LEYBOLD TRIVAC D 2,5 E-LD User manual

Part Nos.
140 020
140 021
140 022
E 140 020
TRIVAC E 2
D 2,5 E for Leak Detector
Dual-Stage Rotary Vane Vacuum Pump
Operating Instructions GA01601_002_C1
This modified vacuum pump is intended for operation in the leak detector only.

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 Risk of damaging the pump 8
1 Description 9
1.1 Function 10
1.2 Supplied Equipment 12
1.3 Technical Data 13
2 Transport and Storing 17
3 Installation 18
3.1 Placement 18
3.2 Normal use 19
3.2.1 Abnormal use 20
3.3 Connection to the System 20
3.4 Electrical Connection 22
4 Operation 22
4.1 Media Compatibility 22
4.2 Start-up 22
4.3 Operation 23
4.3.1 Pumping of Non-Condensable Gases and Vapours 23
4.3.2 Pumping of Condensable Gases and Vapours 23
4.3.3 Operating Temperature 24
4.4 Shutdown 25
4.4.1 Shutdown through Monitoring Components 25
4.4.2 Controller/Mains Power Failure 25

Contents
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Original installation and operating instructions.
5 Maintenance 26
5.1 Maintenance Plan 27
5.2 Leybold Service 28
5.3 Monitoring the Oil Level 29
5.4 Oil Change 30
5.5 Removing and Inserting the Internal Demister 32
5.6 Disassembly and Reassembly of the Electric Motor 33
5.7 Full maintenance 34
6 Troubleshooting 35
7 Wearing Parts and Original Spare Parts 37
7.1 Maintenance Kits and Repair Sets 37
7.2 Ordering Information for the Maintenance Kits
and the Repair Sets 38
7.3 Ordering Information for the Special Tools 38
8 Waste Disposal 42
EC Declaration of Conformity 43
Page

Notes
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Obligation to Provide Information
Before installing and commissioning the TRIVAC D 2,5 E-LD, carefully read
these Operating Instructions and follow the information so as to ensure
optimum and safe working right from the start.
The TRIVAC D 2,5 E-LD 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.
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

Safety information
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0 Important Safety Information
0.1 Mechanical hazards
1 Avoid exposing any part of the human body to the vacuum.
2 2Never operate the pump without a connected intake line or without
fitting a blank flange.
3 3Do not operate the pump with any of the covers removed.
Serious injury may result.
4 The location at which the TRIVAC (including its accessories) is being
operated should be such that angles over 10° from the vertical are
avoided.
5 The pump when filled with oil must only be moved in its vertical positi-
on. 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 relative to the atmospheric pressure. 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 damage or even burst open the pump. Thus the exhaust line
must be checked from time to time to ensure that there are no obst-
ructions.
8 When moving the TRIVAC always use the lifting means provided.
0.2 Electrical hazards
1 The electrical connections must only be provided by a trained electri-
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
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

Safety information
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0.3 Thermal hazards
1 Under certain ambient conditions the TRIVAC may attain a
temperature 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.
0.4 Hazards caused by materials and substances
1 Before pumping oxygen (or other highly reactive gases) at concen-
trations 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 degreased, and an inert special lubricant
(like PFPE) must be used
2 Before commissioning the TRIVAC, make sure that the media which
are to be pumped are compatible with each other so as to avoid
hazardous situations. All relevant safety standards and regulations
must be observed.
3 When pumping toxic, chemical, radioactive and corrosive gases as
well as pyrophorous substances, the user is under the obligation to
comply with the national and international safety regulations and
guidelines. Regarding the suitability of the TRIVAC pumps for special
applications in which such gases shall be pumped, Leybold should be
consulted first.
4 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.
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.
5 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
necessary precautions when handling contaminated parts.
CAUTION
DANGER

Safety information
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0.5 Danger of ignition
1 The standard version of the TRIVAC is not suited for operation in
explosion hazard areas.
2 The TRIVAC pumps including the accessories are fundamentally not
suited for pumping of combustible and explosive gases or 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 the-
refrom derive the necessary safety measures which must be intro-
duced.
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 (a nitrogen purge, for example) dilute all
ignitable 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.
CAUTION

