LEYBOLD TRIVAC E2, D5E, D16E, D10E Operating Instructions Manual

Contents

Contents

Page

IMPORTANT SAFETY CONSIDERATIONS . . 4

1 Description . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.1 Principle of Operation . . . . . . . . . . . . . . . . . . .6

1.2 Supplied Equipment . . . . . . . . . . . . . . . . . . . .8

1.2.1 Notes on the Oil and how to Order . . . . . . . . .8

1.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . .9

1.4.1 Motor Dependent Data . . . . . . . . . . . . . . . . . .9

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.2 Connection to the System . . . . . . . . . . . . . . .12

2.3 Electrical Connection . . . . . . . . . . . . . . . . . .13

2.3.1 Pumps with AC Motor . . . . . . . . . . . . . . . . . .13

2.3.2 Pumps with Three-Phase Motor . . . . . . . . . .13

2.4 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5.1 Pumping of Non-Condensable Gases

and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5.2 Pumping of Condensable Gases

and Vapours . . . . . . . . . . . . . . . . . . . . . . . . .16

2.5.3 Operating Temperature . . . . . . . . . . . . . . . . .16

2.6 Shut Down / Shelving . . . . . . . . . . . . . . . . . .17

2.6.1 Shut Down through Monitoring

Components . . . . . . . . . . . . . . . . . . . . . . . . .17

2.6.2 Failure of the Control System or

the Mains Power . . . . . . . . . . . . . . . . . . . . .17

Page

3 Checking / Maintenance . . . . . . . . . . . . . . .18

3.1 Checking the Oil Level . . . . . . . . . . . . . . . . .18

3.1.1 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.2 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2.1 Disposal of Used Pump Materials . . . . . . . . .19

3.3 Cleaning the Dirt Trap . . . . . . . . . . . . . . . . . .20

3.4 Removing and Inserting the

Internal Demister . . . . . . . . . . . . . . . . . . . . .20

3.5 Disassembly and Assembly of the

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . .21

3.5.1 Instructions for the TRIVAC D 5 E - D 10 E . .21

3.5.2 Instructions for the TRIVAC D 16 E . . . . . . . .22

3.6 Full Maintenance . . . . . . . . . . . . . . . . . . . . .23

3.7 Leybold Service . . . . . . . . . . . . . . . . . . . . . .23

3.8 Shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4 Maintenance Plan . . . . . . . . . . . . . . . . . . . .24

5 Maintenance Kits and Repair Sets . . . . . . .26

5.1 Ordering Information for the Maintenance Kits

and the Repair Sets . . . . . . . . . . . . . . . . . . .30

5.2 Ordering Information for the Special Tools . . .30

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . .31

EC - Declaration of Conformity . . . . . . . . .32

We reserve the right to modify the design and the

specified data.The illustrations are not binding.

2

GA 01.600/10.02 - 07/01

Directions

We strongly recommend that you read
these Operating Instructions with care so as
to ensure optimum operation of the pump
right from the start.

Indicates procedures that must be strictly
observed to prevent hazards to persons.

Indicates procedures that must strictly be
observed to prevent damage to, or destruc­tion of the pump.

Figures

The references to diagrams, e.g. (1/2) consist of the Fig.
No.and the Item No. in that order.

Leybold-Service

If a pump is returned to LEYBOLD, indicate whether the
pump is free of substances damaging to health or
whether it is contaminated.

If it is contaminated also indicate the nature of the
hazard. LEYBOLD must return any pumps without a
„Declaration of Contamination“ to the sender’s address.

Disposal of Waste Oil

Owners of waste oil are entirely self-responsible for pro­per disposal of this waste.

Waste oil from vacuum pumps must not be mixed with
other substances or materials.

Waste oil from vacuum pumps (Leybold oils which are
based on mineral oils) which are subject to normal wear
and which are contaminated due to the influence of oxy­gen in the air, high temperatures or mechanical wear
must be disposed of through the locally available waste
oil disposal system.

Waste oil from vacuum pumps which is contaminated
with other substances must be marked and stored in
such a way that the type of contamination is apparent.
This waste must be disposed of as special waste.

European, national and regional regulations concerning
waste disposal need to be observed.Waste must only be
transported and disposed of by an approved waste dis­posal vendor.

3

GA 01.600/10.02 - 07/01

The oil for the TRIVAC E vacuum pumps is
supplied separately.

Caution

Warning

Caution

4

GA 01.600/10.02 - 07/01

IMPORTANT SAFETY CONSIDERATIONS

The Leybold TRIVAC E vacuum pump is designed for safe and efficient operation when used properly and in accor­dance with this manual. It is the responsibility of the user to carefully read and strictly obser ve all safety precautions
described in this section and throughout the manual. This product 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 your nearest Leybold Vacuum office.

Warning Failure to observe the following precautions could result in serious personal injury:

• Before beginning with any maintenance or service work on the TRIVAC E, 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 E is not suited for operation in explosion hazard areas .Contact us
before planning to use the pump under such circumstances.

• Before starting up for the first time, the motor circuit (3 phase) 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).

• The TRIVAC E is not suited for pumping of:

- combustible and explosive gases or vapours

- radioactive and toxic substances

- pyrophorous substances.

- oxidations substances.

• Avoid exposing any part of the human body to the vacuum.

• Never operate the TRIVAC E without a connected intake line or blank flange.

• The location at which the TRIVAC E (including its accessories) is operated should be such that angles
over 10° from the vertical are avoided.

• The location of the TRIVAC E should be such that all controls are easily accessible.

