MANUAL_Trivac B D16 and D25.pdf

TRIVAC® B

D 16 B / D 25 B Rotary Vane Vacuum Pump ATEX Categories 3 i and 3 i/o

■ with mineral oil

Operating Instructions GA01217_002_C3

Part Nos.

113 28 /38 113 33 /33J 140 160 /V /170 3i/o 140 165 898 199 /199-1 /208 /698 898 229 912 65-1 /65-2 912 75-2 914 63-1

Contents

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Page

0 Important Safety Information 5

0.1 Mechanical hazards 5

0.2 Electrical hazards 5

0.3 Thermal hazards 6

0.4 Hazards caused by materials and substances 6

0.5 Danger of ignition 7

0.6 Hazard caused by noise 7

0.7 Risk of damaging the pump 8

TRIVAC B ATEX Categories 3 i and 3 i/o Vacuum Pump 9

Classification and Marking of the Pump 9

Explanation of the Symbols 10

Protective Measures 11

1 Description 13

1.1 Function 15

1.2 Lubricants 17

1.3 Supplied Equipment 18

1.4 Technical Data 19

1.5 Accessories 28

2 Transport and Storage 29

3 Installation 30

3.1 Placement 30

3.2 Conforming Utilization 31

3.2.1 Non-conforming Utilization 32

3.3 Connection to the System 34

3.4 Electrical Connections 36

3.4.1 Pump with Single-Phase AC Motor 36

3.4.2 Pump with Three-Phase AC Motor 37

3.5 Connecting the ATEX-Motor 39

3.5.1 General Installation Information 40

3.5.2 Fitting the Coupling 41

3.5.3 Fitting the Motor 42

3.5.4 Electrical Connection 42

Contents

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Original installation and operating instructions.

4 Operation 43

4.1 Media Compatibility 43

4.2 Start-up 43

4.3 Operation 44

4.3.1 Pumping of Non-Condensable Gases and Vapours 44

4.3.2 Pumping of Condensable Gases and Vapours 44

4.3.3 Operating Temperature 45

4.4 Shutdown 45

4.4.1 Controller/Mains Power Failure 46

5 Maintenance 47

5.1 Maintenance Plan 48

5.2 Leybold Service 49

5.3 Monitoring the Oil Level 50

5.3.1 Checking the Condition of the Oil 50

5.4 Oil Change 51

5.5 Cleaning the Inlet Screen 53

5.6 Removing and Fitting the Internal Demister 53

5.7 Disassembly and Reassembly of the Electric Motor 55

5.7.1 Checking the Coupling 56

5.8 Replacing the Shaft Seal 56

5.9 Removing and Remounting the Pump Module 59

5.9.1 Removing the Pump Module 59

5.9.2 Remounting the Pump Module 60

6 Troubleshooting 61

7 Wearing Parts and Original Spare Parts 63

8 Waste Disposal 63

EU Declaration of Conformity 64

EU Incorporation Declaration 67

Safety information

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IObligation to Provide Information Before installing and commissioning the TRIVAC B, carefully read these Operating Instructions and follow the information so as to ensure optimum and safe working right from the start.

The Leybold TRIVAC B has been designed for safe and efficient operation when used properly and in accordance with these Operating Instructions. It is the responsibility of the user to carefully read and strictly observe all safety precautions described in this section and throughout the Operating Instructions. The pump must only be operated in the proper condition and under the conditions described in the Operating Instructions. It must be operated and maintained by trained personnel only. Consult local, state, and national agencies regarding specific requirements and regulations.

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

“Trained personnel” for the operation of this pump are

■■ skilled workers with knowledge in the fields of mechanics, electrical engi-neering and vacuum technology, and

■■ personnel specially trained for the operation of vacuum pumps.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to notify users of installation, operation, programming or maintenance information that is important, but not hazard related.

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

We reserve the right to alter the design or any data given in these Operating Instructions. The illustrations are not binding.

Retain the Operating Instructions for further use.

NOTICE

DANGER

WARNING

CAUTION

NOTICE

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0 Important Safety Information

2 Never operate the pump without a connected intake line or without fit-ting a blank flange.

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

Serious injury may result.

4 The location at which the TRIVAC B (including its accessories) is being operated should be such that angles over 10° from the vertical are avoided. Select the operating place so that all controls are easily accessible.

5 The pump when filled with oil must only be moved in its vertical posi-tion. Spilled oil involves the risk of falling.

6 Make sure that the gas flow from the exhaust port is not blocked or restricted in any way.

7 If exhaust gases must be collected or contained, do not allow the exhaust line to become pressurised. The pressure in the oil box must not exceed 0.5 bar (g). An exhaust line which is too small in diameter or which is blocked can result in the formation of overpressures within the pump. Possible consequences can be a damaged or even burst open pump. Thus the exhaust line must be checked from time to time to ensure that there are no obstructions.

8 When moving the TRIVAC B always use the allowed means.

Please observe the national regulations in the country of use like EN 50110-1 for Europe, for example.

2 Lethal voltages are present at the mains connections. Before starting with any maintenance and service work, de-energise (lockout/tagout) the product first.

3 Lay connecting lines so that they cannot be damaged. Protect the lines against humidity and contact with water. Avoid any heat stress on the line due to unfavourable laying conditions.

