LEYBOLD 1127618 Operating Instructions Manual Download | Manualshive

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GA01208_002_C0 - 11/2016 - © Leybold

1.2 Lubricants / Gaskets

These pumps must only be operated with brake fluids in accordance with
DOT-3 and DOT-4 or alternative operating agents which have been approved
by Leybold.

TRIVAC-B-DOT pumps and accessories are equipped with special seals
which are capable of resisting exposure to brake fluids.

Fig. 3 Schematic of the lubricating system

Fig. 4 Hydropneumatic anti-suckback valve

Description

1 Accessories
2 Bearings
3  Non-return valve
4  Pump chamber of the TRIVAC
5  Oil reservoir
6  Oil pump

1 Oil reservoir

5 Valve seat

2 Spring

6 Valve disk

3 Control piston

7 Gas inlet

4 Anti-suckback piston

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Summary of Contents for 1127618

Page 1: ...TRIVAC B DOT D 16 B DOT D 25 B DOT D 40 B DOT Part Nos 11406 11410 1127618 1128612 91463 1 Operating Instructions GA01208_002_C0 ...

Page 2: ...plied Equipment 13 1 4 Technical Data 13 1 5 Accessories 16 2 Transport and Storing 17 3 Installation 18 3 1 Placement 18 3 2 Conforming Utilization 19 3 3 Connection to the System 21 3 4 Electrical Connections 22 4 Operation 24 4 1 Media Compatibility 24 4 2 Start up 24 4 3 Operation 25 4 3 1 Pumping of Non Condensable Gases and Vapours 25 4 3 2 Pumping of Condensable Gases and Vapours 25 4 3 3 O...

Page 3: ... Inlet Screen 34 5 6 Removing and Fitting the Internal Demister 34 5 7 Disassembly and Reassembly of the Electric Motor 36 5 8 Replacing the Shaft Seal 37 5 9 Removing and Remounting the Pump Module 40 5 9 1 Removing the Pump Module 40 5 9 2 Remounting the Pump Module 41 6 Troubleshooting 42 7 Waste Disposal 44 EC Declaration of Conformity 45 Contents Page Original installation and operating instr...

Page 4: ... state and national agencies regarding specific requirements and regu lations Address any further safety opera tion 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 i...

Page 5: ...exhaust line must be checked from time to time to ensure that there are no obstructions 8 When moving the TRIVAC B DOT always use the allowed means 0 2 Electrical hazards 1 The electrical connections must only be provided by a trained elec tri 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...

Page 6: ...ble 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 operating company is under the obligation to comply with the national and international safety regula tions and guidelines Regarding the suitability of the TRIVAC pumps for special ...

Page 7: ...es which must be intro duced 3 Provided ignitable or pyrophorous substances are present in the equipment you must n ensure that no air can enter into the equipment n ensure that the system is leak tight n with an inert gas purge with nitrogen 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 concentra...

Page 8: ...es 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...

Page 9: ...g The bearing points of the pump module are force lubricated sliding bearings All controls as well as the oillevel glass and the nameplate are arranged on the front All connections are to be found at the sides of the pump The oil level glass is provided with prisms for better observation of the oil level The pump module consists of assembly parts which are pin fitted so as to allow easy disassembl...

Page 10: ...is prevented by admitting a very small amount of air into the pump chamber The compressed gas in the pump chamber is ejected through the exhaust valve 2 10 The oil entrained in the gas is coarsely trapped in the internal demister 2 11 there the oil is also freed of mechanical impurities The gas leaves the TRIVAC B DOT through the exhaust port During compression a controlled amount of air the so ca...

Page 11: ... even at high intake pressures The vacuum is maintained by the TRIVAC B DOT through an integrated hydropneumatic anti suckback valve 2 3 which is controlled via the oil pressure During operation of the TRIVAC B DOT the control piston 4 3 remains sealed against a spring 4 2 by the oil pressure The valve disk 4 6 of the anti suckback valve is held at the lower position by its own weight valve open W...

Page 12: ...VAC B DOT pumps and accessories are equipped with special seals which are capable of resisting exposure to brake fluids Fig 3 Schematic of the lubricating system Fig 4 Hydropneumatic anti suckback valve Description 1 Accessories 2 Bearings 3 Non return valve 4 Pump chamber of the TRIVAC 5 Oil reservoir 6 Oil pump 1 Oil reservoir 5 Valve seat 2 Spring 6 Valve disk 3 Control piston 7 Gas inlet 4 Ant...