• Under certain ambient conditions the TRIVAC E 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 clothing.

• 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 modified and de-greased, and an inert special lubricant (like PFPE) must be used.

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GA 01.600/10.02 - 07/01

• Before operating the TRIVAC E 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 E, 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.

• It is recommended to always operate the TRIVAC E with a suitable exhaust line which is properly
connected. It must slope down and away from the pump.

• When moving the TRIVAC E always use the allowed means.
A lifting eye is provided as standard on the pump.

Failure to observe the following precautions could result in damage 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 Ser vice when planning
to pump vapours other than water vapour.

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

• Avoid vapours that can condense into liquids upon compression inside the pump, if these substances
exceed the vapour tolerance of the pump.

• Before pumping vapours, the TRIVAC E should have attained its operating temperature, and the gas
ballast should be set to position I - III (position 0 = closed, position 3 = max. water vapour tolerance,
30 mbar).
The pump will have attained its operating temperature about 30 min utes 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 backstreaming into the pump.

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

• 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.

This information will help the operator to obtain the best performance from the equipment:

• Normal amounts of humidity within the range of the pump’s vapour tolerance will not significantly affect
pump performance when the gas ballast is active.Preferably use the e xhaust flange located on the side
of the motor.

Caution

Note

Warning

Description

6

GA 01.600/10.02 - 07/01

1 Description

The TRIVAC D 5 - 16 E are dual stage oil sealed rotary
vane vacuum pumps.

The number in the designation of the pump indicates the
pumping speed of this 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 5 to 16 E 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 force-lubricated 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.

1.1 Principle of Operation

The rotor (2/6) which is eccentrically arranged in the
pump housing (pump chamber) has two radially sliding
vanes (2/7 and 2/9) which divide the pump chamber of
the pump into several chambers.

The volume of each chamber changes periodically with
each turn of the rotor so that the gas at the intake port
(1/1) 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 chamber
through 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 e xits the pump through the
exhaust port.

Oil injected into the pump chamber serves the purpose
of sealing and lubrication. 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.

TRIVAC

OUT

IN

OUT

IN

OIL

B

G

0

1

2

3

1

2

3

4

5

6

7

8

Key to Fig. 1

1 Intake port
2 Oil drain
3 Oil level indicator
4 Name plate
5 Oil fill
6 Exhaust port
7 Gas ballast valve
8 Mains power connection

Fig. 1 TRIVAC D 5 E rotary vane pump (other TRIVAC E models are similar)

Description

7

GA 01.600/10.02 - 07/01

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 compression process is in
progress. The gas ballast will prevent the condensation
of vapours within the pump up to the extent of the v apour
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 oper ation
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 system 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 valv e 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.

The gas ballast valve (GB) is opened or closed by tur­ning it (positions 0, 1, 2, 3).

Available as an option is a gas ballast valve having a
knurled screw (see Fig. 13 on page 28). When fully
opening this valve, the resulting gas flow will correspond
to that of valve position 3 in the following Table.

GB position Explanation

0 no gas ballast

maximum ultimate pressure

1 for cleaning the pump’s oil at a good ulti-

mate pressure and low oil consumption

2 good water vapour tolerance -

without producing excessive noise

3 maximum water vapour tolerance in

accordance with the technical data on
page 6.

Key to Fig. 2

1 Gas ballast valve
2 Gas ballast inlet
3 Tandem valve

(vacuum protection)
4 Intake port
5 Oil feed (oil pump)
6 Rotor
7 Vane (HV)
8 High vacuum stage

(pump chamber)
9 Vane (FV)
10 Forevacuum stage

(pump chamber)
11 Non-return valve
12 Diaphragm valve
13 Exhaust valve
14 Bypass valve
15 Exhaust port

Fig. 2 Sectional view through a TRIVAC D 5 E pump

(other TRIVAC E models are similar)

B

G

0

1

2

3

15

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Description

8

GA 01.600/10.02 - 07/01

When the pump is at standstill (mains power failure, or
when the pump is shut down) the pump chamber is her­metically sealed off by two safety valves (tandem valve
and gas ballast diaphragm valve) which are controlled
through the oil pressure.

This reliably avoids any inadvertent venting of the vacu­um chamber and the backstreaming of oil.

1.2 Supplied Equipment

Each TRIVAC D 5 - D 16 E pump is supplied with the
following basic equipment:

• Pump with motor

• Separately included oil filling (see Section 1.2.1)

• Separately included dirt sieve with O-ring

• Operating Instructions

• “Declaration of Contamination” form

The connection ports are provided with foil protectors for
protection during shipping.

The TRIVAC E pumps having an AC motor are supplied
ready for operation, complete with switch, b uilt-in thermal
motor overload protection, mains cord (1.8 m long) and
a mains plug which depends on the country of use.

The three-phase models do not come with the accesso­ries needed for the electrical connection.However , these
accessories are available upon request.

1.2.1 Notes on the Oil and how to Order

Oil N 62 or HE 200 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.

Not all types of oil have been released f or all pumps.You
must only use the kind of oil which has been specified for
the particular pump.

1.3 Accessories

Cat. No. /Order No.

