is
ensured at ambient temperatures between 10 °C and
50 °C, with the exception of the pump models for the
USA and Japan where a range of 10 °C to 40 °C applies.
When using SHC 224 Arctic oil, the pump will reliably run
up even at a temperature of 5 °C.
When the pump is warm, the temperature at the surface
of the oil box may rise to between 40 °C and 80 °C,
depending on the load on the pump.
Warning TRIVAC E pumps may attain surface temperatures of over 80 °C.
There is the danger of receiving burns.
In the case of cyclic or repetitive processes the TRIVAC
D 5 E - D 16 E should not be switched off during the breaks between the individual work phases (low energy
requirement when running at ultimate pressure). The gas
ballast valve should be opened and the intake line
should be sealed (through a valve, if possible).
When all vapours have been pumped from a process
(drying, for example) the gas ballast valve can be closed
to improve the attainable ultimate pressure.
16
GA 01.600/10.02 - 07/01
Operation
2.6 Shut Down /
Shelving
2.6.2 Failure of the Control System
or the Mains Power
During normal use of the TRIVAC D 5 E - D 16 E it will
be sufficient to electrically switch off the pump. Further
measures are not required.
Warning In order to prevent the pump from running
After having pumped condensable media, let the pump
run for some time with the gas ballast valve open and the
intake line blocked (see Section 2.5.2).
up unexpectedly after a mains power failure, the pump must be integrated in the
control system in such a way that the pump
can only be switched on again manually.
This applies equally to emergency cut-out
arrangements.
When pumping aggressive or corrosive media and also
in the case of long process interruptions (overnight, for
example) we recommend that you let the pump run with
the intake line sealed and with the gas ballast switched
on.
This helps to prevent the occurrence of standstill corrosion.
If the pump is to be switched off for a longer period of
time after it has been pumping aggressive or corrosive
media or if the pump is to be shelved, proceed as
follows:
Warning When hazardous substances have been
pumped ensure that the appropriate safety
precautions are observed.
For more information please contact our
technical sales department.
Seal off the intake port. The use of special conservation
or anti-corrosion oils is not required.
2.6.1 Shut Down through Monitoring
Components
Warning When the pump has been switched off due
to overheating sensed by the motor coil protector (single phase pumps only), the pump
must only be started manually after the
pump has cooled down to the ambient temperature and after having removed the
cause first.
GA 01.600/10.02 - 07/01
17
Checking / Maintenance
3 Checking / Maintenance
Warning Before starting any disassembly work, disconnect all electrical connections to the
pump. Reliably prevent the pump from running up.
When the pump has been pumping hazardous substances, determine the nature of
the hazard and make sure that the appropriate safety measures are observed.
3.1 Checking the Oil Level
During operation the oil level of the TRIVAC E must
always be visible between the marks on oil viewing glass
(7/2 and 7/3). The quantity of oil must be checked and
topped up as required.
Recommendation:
The oil level should always be
visible in the middle of the oil
viewing glass.
Observe all safety regulations!
Caution
Caution
When disposing of the waste oil, observe
the applicable regulations for the safety of
the environment.
Due to the concept of the TRIVAC E these pumps will
hardly require any maintenance under normal operating
conditions. The necessary maintenance work is described in the following sections. In addition a maintenance
plan is provided in Section 4.
Caution
3.1.1 Oil Check
The ageing process of the standard operating agent
N 62 / HE 200 (see Section 1.2.1) basically depends on
the operating conditions of the pump. You may check the
condition of the oil as follows:
All work should be left to trained personnel.
Improperly performed maintenance or
repair work endangers the durability and
operational readiness and will lead to difficulties when wanting to file any warranty
claims.
•
Also available from LEYBOLD are seminars covering
practical aspects like maintenance, repair and checking
of the TRIVAC E which are run under the supervision of
our experts. For more information on these seminars
please contact us at LEYBOLD.
•
Caution
If the pump is used in strongly contaminated ambient air you must ensure that operation of the gas ballast system and the air
cooling is not impaired.
When the TRIVAC E has been pumping
corrosive media, we strongly recommend
that you conduct any possibly due maintenance immediately in order to avoid corrosion during standstill.
Spare Parts are contained in the Repair Sets and in the
Maintenance Kits. If required, ask us for a quotation on
spare parts.
The pump must be switched off before topping up any oil.
Visually
Normally the oil will be light and transparent. In the case
of increasing discolouration of the oil (it becomes darker)
we recommend that you exchange the oil.
