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LEYBOLD 1019040V00, Operating Instructions Manual

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LEYBOLD 1019040V00 Operating Instructions Manual Download Page 34

7  Operation

WARNING: OPERATION SAFETY

Risk of damage to the equipment. Do not start the pump more than six times within
one hour to prevent the overloading of the motor. If frequent starts are needed, the
pump must operate continuously and be linked to the vacuum vessel using a valve. In
that case, regulation will be made by the valve and not by the start/stop of the pump.
With the valve closed, the pump consumes less energy.

WARNING: HOT SURFACE

Risk of burns. The pump in operation is hot and some surfaces could reach a
temperature higher than 80°C (176°F). There is a risk of burn by touching. Take note
of warning labels on the pump. Let the pump cool down before you start any work.

WARNING: HAZARDOUS WORKING CONDITIONS

Risk of injury. Wear ear protection in case of operation at high inlet pressure.

7.1  Media compatibility

Pumps can pump condensable gases and vapours, provided that the gas
ballast valve is open and the pump has attained its operating temperature.

7.2  Start-up

WARNING: AUTOMATIC RESTART

Risk of injury or damage to the equipment. To prevent the pump from operating
unexpectedly after a mains power failure, the pump must be integrated with 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.

WARNING: OPERATION SAFETY

Risk of injury or damage to the pump. Before starting the pump make sure that the
pump and the fitted accessories meet the requirements of your application and that
safe operation can be guaranteed.

WARNING: VACUUM HAZARD

Risk of exposure to the vacuum. Do not operate the pump with an open intake port.
Vacuum connections, oil feed and discharge openings must not be opened while the
pump is operating. Avoid exposing any part of the human body to the vacuum. There
is the risk of suffering injury. Observe safety information given in 

Mechanical hazards

on page 8.

Note:

The pump is delivered filled with oil. Before you switch on the pump, make
sure that the pump contains enough oil. The normal oil level in a standstill
pump is in the upper half of the sight glass. Each time before you start up
check the oil level. Do not operate the pump with an oil level below the

300956027_002_A0 - 03/2022 - © Leybold

34

Operation

Summary of Contents for 1019040V00

Page 1: ...L Rotary Vane Vacuum Pump Operating instructions 300956027_002_A0 Part Numbers 1019040V00 1019040V01 1019040V02 1019040V03 1019063V00 1019063V01 1019063V02 1019063V03 1019090V00 1019090V01 1019090V02 1019090V03 and their variants ...

Page 2: ... far as practical we have ensured that the products have been designed and constructed to be safe and without risks when properly installed and used in accordance with their operating instructions We accept no liability for loss of profit loss of market or any other indirect or consequential loss whatsoever Product warranty and limit of liability are dealt with in our standard terms and conditions...

Page 3: ...mp 11 3 Description 13 3 1 Principle of operation 13 3 2 Lubricants and oil 14 3 3 Supplied equipment 14 4 Technical data 16 4 1 Dimension drawing 16 4 2 Performance curves 21 4 3 Material of construction 22 4 4 Ordering information 23 5 Transportation 24 5 1 Transport and packaging 24 5 1 1 Unpack 24 5 1 2 Remove the pump 25 5 1 3 Lift the pump 26 5 2 Mounting orientation 27 6 Installation 29 6 1...

Page 4: ...nce intervals 39 8 3 Maintenance work 43 8 3 1 Check the oil level 43 8 3 2 Check the oil condition 43 8 3 3 Change the oil 44 8 3 4 Clean or replace the oil sight glass 45 8 3 5 Clean the intake port dirt trap and anti suck back valve 46 8 3 6 Check the coupling and coupling element 47 8 3 7 Replacement of electrical motor 48 8 3 8 Clean the motor cooling fan 49 8 4 Service 49 8 4 1 Return the eq...

Page 5: ...wing TRIVAC D 90 L 18 Figure 5 Pumping speed curve TRIVAC D 40 L 21 Figure 6 Pumping speed curve TRIVAC D 63 L 22 Figure 7 Pumping speed curve TRIVAC D 90 L 22 Figure 8 Installation drawing TRIVAC D 40 L 32 Figure 9 Installation drawing TRIVAC D 63 L 32 Figure 10 Installation drawing TRIVAC D 90 L 32 5 300956027_002_A0 03 2022 Leybold List of Figures ...