Safety information
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0.6 Risk of damaging the pump
1 Before starting up for the first time, the motor circuit must be equipped
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
adhesive 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 should have attained its
operating 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 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.
12 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.
13 In the case of custom pumps (with part numbers deviating from those
stated in the EC Declaration of Conformity) please note the information
provided in the supplementary sheets.
NOTICE

Description
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Fig. 1 Rotary vane pump TRIVAC D 2,5 E-LD
1
2
3
4
5
6
78
1 Oil drain
2 Name plate
3 Exhaust port
4 Gas ballast valve
5 Intake port
6 Mains power connection
7 Oil fill
8 Oil level indicator
1 Description
The TRIVAC D 2,5 E-LD is a dual stage oil sealed rotary vane vacuum
pump.
The number in the designation of the pump indicates the pumping speed
of the pump in m3· h-1.
These pumps are capable of pumping gases and vapours out of vessels
and vacuum systems down into the fine vacuum pressure range. The
standard pumps are not designed to handle oxygen at concentrations
exceeding the concentration of oxygen in the atmosphere. Moreover, these
pumps are not suited for pumping of hazardous gases or extremely
aggressive or corrosive media.
The drive motor of the TRIVAC D 2,5 E-LD is screwed directly to the
bearing piece. The shaft of the pump and the shaft of the motor are linked
by a coupling piece. The bearings in the inner pump body are forcelubrica-
ted sliding bearings.
The oil level glass for viewing the minimum/maximum oil level and the oil
drain plug as well as the name plate are located on the front of the pump.
The connection components, the gas ballast knob and the oil fill plug are
located on the top of the pump.

Description
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1.1 Function
The rotor (2/5) which is eccentrically arranged in the pump housing (pump
chamber) has two radially slidingvanes (2/6 and 2/8) which divide the pump
chamber ofthe pump into several chambers.
The volume of each chamber changes periodically witheach turn of the rotor
so that the gas at the intake port(2/3) is sucked in. The gas enters the pump
chamber, and after the admission aperture has been sealed off by the vane,
the gas is compressed and moved on.
The compressed gas is ejected from the pump chamberthrough the exhaust
valve. Oil which is entrained in the gas is roughly separated by an internal
demister and at the same time any mechanical contaminations are also
removed from the oil. The gas exits the pump through the exhaust port
(2/13).
Oil injected into the pump chamber serves the purpose of sealing and lubri-
cation. The knocking noise (oil slap) which normally occurs when the pump
approaches its ultimate pressure is avoided by injecting a small amount of air
into the oil so that a silencing effect is attained.
2
3
4
5
6
7
8
9
10
12
13
1
11
1 Gas ballast valve
2 Tandem valve
(vacuum protection)
3 Intake port
4 Oil feed (oil pump)
5 Rotor
6 Vane (HV)
7 High vacuum stage
(pump chamber)
8 Vane (FV)
9 Forevacuum stage
(pump chamber)
10 Non-return valve
11 Exhaust valve
12 Bypass valve
13 Exhaust port
Fig. 2 Principle of operation of the TRIVAC D 2,5 E-LD

Description
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By opening the gas ballast valve (2/1, optional) it is possible to admit a
controlled quantity of air (gas ballast) into the pump chamber while the com-
pression process is in progress. The gas ballast will prevent the condensation
of vapours within the pump up to the extent of the vapour tolerance levels as
stated in the specifications for the pump (these data refer to water vapour).
A special lubrication system with forced lubrication of the sliding bearings has
been developed to enable operation of the pump at intake pressures up to
1000 mbar.
An oil pump supplies the oil from the oil reservoir into a high pressure oil sys-
tem which in turn supplies all bearings. From here the oil enters the pump
chamber of the vacuum pump. The oil pump is located in bearing piece of
the high vacuum stage. Separation of oil and gas in the pump involves two
stages. First an internal demister which is arranged ahead of the exhaust
valve ensures the creation of larger droplets.
Next these are returned back to the oil reservoir via a separation panel. This
ensures a minimal loss of oil.
This and the combination with the large usable oil reservoir, results in long
intervals between the oil exchanges, even at high intake pressures.
When the pump is at standstill (mains power failure, or when the pump is
shut down) the pump chamber is hermetically sealed off by a safety valve
(tandem valve) which is controlled through the oil pressure.This requires that
the gas ballast solenoid valve be closed.
This reliably avoids any inadvertent venting of the vacuum chamber and the
backstreaming of oil.