Chemically
The neutralisation value for N 62 is determined in accordance with DIN 51558. When the neutralisation value
exceeds the value of 2 you must change the oil.
•
Mechanically
When the viscosity of N 62 exceeds a value of 240 mPas
at 25 °C (20 % over viscosity of fresh oil) we recommend
that you change the oil.
When gases or liquids are dissolved in the oil, the attainable ultimate pressure will be impaired. In such cases the
oil may possibly be degassed by letting the pump run for
about 30 minutes with the intake line closed and the gas
ballast valve open.
In the case of custom models and variants please always
state the custom, variant and serial number.
18
GA 01.600/10.02 - 07/01
Checking / Maintenance
IN
3.2 Oil Change
O
U
T
1
reactive gases) at concentrations exceeding the concentration in the atmosphere
(> 21 % for oxygen) it will be necessary to
use a special pump. Such a pump will have
to be modified and de-greased, and an inert
special lubricant (like PFPE) must be used.
TR
IVA
C
2
3
For proper operation of the pump, it is essential that the
pump has an adequate supply of the correct and clean
oil at all times.
The oil must be changed when it looks dirty or if it
appears chemically or mechanically worn out (see Section 3.1.1).
The oil should be changed after the first 100 operating
hours and then at least every 2,000 to 3,000 operating
hours or after one year. At high intake pressures and
intake temperatures and/or when pumping contaminated
gases, the oil will have to be changed much more frequently.
Further oil changes should be made before and after
long-term storage of the pump.
Caution
Only change the oil after the pump has
been switched off and while the pump is still
warm.
Required tool: Allen key 8 mm.
Remove the oil drain plug (7/4) and let the used oil drain
into a suitable container. When the flow of oil slows
down, screw the oil drain plug back in, briefly switch on
the pump (max. 10 s) and then switch it off again. Remove the oil drain plug once more and drain out the remaining oil.
Screw the oil drain plug back in (check the gasket and
reinstall a new one if necessary).
Remove the oil fill plug (7/1) and fill in fresh oil.
Screw the oil fill plug (7/1) back in.
Warning If there is the danger that the operating
IN
T
IL U
O O
Warning Before pumping oxygen (or other highly
4
Key to Fig. 7
1 Oil fill plug
2 Oil level mark “maximum”
3 Oil level mark “minimum”
4 Oil drain plug
Fig. 7 Oil change
Caution
We can only guarantee that the pump operates as specified by the technical data if
the lubricants recommended by us are
used.
3.2.1 Disposal of Used Pump Materials
The corresponding national environmental and safety
regulations apply. This applies equally to used filters and
filter elements (oil filter, exhaust filter and dust filter).
Warning - In the case of hazardous substances
determine the kind of hazard first and
observe the applicable safety regulations.
If the potential hazard still persists, the
pump must be decontaminated before
starting with any maintenance work. For
professional decontamination we recommend our Leybold service.
- Never exchange the oil or the filters while
the pump is still hot. Let the pump cool
down to uncritical temperatures first. You
must wear suitable protective clothing.
agent may present a hazard in any way due
to decomposition of the oil, or because of
the media which have been pumped, you
must determine the kind of hazard and
ensure that all necessary safety precautions are taken.
GA 01.600/10.02 - 07/01
19
Checking / Maintenance
9
8
0
7
G
* only D 16 E
10
1
2
3
Key to Fig. 8
1 Oil drain plug
2 Oil box
3 Hex. socket screw (4x)
4 Oil fill plug
5 Spring
6 Guide panel
7 Sealing strip for the guide panel*
8 Holding frame for the internal demister
9 Internal demister
10 Dirt trap with O-ring
11 Gasket for the oil box
12 Enlarged detail of the gasket for
the oil box
B
6
5
4
IN
T
U
O
3
IN
T
IL U
O O
TR
IVA
C
2
1
12
11
Fig. 8 Removing and inserting the internal demister
3.3 Cleaning the Dirt Trap
Located in the intake port is a wire mesh sieve acting as
a dirt trap (8/10) for foreign objects. This sieve must be
kept clean in order to avoid any throttling of the pump.
To clean the dirt trap remove it from the intake and clean
it in a vessel using a solvent. Then thoroughly dry it with
compressed air. If the dirt trap is faulty you must replace
it.
Caution
Depending on the operating conditions the internal demister will have to be cleaned regularly or it must be
exchanged. Cleaning must be performed using a suitable
solvent.
