Leybold vacuum TRIVAC B D 40 BCS User manual

v
acuum
Part Nos.
113 88/89/98/99
154 52/54
OPERATING INSTRUCTIONS
GA01301_0702
TRIVAC®B
D 40 BCS / D 65 BCS
Rotary Vane Vacuum Pump
■with mineral oil
■with PFPE

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2
Contents
Page
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.1 Standard Accessories and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.2 TRIVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2Transport and Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Conforming Utilisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Connection to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.1 Non-Condensable Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.2 Condensable Gases and Vapours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.3 Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Switching Off/Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Maintenance Plan (Recommendation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Leybold Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Checking the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Cleaning the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6 Removing and Fitting the Internal Demister . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7 Disassembly and Reassembly of the Electric Motor . . . . . . . . . . . . . . . . . . . . 34
5.8 Replacing the Outer Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9 Removing and Remounting the Pump Module . . . . . . . . . . . . . . . . . . . . . . . . 38
6Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7Shelving after Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8Waste Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section

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Safety Information
Caution
Warning
Note
Important
Safety Information
Indicates procedures that must be strictly observed to prevent hazards to
persons.
Indicates procedures that must be strictly observed to prevent damage to,
or destruction of the product.
Emphasises additional application information and other useful information
provided within these Operating Instructions.
The Leybold TRIVAC BCS has been designed for safe and effi-
cient operation when used properly and in accordance with these
Operating Instructions. It is the responsibility of the user to careful-
ly read and strictly observe all safety precautions described in this
section and throughout the Operating Instructions. The TRIVAC
BCS must only be operated in the proper condition and
under the conditions described in the Operating Instruc-
tions. It must be operated and maintained by trained personnel
only. Consult local, state, and national agencies regarding speci-
fic requirements and regulations. Address any further safety, ope-
ration and/or maintenance questions to your nearest Leybold
Vacuum office.
Failure to observe the following precautions could result in serious
personal injury!
■Before beginning with any maintenance or service work on the
TRIVAC BCS (PFPE), disconnect the pump from all power
supplies.
■Do not operate the pump with any of the covers removed.
Serious injury may result.
■If exhaust gases must be collected or contained, do not allow
the exhaust line to become pressurised.
■Make sure that the gas flow from the exhaust port is not
blocked or restricted in any way.
■The standard version of the TRIVAC BCS (PFPE) is not suited
for operation in explosion hazard areas. For this applications
we offer the TRIVAC B ATEX pumps. Contact us before plan-
ning to use the pump under such circumstances.
■Before starting up for the first time, the motor circuit must be
equipped with a suitable protective motor switch. Please take
note of the information in these Operating Instructions or on
the electric motor (wiring diagram).
Warning

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■The TRIVAC BCS (PFPE) is not suited for pumping of:
■combustible and explosive gases or vapours
■radioactive and toxic substances
■pyrophorous substances.
■Avoid exposing any part of the human body to the vacuum.
■Never operate the TRIVAC BCS (PFPE) without a connected
intake line or blank flange.
■The location at which the TRIVAC BCS (PFPE) (including its
accessories) is operated should be such that angles over 10°
from the vertical are avoided.
■The location of the TRIVAC BCS (PFPE) should be such that
all controls are easily accessible.
■Under certain ambient conditions the TRIVAC BCS (PFPE)
may attain a temperature of over 80 °C (176 °F). There then
exists the danger of receiving burns.
Note the symbols on the pump pointing to the hazards, and
in the case of a hot pump wear the required protective clo-
thing.
■The noise level of the TRIVAC BCS (PFPE) is between 57 and
59 dB(A). Introduce suitable hearing protection.
■Before pumping oxygen (or other highly reactive gases) at
concentrations exceeding the concentration in the atmosphe-
re (> 21 % for oxygen) it will be necessary to use a special
pump. Such a pump will have to be modified and de-greased,
and an inert special lubricant (like PFPE) must be used.
■Before operating the TRIVAC BCS (PFPE) with atmospheric
gas ballast (optional) check first compatibility with the pumped
media so as to avoid hazardous conditions during operation
right from the start.
■Before commissioning the TRIVAC BCS (PFPE), make sure
that the media which are to be pumped are compatible with
each other so as to avoid hazardous situations.
All relevant safety standards and regulations must be obser-
ved.
■It is recommended to always operate the TRIVAC BCS (PFPE)
with a suitable exhaust line which is properly connected. It
must slope down and away from the pump.
■When moving the TRIVAC BCS (PFPE) always use the allo-
wed means. A lifting eye is provided as standard on the
pump.
Safety Information