4 Suitably support the connecting lines so that the pumps are not exposed to any major mechanical stress.

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

This also applies in the case of an emergency shutdown. In order to prevent the pump from running up automatically again, the pump must be integrated within a control arrangement such that it can only be switched on manually again after the mains power has returned.

6 Provide an adequate ground connection for the pump so as to avoid any electrostatic charging.

WARNING

WARNING

Warning label

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ture of over 70 °C (158 °F). There then exists the danger of receiving burns.

Note the symbols on the pump pointing to the hazards, and in the case of a hot pump wear the required protective clothing. All work on the “pump still warm from operation” should only be done using pro-tection gloves.

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

3 Note the warning information on the housing surface. If these warning notices have been removed, covered or obstructed, include corre-sponding additional warning notices.

process gases may escape or the pumped gases can react with air or atmospheric humidity. After installation of the pump and after servicing work on the vacuum system, a leak search will always be necessary.

When pumping hazardous gases we recommend a leak search on a regular basis. Leaks in the pump cannot be ruled out under all circum-stances. When pumping hazardous gases, the operator must ensure that that leaks at the pump will not be a hazard.

2 Since not all application related hazards for vacuum systems can be described in detail in these Operating Instructions, Leybold has availa-ble a separate document (Safety Booklet) 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 in these Operating Instructions first. You can download the Safety Booklet from our homepage.

3 The pump is not suited for oxygen operation.

4 Before commissioning the TRIVAC B, make sure that the media which are to be pumped are compatible with each other so as to avoid haz-ardous situations. All relevant safety standards and regulations must be observed.

5 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 regulati-ons and guidelines. Regarding the suitability of the TRIVAC B pumps for special applications in which such gases, respectively substances shall be pumped, Leybold should be consulted first.

6 If the pump has previously handled hazardous gases, implement the proper precautionary measures before opening the intake or exhaust connection.

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

DANGER

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If necessary, use gloves, a respirator and/or protective clothing and work under an exhaust hood. Firmly seal off the pump.

When shipping the contaminated pump for servicing, please also state the type of hazard. For this you must use a form which we have pre-pared for you.

7 When cleaning a system in which a TRIVAC pump has been integrat-ed, all parts in contact with the medium need to be compatible with the cleaning agent so as to prevent a chemical reaction. Residues of the cleaning agent within the pump must be avoided.

8 Contaminated parts can be detrimental to health and environment.

Before beginning with any work, first find out whether any parts are contaminated. Adhere to the relevant regulations and take the neces-sary precautions when handling contaminated parts.

suited for operation in the explosion hazard areas approved for the pumps.

Please take note of the marking on the type plates and any additional information on the pump.

2 The standard version of the TRIVAC B is not suited for operation in explosion hazard areas.

3 The TRIVAC pumps including the accessories are fundamentally not suited for pumping of combustible and explosive gases or vapours.

The pump including accessories is only suited within the scope of the ATEX guideline for pumping of explosive gases and vapours. Mixtures of substances may, regarding the fire and explosion risk be critical or uncritical. The operating company is under the commitment to analyse this and rate the hazard potential accordingly so as to therefrom derive the necessary safety measures which must be introduced.

4 Provided ignitable or pyrophorous substances are present in the equipment you must:

■ ensure that no air can enter into the equipment,

■ ensure that the system is leak-tight,

■ with an inert gas purge (with dry nitrogen, for example) dilute all ignit-able gases or vapours which may enter into the pump through the pump’s inlet and/or with an inert gas purge reduce the concentration of ignitable gases or vapours in the pump and in the exhaust line to less than a quarter of the lower explosion limit (LEL) published for the respective gases.

0.6 Hazard caused by noise

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with a suitable protective motor switch. Please take note of the infor-mation in these Operating Instructions and on the electric motor (wiring diagram).

2 Do not allow the ingestion of small objects (screws, nuts, washers, pieces of wire, etc.) through the inlet port. For this reason always use the inlet screen which is supplied as standard.

3 Do not use the pump for applications that produce abrasive or adhe-sive powders or condensable vapours that can leave adhesive or high viscosity deposits. When planning to pump vapours other than water vapour please contact our sales or service department for advice.

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

5 Avoid vapours that can condense into liquids when being compressed inside the pump, if these substances exceed the vapour tolerance of the pump.

6 Before pumping vapours the TRIVAC B should have attained its oper-ating temperature. This will be the case approximately 30 minutes after having started the pump. During this warming up phase, the pump should be separated from the process, by a blocking valve in the intake line, for example.

7 In the case of wet processes we recommend the installation of liquid separators upstream and downstream of the pump as well as the use of the gas ballast.

8 The exhaust line should be laid so that it slopes down and away from the pump so as to prevent condensate from backstreaming into the pump.

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

10 Reactive or aggressive substances in the pump chamber may impair the operating oil or modify it. In addition, such substances may be incompatible with the materials of the pump (Viton, grey cast iron, alu-minium, steel, resins, glass etc.).

11 Corrosion, deposits and cracking of oil within the pump are not allowed.

12 Normal amounts of humidity within the range of the pump’s water vapour tolerance will not significantly affect pump performance when the gas ballast is active.

13 When operating the pumps at gas throughput, it is urgently recom-mended to connect an exhaust filter or use a suitable exhaust line.