Switch the pump off and drain out the oil (in accordance
with Section 3.2).
In order to collect the remaining oil in the oil box we
recommend that you lift the pump up slightly at the side
of the motor.
Unscrew the four hex. socket screws (8/3) of the oil box.
Adapt the cleaning intervals according to
the requirements. If large quantities of abrasive materials are involved you should
install a dust filter in the intake line.
3.4 Removing and Inserting
the Internal Demister
Pull the oil box (8/2) out to the front.
Remove the gasket (8/11) of the oil box.
Use a pair of pliers to pull the spring (8/5) out to the front.
Detach the holding frame (8/8) and the internal demister
(8/9).
Clean all parts and check them for perfect condition and
replace them as required.
Simple maintenance on the side of the pump using
Maintenance Kit 1
Reassemble in the reverse order.
Required tools:
Caution
Allan keys 4 and 8 mm
Make sure to fit the gasket for the oil box
(8/11) with the flat side in the groove, see
item 12 in Fig. 8.
The internal demister has been installed in a resiliant
frame. When it has clogged it will lift itself up periodically
at high intake pressures in order to equalise the resulting
pressure difference.
Torque for the hex. socket screws (8/3) is
5.5 Nm.
The increased noise level at high intake pressure is thus
a sign for a clogged internal demister.
20
GA 01.600/10.02 - 07/01
Checking / Maintenance
4
3
2
1
IL
O
5
Key to Fig. 9
1 Oil box
2 Mounting bolts (2x)
3 Fan cowl
4 Tie rod
5 Electric motor
6 End plate A
7 HV bearing piece
8 Foot of the pump
9 Hex. socket screws (4x)
6
7
8
9
Fig. 9 Disassembly and assembly of the electric motor (TRIVAC D 5 E - D 10 E)
3.5 Disassembly and
Assembly of the Electric
Motor
Detach the motor (lever off using two screwdrivers inserted in parallel between the end plate A and the HV bearing piece (9/6 and 9/7).
Warning Before starting with any work on the pump,
In case of wear exchange the coupling bushings; these
are included in Repair Set 1.
always reliably disconnect the motor from
its power supply.
Remove the mains connection (three-phase
motors only) or pull the mains plug.
Clean all parts and make sure that they are in perfect
condition; replace any parts as required.
Reassemble in the reverse order.
Tighten the tie rods crosswise to 4 Nm.
Tighten the bolts for the pump’s base to 23 Nm for the
D 5 to 10 E.
Caution
3.5.1 Instructions for the
TRIVAC D 5 E - D 10 E
Especially note the position of the oil ejection hole (see arrow in Fig. 9) in the end
plate A. The hole must always lead downward.
Required tools:
Spanner size 8 and special tool for the tie rod.
We recommend that you remove the foot (9/9) of the
pump.
Place the pump on the front side of the oil box (9/1).
Remove the two (four) hex. screws (9/2) from the fan
cowl (9/3).
Detach the fan cowl.
Unscrew the tie rod (9/4).
GA 01.600/10.02 - 07/01
21
Checking / Maintenance
5
6
4
3
7
2
8
0
1
1
2
3
G
B
9
IN
T
U
O
IN
T
IL U
O O
10
TR
IVA
C
11
12
15
13
14
Key to Fig. 10
1 Oil box
2 O-ring
3 End plate A with motor rotor
4 Hex. socket screws (4x)
5 Key
6 Spring washer
7 Motor stator
8 Phillips screws (4x)
9
10
11
12
13
14
15
Fan cowl of the motor
Securing ring
Tie rod
Fan blade
End plate B
Hex. socket screws (2x)
Foot of the pump
Fig. 10 Disassembly and assembly of the electric motor (TRIVAC D 16 E)
3.5.2 Instructions for the TRIVAC D 16 E
Lift off the stator (10/7) from the motor.
Required tools:
Unscrew the size 4 hex. socket screws (10/4) from end
plate A (10/3).
Phillips screwdriver, special tool for the tie rod, puller (twopoint) for fan cowl, pliers for securing rings, combination
pliers, size 4 Allan key.
We recommend to remove the foot (10/15) of the pump.
Place the pump on the front side of the oil box (10/1).
Remove the Phillips screws (10/8) from the fan cowl
(10/9). Detach the fan cowl.
Disassemble the securing ring (10/10) of the fan blade
(10/12).
Detach end plate A with the motor rotor and the spring
washer (10/6).