GA01301_0702 - 04/2006 - © by Leybold Vacuum 5
Failure to observe the following precautions could result in dama-
ge to the pump!
■Do not allow the ingestion of small objects (screws, nuts,
washers, pieces of wire, etc.) through the inlet port. Always
use the screen which is supplied with every pump.
■Do not use the pump for applications that produce abrasive
or adhesive powders or condensable vapours that can leave
adhesive or high viscosity deposits. Please contact Leybold
Sales or Service to select a suitable separator. Also pease
contact Leybold Sales or Service when planning to pump
vapours other than water vapour.
■This pump is suited for pumping water vapour within the spe-
cified water vapour tolerance limits.
■Avoid vapours that can condense into liquids upon compres-
sion inside the pump, if these substances exceed the vapour
tolerance of the pump.
■Before pumping vapours, the TRIVAC BCS (PFPE) should have
attained its operating temperature, and the gas ballast should
be set to position I (position 0 = closed, position I = max. water
vapour tolerance, 25 mbar). The pump will have attained its
operating temperature about 30 minutes after starting the
pump. During this time the pump should be separated from the
process, by a valve in the intake line, for example.
■In the case of wet processes we recommend the installation
of liquid separators upstream and downstream of the pump
as well as the use of the gas ballast.
■The exhaust line should be laid so that it slopes down and
away from the pump so as to prevent condensate from back-
streaming into the pump.
■The entry of particles and fluids must be avoided under all cir-
cumstances.
■Reactive or aggressive substances in the pump chamber
may impair the operating oil or modify it. In addition, such
substances may be incompatible with the materials of the
pump (Viton, grey cast iron, aluminium, steel, resins, glass
etc.).
■Corrosion, deposits and cracking of oil within the pump are
not allowed.
■Normal amounts of humidity within the range of the pump’s
vapour tolerance will not significantly affect pump performan-
ce when the gas ballast is active.
In the case of custom pumps (with a Part No. deviating from
the Part No. stated in the EC Declaration of Conformity)
please note the information provided on a separate sheet.
Safety Information
Caution
The references to diagrams, e.g. (1/2) consist of the Fig. No. and the Item
No. in that order.
We reserve the right to modify the design and the specified data. The illu-
strations are not binding.
Figures
Note

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Description
1Description
TRIVAC BCS pumps are oil-sealed rotary vane pumps. The TRIVAC D 40
BCS and D 65 BCS are dual-stage pumps. The number in the type desi-
gnation (40 or 65) indicates the pumping speed in m3· h-1.
The TRIVAC BCS-PFPE have been prepared especially for operation with
perfluoropolyther.
TRIVAC BCS pumps can pump gases and vapours, and evacuate vessels
or vacuum systems in the fine vacuum range.
They have been designed particularly for use in connection with corrosive
or aggressive media. Moreover, the pump has been prepared for the instal-
lation of an electric monitoring facility. Leybold have developed for the TRI-
VAC BCS a range of accessories which considerably extend the range of
applications for this kind of pump. These accessories which in connection
with the TRIVAC BCS vacuum pump make up the TRIVAC system, are
described briefly in Chapter 1.5.
The drive motor of the TRIVAC BCS is directly flanged to the pump at the
coupling housing. The pump and motor shafts are directly connected by a
flexible coupling. The bearing points of the pump module are force lubrica-
ted 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.
Fig. 1 TRIVAC BCS pump with accessories
Drive concept
Areas of application