Exhaust filter AF 10, DN 25 KF . . . . . . . . . . . . .190 51

Exhaust filter AF 16, DN 25 KF . . . . . . . . . . . . .190 52

Replacement filters FE 10 (set of 5) . . . . . . . . . .190 81

Replacement filters FE 16 (set of 5) . . . . . . . . . .190 82

Drain clock for the exhaust filter AF 8/10/16 . . . .190 95

Condensate separator AK 10, DN 25 KF . . . . . .190 61

Condensate separator AK 16, DN 25 KF . . . . . .190 62

Oil drain cock (for D 5 E - D 16 E) . . . . . . . . . . .190 90

Manual oil return via the gas ballast port . . . . . .190 93

(Kit for AF 8-16) ARM

Connection components required to connect the exhaust
filter and the condensate separators in each case:

1 Pipe bend DN 25 KF 184 37
2 Centering rings with O-ring DN 25 KF 183 27
2 Clamping rings DN 25 KF 183 42

Description

9

GA 01.600/10.02 - 07/01

1.4 Technical Data

Nominal pumping speed* 50/60 Hz m3·h

-1

6/7,3 12/14,6 21/23,6

Pumping speed 50/60 Hz m3·h

-1

5,2/6 9,9/11,3 16/19

Ult.partial pressure without gas ballast mbar ≤5 x 10

-4

≤5 x 10

-4

≤5 x 10

-4

Ult.total pressure without gas ballast** mbar ≤2 x 10

-3

≤2 x 10

-3

≤2 x 10

-3

Ult.total press.w.gas ballast (stage 2)** mbar ≤3 x 10

-2

≤3 x 10

-2

≤3 x 10

-2

Water vapour tolerance

Stage 1 mbar 10 10 10
Stage 2 mbar 30 20 20

Stage 3 mbar 40 30 30
Connection port DN 16 KF 25 KF 25 KF
Noise level (50 Hz) dB (A) ≤49 ≤49 ≤52
Permissible ambient temperature °C 10 bis 50 (EURO - Motor) / 10 to 40 (USA/Japan - Motor)
Oil filling max./min l 1,25/0,75 1,25/0,75 1,25/0,75
Motor power 50/60 Hz W 450/550 450/550 700/850
Speed 50/60 Hz rpm 1350/1650 1350/1650 1380/1650
Protection IP 54 54 54
Weight with operating agent***kg kg 22,1 24,2 30,7
Dimensions (W x H x D)*** mm 156 x 258 x 416 156 x 258 x 435 170 x 258 x 494

* to DIN 28 426 T1 ** to DIN 28 4oo and subsequent numbers *** Dimensions and weights with Euro motor

D 5 E D 10 E D 16 E

1.4.1 Motor Dependent Data

Euro 1~ 220-240/230 50/60 ±5 % 450/540 2,5/2,4 10 54 1350/1650
Three-ph.motor ∆220-240/ 50 ±5 % 550 2,8 6 54 1500

3~ Y 346/415 1,6

∆200-266/ 60 ±5 % 650 2,8 6 54 1800
Y 346-460 1,6

Euro 1~ 220-240/230 50/60 ±5 % 450/540 2,5/2,4 10 54 1350/1650
Three-ph.motor ∆220-240/ 50 ±5 % 550 2,8 6 54 1500

3~ Y 346/415 1,6

∆200-266/ 60 ±5 % 650 2,8 6 54 1800

Y 346-460 1,6
Wide voltage- 110-120; 50/60 ±5 % 490/550 6,8/5,6 10 54 1350/1650
motor 1~ 208-240 3,4/2,8

Euro 1~ 220-240 50/60 ±5 % 700/850 5,3/4,6 10 54 1380/1650
Three-ph.motor ∆220-240/ 50 ±5 % 650 4 10 54 1430

3~ Y 346-415 2,3

∆200-277/ 60 ±5 % 750 3,6 10 54 1720

Y 346-480 2,1

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 5 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 10 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

Motors for Voltage FrequencyVoltage Power consumption Nom.currentFuse* ProtectionNom.speed

D 16 E (V) (Hz) tolerance (W) (A) (A) IP (rpm)

*The values stated for the fuses are recommended values only
Values for up-front fuses for short circuit protection.Please take note of the information provided by the manufacturers of contactors and motor protection switches.

Description

10

GA 01.600/10.02 - 07/01

DN

DN

OUT

IN

OUT

IN

OIL

M

L

K

J

G

E

F

A

H

N

C

D

B

TRIVAC

P

O

Q

R

Fig. 3 Dimensional drawings for the TRIVAC D 5 - D 16 E rotary vane vacuum pumps

X

View of ”X”

10

-4

2

10

-1

Saugvermögen

Druck

h

3

.

m

10

2

10

1

10

0

8
6

4

2

864

10-310-210

-1

10

1

10

0

mbar

10

3

10

2

-1

D 5 E

D 10 E

D 16 E

Description

11

GA 01.600/10.02 - 07/01

Pumping speed

Pressure

Description D 5 E D 10 E D 16 E

A 1~, EURO 421 440 494

1~,World - 440 ­3~,World 421 440 479

B 1~, EURO 231 231 242

1~,World - 249 ­3~,World 212 212 228

C 1~, EURO 156 156 170

1~,World - 156 ­3~,World 156 156 170

D 1~, EURO 182 183 171

1~,World - ** ­E 192 195 231
F 77 80 116
G 143 140 176
H 300 300 300
J 258 258 258
K 253 253 253
L 210 210 210
M 205 205 205
N 140 140 140
O383838
P292929
Q 110 110 110
R 105 105 105
DN 16 25 25

* Capacitor at both sides of the motor all dimensions in mm
** Capacitor in the terminal box

Table of dimensions for Fig. 3

Fig. 4 Pumping speed characteristics of the TRIVAC D 5 E - D 16 E

Operation

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GA 01.600/10.02 - 07/01

2.1 Installation

The TRIVAC D 5 E - D 16 E can be placed freely on a flat
and horizontal surface.