Page 13: ...B A 54 56 54 56 57 59 without with gas ballast Admissible ambient temperatur C 12 40 12 40 12 40 Weight kg 26 32 68 Connections intake and exhaust side DN 25 KF 25 KF 40 KF 1 To DIN 28 400 and subsequent numbers 1 3 Supplied Equipment The equipment supplied with the TRIVAC pump includes Pump with a motor Pump filled with brake fluid according to DOT 4 1 centering ring 1 centering ring with dirt tr...

Page 14: ... b2 b 3 h l1 DN n m l c a h1 b1 o h2 h b2 b Dimensional drawing for the TRIVAC D 16 B DOT D 25 B DOT Dimensional drawing for the TRIVAC D 40 B DOT a b b1 b2 c h h1 h2 h3 m n o D 16 B 82 190 175 150 135 298 250 226 263 280 140 132 D 25 B 143 190 175 150 135 298 250 226 263 280 140 132 DN a b b1 b2 c h h1 h2 m n o D 40 B 40 KF 135 254 234 206 166 355 336 308 382 191 190 25 KF 25 KF ...

Page 15: ...umber of poles 4 4 Nom output power at 50 Hz 2200 W 750 W Nom output power at 60 Hz 2200 W 750 W Nom in frequency 50 Hz 50 Hz 60 Hz 60 Hz Nom voltage range and nom current at 50 Hz 200 240 V 15 0 A 200 240 V 3 6 A 200 V 10 4 A IE2 200 V 3 6 A IE2 380 400 V 5 2 A 380 400 V 1 8 A 380 400 V 5 2 A IE2 380 400 V 1 8 A IE2 Nom voltage range and nom current at 50 Hz 200 240 V 12 0 A 200 240 V 3 4 A 208 2...

Page 16: ...ns frequency of 60 Hz 2 Key to the certificates UL certification mark for approved components for the USA UL certification mark for energy efficiency for listed products and approved components for Canada and the USA Observe the data given on the motor name plate For special pumps please note the information contained in the supple mental sheet 1 5 Accessories Part Nos Exhaust filter AF 16 25 DOT ...

Page 17: ...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 the shipping seals which are provided upon delivery The gas ballast switch must be se...

Page 18: ...u wish firmly install the pump in place insert bolts through bore holes in the rubber feet The rubber feet act as vibration absorbers They must therefore not be compressed by screws The site chosen should allow adequate air circulation to cool the pump keep front and rear unobstructed The oil level glass must be visible Note the ambient conditions during operation The ambient temperature should no...

Page 19: ... 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 as well as the use of the gas ballast Pumping of dust or much contaminated media The pumps are not suited for pumping of liquids or media which carry large quantities of dust Corresponding p...

Page 20: ... Connections and controls 1 Handle 2 Intake port 3 Exhaust port 4 Level glass for the operating agent 5 Gas ballast knob 6 Threaded connection M 16 x 1 5 for inert gas ballast 7 Adaptor 8 Cover plate 9 Cover plate connection for the operating agent filter ...

Page 21: ...take line may outgas and adversely affect the vacuum The connecting flanges must be clean and undamaged The maximum throughput of the pump is equivalent to the pumping speed of the pump Note the specified cross sections for the connection lines 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 A...

Page 22: ...ntities of gas must be available about 1 10 of the pumping speed 3 4 Electrical Connections TRIVAC B pumps are supplied with three phase motor but without accessories for electrical connection They must be connected via the appropriate cable and a suitable motor protection switch When operating the unit at its operational limits at an ambient temperature of 12 C and at undervoltage for example it ...

Page 23: ...ons EN 50110 1 Note the national regulations of the country in which the equipment is being operated During all connection work the mains power supply lines must be de energised lockout tag out In order to prevent the pump from running 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 Thi...

Page 24: ...irection of rotation before starting the pump for the first time and after each change in the electrical connection see Chapter 3 4 On initial start up after prolonged idle periods or after an oil change the specified ultimate pressure cannot be attained until the oil is degassed This can be done by running the pump for approx 30 min with the intake line closed and the gas ballast valve 7 5 open U...