Page 6: ...ghlighted as warning and caution instructions Obey these instructions WARNING If you do not obey a warning there is a risk of injury or death Different symbols are used according to the type of hazard CAUTION If you do not obey a caution there is a risk of minor injury damage to equipment related equipment or process NOTICE Information about properties or instructions for an action which if ignore...

Page 7: ...voltage Identifies possible hazards from dangerous voltages Warning Heavy object Identifies a possible hazard from a heavy object Warning Hot surfaces Identifies a potential hazard from a hot surface Warning Trip hazard There is a risk of slipping tripping or falling as a result of spilled liq uids trailing cords and pipes or other low lying objects Warning Wear hearing protection Warning Protecti...

Page 8: ...ve during operation of the pump as there is a risk of serious injury The location at which the pump including its accessories is being operated must not have an angle more than 10 degrees from the vertical Check that the inclination of the pump is less than 10 degrees from the vertical Select the operating place so that all controls are easily accessible Move the pump filled with oil only in its v...

Page 9: ...gs and the line connectors are not subjected to excessively high mechanical stresses Take appropriate precautions to make sure that the pump does not start while laying electric feed lines 2 3 Thermal hazards WARNING HOT SURFACE Risk of burn During normal operation the pump surface temperature can reach above 70 C 158 F There is a risk of getting burns Note the symbols on the pump indicating the h...

Page 10: ... document safety booklet available in which the hazards and general safety concepts for design operation and maintenance of vacuum systems are explained When planning to pump hazardous substances with this pump read the related chapters in the safety booklet and these operating instructions first You can download the safety booklet from our homepage The pump is not suitable for oxygen pumping oper...

Page 11: ...This pump is suitable for pumping water vapour within the specified water vapour tolerance limits Avoid vapours that can condense into liquids when being compressed inside the pump if these substances exceed the vapour tolerance of the pump Before pumping vapours the pump must attain its operating temperature It takes approximately 30 minutes for the pump to attain its operating temperature after ...

Page 12: ...ballast is active When operating the pump at gas throughput it is recommended to connect an exhaust filter or use a suitable exhaust line The exhaust line must slope down and away from the pump In the case of custom pumps note the information provided in the supplementary sheets 300956027_002_A0 03 2022 Leybold 12 Important safety information ...

Page 13: ...mounted eccentrically in the pump housing has two radially sliding vanes which divide the pump chamber into several compartments The volume of each compartment changes periodically with the rotation of the rotor As a result gas is sucked in at the intake port The gas passes through a dirt trap sieve and open the anti suck back valve then enters the pump chamber In the pump chamber the gas is passe...

Page 14: ... 9 Anti suck back valve 3 2 Lubricants and oil The standard pumps are ready for operation with mineral oil For operating a pump we specify our vacuum pump oils which are supplied with the pumps Recommended oil LEYBONOL LVO 130 For specific applications and pumping gas mixture consult your local representative to select the right lubricant 3 3 Supplied equipment The equipment supplied with the pump...

Page 15: ...ring shipment the connection ports are each blanked off by the blank flange The pumps delivered from the factory are filled with oil given in Lubricants and oil on page 14 15 300956027_002_A0 03 2022 Leybold Description ...

Page 16: ...in mm inch 1 Inlet port 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug 1 Inlet port 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug For variants with motor 300956027_002_A0 03 2022 Leybold 16 Technical data ...

Page 17: ...ort 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug 1 Inlet port 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug For variants with motor 17 300956027_002_A0 03 2022 Leybold Technical data ...

Page 18: ...ort 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug 1 Inlet port 2 Exhaust port 3 Oil filling plug 4 Oil sight glass 5 Oil drain valve 6 Gas ballast 7 Lifting lug For variants with motor 300956027_002_A0 03 2022 Leybold 18 Technical data ...