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Description
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.
Those of standard design are not suitable for pumping greater
than atmospheric concentrations of oxygen.
Before pumping oxygen (or other highly reactive gases) at con-
centrations exceeding the concentration in the atmosphere
(> 21 % for oxygen) it will be necessary to use a special pump.
Such a pump will have to be modified and de-greased, and an
inert special lubricant (like PFPE) must be used.
1.1 Design and 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
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 (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 TRI-
VAC BCS PFPE pumps do not have an internal demister. The gas leaves
the TRIVAC BCS-PFPE 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 cham-
ber up to the limit of the water vapour tolerance as specified in the techni-
cal data for the pump.
The gas ballast valve is opened (position I) and closed (position 0) by tur-
ning the gas ballast knob (7/5) on the front.
The gas ballast facility of the TRIVAC BCS pump has been prepared for
connecting the inert gas system IGS.
To enable the TRIVAC BCS to be used at intake pressures as high as 1,000
mbar, a special lubricating system was developed featuring force-lubricati-
on 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.
Warning
Operating principle
Oil filter
Operation with gas ballast
Lubrication system

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Description
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
reservoir.
The oil is separated from the gas in the TRIVAC BCS 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 pressures.
The vacuum is maintained by the TRIVAC BCS through an integrated
hydropneumatic anti-suckback valve (2/3) which is controlled via the oil
pressure.
During operation of the TRIVAC BCS the control piston (4/3) remains sea-
led against a spring (4/2) by the oil pressure. The valve disc (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
failure), 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 reservoir (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.
Fig. 2 Sectional drawing of the TRIVAC BCS
Key to Fig. 2
1Intake port
2Dirt trap
3Anti-suckback valve
4Intake channel
5Vanes
6Pump chamber
7Rotor
8Cover plate, connection for inert gas ballast
9Exhaust channel
10 Exhaust valve
11 Internal demister
12 Spring buckles
13 Cover plate, connection for oil filter
Separation of oil and gas
Anti-suckback valve

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Description
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.
All aluminium surfaces of the TRIVAC BCS are surface protected and thus
particularly capable of resisting aggressive chemicals. A thermocouple has
been incorporated in the pump which is used in connection with the optio-
nal electrical monitoring facility. The thermocouple may be accessed
through the built-in connector (7/8).
Via a second oil fill opening, an exhaust line may be connected for venting
the oil case when using the inert gas purging facility.
Fig. 3 Schematic of the lubricating system
Fig. 4 Hydropneumatic anti-suckback valve
Key to Fig. 3
1Accessories
2Bearings
3Non-return valve
4Pump chamber of the TRIVAC
5Oil reservoir
6Oil pump
Key to Fig. 4
1Oil reservoir 5 Valve seat
2Spring 6 Valve disk
3Control piston 7 Gas inlet
4Anti-suckback piston
Surface protection
Thermocouple

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Description
1.2 Lubricants
The standard TRIVAC BCS pumps are either ready for operation with mine-
ral oil or with the special lubricant, perfluoropolyther (PFPE).
If mineral oil and PFPE come into contact they will emulsify. That’s why the
pumps must only be run with the type of lubricant specified for the pump.
If you want to change the type of lubricant Leybold should do the change.
In case of operation with mineral oil we recommend our vacuum pump oil
N 62.
In case of operation with PFPE we recommend our vacuum pump oil NC
1/14.
When handling PFPE you should observe the following:
During thermal decomposition at temperatures over 290 °C toxic
and corrosive gases are released. When handling PFPE keep it
way from open fires. Do not smoke in the work area.
Touch the inner sections of the pumps only while wearing clean gloves, and
use clean tools;
Do the necessary work in clean and dry rooms;
After having removed the pump from its packaging, start it up as quickly as
possible;
While working on the pump, do not eat, drink or smoke.
As cleaning agents solvents based on hydrofluorether compounds may be
used.
The Operating Instructions GA 07.009 “PFPE for Vacuum Pumps“
will be enclosed with all TRIVAC BCS pumps. Observe the hand-
ling notes for PFPE collected in these Operating Instructions.
Warning
Caution