The rubber elements under the pump’s base prevent the
pump from slipping. If the pump is to be per manently
attached, this may be done by making use of the holes
in the rubber elements and a threaded bolt or similar.

The inclination of the pump (without additio­nal fixing means) and with possibly atta­ched standard accessories must not
exceed an angle of 10 ° from the vertical
axis.

The rubber elements act as vibration absor­bers.For this reason they must not be com­pressed by the screws.When installing the
pump you must ensure accessibility of all
connections and controls.

Select a place for the pump which ensures a sufficient air
circulation for cooling the pump (keep front and rear
sides unobstructed).

The ambient temperature around the pump should not
exceed 50 °C (in the case of USA and Japan motors
40 °C) and not drop below 10 °C (see Section 2.5.3).

If required the crane eye or the handle may be removed.

The oil filling has been included separately.
Before operating the pump you must fill in
the correct quantity of oil (see Section 3.2).

2.2 Connection to the
System

Before connecting the pump, the shipping seals on the
connection flanges (6/1 and 6/2) 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.

Insert the dir t sieve (6/8) with the O-ring.
The intake and exhaust lines are 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.

An exhaust line which is too small in diameter can result
in the formation of overpressures within the pump. Pos­sible consequences are damaged shaft seals and possi­bly also an oil leak.

The pressure in the oil box must not exceed 1.5 bar
(abs.)

When pumping vapours we strongly recommend the
installation of a condensate separator on the suction
side and also on the exhaust side.

The exhaust line must be laid so that it slopes down and
away from pump (lower than the pump) to prevent any
condensate from flowing back into the pump.If a sloping
line can not be installed, a separator must be fitted.

When the oil mist is to be removed from the exhaust gas
flow we recommend the installation of an exhaust filter.

When pumping inert gases the pump’s gas ballast inlet
can directly be connected to the system by an adaptor
(for this the gas ballast knob must be removed).

Intake and exhaust port are of the screwed type and can
be replaced by direct connection to the system.

2 Operation

Caution

Caution

Operation

13

GA 01.600/10.02 - 07/01

2.3 Electrical Connection

During all electrical work ensure that the
power supply lines have reliably been swit­ched off and protected against being swit­ched on inadvertently.

In order to prevent the pump from running
up unexpectedly after a power failure, the
pump must be connected to the system
controller in such a way that the pump may
only be re-started manually. This applies
equally after the pump has been switched
off through an emergency switch.

The electrical connections may only be
made by an electrician as defined by VDE
0105 in accordance with the VDE 0100 gui­delines.

The pumps are supplied with either an AC motor or a
three-phase motor.

2.3.1 Pumps with AC Motor

The pump may be directly connected via its mains cable
and its plug to the mains.

In the case of 230 V mains, 6 A slow blow or 10 A fast
blow fusing is required as a minimum.

A check on the direction of rotation is not required since
this is fixed.

The thermal motor overload protector protects the motor
in case it is overloaded.

The mains voltage must comply with the voltage stated
on the name plate.

When the thermal motor overload protec­tion system has switched the motor off, the
motor will automatically cut in again when
the temperature has dropped below the
maximum permissible operating tempera-

ture.

2.3.2 Pumps with Three-Phase Motor

The TRIVAC E pumps equipped with a three-phase
motor are delivered without the components required for
their electrical connection.

You must connect the pump using an appropriately rated
cable (we recommend: AWG 18 for the 5 to 10 type
models and AWG 16 for the 16 type modes) and a sui­tably rated motor protection switch.The value set on the
motor protection switch must correspond to the current
rating stated on the name plate of the motor.

Shown in Fig. 5 is the way in which the pump having a
three-phase motor (50/60 Hz) may be connected in Star
or Delta fashion.Please also take note of the information
given on the name plate of the motor.

After having connected the motor and each
time after having made a change to the
wiring you must check the direction of rota­tion.
For this switch the motor on briefly and
determine whether or not a suitable plate (a
blank flange, for example) held in front of
the intake is sucked towards the pump’s
body. If this is not the case you must inter­change two of the mains phases.
Note the direction indicating arrow on the
fan cowl.

Caution

Warning

Warning

14

GA 01.600/10.02 - 07/01

Operation

Fig. 5 Wiring diagram for the TRIVAC E pumps with three-phase motor

Delta circuit Star circuit

Voltage ranges for Max. current consumption Min. current Setting for the
the three-phase at an intake pressure of consumption at motor protection
motors about 300 mbar ultimate pressure switch (motor data)

D 50 Hz 200 V - 240 V 2.2 A - 2.6 A 1.6 A - 2.5 A 2.8 A

60 Hz 200 V - 266 V 2.5 A - 2.3 A 1.4 A - 1.9 A 2.8 A

Y 50 Hz 346 V - 415 V 1.2 A - 1.5 A 0.9 A - 1.4 A 1.6 A

60 Hz 346 V - 460 V 1.4 A - 1.35 A 0.8 A - 1.2 A 1.6 A

D 50 Hz 200 V - 240 V 3 A - 3.8 A 2 A - 3.3 A 4 A

60 Hz 200 V - 277 V 3.3 A - 3.5 A 1.8 A - 3.1 A 3.6 A

Y 50 Hz 346 V - 415 V 1.8 A - 2.1 A 1 A - 1.5 A 2.3 A

60 Hz 346 V - 480 V 1.95 A - 2 A 0.95 A - 1.45 A 2.1 A

TRIVAC D 5 / 10 E

TRIVAC D 16 E

2.3.2.1 Current Drawn by the Three-Phase Motors of the TRIVAC D 5 E - D 16 E

15

GA 01.600/10.02 - 07/01

Operation

2.4 Start Up

Check the oil level each time before swit­ching on the pump (see Section 3.2).
After having connected the motor and each
time after having made a change to the
wiring you must check the direction of rota­tion (see Section 2.3.2).

