LEYBOLD VARODRY VD65 User manual

VARODRY VD65-200
Minor Service
Manual Belt
Replacement
Operating Instructions 300757580_002_C3
Part Numbers
111065V10 VARODRY VD 65, 50Hz
111065V11 VARODRY VD 65, 60Hz
111065V15 VARODRY VD 65, 50Hz, Purge
111065V16 VARODRY VD 65, 60Hz, Purge
111100V10 VARODRY VD 100, 50Hz
111100V11 VARODRY VD 100, 60Hz
111100V15 VARODRY VD 100, 50Hz, Purge
111100V16 VARODRY VD 100, 60Hz, Purge
111160V10 VARODRY VD 160, 50Hz
111160V11 VARODRY VD 160, 60Hz
111160V15 VARODRY VD 160, 50Hz, Purge
111160V16 VARODRY VD 160, 60Hz, Purge
111200V10 VARODRY VD 200, 50Hz
111200V11 VARODRY VD 200, 60Hz
111200V15 VARODRY VD 200, 50Hz, Purge
111200V16 VARODRY VD 200, 60Hz, Purge

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0 Important safety information 4
1.1 Mechanical hazards 4
1.2 Electrical hazards 4
1.3 Thermal hazards 4
1.4 Hazards caused by materials and substances 4
1 Belt replacement 5
1.1 Tools needed to start work 5
1.2 Maintenance kits 5
1.3 Procedure 6
1.3.1 Disassemble pump enclosure 6
1.3.2 Disassemble drive enclosure 7
1.3.3 Disassemble rotor disc, screw and fan 8
1.3.4 Disassemble belt chamber cover 9
1.3.5 Disassemble fail safe gear II 10
1.3.6 Loose the motor screws and push motor to loosen the belt 11
1.3.7 Disassemble tooth belt 12
1.3.8 Assemble tooth belt 13
1.3.9 Tighten tooth belt by tool 14
1.3.10 Motor screw 15
1.3.11 Fail safe gear assembly 16
1.3.12 Belt chamber cover assembly 18
1.3.13 Fan assembly 19
1.3.14 Drive enclosure assembly 20
1.3.15 Electric connection 21
1.3.16 Cable route 22
1.3.17 Verify motor rotation 23
1.3.18 Install the enclosure 24
Original operating instructions.

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Obligation to Provide Information
Before installing and commissioning the pump, carefully read these
Operating Instructions and follow the information so as to ensure
optimum and safe working right from the start.
NOTICE
The Leybold VARODRY VD65-200 has been designed for safe and efficient
operation when used properly and in accordance with these Operating Instruc-
tions. 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. Moreover, observe the information in all additionally
supplied Operating Instructions for switches or valves, for example.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 person- nel only. Consult local, state, and national
agencies regard- ing specific require- ments and regulations. Address any
further safety, opera- tion and/or maintenance questions to our nearest
office.
DANGER indicates an imminently hazardous situation which, if not avoid-
ed, 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
main- tenance information that is important, but not hazard related.
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.
DANGER
WARNING
CAUTION
NOTICE

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0 Important safety information
0.1 Heavy object. Risk of physical injury. Use suitable lifting equipment.
NOTICE
DANGER
CAUTION
DANGER
1 Mechanical hazards
1.2 Electrical hazards
1 Do not operate the pump with any parts of the enclosures removed or
damaged as there may be a risk of an electric shock.
1.3 Thermal hazards
1 Risk of burns. Do not touch the pump inlet or exhaust ports whilst the pump
is running since the temperatures of these parts could be high enough to
cause harm. Elevated temperatures could remain after the pump has
stopped.
1.4 Hazards caused by materials and substances
1 If within the system toxic substances or gases are being used, then the
operator will be responsible for ensuring that the corresponding safety
precautions are introduced!
2 If the pump has previously pumped hazardous gases take the appro-
priate safety measures before opening the intake or exhaust ports. Use
gloves, a breathing mask or protective clothing to avoid skin con- tact with
toxic or highly corrosive substances. Work under a fume hood.
3 Contaminated parts can be detrimental to health and environment.
Before beginning with any work, first find out whether any parts are
contami- nated. Adhere to the relevant regulations and take the neces- sary
precautions when handling contaminated parts.