Clean all parts and make sure that they are in perfect
condition; replace any parts as required (Repair Set 1).
Reassemble in the reverse order.
Tighten the tie rods crosswise to 5 Nm.
Also tighten the bolts at the A bearing plate to 5 Nm. The
bolts at the pump’s base are tightened to 23 Nm.
Use the puller to detach the blade wheel.
Use a pair of pliers to disassemble the key (10/5).
Unscrew the tie rod (10/11), detach end plate B (10/13).
22
GA 01.600/10.02 - 07/01
Checking / Maintenance
Caution
Especially note the position of the oil
ejection hole (see arrow in Fig. 10) in the
end plate A. The hole must always lead
downward.
3.6 Full Maintenance
Clean the pump and run maintenance on it.
Clean and perform maintenance on the pump as described in the instructions for Maintenance Kit 2.
3.7 Leybold Service
If a pump is returned to Leybold, indicate whether the
pump free of substances damaging to health or whether
it is contaminated.
If it is contaminated also indicate the nature of the
hazard. For this you must use a form which has been
prepared by us which we will provide upon request.
3.8 Shelving
Caution Before putting a pump into operation once
more it should be stored in a dry place preferably at room temperature (20 °C). Before
the pump is shelved it must be properly disconnected from the vacuum system, purged
with dry nitrogen and the oil should be
changed too.
The inlets and outlets of the pump must be
sealed with suitable seals.
The gas ballast valve must be set to the „0“
position and if the pump is to be shelved for
a longer period of time it should be sealed
in a PE bag containing some desiccant (silica gel).
When a pump is put into operation after it has been shelved for over one year, standard maintenance should be
run on the pump and the oil should also be exchanged
(see Section 3.2). We recommend that you contact the
Leybold Service.
A copy of this form is reproduced at the end of these
Operating Instructions: „Declaration of Contamination of
Vacuum Instruments and Components“.
Please attach this form to the pump or enclose it with the
pump.
This „Declaration of Contamination“ is required to meet
the requirements of German Law and to protect our personnel.
Caution
Leybold must return any pumps without a
„Declaration of Contamination“ to the sender’s address.
Warning The pump must be packed in such a way,
that it will not be damaged during shipping
and so that any contaminants are not released from the package.
GA 01.600/10.02 - 07/01
23
Maintenance Plan
4 Maintenance Plan (Recommendation)
No.
Rotary vane pumps
TRIVAC D 5 E - D 16 E
Measurem./ test quantity
Operating / auxiliary
agents
1
Operate the pump with gas ballast for at least 45 minutes.
2
Check the oil level and change
the oil as required.
Oil: N 62 or special and
alternative types of oil,
see Section 3.1
3
Check the quality of the oil and
change the oil as required.
visually
4
Clean the dirt trap in the intake
and exchange it as required.
Interval
VE
t
Remarks
6m a n-a
See also Op. Instructions,”Individual Components”
x
Condensed water is thereby removed from the oil.
x
x
Topping up: only after the pump has been switched
off.
x
x
Visually: Normal condition light and transparent, oil
change is required at increasing discolouration.
chemically
x
Chemically: To DIN 51558, when the neutralization
value exceeds 2, then an oil change is required.
mechanically
x
Mechanically: When the dynamic viscosity at
25 °C > 240 mPas, then an oil change will be required.
Disposal of the used oil:
see Section 3.2.1
Suitable cleaning agent and
compressed air.
x
❏ Clean the dirt trap with a cleaning agent and blow it
clean with compressed air under a suction hood.
❏ Replace the faulty dirt trap.
Use a cleaning agent which complies with national /
international specifications.
Observe the safety regulations which apply to the
cleaning agent used.
5
Clean the internal demister and
change it as required.
Suitable cleaning agent.
x
Perform cleaning also in advance of the scheduled
maintenance interval when the noise increases more
and more.
❏ Clean the internal demister with cleaning agent.
❏ Replace a faulty internal demister.
❏ Dispose of the used internal demister as special
waste.
Use a cleaning agent which complies with national /
international specifications.
Observe the safety regulations which apply to the
cleaning agent used.
(parts are contained in Maintenance Kit 1)
(see Section 5)
6
24
Check the coupling bushings for
damage and wear.
3
Check also in advance of the scheduled maintenance
interval in case of extreme noise.
(parts are contained in Repair Set 1, see Section 5)
GA 01.600/10.02 - 07/01
Maintenance Plan
No.