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

14 In the case of custom pumps please note the information provided in the supplementary sheets.

ATEX

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TRIVAC B ATEX Categories 3 i and 3 i/o Vacuum Pump

Operating Instructions for Operation in Explosion Hazard Areas The vacuum pumps are designed and constructed in such a way that the occurrence of foreseeable ignition sources during normal operation can be excluded. Operated in accordance with the parameters specified in the inst-ructions for use, the pump provides a normal level of protection. It is therefo-re suitable for use in conditions where explosive atmospheres caused by gases, vapours or mists in the air are unlikely to occur or, if they do occur, this will be very rarely and only for a short period of time (i.e. Zone 2).

The pump is not suited for utilisation in dusty areas.

The pumps (part no.: 140160, 140160V and 140170) with appropriate mar-king on pump and motor may be installed and operated in explosion hazard areas.

Please observe the information on gas group, temperature class as well as restrictions on speed, temperature range and additional instructions on the pump.

The pumps (part no.: 112 65 /66 /66J /75 /76 /76J, and 11325, and 11335) have an ATEX approval only for the pump interior (= the process gas side of the pump). These pumps are not suitable for installation in explosion hazard areas.

Classification and Marking of the Pump The pumps (part no.: 140160, 140160V, 140170) are marked as follows:

II 3/3G Ex h IIC T4 (50 Hz) Gc / Ex h IIC T3 (50 Hz) Gc 12 °C ≤ Ta ≤ 40 °C

The pumps (part no.: 112 65 /66 /66J /75 /76 /76J, 11325, 11335) are marked as follows:

II 3/-G Ex h IIC T4 (50 Hz) Gc

II 3/-G Ex h IIC T3 (60 Hz) Gc

12 °C ≤ Ta ≤ 40 °C

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Explanation of the Symbols

ATEX logo

„ .. / .. ” means that the product has two different categories

„ - ” means that part of the product does not comply with the standard and is not intended for use in an explosion hazard area.

II 3/-G (Gc) the pump can extract gases from zone 2, but must be installed outside explosion hazard areas.

(i)/(o) specifies the category/conditions under which the inside (i) (i.e. parts of the equipment in contact with the process gas flow) and the outside (o) of the equipment are classified, where these differ.

G for areas with potentially explosive atmospheres caused by gases, vapours or mists in the air.

h this code letter applies to all non-electrical devices, regardless of which type of protection is used; see DIN EN ISO 80079-37: Non-electrical equipment for explosive atmospheres - Non-electrical type of protection constructional safety „c“, control of ignition sources „b“, liquid immersion „k“

IIC Explosion Groups

T4, T3 Temperature class Example: Pumps with temperature class T3 may only be used to pump gases with an ignition temperature of more than 200 °C.

50 Hz, 60 Hz for temperature class T4 the maximum permissible frequency is 50 Hz, for temperature class T3 the maxi-mum permissible frequency is 60 Hz.

Gc the marking has now been supplemented by the level of protection of the equipment. This Equipment Protection Level (EPL) consists of two letters. The first letter indicates the type of explosive atmosphere: G for gas, D for dust. The actual protection level is defined by the letters a, b or c.

Ta Permissible ambient temperature for operating the pump: +12 °C ≤Ta≤ +40 °C.

Overview of equipment groups, categories, zones, and equipment protection levels (EPL)

EN ISO 80079-36 Directive 2014/34/EU EN IEC 60079-10-X

EPL Group Equipment group Equipment category Zones

Ma I I

M1 not applicable

Mb M2

Ga

II

II

1G 0

Gb 2G 1

Gc 3G 2

Da

III

1D 20

Db 2D 21

Dc 3D 22

Protective Measures

Protection by housing

Symbol Zone Adequate safety ta 20 for rarely occuring errors tb 21 for predictable errors tc 22 for normal operation

Classifications of dusts

IIIA combustible flyings

IIIB non-conductive dust

IIIC conductive dust

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Hot Surfaces

During normal operation of the vacuum pump, compression of the gases causes the surfaces to heat up resulting in hot surfaces. Tests have shown in the case of conforming operation of the pump (in accordance with these instructions) that at the inside of the pump which might come into contact with a potentially explosive atmosphere attains during operation with a 50 Hz motor a maximum temperature of less than 135 °C and during operation with a 60 Hz motor a maximum temperature of less than 200 °C.

The maximum temperatures are attained during continuous operation at an inlet pressure ranging between 300 and 500 mbar. The actually attained temperature depends on the inlet pressure.

The outside of the pump may attain under these conditions a surface tem-perature of over 80 °C. The maximum temperature is in the case of opera-tion with a 50 Hz motor less than 135 °C and in the case of operation with a 60 Hz motor less than 200 °C.

Higher maximum surface temperatures can occur when filling and operat-ing the pump with types of oil which differ from the Leybold oil LVO 100.

This is due to the frequently worse lubrication and cooling properties of such oil.

Hot Exhaust Gases

Due to the compression of the gases, the pump will produce in the case of normal operation hot exhaust gases. The exhaust gas temperatures do not exceed the maximum surface temperatures stated for the pump.

The exhaust gases need to be disposed of through a suitable exhaust gas system.