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1 Belt replacement
1.1 Tools needed to start work
Sr No. Description Quantity Kit number
1 10mm spanner 1 -
2 5mm Allen key 1 -
3 8mm Allen key 1 -
4 17mm wrench 1 -
5 Torque wrench 1 -
6 Small screw driver 1 -
7 Special tool kit for belt replacement
(Tool for belt tension adjustment x 1
Tool for belt tension measurement x 1
Equip. fail safe gear adjustment x 1
1 EK6530942
1.2 Maintenance kits
Sr No. Description Quantity Kit Number
1 Toothed Belt DSTD-960-DS8M-15 CXP 50Hz 1 E6525604
2 Toothed Belt DSTD-960-DS8M-15 CXP 60Hz 1 E6525605
3 Kit Fail safe gear NR Polyamid 1 EK6530258
Fail-safe gear NR Polyamid 1 -
O-ring 2 -
Bushing 2 -
Screw,soc. HD CP-M6x20,DIN912 2 -

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Figure 1 – Pump enclosure removal
1.3 Procedure
1.3.1 Disassemble pump enclosure
Items:
1. Hex screw M6X20 8.8
2. Pump enclosure
DANGE
R
Procedure:
1. Switch off the pump and isolate from the electrical supply (Certified electrician).
2. Using 10mm spanner to loosen the 8 screws (Figure 1, item 1) which secure
pump enclosure and carefully lift the pump enclosure (Figure 1, item 2) by
hand.
CAUTION

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Figure 2 – Drive enclosure removal
1.3.2 Disassemble drive enclosure
Items:
1. Cap screw M6X16 8.8
2. Drive enclosure
Procedure:
1. Using 5mm Allen key, remove the 3 screws (Figure 2, item 1) which secure
drive enclosure and carefully separate the drive enclosure (Figure 2, item 2)
from pump.
CAUTION

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Figure 3 – Fan removal
CAUTION
1.3.3 Disassemble rotor disc, screw and fan
Items:
1. Cap screw M10X30 8.8
2. Spring washer
3. Rotor washer
4. Fan
Procedure:
1. Using an 8 mm Allen key, remove the screws, washer and rotor washer (Figure
3, Item 1, 2, 3) which secure the fan on belt chamber.
2. Separate fan (Figure 3, Item 4) from pump.

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Figure 4 – Belt chamber cover removal
1.3.4 Disassemble belt chamber cover
Items:
1. Cap screw M6X16 8.8
2. Belt chamber cover
Procedure:
1. Using 5mm Allen key remove the 4 screws (Figure 4, item 1) which secure
belt chamber cover (Figure 4, item 2).
2. Carefully separate belt chamber cover (Figure 4, item 2) from pump.
CAUTION

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Figure 5 – Fail safe gear removal
1.3.5 Disassemble fail safe gear II
Items:
1. Fail-safe gear NR Polyamid
2. O-ring
3. Cap screw M6X20 8.8
4. Bushing, fail-safe gear
5. Fail safe gear AR Metal
CAUTION
Procedure:
1. Use a 17mm spanner to interlock the rotors and loosen 4x bolts (Figure 5, Item
3) by 1 rotation with 5mm Allen key and remove 4x bolts.
2. Remove the bushing (Figure 5, Item 4), o-ring (Figure 5, Item 2) and fail-safe
gears
(Figure 5, Item 1 & Item 5).

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Figure 6 – Motor screw removal
1.3.6 Loose the motor screws and push motor to loosen the belt
Items:
1. Cap screw M10X30 8.8
2. Washer 10.5
Procedure:
1. To enable belt removal, using an 8mm Allen key loosen the 4 screws
(Figure 6 items 1 & 2) which secure the motor and pulley to the bearing
flange (Figure 6 items 3).
2. Push motor towards pump body to loosen the belt.
CAUTION

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Figure 7 – Tooth belt removal
CAUTION
1.3.7 Disassemble tooth belt
Items:
1. Tooth belt
Procedure:
1. Take tooth belt out of gears and pulley.
2. Clean gears and pulley with recommended cleaning agent.
3. Old toothed belt to be disposed of once removed.