Page 25: ...specified by the technical data If the vapour pressure increases above the permissible level the water vapour will condense in the oil of the pump When pumping vapours ensure that the gas ballast valve is open and that the pump has been warmed up for approximately 30 minutes with the intake line closed Pumping of Vapours Vapour phases may only be pumped up to the permissible limit after the pump h...

Page 26: ... V 10 342 V and a mains frequency of 60 Hz 4 4 Shutdown If the pump was exposed to aggressive and corrosive media we recom mend that you let the pump continue to operate even during long non wor king intervals e g overnight with the intake line closed and the gas ballast valve open This avoids corrosion during idle periods and difficulties when re starting the pump under conditions where the lubri...

Page 27: ...t and Storing 4 4 1 Shutdown through Monitoring Components When the pump has been switched off by monitoring components at the pump e g thermal sensor the pump must only be started manually after the pump has cooled down to the ambient temperature and after having removed the cause first 4 4 2 Controller Mains Power Failure In order to prevent the pump from running up unexpectedly after a mains po...

Page 28: ... Informations 0 4 When disposing of used oil you must observe the applicable environmental regulations Due to the design concept TRIVAC B DOT pumps require very little maintenance when operated under normal conditions The work required is described in the sections below In addition to this a maintenance plan is provided in Section 5 1 All work must be carried out by suitably trained personnel Main...

Page 29: ...y regulations when using cleaning agents 5 Check the edges of the teeth on x the coupling element for any damages change the coupling element as required 6 Change the oil Oil DOT 4 x Oil change n First oil change after 100 operating hours n Pump switched off and cold and Exchange the oil while the pump is cold so as to avoid releasing adsorbed gases clean the oil level glass Suitable cleaning agen...

Page 30: ...nload Documents Declaration of contamination of vacuum equipment and components Another suitable form is available from the Leybold homepage www leybold com Documents Download Documents Connect the form at the device or lay it to the device This statement detailing the contamination is required to satisfy legal requirements and for the protection of our employees Pumps which are not accompanied by...

Page 31: ...e the refill the kind of oil in the pump and fill in only suitable oil or change the oil When operating the TRIVAC in connection with the exhaust filter with lubri cant return ARS 40 65 the checking intervals are extended When using the oil float switch LSS remote monitoring of the lubricant is possible Connect the oil float switch as follows 1 0 V 2 24 V With reaching the lower oil level limit th...

Page 32: ... und 0 4 Change the oil while the pump is cold so as to avoid releasing adsorbed gases If releasing adsorbed gases is no problem change the oil after the pump has been switched off and while the pump is still warm Risk of suffering burns With the pump warm from operation both pump and oil can get so hot that there is the risk of suffering burns If required wear gloves Check and top up oil only aft...

Page 33: ...lug back in check the gasket and reinstall a new one if necessary Remove the oil fill plug 9 1 and fill in fresh oil Screw the oil fill plug 9 1 back in The tightening torque for the bolts 9 1 and 9 4 has been specified at 10 Nm When an exhaust filter with lubricant return has been installed on the pump please also exchange the oil there We can only guarantee that the pump operates as specified by...

Page 34: ... 10 3 For material No see spare parts list The internal demister is spring mounted in a frame When it is clogged it rises periodically to reduce the pressure difference created The resultant noise at high intake pressures indicates that the internal demister is dirty Periodically clean or replace the internal demister the maintenance interval depends on the application Use a suitable solvent for c...

Page 35: ...B DOT 1 Screw with small washer spring large washer and O ring 2 Holding frame for demister 3 Demister 4 Case for the operating agent 5 Gasket 6 Fixing screws TRIVAC D 16 25 B DOT 1 Case for the operating agent 2 Spring buckles 3 Demister 4 Frame for demister 5 Hex socket screws 5 pcs 6 Silencing nozzle 7 Gasket ...

Page 36: ...aused by an electric shock Before starting work always disconnect the motor from the mains Pull the mains plug Observe Safety Informations 0 2 Maintenance DANGER Fig 11 Disassembly and reassembly of the electric motor 1 Gasket 2 Handle 3 Hex socket screws 4 Electric motor 5 Intermediate flange 6 Hex socket screws 7 Coupling 8 Threaded pin ...

Page 37: ...h new parts Reassemble in the reverse order 5 8 Replacing the Shaft Seal Required tools Allen keys size 3 5 and 8 flat nose pliers plastic hammer shaft seal driver possibly a puller for the coupling Required spare parts Shaft seal 12 8 For material No see spare parts list Bushing 12 6 For material No see spare parts list The TRIVAC B DOT has one shaft seal Oil marks under the coupling hou sing are...