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Description
1.3 Supplied Equipment
Pump with motor,
1 centering ring,
1 centering ring with dirt trap,
2 clamping rings DN 40 KF.
Plug without cable to protect the socket for the temperature switch.
For protection during shipment, the connection ports are each blanked off
by rubber diaphragms and supporting rings.
The pump is contained with some silica gel in an air-tight plastic bag.
TRIVAC BCS for operation with mineral oil
Upon delivery from Leybold Cologne the pumps will be filled with N62 oil.
TRIVAC BCS for operation with PFPE
The pumps will be supplied without lubricant. However, the pump will still
contain residues (about 0.7 litres) of the NC 1/14 lubricant.
The oil fill plugs have been removed and are supplied separately.
In the case of custom pumps (with a Part No. deviating from the
Part No. stated in the EC Declaration of Conformity) please note
the information provided on a separate sheet.
Caution

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12
Description
In the case of custom pumps (with a Part No. deviating from the
Part No. stated in the EC Declaration of Conformity) please note
the information provided on a separate sheet.
Motor voltage and current may differ from these data. Observe the
data given on the name plates.
1.4 Technical Data
TRIVAC BCS D 40 BCS D 65 BCS
two-stage two-stage
Nominal pumping speed 1) m3· h-1 (cfm) 46 (27.1) 75 (44.2)
Pumping speed1) m3· h-1 (cfm) 40 (23.6) 65 (38.3)
Ult. partial pr. without gas ballast1) mbar 10-4
Torr 0.75 · 10-4
Ultimate total pr. without gas ballast1) mbar < 2 · 10-3
Tor r < 1.5 · 10-3
Ultimate total pr. with gas ballast 1) mbar < 5 · 10-3
Tor r < 3.8 · 10-3
Water vapour tolerance1) mbar 40
Tor r 30
Water vapour capacity g · h-1 1184 1925
Oil filling, min./max. l 1.7 / 2.6 2.0 / 3.3
Noise level to DIN 45 635
without/with gas ballast dB (A) 57 - 59
Admissible ambient temperature °C 12 - 40
Motor power W 2200
Speed (50 / 60 Hz) rpm 1500 / 1800
Motor protection IP 55
Voltage range 50 Hz V 218-242/380-420
60 Hz V 230-277/414-480
Nom. current 50 Hz A 9.9/5.7
60 Hz A 8.5/4.9
Weight kg 68 80
Connections, intake and exhaust side DN 40 KF
TRIVAC BCS
with three-phase motor Part No. Part No.
230/400 V, 50 Hz / 250/440 V, 60 Hz 113 88 113 98
1) To DIN 28 400 and subsequent numbers
Caution