7
Rotary vane pumps
TRIVAC D 5 E - D 16 E
Measurem./ test quantity
Operating / auxiliary
agents
Change the oil and
Oil: N 62 or special and
alternative types of oil
clean the oil level glass.
Suitable cleaning agent and
compressed air.
Interval
VE
t
Remarks
6m a n-a
x
See also Op. Instructions,”Individual Components”
Oil change (see Section 3.2)
• First oil change after 100 operating hours.
❏ Clean the oil level glass with a cleaning agent and
blow it clean with compressed air under a suction hood.
Use a cleaning agent which complies with national /
international specifications.
Observe the safety regulations which apply to the
cleaning agent used.
Quantity of oil: see Section 1.4.
Disposal of oil: see page 2.
8
Check the pump’s fan, the motor Brush and industrial vacuum
fan and the cooling fins of the
cleaner.
motor for dirt, and clean as required.
9
Full maintenance
Maintenance Kit 2.
x
When the pump or the motor is getting too warm clean
before the stated maintenance interval.
Caution: Switch the pump off and secure it against
being started inadvertently (disconnect from the
mains).
3
Clean and perform maintenance on the pump as
described in the instructions included with Maintenance
Kit 2 (see Section 5).
Key to the maintenance plan
VE = Perform maintenance before switching the system on
t
= Daily maintenance
6m = Maintenance every 6 months
a = Annual maintenance
n-a = Maintenance every n years
Every 3 years we recommend servicing of the pump involving the following steps:
• Cleaning
• Checking of individual components
• Exchange of all gaskets
• Functional check.
This check should be performed by the Leybold Service.
GA 01.600/10.02 - 07/01
25
Maintenance Kits and Repair Sets
5 Maintenance and Repair Kits
The maintenance and repair kits have been so arranged
that the spare and exchange parts they contain cover
any servicing work which might be required.
Each set comes with brief instructions in which the
necessary work is detailed. This very much simplifies the
servicing or repair work.
Given in the following is a brief description of the individual kits and how to use these (in connection with the
TRIVAC D 10 E, other pumps are similar)
Maintenance Kit 1
This kit is recommended for maintenance after an operating period of one year. It contains the gaskets for the
oil box, the internal demister which separates the oil from
the gas (for contents see page 27, Fig. 11).
Repair Kit 1
This kit is used for the seal on the side of the motor. It
contains the gaskets for the side of the motor, the shaft
sealing ring as well as the following wearing parts: coupling sleeves and compression spring for the oil pump
(for contents see page 27, Fig. 12).
Repair Kit 2
This set will only be required in those cases where the
pump is not capable of attaining its ultimate pressure.
This kit contains the valves, the internal demister which
separates the oil from the gas as well as the gaskets for
the oil box (for contents see page 28, Fig. 13).
Maintenance Kit 2 / Repair Kit 3
These kits are identical. They contain all wearing parts,
all gaskets and the internal demister which separates the
oil from the gas.
They are used as follows:
1.
Maintenance after three years of operation
2.
Complete repair
(for contents see pages 27, 28 and 29, Fig. 12, 13 and 14).
26
GA 01.600/10.02 - 07/01
Maintenance Kits and Repair Sets
14
15
13
12
11
10
0
9
1
2
3
G
8
B
7
6
5
IN
O
Key to Fig. 11
1 Oil drain plug
2 Gasket
3 Oil box
4 Hex. socket screw
5 Washer
6 Gasket
7 Oil fill plug
8 Oil box seal
9 Spring clip
10 Guide panel
11 Sealing strip for guide panel (D 16 E only)
12 Holding frame for demister
13 Demister
14 O-ring
15 Dirt trap
U
T
4
IN
T
IL U
O O
TR
IVA
C
3
2
1
Fig. 11 Maintenance kit 1
5
4
3
2
1
6
7
IL
O
Key to Fig. 12
1 Coupling/Oil pump
2 Coupling bushing (2x)
3 Flange for the shaft sealing ring
4 O-ringe (4x)
5 Bolt (4x)
6 Fan cowl