The pump is started up by operating the ON/OFF switch
(6/10 - does not apply in the case of pumps with a three­phase motor). The ON/OFF switch may be operated at
all pressures.

During initial start up and after a longer period during
which the pump has not been used, the pump may not
immediately attain the specified ultimate pressure
because the oil has to be degassed first.

For this you should let the pump run for about 30 minu­tes with the intake line closed and the gas ballast valve
(6/7) open (position 2 of the gas ballast valve).

2.5 Operation

These pumps are capable of pumping gases and
vapours.Vapours can only be pumped provided the gas
ballast valve (optional) is open and provided the pump
has attained its operating temperature.

The maximum vapour tolerance is attained when the gas
ballast valve (6/7) is set to position 3.

2.5.1 Pumping of Non-Condensable Gases
and V apours

In the presence of excess quantities of permanent gases
the pump may be operated without gas ballast, provided
the saturation vapour pressure at the operating tempera­ture is not exceeded during compression.

If the composition of the gases which are to be pumped
is not known and if the possibility of condensation within
the pump can not be excluded, we recommend operati­on of the pump with the gas ballast valve open (in accor­dance with Section 2.5.2).

Caution

TRIVAC

OUT

IN

OUT

IN

OIL

B

G

0

1

2

3

11

1

2

3

4

5

6

7

8

10

9

Key to Fig. 6

1 Intake port
2 Exhaust port
3 Oil drain
4 Oil level indicator
5 Name plate
6 Oil fill
7 Gas ballast valve
8 Dirt sieve
9 O-ring
10 ON/OFF switch
11 Mains connection

Fig. 6 Connections and controls

Operation

16

GA 01.600/10.02 - 07/01

2.5.2 Pumping of Condensable Gases
and V apours

With the gas ballast valve (option) open and when the
pump is running at its operating temperature, pure water
vapour can be pumped up to the extent stated in the
technical data for the pump (position 3 of the gas ballast
valve). When the vapour pressure increases above the
permissible level, the vapour will condense in the oil of
the pump.

When pumping vapours make sure that the gas ballast
valve is open and that the pump has been running for at
least 30 minutes with the intake line closed and with gas
ballast.

It will be possible to pump vapours up to the
permissible limit only after the pump has
reached its operating temperature.
During the pumping process vapours may
dissolve in the oil of the pump.This impairs
the properties of the oil and there is the risk
of corrosion within the pump. For this rea­son the pump must not be switched off
immediately after termination of the pro­cess. The pump must remain on with the
gas ballast valve open and the intake line
sealed until all vapours which were dissol­ved in the oil have been removed.
We strongly recommend that the TRIVAC
D 5 E - D 16 E pumps be left running for
about 30 minutes after termination of the
process.

In the case of cyclic or repetitive processes the TRIVAC
D 5 E - D 16 E should not be switched off during the bre­aks between the individual work phases (low energy
requirement when running at ultimate pressure).The gas
ballast valve should be opened and the intake line
should be sealed (through a valve, if possible).

When all vapours have been pumped from a process
(drying, for example) the gas ballast valve can be closed
to improve the attainable ultimate pressure.

2.5.3 Operating T emperature

Proper operation of the TRIVAC D 5 E - D 16 E is
ensured at ambient temperatures between 10 °C and
50 °C, with the exception of the pump models for the
USA and Japan where a range of 10 °C to 40 °C applies.

When using SHC 224 Arctic oil, the pump will reliably run
up even at a temperature of 5 °C.

When the pump is warm, the temperature at the surface
of the oil box may rise to between 40 °C and 80 °C,
depending on the load on the pump.

TRIVAC E pumps may attain surface tem­peratures of over 80 °C.

There is the danger of receiving burns.

Caution

Warning

17

GA 01.600/10.02 - 07/01

Operation

2.6 Shut Down /
Shelving

During normal use of the TRIVAC D 5 E - D 16 E it will
be sufficient to electrically switch off the pump. Fur ther
measures are not required.

After having pumped condensable media, let the pump
run for some time with the gas ballast valve open and the
intake line blocked (see Section 2.5.2).

When pumping aggressive or corrosive media and also
in the case of long process interruptions (overnight, for
example) we recommend that you let the pump run with
the intake line sealed and with the gas ballast switched
on.

This helps to prevent the occurrence of standstill corro­sion.

If the pump is to be switched off for a longer period of
time after it has been pumping aggressive or corrosive
media or if the pump is to be shelved, proceed as
follows:

When hazardous substances have been
pumped ensure that the appropriate safety
precautions are observed.

For more information please contact our
technical sales department.

Seal off the intake port. The use of special conservation
or anti-corrosion oils is not required.

2.6.1 Shut Down through Monitoring
Components

When the pump has been switched off due
to overheating sensed by the motor coil pro­tector (single phase pumps only), the pump
must only be started manually after the
pump has cooled down to the ambient tem­perature and after having removed the
cause first.

2.6.2 Failure of the Control System
or the Mains Power

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
arrangements.