Description
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1.2 Supplied Equipment
The TRIVAC D 2,5 E-LD pump is supplied as standard with the following
items:
Pump with motor
Series pumps Replacement pump
140 020 - 140 022 E 140 020
Oil is filled into the pump is included separately
Operating Instructions is included with the is included separately
documentaton for the
leak detector
Parts / covers sealing cap adhesive tape
The TRIVAC D 2,5 E-LD pump is supplied ready for operation, complete with
built-in thermal motor overload protection, mains cord (0.37 m long) and a
custom plug
Notes on the Oil and how to order
Oil LVO 310 is used as standard. If any other kind of special oil is being
used, this fact will be indicated by a sticker on the oil box stating the type
of special oil used.
You must only use the kind of oil which has been specified for the
particular pump.
Special oils upon request.
Only use the kind of oil specified by Leybold.
NOTICE

Description
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1.3 Technical Data
D 2,5 E-LD
two-stage
50 Hz / 60 Hz
Nominal pumping speed 1) m3· h-1 3.2 / 3.6
Pumping speed 1) m3· h-1 2,5 / 3,3
Ultimate partial pressure without gas ballastt 1) mbar 3 · 10-3
Ultimate total pressure without gas ballastt 1) mbar 5 · 10-3
Ultimate total pressure with gas ballast 1) mbar 1 · 10-1
Oil filling, min./max.. l 0.3 / 0.55
Noise level to DIN 45 635 dB (A) 47 / 49
(without/with gas ballastt)
Admissible ambient temperature 2) °C +10 ... +40
Connection intake side DN 16 KF
1) In acc. with DIN 28 400 et seq. valid for LVO 310. 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.
10-4 2
10-1
Saugvermögen
Druck
101
100
8
6
4
2
864
10-3 10-2 10-1 101 100mbar 103 102
-1
h
3.
m
Fig. 3 Pumping speed characteristics of the TRIVAC D 2,5 E-LD
Pressure
Pumping speed

Description
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Cat.-No. of the pump 140 020 140 021
Motor type E6A4BS2-506 E6A4BS2-507
Motor L/N 20015408 20015410
IP rating
Operating mode IEC34 / Duty
Isolation class F F
Phases 1~ 1~
Manufacturer Hanning-Elektro-Werke Hanning-Elektro-Werke
GmbH & Co. KG GmbH & Co. KG
33813 Oerlinghausen 33813 Oerlinghausen
Germany Germany
Number of poles 4 4
Nom. output power at 50 Hz 200 W
Nom. output power at 60 Hz 250 W 250 W
Nom. in frequency 50 Hz
60 Hz 60 Hz
Nom. voltage range
and nom. current at 50 Hz 220-240 V / 1.0 A
Nom. voltage range
and nom. current at 60 Hz 230 V / 1.2 A 110-120 V / 2.4 A
Tolerances of voltage range1) ±5 % ±5 %
Nom. speed at 50 Hz 1420 min-1
Nom. speed at 60 Hz 1720 min-1 1720 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 above sea level
Max. ambient temperature when operating1) 40 °C 40 °C
T-board / plug Mains cord (0.37 m) Mains cord (0.37 m)
with custom plug with custom plug
Certificates2) for the motor
Length of the pump 456 mm 456 mm
Weight 13.4 kg 13.4 kg

Description
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Cat.-No. of the pump 140 022
Motor type E6A4BS2-508
Motor L/N 20015409
IP rating
Operating mode IEC34 / Duty
Isolation class F
Phases 1~
HManufacturer Hanning-Elektro-Werke
GmbH & Co. KG
33813 Oerlinghausen
Germany
Number of poles 4
Nom. output power at 50 Hz 200 W
Nom. output power at 60 Hz 250 W
Nom. in frequency 50 Hz
60 Hz
Nom. voltage range
and nom. current at 50 Hz 100 V / 2.3 A
Nom. voltage range
and nom. current at 60 Hz 100 V / 2.6 A
Tolerances of voltage range1) ±5 %
Nom. speed at 50 Hz 1420 min-1
Nom. speed at 60 Hz 1720 min-1
Disposal local directives have to be considered
Max. altitude above sea level 1000 m above sea level
Max. ambient temperature when operating1) 40 °C
T-board / plug Mains cord (0.37 m)
with custom plug
Certificates2) for the motor
Length of the pump 456 mm
Weight 13.4 kg