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Description
TRIVAC BCS-PFPE D 40 BCS-PFPE D 65 BCS-PFPE
two-stage two-stage
Nominal pumping speed 1) m3· h-1 (cfm) 46 (27.1) 75 (44.2)
Pumping speed1) m3· h-1 (cfm) 40 (23.6) 65 (38.3)
Ult. partial pr. without gas ballast1) mbar < 8 · 10-4
Tor r < 6 · 10-4
Ultimate total pr. with gas ballast 1) mbar < 5 · 10-3
Tor r < 3.8 · 10-3
Oil filling, min./max. l 1.5 / 2.5 2.0 / 3.5
upon delivery l 0.6 0.75
Noise level to DIN 45 635
without/with gas ballast dB (A) 57 - 59
Admissible ambient temperature °C 12 - 40
Motor power W 2200
Speed (50 / 60 Hz) min-1 1500 / 1800
Motor protection IP 55
Voltage range 230/400 V, 50 Hz V 218-242/380-420
(for motor) 250/440 V, 60 Hz V 240-277/414-480
200/400 V, 50 Hz V 190-220/380-440
200/400 V, 60 Hz V 190-240/380-480
Nom. current 230/400 V, 50 Hz A 8.65/5.0 or 9.9/5.7*
(for motor) 250/440 V, 60 Hz A 7.8/4.5 or 8.5/4.9*
200/400 V, 50 Hz A 11.8/5.9 or 15/7.5*
200/400 V, 60 Hz A 10/5.0 or 11.5/5.9*
Weight kg 71 83
Connections, intake and exhaust side DN 40 KF
TRIVAC BCS-PFPE
with three-phase motor Part No. Part No.
230/400 V, 50 Hz / 250/440 V, 60 Hz 113 89 113 99
200/400 V, 50 Hz / 200/400 V, 60 Hz 154 52 154 54
*depending on the mounted motor. Observe the data given on the motor name plate
Fig. 6 Dimensional drawings for the TRIVAC BCS pumps
(dimensions a, l, b to b2and h1are approximate,
dimensions in mm) (1inch = 25.4 mm)
m
c
a
l
1
h
2
h
3
h
h
2
bb
1
b
o
DN
n
Saugverm gen
10-2
10-1
10 0
10 1
mh
3-1
.
10 2
103
101mbar
100
10-1
10-2
-3
10
-4
10
-5
10
Druck
D 40 BCS
D 65 BCS
Fig. 5 Pumping speed characteristics for the
TRIVAC BCS pumps (50 Hz operation, SI units)
Type DN a b b1 b2 c h h1 h2 h3 l m n o
D 40 BCS 40 KF 135 264 234 206 166 355 308 336 – 715 382 191 190
D 65 BCS 40 KF 213 793
D 40 BCS-PFPE 40 KF 135 264 234 206 166 355 308 336 – 716 382 191 190
D 65 BCS-PFPE 40 KF 213 794
Ultimate partial pressure without gas ballast
Ultimate total pressure without gas ballast
Ultimate total pressure with gas ballast
Pumping speed
Pressure

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14
Description
1.5 Accessories
1.5.1 Standard Accessories and Lubricants
Part No.
Separator AK 40-65, DN 40 KF 188 16
Exhaust filter AF 40-65, DN 40 KF 189 16
Drain tap for condensate trap, exhaust filter, oil drain of the pump,
vacuum-tight 190 90
oil-tight 190 91
Exhaust filter with lubricant return AR 40-65, DN 40 KF 189 22
Exhaust filter with lubricant return ARS 40-65, DN 40 KF 189 57
Dust filter 186 15
Dust separator 186 16
Fine vacuum adsorption trap (with zeolite) 187 15
Adsorption trap (with aluminium oxide) 854 16
Oil filter OF 40-65 101 92
Chemical filter CF 40-65 101 97
Adaptor for RUVAC 151/251 Roots pumps 168 30
Adaptor for gas ballast port
M 16 x 1.5 – DN 16 KF 168 40
M 16 x 1.5 – 3/8inch NPT 99 175 011
Oil N 62
1 l 177 01
5 l 177 02
20 l 177 03
(Order through Leybold Cologne, Germany)
NC 1/14, 1 l 177 38
HE 1600, 10 lb 898 564
(Order through LHVP, Export, Pa, USA)
Special oils upon request.
Use only the kind of oil specified by Leybold. Alternative types of
oil upon request.
1.5.2 TRIVAC System
Leybold has developed the TRIVAC system especially for processes which
depend on the reliability of the pump under difficult conditions (pumping of
aggressive gases or vapours, for example).
Moreover, the pump status may be monitored continuously through visual
and electric indicators.
Caution