Warning

Warning

Warning

18

GA 01.600/10.02 - 07/01

Checking / Maintenance

Before starting any disassembly work, dis­connect all electrical connections to the
pump. Reliably prevent the pump from run­ning up.

When the pump has been pumping hazar­dous substances, determine the nature of
the hazard and make sure that the appro­priate safety measures are observed.

Observe all safety regulations!
When disposing of the waste oil, observe

the applicable regulations for the safety of
the environment.

Due to the concept of the TRIVAC E these pumps will
hardly require any maintenance under normal operating
conditions. The necessary maintenance work is descr i­bed in the following sections. In addition a maintenance
plan is provided in Section 4.

All work should be left to trained personnel.
Improperly performed maintenance or
repair work endangers the durability and
operational readiness and will lead to diffi­culties when wanting to file any warranty
claims.

Also available from LEYBOLD are seminars covering
practical aspects like maintenance, repair and checking
of the TRIVAC E which are run under the supervision of
our experts. For more information on these seminars
please contact us at LEYBOLD.

If the pump is used in strongly contamina­ted ambient air you must ensure that opera­tion of the gas ballast system and the air
cooling is not impaired.
When the TRIVAC E has been pumping
corrosive media, we strongly recommend
that you conduct any possibly due mainten­ance immediately in order to avoid corrosi­on during standstill.

Spare Parts are contained in the Repair Sets and in the
Maintenance Kits. If required, ask us for a quotation on
spare parts.

In the case of custom models and variants please always
state the custom, variant and serial number.

3.1 Checking the Oil Level

During operation the oil level of the TRIVAC E must
always be visible betw een the marks on oil viewing glass
(7/2 and 7/3). The quantity of oil must be checked and
topped up as required.

Recommendation: The oil level should always be

visible in the middle of the oil
viewing glass.

The pump must be switched off before top­ping up any oil.

3.1.1 Oil Check

The ageing process of the standard operating agent
N 62 / HE 200 (see Section 1.2.1) basically depends on
the operating conditions of the pump.You may check the
condition of the oil as follows:

• Visually

Normally the oil will be light and transparent. In the case
of increasing discolouration of the oil (it becomes darker)
we recommend that you exchange the oil.

• Chemically

The neutralisation value for N 62 is determined in accor­dance with DIN 51558. When the neutralisation value
exceeds the value of 2 you must change the oil.

• Mechanically

When the viscosity of N 62 exceeds a value of 240 mP as
at 25 °C (20 % over viscosity of fresh oil) we recommend
that you change the oil.

When gases or liquids are dissolved in the oil, the attain­able ultimate pressure will be impaired.In such cases the
oil may possibly be degassed by letting the pump run for
about 30 minutes with the intake line closed and the gas
ballast valve open.

Warning

3 Checking / Maintenance

Caution

Caution

Caution

Caution

19

GA 01.600/10.02 - 07/01

Checking / Maintenance

3.2 Oil Change

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 modified and de-greased, and an inert
special lubricant (like PFPE) must be used.

For proper operation of the pump, it is essential that the
pump has an adequate supply of the correct and clean
oil at all times.

The oil must be changed when it looks dirty or if it
appears chemically or mechanically worn out (see Sec­tion 3.1.1).

The oil should be changed after the first 100 operating
hours and then at least every 2,000 to 3,000 operating
hours or after one year. At high intake pressures and
intake temperatures and/or when pumping contaminated
gases, the oil will have to be changed much more fre­quently.

Further oil changes should be made before and after
long-term storage of the pump.

Only change the oil after the pump has
been switched off and while the pump is still

warm.
Required tool: Allen key 8 mm.
Remove the oil drain plug (7/4) and let the used oil drain

into a suitable container. When the flow of oil slows
down, screw the oil drain plug back in, briefly switch on
the pump (max.10 s) and then switch it off again. Remo­ve the oil drain plug once more and drain out the remai­ning oil.

Screw the oil drain plug back in (check the gasket and
reinstall a new one if necessary).

Remove the oil fill plug (7/1) and fill in fresh oil.
Screw the oil fill plug (7/1) back in.

If there is the danger that the operating

agent may present a hazard in any way due

to decomposition of the oil, or because of

the media which have been pumped, you

must determine the kind of hazard and

ensure that all necessary safety precau-

tions are taken.

We can only guarantee that the pump ope­rates as specified by the technical data if
the lubricants recommended by us are
used.

3.2.1 Disposal of Used Pump Materials

The corresponding national environmental and safety
regulations apply.This applies equally to used filters and
filter elements (oil filter, exhaust filter and dust filter).

- In the case of hazardous substances
determine the kind of hazard first and
observe the applicable safety regulations.
If the potential hazard still persists, the
pump must be decontaminated before
starting with any maintenance work. For
professional decontamination we recom­mend our Leybold service.

- Never exchange the oil or the filters while
the pump is still hot. Let the pump cool
down to uncritical temperatures first. You
must wear suitable protective clothing.

Caution

Warning

Caution

Fig. 7 Oil change

Key to Fig. 7

1 Oil fill plug
2 Oil level mark “maximum”
3 Oil level mark “minimum”
4 Oil drain plug

TRIVAC

OUT

IN

OUT

IN

OIL

1

2

3

4

Warning

Warning

20

GA 01.600/10.02 - 07/01

Checking / Maintenance

3.3 Cleaning the Dirt Trap

Located in the intake port is a wire mesh sieve acting as
a dirt trap (8/10) for foreign objects. This sieve must be
kept clean in order to avoid any throttling of the pump.