Page 38: ...d the use of a new shaft seal and bushing for reassembly Before fitting the new shaft seal moisten it slightly with a little vacuum pump oil Using a suitable plastic or aluminium cylinder shaft seal driver and a plastic hammer force the shaft seals 12 8 carefully and without bending them into the centering disk for position of shaft seal see Fig 12 Maintenance Note the position of the shaft sealin...

Page 39: ...k 12 9 with bolts 12 10 Insert the bushing 12 6 carefully at the center of the centering disk 12 9 Insert the key 12 5 Mount the pump half of the coupling 12 4 on the shaft Install the spring washer 12 3 and tighten the screw 12 2 Insert the coupling element 12 1 into the coupling and mount the motor see Chapter 5 7 Maintenance Fig 13 Shaft sealing ring driver bottom centering disk with shaft seal...

Page 40: ... and remove the oil case see Chapter 5 6 Unscrew the hex nuts 14 1 Pull the entire pump module 14 2 forward off the tie rods 14 6 When doing so ensure that the individual pin fitted parts are not loosened Further disassembly of the pump module should only be carried out by a trained service engineer Remove the gasket 14 4 Remove the coupling element 14 5 Maintenance NOTICE Fig 14 Removing and remo...

Page 41: ... with the new pump module only if the old ones are damaged To do so unscrew the old tie rods with lock nuts and screw in the new ones With the aid of the lock nuts tighten the tie rods Then remove the lock nuts Before installing the pump module please check wether the washer 14 3 is correctly seated in its opening Push the gasket 14 4 onto the tie rods 14 6 push the coupling element 14 5 onto one ...

Page 42: ...s unsuitable Measure the pressure directly at the pump s intake port External leak1 Repair the pump Service Anti suckback valve is malfunctioning Repair the valve Service Exhaust valve is malfunctioning Repair the valve Service Oil is unsuitable Change the oil degas it if necessary 5 4 Vacuum lines are dirty Clean the vacuum lines Pump is too small Check the process data replace the pump if necess...

Page 43: ... Service Pump module is worn out Replace the pump module 5 9 Oil comes from the vacuum system Check the vacuum system Anti suckback valve is blocked Clean or repair the anti suckback valve Service Sealing surfaces of the anti suckback Clean or repair intake and valve are damaged or dirty anti suckback valve Service Oil level is too high Drain out excess oil 5 3 Condensation Degas the oil or change...

Page 44: ...ervice Further details are available on request When sending us any equipment observe the regulations given in Section 5 2 Leybold Service Disposal of Waste Oil Owners of waste oil are entirely self responsible for proper disposal of this waste 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 w...

Page 45: ... 45 GA01208_002_C0 11 2016 Leybold EC Declaration of Conformity ...

Page 46: ... 46 GA01208_002_C0 11 2016 Leybold ...

Page 47: ...are a large number of applications and internal uses which in some cases are not known to us On the other hand the handling of different materials and substances can result in hazards for our employees Many thanks for your understanding Hazards due to chemicals The relevant legislation has divided chemicals into various categories of risk with different symbols for different hazardous substances s...

Page 48: ...of oil ForeVacuum Pumps Application Process B Condition of the equipment No1 Yes No Contamination No1 Yes 1 1 Has the equipment been used toxic 2 Drained Product service fluid corrosive 3 All openings sealed airtight flammable 4 Purged explosive 2 If yes which cleaning agent radioactive 2 and which method of cleaning microbiological 2 1 If answered with No go to D other harmful substances C Descri...

Page 49: ... 49 GA01208_002_C0 11 2016 Leybold 49 GA01208_002_A4 02 2014 Leybold Notes ...

Page 50: ...308 40 60 service zh leybold com Spain Leybold Spain S A C Huelva 7 E 08940 Cornellà de Llobregat Barcelona Sales T 34 93 666 43 11 F 34 93 666 43 70 sales ba leybold com Service T 34 93 666 46 11 F 34 93 685 43 70 service ba leybold com America USA Leybold USA Inc 5700 Mellon Road USA Export PA 15632 T 1 724 327 5700 F 1 724 325 3577 info ex leybold com Sales T 1 724 327 5700 F 1 724 333 1217 Ser...

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