Page 19: ...5 x 10 2 Water vapour tolerance with gas ballast OP2 mbar Torr 35 26 2 30 22 5 25 18 75 Water vapour capacity 50 60 Hz g h lb h 1090 2 40 1308 2 88 1334 2 94 1601 3 52 1464 3 22 1757 3 87 Oil filling minimum maximum l qt 3 1 4 1 3 2 4 3 3 3 4 4 3 4 4 6 3 6 4 8 3 8 5 0 Admissible ambient temperature C F 10 40 50 104 Noise level without with gas ballast 2 OP1 dB A 58 60 Pump dimensions L x W x H mm ...

Page 20: ...istance of 1 m Table 2 Unit conversion Conversion factors Different pressure units Different pumping speed units mbar milli bar torr inches Hg vacuum m3 h 1 m3 h ls 1 l s cfm cubic feet per minute 1013 760 0 m3 h 1 m3 h 1 0 278 0 589 1 lb 0 453 kg 400 300 18 12 ls 1 l s 3 60 1 2 12 1 qt 0 946 l 133 100 25 98 cfm cubic feet per minute 1 699 0 472 1 1 hp 0 735 kW 4 3 29 80 1 rpm 1 min 1 1 0 75 29 89...

Page 21: ...019040V02 200 380 60 TRIVAC D 63 L LVO 130 220 230 380 400 50 1 5 1019063V00 220 230 380 400 415 50 1 5 1019063V01 230 460 60 1 8 200 50 2 2 1019063V02 200 380 60 TRIVAC D 90 L LVO 130 220 230 380 400 50 2 2 1019090V00 220 230 380 400 415 50 2 2 1019090V01 230 460 60 2 6 200 50 3 0 1019090V02 200 380 60 3 0 4 2 Performance curves Figure 5 Pumping speed curve TRIVAC D 40 L 21 300956027_002_A0 03 20...

Page 22: ...Pumping speed curve TRIVAC D 90 L 4 3 Material of construction Table 4 Material of construction Component Material Cylinder End plate Cast iron Rotor Alloy structure steel Coupling housing Cast aluminium 300956027_002_A0 03 2022 Leybold 22 Technical data ...

Page 23: ...rt number TRIVAC D 40 L EU CN LVO 130 1019040V00 TRIVAC D 40 L EU US LVO 130 1019040V01 TRIVAC D 40 L JP KR LVO 130 1019040V02 TRIVAC D 40 L BS LVO 130 1019040V03 TRIVAC D 63 L EU CN LVO 130 1019063V00 TRIVAC D 63 L EU US LVO 130 1019063V01 TRIVAC D 63 L JP KR LVO 130 1019063V02 TRIVAC D 63 L BS LVO 130 1019063V03 TRIVAC D 90 L EU CN LVO 130 1019090V00 TRIVAC D 90 L EU US LVO 130 1019090V01 TRIVAC...

Page 24: ...ithin three days state the item number of the pump together with the order number and the supplier s invoice number Retain all packing materials for inspection Do not use the pump if it is damaged Use a forklift to transport the pallet If possible transport the pump in its original packaging if not available exercise due care For TRIVAC D 40 L and TRIVAC D 63 L For TRIVAC D 90 L 5 1 1 Unpack Wear ...

Page 25: ...or TRIVAC D 90 L 5 1 2 Remove the pump The pump is attached by screws Remove the screws under the pallet using a 13 mm wrench The pump is then ready to be shifted or lifted off the pallet Recycle or dispose of the packing materials according to environmental laws 25 300956027_002_A0 03 2022 Leybold Transportation ...

Page 26: ...ye bolts must be screwed in properly with full contact to the pump surface Mounted eye bolts are only suitable for lifting the respective pump They must not be used for other loads Eye bolts must only be used in accordance with the conforming utilisations Use eye bolts only with appropriate lifting devices Pumps that are filled with oil must only be moved while standing upright Otherwise the oil m...