7 Tie rods (4x)
8 A-bearing plate
9 O - ring
10 Stopper
11 Compression spring
12 HV-bearing piece
13 Base
14 Hex. socket bolt (4x)
15 Shaft sealing ring
- parts contained in the maintenance kit
8
- parts included in the repair kit
Sectional view of the flange for
the shaft sealing ring and
orientation of the shaft
sealing ring
9
10
11
12
15
13
14
Fig. 12 Repair kit 1
GA 01.600/10.02 - 07/01
27
Maintenance Kits and Repair Sets
13 14 15 16 17
- Option Gas ballast valve
Model with knurled screw
12
37
11
10
9
8
7
6*
5
4
3
2
1
A
18
26
27
28
29
30
31
19
32
33
B
34
20 21 22 23 24 25
35
36
C
Key to Fig. 13
1 Hex. socket bolt
2 Washer
3 Gasket
4 Oil fill plug
5 Guide panel
6 Sealing strip for guide panel*
7 Oil or gas ballast pipe
8 Spring clip
9 Rubber insert (4x)
10 Holding frame for demister
11 Demister
12 HV bearing piece
13 Hex. socket bolt
14
15
16
17
18
19
20
21
22
23
24
25
26
Flat gasket
Gas ballast valve - cap
Gas ballast valve
Flat gasket
Forevacuum pot
Hex. socket bolt
Valve holder
Restrictor
Compression spring
Sealing element
Valve bracket
Bypass valve
End disk
27
28
29
30
31
32
33
34
35
36
37
Compression spring
Non-return valve
Gas ballast orifice
O-ring
Diaphragm valve
Hex. socket bolt
Oil box seal
Oil box
Gasket
Oil drain plug
Gasket
* D 16 E only
- parts contained in the repair kit
Fig. 13 Repair kit 2
28
GA 01.600/10.02 - 07/01
Maintenance Kits and Repair Sets
Oil pump
Nozzel
10
11
G
View ”G”
9
8
7
6
5
12
4
3
2
1
13
14
15
15
18
16
17
18
19
Key to Fig. 14
1 End plate
2 O-ring
3 Forevacuum pot
4 Sealing nipple
5 Rotor
6 Shaft sealing ring
7 Flat seal
8 Tandem valve
9 Compression spring
10 Intake port
Enlarged view F
Position of the HV vanes
11
12
13
14
15
16
17
18
19
O-ring
High vacuum bearing piece
Oil guiding panel
Position/shaft sealing ring
Vane (HV)
Compression spring
Guide pin
Vane (FV)
Hex. socket bolt
- Parts included in the complete kit
Fig. 14 Complete kit
GA 01.600/10.02 - 07/01
29
Maintenance Kits and Repair Sets
5.1 Ordering Information for the Maintenance Kits
and the Repair Sets
TRIVAC
D5E2
D 10 E 2
D 16 E 2
Maintenance Kit 1
Maintenance Kit 2
200 40 023
E 100 000 348
200 40 023
E 100 000 349
200 40 044
E 100 000 350
Repair-Set 1
Repair-Set 2
Repair-Set 3
E 100 000 352
200 40 054
E 100 000 348
E 100 000 352
200 40 054
E 100 000 349
200 40 043
200 40 056
E 100 000 350
The use of the Maintenance Kits and the Repair Sets is detailed in the Tables 4 - Troubleshooting and 5 - Maintenance Plan.
5.2 Ordering Information for the Special Tools
TRIVAC
Special tool for
the tie rods
30
D5E2
D 10 E 2
D 16 E 2
200 02 760
GA 01.600/10.02 - 07/01
Troubleshooting
6 Troubleshooting
Fault
Possible cause
Remedy
Repair*
Pump does not start Faulty wiring.
Motor protection switch not set correctly.
up.
(three-phase motors only)
Power supply voltage does not match the rating of the motor.
Motor faulty.
Oil temperature less than 12 °C.
Oil is too thick.
Exhaust filter or exhaust line is clogged.
Pump has seized (Sign: blocked pump).
Check the wiring and repair it.
Properly set up the motor protection switch.
2.3.2
Exchange the motor.
Exchange the motor.
Warm up the pump and the oil of the pump or use a different oil.
Change the oil.
Exchange the filter or clean the exhaust line.
Repair the pump.
3.5
3.5
2.5.3/3.2
3.2
Service
Pump does not Method of measurement or measuring instrument not suitable.
attain its ultimate
pressure.
External leak1).
Dirty internal demister.
Faulty exhaust valve.
Unsuitable oil.
Intake line dirty or leaky.
Pump too small.
Use the right method of measurement or measuring instrument.
Measure the pressure directly at the intake port of the pump.
Repair the pump.
Perform maintenance.
Repair the valve.
Change the oil (possibly degas it).
Clean or exchange the intake line.
Check process data, possibly change the pump.
-
Pumping speed of Dirt trap in the intake line is clogged.
the pump is too low.