Mechanical Sparks

During normal operation no mechanically produced sparks occur since the internal surfaces of the pump are covered with oil. The external fan and the fan cover are so designed that a sufficient clearance is maintained thereby excluding the possibility of a contact.

Sucking in of particles into the pump needs to be avoided so as to prevent the formation of hot spots due to friction.

CAUTION

NOTICE

CAUTION

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Electric Sparks

These can be caused by the electric motor and the accessories supplied with the pump. If the pump has been approved for operation in areas with an explosive atmosphere, then motor and supplied accessories have the same classification as the pump. Motor and accessories need to be installed and used in agreement with the enclosed manufacturer’s informa-tion.

Static Electricity

The pump needs to be sufficiently grounded so as to avoid any electrostat-ic charging. This is attained when properly connecting the electric ground conductor to the motor. During normal operation no hazardous generation of charges will occur on the elastomer coupling or the fan.

Wipe plastic parts on the pumps of category 3G outside only with a moistened piece of cloth.

Only original Leybold oil filters and gas inlet filters must be used since these have been designed such that proper connection to ground is ensured. Dust on the surfaces must only be removed using a moist piece of cloth so as to exclude the possibility of generating sparks.

Chemical Reactions

The pump must not be used in connection with reactive or corrosive gases, which might result in an exothermal chemical reaction.

Additional Safety Measures Overheating the pump can give rise to temperatures which exceed the maxi-mum permitted surface temperature.

In order to prevent overheating, installation and maintenance need to be done in accordance with the information provided in these Operating Instructions. Especially the correct oil level needs to be maintained.

The oil must be exchanged within the recommended interval or earlier if con-taminated by the process gas.

Additional Maintenance Requirements In those cases where dust can deposit itself on the pump or the motor sur-faces, measures must be introduced which ensure that such deposits are removed on a regular basis.

In order to ensure that the defined safety level is complied with, use only original Leybold spare parts.

In addition to the maintenance work described in the Operating Instructions every 15,000 operating hours or every three years a complete refurbishment of the pump including a replacement of the bearings, the motor and the coupling element should be scheduled.

DANGER

DANGER

Maintain the correct oil level

Description

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1 2 3

Fig. 1 TRIVAC B pump with accessories

1 Description TRIVAC B pumps are oil-sealed rotary vane pumps. The TRIVAC D 16 B and D 25 B are dual-stage pumps. The number in the type designation (16 or 25) indicates the pumping speed in m3 · h-1.

The vacuum pumps from the line TRIVAC B Category 3 have been designed and manufactured especially for the purpose of fulfilling the requirements of Equipment Group II, Category 3 of the “ATEX Directive” (2014/34/EU) for conforming utilisation of equipment and protection systems in explosion haz-ard areas”.

TRIVAC B pumps are capable of pumping gases and vapours and evacuat-ing vessels or vacuum systems down into with the medium vacuum range.

The standard versions of the pump are not suited for pumping of oxygen exceeding the concentration as found in the atmosphere, and are also not suited for pumping of hazardous gases or extremely aggressive or corrosive media.

The inside (the process gas side) of this vacuum pump is so designed and rated that the occurrence of foreseeable ignition sources can be excluded during normal operation. Provided the pump is operated within the limits of the parameters specified in the Operating Instructions, the pump will offer a normal degree of protection. It is therefore suited for operation under condi-tions under which it is unlikely that explosive atmospheres are caused by gases, vapours or mists in the air or should these occur then only rarely and for a short period of time (i.e. Zone 2). The same conditions apply to outside components of the pumps which have been certified.

Areas of application

Process gas side

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If only the inside of the pump (process side) has been certified for use in explosive atmospheres, then the pump itself must not be installed and operated within explosion hazard areas.

Areas in which explosive atmospheres (gases, vapours or mists) in the air can occur are classified in three zones according to the frequency and the dura-tion of the occurrence of an explosive atmosphere.

These zones are designated as Zone 0, 1 and 2. The definitions for these zones are described in the Annex I of the “Atex Directives (Directive 99/92/ EG) for the improvement of health protection and safety of staff which might be endangered by explosive atmospheres”.

Conforming utilisation of the TRIVAC pumps and compliance with the statu-tory requirements of the ATEX operator directive (99/92/EG) is the responsi-bility of the operator.

Via an intermediate flange the drive motor of the TRIVAC B is mounted to the coupling housing. The pump and motor shafts are directly connected by a flexible coupling. The bearing points of the pump module are force lubricated sliding bearings. All controls as well as the oil-level 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 disassembly and reassembly. The pump module can be easily removed without special tools.

DANGER

Outside of the pump

Zone 0, 1 and 2

Responsibility of the operator

Drive concept

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Fig. 2 Sectional drawing of the TRIVAC B

1.1 Function

The rotor (2/7), mounted eccentrically in the pump housing (2/6), has two radially sliding vanes (2/5) which divide the pump chamber into several com-partments. The volume of each compartment changes periodically with the rotation of the rotor.

As a result, gas is sucked in at the intake port (2/1). The gas passes through the dirt trap sieve (2/2), flows past the open anti-suckback valve (2/3) and then enters the pump chamber. In the pump chamber, the gas is passed on and compressed, after the inlet aperture is closed by the vane.

The oil injected into the pump chamber is used for sealing and lubricating.