Page 27: ... falling due to oil leakage from the pump Check the pump for the presence of any oil leaks There is a risk of falling due to oil spills Take appropriate safety measures Make sure that all safety regulations are observed Use suitable lifting equipment according to the pump weight 27 300956027_002_A0 03 2022 Leybold Transportation ...

Page 28: ...ting devices Refer to the Installation drawing on page 32 for the space required to install the pump A pump that has been filled with oil must only be moved in the upright position horizontally Otherwise the oil may escape The angle of the slope must not be more than 10 degrees Avoid any other orientations while you move the pump 300956027_002_A0 03 2022 Leybold 28 Transportation ...

Page 29: ...when being compressed inside the pump if these substances exceed the vapour tolerance of the pump In the case of wet processes we recommend the installation of liquid separators upstream and downstream of the pump 6 2 Non conforming utilisation WARNING HAZARDOUS SUBSTANCES Risk of injury or damage to the equipment The pump is not suited for pumping of radioactive and toxic substances pyrophoric su...

Page 30: ... F refer to Table Technical data For installation sites 1000 m above mean sea level or relative atmospheric humidity of over 90 you must discuss this with technical sales The maximum amount of heat given off approximately corresponds to the rated motor power Install the pump such that only minimal quantities of dust can deposit on the surfaces In those cases where dust deposits form measures need ...

Page 31: ...e for horizontal connection Connect the intake and exhaust lines with a centering ring and a clamping ring each Use the centering ring with a dirt trap for the intake port Connect the intake and exhaust line using anti vibration bellows without placing any strain on the pump The maximum intake pressure must not exceed atmospheric pressure 1013 mbar The intake line must be clean Deposits in the int...

Page 32: ...sions given are in mm inch A Space for the motor ventilation B Space for pump ventilation C Cooling air pump D Cooling air motor A Space for the motor ventilation B Space for pump ventilation C Cooling air pump D Cooling air motor Figure 10 Installation drawing TRIVAC D 90 L All dimensions given are in mm inch A Space for the motor ventilation B Space for pump ventilation C Cooling air pump D Cool...

Page 33: ...e sequence indicator Prolonged operating of the motor in the wrong direction of rotation will damage the pump In the case of custom pumps note the information provided on a separate sheet For connecting the motor follow the schematics provided on the motor nameplate or in its junction box given your local mains voltage and frequency Electrical connection work must only be carried out by a qualifie...

Page 34: ...ury or damage to the equipment To prevent the pump from operating unexpectedly after a mains power failure the pump must be integrated with 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 WARNING OPERATION SAFETY Risk of injury or damage to the pump Before starting the pump make sure that the pump and the ...

Page 35: ...ting temperature 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 g An exhaust line that is too small in diameter or which is blocked can result in the formation of overpressure within the pump The pump may get damaged or burst if the pump is opened Thus the exhaust line must be checked from time...

Page 36: ... KF connection available as an accessory Refer to Accessories on page 58 For remote control fit an EM gas ballast valve kit available as an accessory refer to Accessories on page 58 The EM gas ballast valve must be supplied with 24 V d c The pump is slightly louder if the gas ballast valve is open With the gas ballast valve open position I or II and when the temperature is stabilised the pump can ...

Page 37: ...e CAUTION HOT SURFACES Risk of injury There is the danger of receiving burns Observe safety information given in Thermal hazards on page 9 Proper operation of the pump is ensured in the ambient temperature range between 10 C to 40 C 55 F to 104 F At operating temperature the surface temperature of the pump can be higher than 70 C 156 F If due to the ambient conditions this temperature range is to ...

Page 38: ...x mark Seal the connection ports Special conservation or anti corrosion oils are not necessary Also take note of the information given in Transportation on page 24 and Storage on page 56 7 4 Ultimate pump pressure If the system cannot produce the pressures specified in the technical data measure the ultimate pressure directly at the intake port of the pump after you disconnect the pump from the sy...

Page 39: ...be carried out by suitably trained personnel Maintenance or repairs carried out incorrectly will affect the life and performance of the pump and will void any warranty claims Note Due to the design concept the pumps require very little maintenance when operated under normal conditions The maintenance required is described in the sections below In addition to this a maintenance plan is provided in ...