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Description
The TRIVAC system consists of the TRIVAC BCS pump and the following
accessories:
CFS 40-65 chemical filter with safety separating valve
Part No. 101 77
The CFS is a main flow lubricant filter incorporating a safety separating
valve which may be exchanged while the pump continues to operate. The
status of the interchangeable filters is indicated.
ARS 40-65 exhaust filter with lubricant return
Part No.: 189 57
The ARS filter collects the droplets of lubricant entrained in the exhaust gas
and returns the collected lubricant back into the pump by means of a float
controlled valve. This reduces the consumption of lubricant by the pump to
an insignificant level so that a daily oil check will no longer be necessary.
The status of the filter element may be checked at any time through the dif-
ferential pressure indicator.
IGS 40-65 inert gas system
Part No.: 161 77
This accessory which may be controlled through a solenoid valve allows the
definite injection of controlled quantities of gas into the TRIVAC BCS.
Thus it offers the possibility of effectively reducing contaminants in the lubri-
cant of the system and the materials of the system itself.
LSS 40-65 limit switch system
Part No.: 161 07
This accessory consists of a package of limit switches and serves the pur-
pose of monitoring the operation of the system.
Included with the limit switch system are one each:
■oil pressure switch (operating pressure)
■float switch (oil level monitoring)
■flow switch (inert gas)
■differential pressure switch (chemical filter)
■pressure switch (exhaust filter)
■connection cable for the built-in temperature switch
EIS 40-65 electrical indicator system
Part No.: 160 97
This accessory combines all switch status signals and indicates the status
of these switches through LEDs: “GREEN” for normal operation, “RED” for
fault. Through a multi-way connector all signals may be accessed for trans-
mission to a remote processing unit.

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16
Transport and
Storing / Installation
2Transport and
Storing
■Pumps which are filled with operating agents must only be
moved while standing upright. Otherwise oil may escape.
Avoid any other orientations during transport.
■Check the pump for the presence of any oil leaks, since there
exists the danger that someone may slip on spilt oil.
■When lifting the pump you must make use of the crane eyes
provided on the pump for this purpose; also use the recom-
mended type of lifting device.
3Installation
3.1 Placement
The standard pump is not suited for installation in explosion
hazard areas. When planning such an application please contact
us first.
A fully assembled TRIVAC system D 65 must not be lifted at the
eye bolt (7/1). First unscrew the eye bolt and fit an adaptor with a
stronger eye bolt (Ref. No. 200 09 675).
The TRIVAC BCS pump can be set freely 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 or similar through the
bore holes in the rubber feet.
The rubber feet act as vibration absorbers. They must therefore not be
compressed by bolts.
When installing the TRIVAC BCS pump, make sure that the connections
and controls are readily accessible.
Max. tilt for the pump (without further attachment) with possibly fitted stan-
dard accessories is 10° from the vertical.
The site chosen should allow adequate air circulation to cool the TRIVAC
BCS (keep front and rear unobstructed). The ambient temperature should
not exceed +40 °C (104 °F) and not drop below +12 °C (55 °F).
The max. amount of heat given off approximately corresponds to the rated
motor power.
Warning
Caution
Caution
Warning
Ambiant conditions

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Installation
3.2 Conforming Utilisation
TRIVAC BCS pumps are oil-sealed rotary vane pumps.
The TRIVAC BCS-PFPE have been prepared especially for operation with
perfluoropolyther.
TRIVAC BCS pumps can pump gases and vapours, and evacuate vessels
or vacuum systems in the fine vacuum range. They have been designed
particularly for use in connection with corrosive or aggressive media.
They are not suited for operation in explosion hazard areas.
The TRIVAC BCS (PFPE) is not suited for pumping of:
■combustible and explosive gases or vapours
■radioactive and toxic substances
■pyrophorous substances.
TRIVAC BCS of standard design are not suitable for pumping greater than
atmospheric concentrations of oxygen.
Before pumping oxygen (or other highly reactive gases) at concentrations
exceeding the concentration in the atmosphere (> 21 % for oxygen) it will
be necessary to use a special pump. Such a pump will have to be modi-
fied and de-greased, and an inert special lubricant (like PFPE) must be
used.
The pumps are not suitable for pumping of liquids or very dusty
media. Suitable protective devices must be installed.
Our technical sales department is available for further advice in these mat-
ters.
Caution