Clogged exhaust filter.
Connection lines too narrow or too long.
Clean the dirt trap.
Preventive action: install a dust filter in the intake line.
Exchange the filter element.
Use sufficiently wide and short intake lines.
3.3
After switching the
pump off the pressure in the system
increases to fast.
Check the system.
Repair the valve.
Exchange the shaft seal.
Repair the valve(s).
Rep. Set 3
Rep. Set 3
Rep. Set 2
Pump gets hotter Supply of cooling air is obstructed.
than
previously Ambient temperature is too high.
Process gas is too hot.
observed.
Not enough oil.
Unsuitable oil.
Oil circulation is obstructed.
Clogged exhaust filter or exhaust line.
Exhaust valve faulty.
Deviating mains supply voltage.
Properly install the pump.
Properly install the pump.
Change the process.
Fill in oil.
Change the oil.
Clean or repair the oil channels.
Change the exhaust filter, clean the exhaust line.
Repair the valve.
Check power supply rating of the motor and the mains supply.
2.1
2.1/2.5.3
-
Oil in the intake line Oil coming from the system.
or
the
vacuum Blocked tandem valve.
chamber.
Check the system.
Clean the valve or repair it.
Rep. Set 3
Oil is turbid.
Degas the oil or change the oil and clean the pump.
Preventive action: open the gas ballast valve or fit a separator.
2.5.2/3.2
Top up some oil.
Reduce the intake pressure.
Clean or replace the internal demister.
Replace the coupling bushings.
Repair the pump.
Exchange the motor bearing.
3.2
3.4/Maint.Kit 1
Rep. Set 1
Service
Service
Exchange the shaft seal.
Rep. Set 1
System has a leak.
Faulty tandem valve.
Inner shaft seal is faulty.
Faulty exhaust or bypass valve.
Condensation.
The pump is extre- Oil level is much too low (oil is no longer visible).
mely loud.
Intake pressure is too high.
Clogged internal demister.
Coupling bushings worn out.
Damaged vanes or bearings.
Faulty motor bearing.
Oil leak at the side
of the motor
Outer shaft seal damaged or worn out.
Service
Main.kit1/2.3.5
Rep.-Set 2
3.2
-
2.2
Service
Rep. Set 2
*Descriptions relating to the repairs or maintenance work have been included with the respective maintenance kits or repair sets. For ordering information please refer
to Section 5.1.
1)
Bubble test: The warm pump with degassed oil is running without gas ballast with the intake blanked off. The exhaust line is lead into a vessel containing water. If an
evenly spaced row of bubbles appears, then the pump has developed an external leak.
GA 01.600/10.02 - 07/01
31
EC Declaration of Conformity
We - Leybold Vacuum GmbH - herewith declare that the
products defined below meet the basic requirements
regarding safety and health of the relevant EC directives
by design, type and versions which are brought into circulation by us.
The products conform to the following directives:
•
EC Directive on Machinery (98/37/EG)
•
EC Directive on Low-Voltages (73/23)+(93/68/EWG)
•
EC EMC Directive (89/336/EWG)
(91/263/EWG) + (92/31/EWG) + (93/68/EWG)
In case of any product changes made without our approval, this declaration will be void.
Applied harmonised standards:
Designation of the products: Rotary vane pump
dual stage
Models:
Product numbers:
TRIVAC E;
D 5 E / D 10 E / D 16 E
140 030 to 140 055
•
DIN EN 292 Part 1
11.91
•
DIN EN 292 Part 2
06.95
•
DIN EN 1012 Part 2
07.96
•
DIN EN 60 204 Part 1
11.98
•
DIN EN 50 081 - Part 1
03.93
•
DIN EN 50 081 - Part 2
03.94
•
DIN EN 50 082 - Part 1
11.97
•
DIN EN 50 082 - Part 2
02.96
Applied national standards and technical
specifications:
• DIN 31 001
April 1983
Cologne, July 07, 2001
Cologne, July 07, 2001
—————————————————————
K. Kilian, Business Area Manager LPV
Division Industrial
—————————————————————
Dr. Bahnen, Head of R&D LPV
Division Industrial
32
GA 01.600/10.02 - 07/01
GA 01.600/10.02 - 07/01
33
Sales Net worldwide
LEYBOLD VACUUM
Nederland B.V.
Computerweg 7
NL-3606 AV Maarssen
Phone: +31-346-583 999
Fax:
+31-346-583 990
France:
LEYBOLD VACUUM
France S.A.