To clean the dirt trap remove it from the intake and clean
it in a vessel using a solvent.Then thoroughly dry it with
compressed air.If the dir t trap is faulty you must replace
it.

Adapt the cleaning intervals according to
the requirements.If large quantities of abra­sive materials are involved you should
install a dust filter in the intake line.

3.4 Removing and Inserting
the Internal Demister

Simple maintenance on the side of the pump using
Maintenance Kit 1

Required tools:
Allan keys 4 and 8 mm
The internal demister has been installed in a resiliant

frame.When it has clogged it will lift itself up periodically
at high intake pressures in order to equalise the resulting
pressure difference.

The increased noise level at high intake pressure is thus
a sign for a clogged internal demister.

Depending on the operating conditions the internal demi­ster will have to be cleaned regularly or it must be
exchanged.Cleaning must be performed using a suitable
solvent.

Switch the pump off and drain out the oil (in accordance
with Section 3.2).

In order to collect the remaining oil in the oil box we
recommend that you lift the pump up slightly at the side
of the motor.

Unscrew the four hex. socket screws (8/3) of the oil box.
Pull the oil box (8/2) out to the front.
Remove the gasket (8/11) of the oil box.
Use a pair of pliers to pull the spring (8/5) out to the front.
Detach the holding frame (8/8) and the internal demister

(8/9).
Clean all parts and check them for perfect condition and

replace them as required.
Reassemble in the reverse order.

Make sure to fit the gasket for the oil box
(8/11) with the flat side in the groove, see
item 12 in Fig. 8.

Torque for the hex. socket screws (8/3) is

5.5 Nm.

B

G

0

1

2

3

TRIVAC

OUT

IN

OUT

IN

OIL

Fig. 8 Removing and inserting the inter nal demister

Key to Fig. 8

1 Oil drain plug
2 Oil box
3 Hex.socket screw (4x)
4 Oil fill plug
5 Spring
6 Guide panel
7 Sealing strip for the guide panel*
8 Holding frame for the internal demister
9 Internal demister
10 Dirt trap with O-ring
11 Gasket for the oil box
12 Enlarged detail of the gasket for

the oil box

* only D 16 E

Caution

Caution

1

3

4

5

7

8

9

10

11

6

2

12

21

GA 01.600/10.02 - 07/01

Checking / Maintenance

3.5 Disassembly and
Assembly of the Electric
Motor

Before starting with any work on the pump,
always reliably disconnect the motor from
its power supply.
Remove the mains connection (three-phase
motors only) or pull the mains plug.

3.5.1 Instructions for the
TRIVAC D 5 E - D 10 E

Required tools:
Spanner size 8 and special tool for the tie rod.
We recommend that you remove the foot (9/9) of the

pump.
Place the pump on the front side of the oil box (9/1).

Remove the two (four) hex. screws (9/2) from the fan
cowl (9/3).

Detach the fan cowl.
Unscrew the tie rod (9/4).

Detach the motor (lever off using two screwdrivers inser­ted in parallel between the end plate A and the HV bea­ring piece (9/6 and 9/7).

Clean all parts and make sure that they are in perfect
condition; replace any parts as required.

In case of wear exchange the coupling bushings; these
are included in Repair Set 1.

Reassemble in the reverse order.
Tighten the tie rods crosswise to 4 Nm.
Tighten the bolts for the pump’s base to 23 Nm for the

D 5 to 10 E.

Especially note the position of the oil ejec­tion hole (see arrow in Fig. 9) in the end
plate A. The hole must always lead down­ward.

Warning

Caution

OIL

Key to Fig. 9

1 Oil box
2 Mounting bolts (2x)
3 Fan cowl
4 Tie rod
5 Electr ic motor
6 End plate A
7 HV bear ing piece
8 Foot of the pump
9 Hex. socket screws (4x)

1

8

7

5

4 3 2

9

6

Fig. 9 Disassembly and assembly of the electric motor (TRIVAC D 5 E - D 10 E)

22

GA 01.600/10.02 - 07/01

Checking / Maintenance

3.5.2 Instructions for the TRIVAC D 16 E

Required tools:
Phillips screwdriver , special tool f or the tie rod, puller (two-

point) for fan cowl, pliers for securing rings, combination
pliers, size 4 Allan key.

We recommend to remove the foot (10/15) of the pump.
Place the pump on the front side of the oil box (10/1).
Remove the Phillips screws (10/8) from the fan cowl

(10/9). Detach the fan cowl.
Disassemble the securing ring (10/10) of the fan blade

(10/12).
Use the puller to detach the blade wheel.
Use a pair of pliers to disassemble the key (10/5).
Unscrew the tie rod (10/11), detach end plate B (10/13).

Lift off the stator (10/7) from the motor.
Unscrew the size 4 hex. socket screws (10/4) from end

plate A (10/3).
Detach end plate A with the motor rotor and the spring

washer (10/6).
Clean all parts and make sure that they are in perfect

condition; replace any parts as required (Repair Set 1).
Reassemble in the reverse order.

Tighten the tie rods crosswise to 5 Nm.
Also tighten the bolts at the A bearing plate to 5 Nm.The

bolts at the pump’s base are tightened to 23 Nm.