The slap noise of the oil in the pump which usually occurs when attaining the ultimate pressure 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 through the exhaust port.

During compression, a controlled amount of air – the so-called gas ballast – can be allowed to enter the pump chamber by opening the gas ballast valve.

The gas ballast stops condensation of vapours in the pump chamber up to the limit of the water vapour tolerance as specified in the technical data for the pump.

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The gas ballast valve is opened (position I) and closed (position 0) by turning the gas ballast knob (7/5) on the front.

To enable the TRIVAC B to be used at intake pressures as high as 1,000 mbar, a special lubricating system was developed featuring force-lubri-cation of the sliding bearings.

An oil pump (3/6) pumps the oil from the oil reservoir (3/5) into a pressure-lubrication system which supplies oil to all bearing points (3/2). From there the oil enters the pump chamber area (3/4) of the vacuum pump.

The oil pump is fitted in the front end plate on the coupling side of the pump module. The oil suction line is placed low, resulting in a large usable oil reser-voir.

The oil is separated from the gas in the TRIVAC B in two steps as described above. First, small droplets are coalesced into large drops in the internal demister (2/11) fitted above the exhaust valve (2/10). Then, the large drops fall into the oil reservoir as the exhaust gas is diverted by the inner walls of the oil case. Thus a low loss of oil is obtained. This and the large usable oil reservoir ensure long intervals between oil changes even at high intake pres-sures.

The vacuum is maintained by the TRIVAC B through an integrated hydro-pneumatic anti-suckback valve (2/3) which is controlled via the oil pressure.

During operation of the TRIVAC B 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).

When the pump stops (because it has been switched off or because of a fail-ure), the oil pressure drops and the spring (4/2) presses the control piston (4/3) up. Thus a connection is provided between the oil case or the oil reser-voir (4/1) and the piston (4/4) of the anti-suckback valve.

Due to the pressure difference between the oil case and the intake port the oil presses the piston (4/4) up and the valve plate (4/6) against the valve seat (4/5). The quantity of oil in the oil reservoir (4/1) prevents the entry of air into the intake port (2/1) at the beginning of this process.

After the oil has flowed out from the reservoir and when the valve plate rests on the valve seat, air follows in, which vents the pump chamber and forces the valve disc (4/6) against its seat.This effectively prevents backstreaming of oil or oil vapours. The anti-suckback valve (2/3) operates independently of the operating mode of the pump, i.e. also with gas ballast.

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Fig. 3 Schematic of the lubricating system

Fig. 4 Hydropneumatic anti-suckback valve

1.2 Lubricants

The standard TRIVAC B pumps are ready for operation with mineral oil.

For operating a TRIVAC B pump we specify our vacuum pump oils which are supplied with the pumps.

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1.3 Supplied Equipment

The equipment supplied with the TRIVAC-B pump includes:

Pump with motor, 1 centering ring, 1 centering ring with dirt trap, 2 clamping rings DN 25 KF, Operating Instructions, Spare Parts List.

For protection during shipment, the connection ports are each blanked off by rubber diaphragms and supporting rings.

Upon delivery from Leybold Cologne, the pumps are filled with the following types of oil:

P/N Oil Accessories

112 65/66/66J/75/76/76J LVO100

113 25/35 LVO100

113 28/38 LVO100 without motor 1

113 33/33J LVO210

140 160/170 LVO100

140 160V LVO210

898 208 LVO210

898 698 LVO100 Oil drain tap

912 65-1/65-2 LVO100

912 75-2 LVO100

914 63-1 Ucon LB300 XY26

1The fitting of a motor has to comply with the regulations of EN 60204-1 “Safety of machinery - Electrical equipment of machines - Part 1: General require-ments”.

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1.4 Technical Data

Nominal pumping speed 1) m3 · h-1 (cfm) 18.9 (11.1) 29.5 (17.4)

Pumping speed 1) m3 · h-1 (cfm) 16.5 (9.7) 25.7 (15.1)

Water vapour capacity g · h-1 305 476

Oil filling, min./max. l 0.45 / 1.0 0.6 / 1.4

Noise level to DIN 45 635 dB (A) 54 / 56 54 / 56 without/with gas ballast

Admissible ambient temperature 2)

Relative atmospheric humidity % max. 90 max. 90

Mains fusing 3) A 16 16

Weight kg 26 32

Connections, intake and exhaust side DN 25 KF 25 KF

1) In acc. with DIN 28 400 et seq. valid for LVO 100. For other oils the ultimate pressure may differ.

2) The motor may accelerate with a delay when simultaneously an undervoltage is present at the motor and the pump is at the minimum permissible and ambient temperature. Under such operating conditions the motor protection switch may respond. In this case the motor may be started again.