Page 40: ... Normally the oil is light and transparent oil change is re quired when discolourations increase Refer to Check the oil condition on page 43 Chemically 6 months According to DIN 51558 when the neutralisation number exceeds 2 then an oil change will be required Refer to Check the oil condition on page 43 Mechanically 6 months When the viscosity is 20 above the one of fresh oil then an oil change wi...

Page 41: ... the intake port Change them as required Suitable cleaning agent and com pressed air 6 month Clean intake dirt trap with a cleaning agent and blow it out with compressed air under a suction hood Replace the defective intake dirt trap Clean the anti suck back valve with a cleaning agent and dry it Use a cleaning agent which complies with the national inter national specifications Observe the safety...

Page 42: ... the motor cooling fan on page 49 For normal applications the maintenance interval is 1 year or 6000 hours The recommendation above is only for pumps running in normal applications In case of running in medium and harsh applications the maintenance interval needs to be shortened according to application requirements If other type of oil is used for the pump the maintenance interval needs to be adj...

Page 43: ...ange the oil with suitable oil Overfilling leads to oil losses at high intake pressures High oil consumption often indicates that exhaust filters are clogged 8 3 2 Check the oil condition The ageing process for the standard operating fluid refer to Lubricants and oil on page 14 will depend very much on the area of application for the pump There exist the following ways of checking the oil conditio...

Page 44: ...FACE Risk of burn With the pump warm from the operation both pump and oil can get so hot that there is the risk of suffering burns If required wear gloves Note Check and top up oil only after the pump has been shut down When disposing of waste oil observe the applicable environmental protection regulations When changing the oil use the same type of oil which was previously in the pump If you want ...

Page 45: ...en screw the oil filling plug In case of severe pollution the pump should be flushed by filling with fresh oil up to the bottom edge of the oil level glass operate the pump for a short time and then change the oil again When disposing of used oil observe the relevant environmental regulations Note We can only guarantee that the pump operates as specified in the technical data if the lubricants rec...

Page 46: ...he pump to act as a dirt trap for foreign objects It must be kept clean to avoid a reduction of the pumping speed An anti suck back valve is located inside the intake port to stop the oil from returning to the intake pipeline It must be kept clean to prevent function failure leading the oil to return the intake pipeline For this purpose remove the dirt trap and anti suck back valve from the intake...

Page 47: ... Allen key 6 mm to disassemble the intake port Use a plier to take the anti suck back valve out and clean it using a suitable solvent Re assemble the dirt trap in the reverse sequence Refer to Table Inlet valve kit for more information 8 3 6 Check the coupling and coupling element A visual inspection for the presence of any damage needs to be done If the couplings are damaged they must be replaced...

Page 48: ...screw 7 Lock screw 8 Coupling element 9 Coupling pump side 10 Screw 11 Coupling motor side 12 Snap ring 13 Washer 1 Nut 2 Electric motor 3 Motor flange 4 Screws of flange 5 Cooling fan 6 Locking screw 7 Lock screw 8 Coupling element 9 Coupling pump side 10 Screw 11 Coupling motor side 12 Snap ring 13 Washer Required tools Wrench 16 mm Internal snap ring plier Allen key 3 mm Allen key 4 mm Allen ke...

Page 49: ...nts for service Before you send your equipment to us for service or for any other reason you must send us a completed Declaration of Contamination of Vacuum Equipment and Components Form HS2 The HS2 form tells us if any substances found in the equipment are hazardous which is important for the safety of our employees and all other people involved in the service of your equipment The hazard informa...

Page 50: ... of each kit are given in detail Oils Special oils refer to the specific notice of the pump or contact us Shaft seal maintenance kit Major maintenance kit We recommend using these kits which have been defined to allow optimal maintenance or repair Individual spare parts may need a longer delivery time Table 6 Major maintenance kit Part number Part description Remark EK3002614150 Major maintenance ...