7, Avenue du Quebec
Z.A. de Courtaboeuf, B.P. 42
F-91942 Courtaboeuf Cedex
Phone: +33-1-69 82 48 00
Fax: +33-1-69 07 57 38
e-mail:
leybold-vacuum@leybold.fr
Italy:
LEYBOLD VACUUM
Italia S.p.A.
Via Trasimeno 8
I-20128 Milano
Phone:+39-02-27 22 31
Fax: +39-02-27 20 96 41
Spain:
LEYBOLD VACUUM
España S.A.
C/. Mataró,
27 Polígono Industrial Les
Grases
E-08980 Sant Feliu de
Llobregat (Barcelona)
Phone: +34-93-666 46 16
Fax:
+34-93-666 43 70
Sweden:
LEYBOLD VACUUM
Scandinavia AB
Datavägen 57 B
Box 9084
S-40092 Göteborg
Phone: +46-31-68 84 70
Fax:
+46-31-68 39 39
P.R. China:
LEYBOLD (Tianjin) VACUUM
Equipment Manufacturing
Co. Ltd.
Beichen Economic Development Area (BEDA)
Beichen District
Tianjin 300 400
Phone: +86-22 26 972 016
Fax:
+86-22 26 972 017
e-mail:
leybold@public.tpt.tj.cn
Japan:
LEYBOLD VACUUM
Japan Co. Ltd.
Head Office
Tobu AK Bldg. 3-23-3
4th Floor,
Shin-Yokohama
Kohoku-ku, Yokohama-shi
Kanagawa-ken 222
Phone: +81-45-471 33 30
Fax:
+81-45-471 33 23
Singapore:
LEYBOLD
Singapore Pte. Ltd.
1 Tuas South Street 3
Singapore 638043
Phone: +65-865 18 65
Fax:
+65-862 22 95
Taiwan:
LEYBOLD Taiwan Ltd.
2 F, No. 416-1, Section 3
Chung Hsing Road
Chutung HsinChu
Taiwan R.O.C. 310
Phone: +886-3-583 39 88
Fax:
+886-3-583 39 99
Korea:
Korea Ltd.
4th Fl. Shinahn Bldg., 173-1
Jangchung-Dong 2-Ga,
Chung-Ku
Seoul 100-392
C.P.O. Box 709
South Korea
Phone: +82-2-227 11 567
Fax:
+82-2-227 11 568
Switzerland/
Liechtenstein:
LEYBOLD VAKUUM
Schweiz AG
Leutschenbachstraße 55
CH-8050 Zürich
Phone: +41-1-308 40 50
Fax:
+41-1-302 43 73
LEYBOLD VAKUUM GmbH
Bonner Strasse 498 (Bayenthal)
D-50968 Cologne
Tel.: + 49 (221) 347-0
Fax: + 49 (221) 347-1250
http://www.leyboldvac.de
e-mail:documentation@leyboldvac.de
GA 01.600/10.02 - 07/01
Printed in Germany on chlorine-free bleached paper
Belgium/Netherlands/
Luxembourg:
LEYBOLD N.V.
Leuvensesteenweg 542, 9A
B-1930 Nossegem-Zaventem
Phone: +32-2-71 10 083
Fax:
+32-2-72 08 338
Great Britain/Ireland:
LEYBOLD VACUUM UK Ltd.
Waterside Way,
Plough Lane
GB-London SW 17 0HB
Phone: +44-208-97170 00
Fax:
+44-208-97170 01
e-mail:
sales@leybold.co.uk
07.01
Canada:
LEYBOLD Canada Inc.
7050 Telford Way, Unit 5
Mississauga, Ontario
Canada L5S 1V7
Phone: +1-905-672 77 04
Fax:
+1-905-672 22 49
e-mail:
reachus@leybold.on.ca
Germany:
LEYBOLD VAKUUM GmbH
Bonner Straße 498
D-50968 Köln
Phone: +49-(0)221-347-12 34
Fax: +49-(0)221-347-12 45
Internet:
www.leyboldvac.de
e-mail:
sales@leyboldvakuum.com
ASIA
bicom/OF
USA:
LEYBOLD VACUUM
USA Inc.
5700 Mellon Road
Export, PA 15632-8900
Phone: +1-724-327 57 00
Fax:
+1-724-733 12 17
Internet: http://www.
leyboldvacuum.com
EUROPE
LPV_03276_2001
AMERICA
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