3) Europe

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DN

a c b3 b2 b b1 h1 h2 h o

Fig. 6 Dimensional drawings for the TRIVAC B pumps (all dimensions are approximate and in mm; l (length) cf. next pages)

Fig. 5 Pumping speed characteristics for the TRIVAC B pumps (50 Hz operation, SI units)

Ultimate partial pressure without gas ballast Ultimate total pressure without gas ballast Ultimate total pressure with gas ballast

Pressure

P um pi ng s pe ed

TRIVAC DN a b b1 b2 b3 c h h1 h2 m n o

D 16 B 25 KF 82 185 170 151 5.5 135 263 248 228 280 140 132

D 25 B 25 KF 142 185 170 151 5.5 135 263 248 228 280 140 132

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Cat. Nos. of the pumps 112 66/76, 113 33 112 66J /76J / 133 33J 140 160 /160V /170

Motor type AMPH 80Z AA4 AMPH 80Z AA4 EeDA 80L/4

Motor L/N 6506939-IE3 6520730-IE3 20010409

Compliance Certification number CC#046A

IP rating IP55 IP55

Operating mode IEC34 / Duty S1 S1

Isolation class F F

Phases 3~ 3~

Nom. efficiency (η) at nom. vol-tage:

50 Hz and 100 % of nom. load 50 Hz and 75 % of nom. load 50 Hz and 50 % of nom. load 60 Hz and 100 % of nom. load 60 Hz and 75 % of nom. load 60 Hz and 50 % of nom. load

82.5 % (at 400 V)

83.0 % (at 400 V)

81.5 % (at 400 V)

85.5 % (at 460 V)

85.1 % (at 460 V)

83.1 % (at 460 V)

Efficiency class IE3 Premium Efficiency Class

IE3

JIS

due to missing IE3 not for use in the US

Manufacturer Lafert SpA San Donà di Piave

Italy

Emod Motoren GmbH Bad Salzschlirf

Germany

Number of poles 4 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

750 W 750 W

750 W

Nom. in frequency 50 Hz 60 Hz

50 Hz

Nom. voltage range and nom. current at 50 Hz

200-240 V / 3.8 A

200 V / 3.8 A (IE3)

380-400 V / 1.9 A

380-400 V / 1.9 A (IE3)

180-220 V / 3.6 A

200 V / 3.6 A (IE3)

311-380 V / 2.1 A

346 V / 1.9 A (IE3)

219-242 V / 3.35 A

380-420 V / 1.94 A

Nom. voltage range and nom. current at 60 Hz

200-240 V / 3.8 A

208-240 V / 3.4 A (IE3)

380-480 V / 1.9 A

416-480 V / 1.7 A (IE3)

200-240 V / 3.4 A

220 V / 3.1 A (IE3)

342-418 V / 1.9 A

380 V / 1.8 A (IE3)

Tolerances of voltage range1) ±10 % ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1425 rpm

1730 rpm 1440 rpm

1745 rpm 1380 rpm

Disposal local directives have to be considered

Max. altitude above sea level 1000 m (NHN)

Max. ambient temp. when opera-ting1)

40 °C

T-board / plug 9 pins 6 pins

Certificates2) of the motor

Length of the pump 509 mm (D 16 B) 571 mm (D 25 B)

510 mm (D 16 B) 572 mm (D 25 B)

II 3/3G Ex h IIC T4 / Ex h IIC T3

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Cat. Nos. of the pumps 112 65/75 140 165

Motor type LS90PR/T E8CD4B2-8-122

Motor L/N 38066003 110002915

Compliance Certification number

IP rating IP44 IP44

Operating mode IEC34 / Duty S1 H

Isolation class F F

Phases 1~ 1~

Manufacturer Moteurs Leroy-Somer 16015 Angoulême Cedex

France

Hanning-Elektro-Werk GmbH & Co. KG 33813 Oerlinghausen

Germany

Number of poles 4 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

750 W 750 W

590 W 680 W

Nom. in frequency 50 Hz 60 Hz

50 Hz 60 Hz and nom. current at 50 Hz

218 V / 5.0 A 242 V / 5.6 A

218-242 V / 4.2 A and nom. current at 60 Hz

218 V / 5.7 A 242 V / 5.5 A

218-242 V / 3.0 A

Tolerances of voltage range1) ±5 % ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1460 min-1

1750 min-1

1420 min-1

1690 min-1

Disposal local directives have to be considered local directives have to be considered

Max. altitude above sea level 1000 m (NHN) 1000 m (NHN)

Max. ambient temperature when operating1) 40 °C 40 °C

T-board / plug Mains cord (2 m) with shock-proof CEE plug Cable with custom plug

Certificates2) of the motor

Length of the pump 521 mm (D 16 B) 583 mm (D 25 B)

508 mm (D 16 B)

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Cat. Nos. of the pumps 113 25/35

Motor type E9SF4AB3-100

Motor L/N 110001212

Compliance Certification number

IP rating IP54

Operating mode IEC34 / Duty H

Isolation class F

Phases 1~

Manufacturer Hanning-Elektro-Werk GmbH & Co. KG 33813 Oerlinghausen

Germany

Number of poles 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

750 W 750 W

Nom. in frequency 50 Hz 60 Hz

208 – 252 V / 5.7 A

208 – 252 V / 4.9 A

Tolerances of voltage range1) ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1420 min-1

1680 min-1

Disposal local directives have to be considered

Max. altitude above sea level 1000 m (NHN)

Max. ambient temperature when operating1) 40 °C

T-board / plug Multi-pin plug at the junction box

Mains cord 20081091 (1.8 m) with Schuko plug CEE 7/7 (included in delivery)

Mains cord 20081097 (1.8 m) with UK plug BS 1363 (optional)