Page 51: ... 1 1 kW EU CN 1019040V00 G6535554 3 phase IE3 motor 1 1 kW EU US CN 1019040V01 G6535557 3 phase IE3 motor 1 5 kW JA KO 1019040V02 E6535552 3 phase IE3 motor 1 5 kW EU CN 1019063V00 G6535555 3 phase IE3 motor 1 5 kW EU US CN 1019063V01 G6535558 3 phase IE3 motor 2 2 kW JA KO 1019063V02 E6535553 3 phase IE3 motor 2 2 kW EU CN 1019090V00 G6535556 3 phase IE3 motor 2 2 kW EU US CN 1019090V01 G6535559 ...

Page 52: ...witch properly Cause Motor is malfunctioning Remedy Replace the motor Cause The operating voltage does not match that of the motor Remedy Check whether the correct product number was booked Adjust the voltage or replace the motor Cause Oil temperature is below 10 C 50 F Remedy Check the temperature with the team Heat the pump and pump oil or use a different oil Cause Oil is too viscous Remedy Chan...

Page 53: ...an the intake port dirt trap and anti suck back valve on page 46 Cause Connecting lines are too narrow or too long Remedy Use adequately wide and short connecting lines Fault After switching off the pump under vacuum pressure in the system rises too fast Cause System has a leak Remedy Check the system Cause Anti suck back valve is malfunctioning Remedy Repair the valve Refer to Clean the intake po...

Page 54: ...se Oil level is too high Remedy Drain the excess oil Refer to Check the oil level on page 43 Fault Oil is turbid Cause Condensation Remedy Degas the oil or change the oil and clean the pump Refer to Change the oil on page 44 To prevent condensation open the gas ballast valve or insert a condensate trap Fault Pump is excessively noisy Cause Oil level is very low Oil is no longer visible Remedy Add ...

Page 55: ...g sealing gasket failed or casing broken Remedy Replace the oil casing sealing gaskets or replace the oil casing Cause Oil leakage at the shaft seals Remedy Replace the shaft seals Cause Exhaust port blocked or the over pressure valve thread loctite failed Remedy Clear the exhaust line or re loctite the valve thread Cause Plug seals failed or not fasten enough Remedy Replace the plug seals or fast...

Page 56: ...to be shelved for a longer period it must be sealed in a plastic bag containing desiccant silica gel When a pump is put into operation after it has been shelved for over one year standard maintenance of the pump must be done and the oil must also be changed refer to Change the oil on page 44 We recommend that you contact us Store the pump in a dry place at room temperature until the pump is put ba...

Page 57: ... from the pump safely in accordance with all local and national safety and environmental requirements Particular care must be taken with components and waste oil that have been contaminated with dangerous process substances 57 300956027_002_A0 03 2022 Leybold Disposal ...

Page 58: ...KF16 A35924547 Thermal switch 1019040A70 Roots adapter 1019040A60 The stability of the pump is ensured with accessories supplied by us Mounting of any other accessory will engage the responsibility of the user concerning the stability of the pump In case a direct roots pump coupling is used it is important to check the gas temperature due to the roots compression 300956027_002_A0 03 2022 Leybold 5...

Page 59: ...lity Class A Emissions Industrial Immunity 2011 65 EU Restriction of certain hazardous substances RoHS directive as amended by Delegated Directive EU 2015 863 Based on the relevant requirements of harmonised standards EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 1012 2 1996 A1 2009 Compressors and vacuum pumps Safety requirements Vacuum ...

Page 60: ... Emissions Industrial Immunity Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 Relevant designated standards or technical specifications are as follows EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 1012 2 1996 A1 2009 Compressors and vacuum pumps Safety requirements Vacuum pum...

Page 61: ...ubstance is present in certain aluminium brass components Compliance Information incorporated products and assemblies Motors 2009 125 EC Ecodesign directive requirements for energy related products Regulation EU No 2019 1781 electric motors and variable speed drives Based in the requirements of harmonised standard EN 60034 30 2009 Rotating electrical machines Part 30 Efficiency classes of single s...

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Page 64: ...Pioneering products Passionately applied Leybold GmbH Bonner Strasse 498 50968 Cologne GERMANY 49 0 221 347 0 info leybold com www leybold com ...

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