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Figure 8 – Tooth belt assembly
1.3.8 Assemble tooth belt
Items:
1. Tooth belt
Procedure:
Taking a new tooth belt, fit it using following technique on both gears and
pulley.
1. To install the new tooth belt on pulley, keep imprint readable in front.
2. Then move the pulleys 3 times in running direction.
CAUTION

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Figure 9 – Tooth belt removal
CAUTION
1.3.9 Tighten tooth belt by tool
Items:
1. Belt tightening tool
2. VSM mini
Procedure:
1. Install belt tighten tool (Figure 6, Item 1) and clamp VSM mini (Figure 6, Item 2)
on the belt, switch it on, give a little push to the belt, measure input value (Hz).
2. Tighten the belt with wrench 19mm, Ensure the frequency by pushing the
belt, Value 83+/- 5 Hz. Move pulley 5 to 8 times.

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Figure 10 – Motor screw assembly
1.3.10 Motor screw
Items:
1. Cap screw M10X30 8.8
2. Washer 10.5
Procedure:
1. Tighten the motor cap screw (Figure 8, Item 1 and 2) using 8 mm Allen key
by hand. Torque each screw to 40Nm.
2. Remove VSM mini and belt tightening tool.
3. Rotate Pulley by hand 5 to 8 times and make sure that the belt is tightened
and running correctly.
Note: If no torque tool is available closest to the exact torque is acceptable.
2
1
CAUTION
NOTICE

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Figure 11 – Fail safe gear assembly
1.3.11 Fail safe gear assembly
Items:
1. Fail-safe gear NR Polyamid
2. O-ring
3. Cap screw M6X20 8.8
4. Bushing, fail-safe gear
5. Fail safe gear AR Metal
CAUTION
Procedure:
1. Assemble fail-safe gears and other all necessary parts back to original postion
in reverse order of disassembly, check status of fail-safe gear NR Polyamid
(Figure 11, Item 1) and change it in case of necessary.
2. Place the bolts for fastening the gears.
3. Fasten plastic gear with 2 bolts (10Nm).

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NOTICE 5. Rotate the motor pulley by hand 5-8 revolutions counter-clockwise (do not
turn clockwise, until fail-safe gears are fastened).
6 Place gear adjustment tool on gears and fasten it (avoid clockwise rotation
of belt).
7 Tighten the steel gear with 2 bolts (10Nm).
8 Remove the gear adjustment tool.
9 Rotate the motor pully counter clockwise by hand for three revolutions.
Make sure that the gears do not touch.
10 If gears touch, repeat step 28-32.
Note: If no torque tool is available closest to the exact torque is acceptable.

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Figure 12 – Belt chamber cover assembly
1.3.12 Belt chamber cover assembly
Items:
1. Cap screw M6X16 8.8
2. Belt chamber cover
CAUTION
NOTICE
Procedure:
1. Assemble Belt chamber cover (Figure 12, Item 2) onto the bearing flange
with 4 cap screws (Figure 12, Item 1) using 5mm Allen key.
2. Tighten cap screws by hand and torque each screw to 2.5Nm.
Note: If no torque tool is available closest to the exact torque is acceptable.

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Figure 13 – Fan assembly
1.3.13 Fan assembly
Items:
1. Cap screw M10X30 8.8
2. Spring washer
3. Rotor washer
4. Fan
Procedure:
1. Assemble the fan (Figure 13, Item 4) by sequence as shown in figure i.e.
(Figure 13, Item 4,3,2 and 1) using 8mm Allen key.
2. Tighten cap screw by hand and torque screw to 20Nm after locking fan by
span- ner.
Note: If no torque tool is available closest to the exact torque is acceptable.
CAUTION
NOTICE

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Figure 14 – Drive enclosure assembly
1.3.14 Drive enclosure assembly
Items:
1. Cap screw M6X16 8.8
2. Drive enclosure
Procedure:
CAUTION
NOTICE
1. Assemble drive enclosure (Figure 14, Item 2) onto the bearing flange with 3
cap screws (Figure 14, Item 1) using 5mm Allen key.
2. Tighten cap screws by hand and torque each screw to 2.5Nm.
Note: If no torque tool is available closest to the exact torque is acceptable.