Mains cord 20081099 (1.8 m) with CH plug SEV 1011 (optional

Mains cord 20081141 (1.8 m) with US plug NEMA 6-15P (optional)

Certificates2) of the motor

Length of the pump 515 mm (D 16 B) 577 mm (D 25 B)

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Cat. Nos. of the pumps 898 199/199-1 898 208, 912 65-1

Motor type 5K49PN4167 56B17F5558D P

Motor L/N 72260135 72260117

Compliance Certification number

IP rating IP43

Operating mode IEC34 / Duty continuous continuous

Isolation class B F

Phases 3~ 1~

Manufacturer Marathon Electric Motors Wausau, WI 54401

USA

Marathon Electric Motors Wausau, WI 54401

USA

Number of poles 4 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

750 W 750 W

560 W 560 W

Nom. in frequency 50 Hz 60 Hz

50 Hz 60 Hz

208-220 V

380 V

115 V / 13 A

208-230 V / 5.5-6.5 A

208-230 V / 3.6 A

460 V / 1.7 A

115 V / 9.4 A

208-230 V / 4.8-4.7 A

Tolerances of voltage range1) ±5 % ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1500 min-1

1725 min-1

1425 min-1

1725 min-1

Disposal local directives have to be considered local directives have to be considered

Max. altitude above sea level 1000 m above sea level 1000 m (NHN)

Max. ambient temperature when operating1) 40 °C 40 °C

T-board / plug Cable with custom plug Mains cord (1.8 m) with NEMA 5-15P plug

Certificates2) of the motor

Length of the pump 536 mm (D 16 B) 562 mm (D 16 B)

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Cat. Nos. of the pumps 898 229 898 698

Motor type 5K49UN4305AV 35R869R777G1

Motor L/N 72260156 72260187

Compliance Certification number

IP rating IP44

Operating mode IEC34 / Duty continuous continuous

Isolation class F F

Phases 3~ 1~

Manufacturer Marathon Electric Motors Wausau, WI 54401

USA

Baldor Electric Company Fort Smith, AR 72901

USA

Number of poles 4 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

1100 W 1100 W

750 W 750 W

Nom. in frequency 50 Hz 60 Hz

50 Hz 60 Hz

200-240 V / 4.3-3.8 A 380-415 V / 2.5-2.4 A

110 V / 15 A 220 V / 7.5 A

200-240 V / 4.3-3.8 A 380-415 V / 2.5-2.4 A

115 V / 12.4 A

208-230 V / 6.3-6.2 A

Tolerances of voltage range1) ±5 % ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1425 min-1

1725 min-1

1500 min-1

1800 min-1

Disposal local directives have to be considered local directives have to be considered

Max. altitude above sea level 1000 m (NHN) 1000 m (NHN)

Max. ambient temperature when operating1) 40 °C 40 °C

T-board / plug 3 wires (L1, L2, L3) resp.

Plug with assignment L1, L2, L3, GND

Multi-pin plug at junction box

Mains cord (1.8 m) E72127877 with US plug NEMA 5-15P

Mains cord (1.8 m) E72127878 with US plug NEMA 6-15P

Length of the pump 610 mm (D 25 B) 582 mm (D 16 B)

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Cat. Nos. of the pumps 912 65-2 912 75-2

Motor type JQH 56B17F5592E-P 56B17F5577D P

Motor L/N 72260005 72260022

Compliance Certification number

IP rating TEFC IP44

Operating mode IEC34 / Duty continuous continuous

Isolation class B F

Phases 1~ 1~

Manufacturer Marathon Electric Motors Wausau, WI 54401

USA

Marathon Electric Motors Wausau, WI 54401

USA

Number of poles 4 4

Nom. output power at 50 Hz Nom. output power at 60 Hz

550 W 550 W

1100 W 1100 W

Nom. in frequency 50 Hz 60 Hz

50 Hz 60 Hz

208-230 / 5.5-6.5 A

200-230 V / 9.6-9.2 A

208-230 / 4.8-4.7 A

200-230 V / 9.0-8.0 A

Tolerances of voltage range1) ±5 % ±5 %

Nom. speed at 50 Hz Nom. speed at 60 Hz

1500 min-1

1800 min-1

1425 min-1

1725 min-1

Disposal local directives have to be considered local directives have to be considered

Max. altitude above sea level 1000 m (NHN) 1000 m (NHN)

Max. ambient temperature when operating1) 40 °C 40 °C

T-board / plug Mains cord (1.8 m) with US plug NEMA 6-15P

Mains cord (1.8 m) with US plug NEMA 6-15P

Length of the pump 538 mm (D 16 B) 662 mm (D 25 B)

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1) The motor may accelerate with a delay when simultaneously an undervoltage is present at the motor and the pump is at the minimum permissible and ambient temperature. Under such operating condi-tions the motor protection switch may respond. In this case the motor may be started again.

2) Key to the certificates:

CSA certification mark for products certified in accordance with CSA for Canada.

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 nameplate.

For special pumps please note the information contained in the supple-mental sheet.

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1.5 Accessories

Leybold accessories listed below for this pump, like inlet screen, for example, are also suited for operation in explosion hazard areas. The same conditions as for the pump apply.

When using other accessories with the pump, it needs to be ensured that these are suited for operation in explosion hazard areas.

Part No.