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18
Installation
3.3 Connection to the System
When operating the pump with PFPE observe the additional infor-
mation provided in Chapter 1.2 and Operating Instructions GA
07.009.
Before connecting the TRIVAC BCS, remove the shipping seals from the
connection flanges (7/2) and (7/3).
Retain the shipping seals in case you need to store the pump in the future.
The pump is shipped with intake and exhaust flanges mounted for hori-
zontal connection of the connecting lines. You can easily convert the ports
for vertical connection by removing the four capscrews, rotating the flanges
as required, and reinstalling the capscrews. Connect the intake and
exhaust lines with a centering ring and a clamping ring each. Use the cen-
tering ring with dirt trap for the intake port.
Connect the intake and exhaust line using anti-vibration bellows, without
placing any strain on the pump.
The intake line must be clean. Deposits in the intake 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.
The cross-section of the intake and exhaust lines should be at least the
same size as the connection ports of the pump. If the intake line is too nar-
row, it reduces the pumping speed. If the exhaust line is too narrow, over-
pressures may occur in the pump; this might damage the shaft seals and
cause oil leaks. The maximum pressure in the oil case must not exceed 1.5
bar (absolute).
When pumping vapours, it is advisable to install condensate traps on the
intake and exhaust sides.
Install the exhaust line with a downward slope (lower than the pump) so
as to prevent condensate from flowing back into the pump. If this is not
possible, insert a condensate trap.
When oil mist is to be removed from the exhaust flow we recommend the
use of the exhaust filter with lubricant return (ARS) which is part of the TRI-
VAC system.
When pumping aggressive media in particular in connection with PFPE as
the lubricant, we recommend the use of the chemical filter with safety sepa-
rating valve (CFS) which is part of the TRIVAC system. This will considera-
bly extend the service life of the lubricant.
The inlet pressure for the gas ballast should be about 1000 mbar (absolu-
te) and sufficient quantities of gas must be available (about 1/10 of the pum-
ping speed).
Warning
Remove and retain
the shipping seals
without strain
clean
Minimum cross-section
Prevent condensate
from flowing back
Maximum pressure

GA01301_0702 - 04/2006 - © by Leybold Vacuum 19
Installation
Never operate the pump with a sealed exhaust line. There is the
danger of injury.
Before starting any work on the pump, the personnel must be
informed about possible dangers first. All safety regulations must
be observed.
Depending on the type of application or the kind of pumped
media, the corresponding regulations and information sheets
must be observed.
Warning
Fig. 7 Connections and controls
Key to Fig. 7
1Eye bolt for moving the pump
2Intake port
3Exhaust port
4Oil-level glass
5Gas ballast knob ( 0 = OFF, I = ON)
6Cover plate, connection for IGS
7Cover plate, connection for CFS
8Connector for temperature switch

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20
Installation
3.4 Electrical Connections
Before wiring the motor or altering the wiring, ensure that mains
supply for the pump is off and that it can not be applied inadver-
tently.
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. This applies equally to emergency cut-out arran-
gements.
The connections must only be provided by a trained electrician or
must be supervised by a trained electrician working in accordan-
ce with the currently valid IEC (International), EN (European) or
national guidelines.
Observe all safety regulations.
TRIVAC BCS 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.
Set the switch in accordance with the rating on the motor nameplate.
Fig. 8 shows the connection for pumps with 230/380 V, 50 Hz motors. In
the case of pumps equipped as standard with a 60 Hz motor, please obser-
ve the diagram on or at the motor.
After connecting the motor and after every time you alter the wiring, check
the direction of rotation. To do so, briefly switch on the motor and check
whether a suitable cover (e. g. a blank flange) is sucked on at the intake
port. If not, interchange two phases of the connection.
Observe the direction arrow on the coupling housing.
If the connector for the temperature switch is not used, the plug may
remain connected at this socket to protect it. However, there is the danger
that the protruding plug may be damaged.
The built-in temperature switch provides a signal when the pump gets too
hot. We recommend that you access the signal available at this connector
through the LSS and the EIS. Otherwise you may access the signal at pins
1 and 2 (voltage 24 V DC max., power consumption 10 W).
In the case of custom pumps (with a Part No. deviating from the Part No.
stated in the EC Declaration of Conformity) please note the information pro-
vided on a separate sheet.
Warning
Check the direction of rotation
Temperature switch