Description
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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.
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 name plate.
For special pumps please note the information contained in the
supplemental sheet.
NOTICE

Transport and Storing
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2 Transport and Storing
To lift the pumps only use the lifting facilities. When connecting or
removing 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 oil 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.
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 stored 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.
If the pump is to be stored for a longer period of time it should be sealed in a
PE bag containing some desiccant (silica gel).
When a pump is put into operation after it has been stored for over one year,
standard maintenance should be run on the pump and the oil should also be
exchanged. We recommend that you contact the Leybold Service.
CAUTION

Installation
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3 Installation
Instructions for the operating personnel
Before any kind of assembly work the personnel must be informed in
advanced about potential hazards. Observe Safety Informations 0.1 to 05.
3.1 Placement
Explosion risk
The standard pump is not suited for installation in the explosion hazard
areas. Observe Safety Informations 0.5.
The TRIVAC D 2,5 E-LD pump can be set up on a flat, horizontal surface.
Rubber feet under the coupling housing ensure that the pump can not slip.
The location of the TRIVAC should be such that all controls are easily acces-
sible.
Risk of toppling
Max. tilt for the pump with possibly fitted standard accessories is 10° from
the vertical.
If you wish firmly install the pump in place, insert bolts through bore holes
(Ø5mm) in the rubber feet.
1
2
3
4
5
6
7
8
Fig. 7 Connections and controls
1 Intake port
2 Exhaust port
3 Oil fill
4 Oil level indicator
5 Oil drain
6 Name plate
7 Gas ballast valve
8 Mains connection
NOTICE
DANGER
CAUTION

Installation
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The rubber feet act as vibration absorbers. They must therefore not be
compressed by screws.
When installing the TRIVAC pump, make sure that the connections and
controls are readily accessible.
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 +40 °C not exceed and not drop below
+10 °C (seeSection4.3.3).
For installation sites over 1000 m above sea level and/or a relative atmos-
pheric humidity of over 90%, you must discuss this with technical sales.
The maximum heat which is dissipated corresponds approximately to the
installed amount of motor power.
Install the pump so that only minimum quantities of dust can settle on the
surfaces. Remove dust deposits in regular intervals.
The oil filling is included separately in the case of replacement pumps.
Before operating the pump you must fill in the correct quantity of oil, see
Section 5.4.
3.2 Normal use
TRIVAC 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 and we recommend to run the pump for 30
minutes allowing it to warm up before beginning with the pumpdown
process.
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.
Our technical sales department is available for further advice in these matters.
NOTICE
NOTICE

Installation
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3.2.1 Abnormal use
The TRIVAC D 2,5 E-LD is suited only for installation within housings
providing adequate touch protection. This pump must not be operated wit-
hout this additional touch protection.
The TRIVAC is not suited for pumping of:
nradioactive and toxic substances
npyrophorous substances
ncorrosive gases
noxygen (or other highly reactive gases) at concentrations exceeding
that of the atmosphere (> 21 % for oxygen).
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.
3.3 Connection to the System
Before connecting the pump, the shipping seals on the connection flanges
(5/1 and 5/2) must be removed. If residues of adhesives are present on the
connecting flanges you must remove these using a suitable solvent like
alcohol, for example.
We recommend retaining of the shipping seals for use when wanting to
decommission the pump.
The intake line is fitted with standard small flanges. The connection flanges
must be clean and undamaged.
The intake line and the exhaust line must be connected using corrugated
pipes or vacuum hoses so that no mechanical forces can be transferred to
the pump.
The intake line must be clean. Any deposits in the intake line will tend to
degas and impair the attainable vacuum pressures.
The cross section of the intake and exhaust line must at least be of the same
diameter as that of the pump connections.
An intake line which is too small in diameter will throttle the pumping speed.
NOTICE
CAUTION
NOTICE
CAUTION