Separator AK 16-25 188 11

Exhaust filter AF 16-25 189 11

Drain tap for condensate trap, exhaust filter, oil drain of the pump, vacuum-tight 190 90

Exhaust filter with lubricant return AR 16-25 189 21

Exhaust filter with lubricant return ARS 16-25 189 56

Dust separator 186 11

Oil filter OF 4-25 101 91

Chemical filter CF 4-25 101 96

Chemical oil filter with safety isolation valve CFS 16-25 101 76

Adaptor for gas ballast port

Inert-gas-system 16-25 (for BCS versions) 161 76

Limit switch system 16-25 161 06

1) Not approved for ATEX applications

Use only the kind of oil specified by Leybold.

Transport and Storage

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2 Transport and Storage

To lift the pumps only use the crane eyes provided for this purpose, respectively use corresponding lifting facilities. When connecting or remov-ing the pump, do not move under hoisted loads.

If possible transport the pump in its original packaging, if not available exercise due care.

Pumps which are filled with operating agents must only be moved while standing upright. Otherwise oil may escape. Avoid any other orientations dur-ing transport. Check the pump for the presence of any oil leaks, since there exists the danger that someone may slip on spilt oil.

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 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 con-taining 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 5.4). We recommend that you contact the Leybold Service.

Installation

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3 Installation

Instructions for the operating personnel Before conducting any kind of assembly work the personnel must be informed about potential hazards. Observe Safety Information 0.1 to 0.6.

3.1 Placement

Pumps marked as

are not suited for installation in the explosion hazard areas.

Pumps marked as

may only be used in Zone 2.

If the pump (outside) has been certified for operation in areas with explo-sive atmospheres, the special information contained in the Operating Instructions for the electric motor for installation in explosive areas need to be complied with. Additional information is provided in the European stand-ards EN 60079-14 “Electrical apparatus for explosive gas atmospheres Part - 14” and EN 60079-17 “Electrical apparatus for explosive gas atmos-pheres - Part 17”.

Pay attention to the safety information 0.5.

The TRIVAC B pump can be set up on a flat, horizontal surface. Rubber feet under the coupling housing ensure that the pump can not slip.

If you wish firmly install the pump in place, insert bolts through bore holes in the rubber feet.

Risk of toppling Max. tilt for the pump is 10° from the vertical.

If you wish firmly install the pump in place, insert bolts through bore holes (Ø 7 mm) 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.

NOTICE

DANGER

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Note the ambient conditions during operation The ambient temperature should not exceed +40 °C (104 °F) and not drop below +12 °C (55 °F) (see Section 4.3.3).

For installation sites over 1000 m (NHN) and/or a relative atmospheric humidity of over 90 %, you must discuss this with Technical Sales.

When failing, capacitors may heat up excessively and generate smoke.

Therefore the pump must be placed with a sufficient clearance from inflam-mable or combustible material. There exists the risk of fire! The max.

amount of heat given off approximately corresponds to the rated motor power.

Install the pump such that only minimal quantities of dust can deposit themselves on the surfaces. In those cases where dust deposits form, measures need to be introduced which ensure that these are removed on a regular basis.

The maximum gas inlet temperature must not exceed 60 °C.

The maximum pressure at the inlet must not exceed atmospheric pressure (approximately 1013 mbar). Never apply overpressures to the pump’s inlet.

The maximum exhaust pressure must not exceed 0.5 bar (g).

3.2 Conforming Utilization

TRIVAC B pumps can pump gases and vapours, and evacuate vessels or vacuum systems in the fine vacuum range.

The pumps are suited 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. 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 protection devices need to be pro-vided.

Conforming utilisation of the TRIVAC pumps and compliance with the statu-tory requirements of the ATEX operator directive (99/92/EG) is the responsi-bility of the operator.

Our technical sales department is available for further advice in these mat-ters.

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3.2.1 Non-conforming Utilization

The TRIVAC B is not suited for pumping of:

The pumps are not suited for pumping of liquids or media which carry large quantities of dust. Corresponding protection devices need to be pro-vided.

The standard pump is not suited for pumping of hazardous gases or vapours.

When cleaning a system in which a TRIVAC pump has been integrated,all parts in contact with the medium need to be compatible withthe cleaning agent so as to prevent a chemical reaction. Residues of the cleaning agent within the pump must be avoided.

Gas Composition It is important to note that the composition of the gas at the inlet of the pump and at the exhaust may possibly differ. This may possibly have effect on the zone divisions.

Ignition Temperatures of Gases/Vapours Pumps equipped with motors for 50 Hz operation are suited only for applica-tions in which potentially explosive gas or vapour mixtures have an ignition temperature of over 135 °C.

Pumps equipped with motors for 60 Hz operation, are suited only for appli-cations in which potentially explosive gas or vapour mixtures have an ignition temperature of over 200 °C.

The ignition temperatures of gases or vapours, sometimes also termed auto-ignition temperature can be taken from the material safety data sheets.

The pump is not suited for operation with reactive, aggressive or corrosive gases, or gases with an oxygen share exceeding 21 % by volume.

Potential Ignition Sources An assessment of the ignition hazard was performed in accordance with the European standard EN ISO 80079-36 (EN ISO 80079-36 Non-electrical equipment for potentially explosive atmospheres – Part 1: Basic method and requirements).