B

G

0

1

2

3

OUT

IN

OUT

IN

OIL

TRIVAC

15

14

1

2

3

4

5

6

7

8

9

10

11

12

13

Key to Fig. 10

1 Oil box
2 O-r ing
3 End plate A with motor rotor
4 Hex. socket screws (4x)
5Key
6 Spr ing washer
7 Motor stator
8 Phillips screws (4x)

9 Fan cowl of the motor
10 Secur ing ring
11 Tie rod
12 Fan blade
13 End plate B
14 Hex. socket screws (2x)
15 Foot of the pump

Fig. 10 Disassembly and assembly of the electric motor (TRIVAC D 16 E)

23

GA 01.600/10.02 - 07/01

Checking / Maintenance

Especially note the position of the oil
ejection hole (see arrow in Fig. 10) in the
end plate A. The hole must always lead
downward.

3.6 Full Maintenance

Clean the pump and run maintenance on it.
Clean and perform maintenance on the pump as descri-

bed in the instructions for Maintenance Kit 2.

3.7 Leybold Service

If a pump is returned to Leybold, indicate whether the
pump free of substances damaging to health or whether
it is contaminated.

If it is contaminated also indicate the nature of the
hazard. For this you must use a form which has been
prepared by us which we will provide upon request.

A copy of this form is reproduced at the end of these
Operating Instructions: „Declaration of Contamination of
Vacuum Instruments and Components“.

Please attach this form to the pump or enclose it with the
pump.

This „Declaration of Contamination“ is required to meet
the requirements of German Law and to protect our per­sonnel.

Leybold must return any pumps without a
„Declaration of Contamination“ to the sen­der’s address.

The pump must be packed in such a way,
that it will not be damaged during shipping
and so that any contaminants are not relea­sed from the package.

3.8 Shelving

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 suitable seals.
The gas ballast valve 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 containing 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 3.2). We recommend that you contact the
Leybold Service.

Caution

Warning

Caution

Caution

24

GA 01.600/10.02 - 07/01

Maintenance Plan

No.

Rotary vane pumps

TRIVAC D 5 E - D 16 E

Measurem./ test quantity

Operating / auxiliary

agents

VE

t 6m a

n-a

Remarks

1 Operate the pump with gas bal-

last for at least 45 minutes.

x Condensed water is thereby removed from the oil.

2 Check the oil level and change

the oil as required.

Oil: N 62 or special and
alternative types of oil,
see Section 3.1

x x Topping up: only after the pump has been switched

off.

3 Check the quality of the oil and

change the oil as required.

visually

chemically

mechanically

x x

x

x

Visually: Normal condition light and transparent, oil
change is required at increasing discolouration.

Chemically:To DIN 51558, when the neutralization
value exceeds 2, then an oil change is required.

Mechanically: When the dynamic viscosity at
25 °C > 240 mPas, then an oil change will be requi­red.
Disposal of the used oil:
see Section 3.2.1

4 Clean the dirt trap in the intake

and exchange it as required.

Suitable cleaning agent and
compressed air.

x ❏ Clean the dirt trap with a cleaning agent and blow it

clean with compressed air under a suction hood.
❏ Replace the faulty dirt trap.

Use a cleaning agent which complies with national /
international specifications.

Observe the safety regulations which apply to the
cleaning agent used.

Interval

See also Op.Instructions,”Individual Components”

5 Clean the internal demister and

change it as required.

Suitable cleaning agent. x Perform cleaning also in advance of the scheduled

maintenance interval when the noise increases more
and more.

❏ Clean the internal demister with cleaning agent.
❏ Replace a faulty internal demister.
❏ Dispose of the used internal demister as special

waste.
Use a cleaning agent which complies with national /
international specifications.

Observe the safety regulations which apply to the
cleaning agent used.

(parts are contained in Maintenance Kit 1)
(see Section 5)

6 Check the coupling bushings for

damage and wear.

3 Check also in advance of the scheduled maintenance

interval in case of extreme noise.
(parts are contained in Repair Set 1, see Section 5)

4 Maintenance Plan

(Recommendation)

25

GA 01.600/10.02 - 07/01

Maintenance Plan

7 Change the oil and

clean the oil level glass.

Oil: N 62 or special and
alternative types of oil

Suitable cleaning agent and
compressed air.

x

No.

Rotary vane pumps

TRIVAC D 5 E - D 16 E

Measurem./ test quantity

Operating / auxiliary

agents

VE t 6m a n-a

RemarksInterval

See also Op.Instructions,”Individual Components”

8 Check the pump’s fan, the motor

fan and the cooling fins of the
motor for dirt, and clean as requi­red.

Brush and industrial vacuum
cleaner.

x When the pump or the motor is getting too warm clean

before the stated maintenance interval.
Caution: Switch the pump off and secure it against
being started inadvertently (disconnect from the
mains).

Key to the maintenance plan

VE = Perform maintenance before switching the system on
t = Daily maintenance
6m = Maintenance every 6 months
a = Annual maintenance
n-a = Maintenance every n years

Oil change (see Section 3.2)

• First oil change after 100 operating hours.
❏ Clean the oil level glass with a cleaning agent and

blow it clean with compressed air under a suction hood.
Use a cleaning agent which complies with national /
international specifications.

Observe the safety regulations which apply to the
cleaning agent used.

Quantity of oil: see Section 1.4.
Disposal of oil: see page 2.

Every 3 years we recommend servicing of the pump involving the following steps:

• Cleaning

• Checking of individual components

• Exchange of all gaskets

• Functional check.

This check should be performed by the Leybold Service.

9 Full maintenance Maintenance Kit 2. 3 Clean and perform maintenance on the pump as

described in the instructions included with Maintenance
Kit 2 (see Section 5).

Maintenance Kits and Repair Sets

26

GA 01.600/10.02 - 07/01

5 Maintenance and Repair Kits

The maintenance and repair kits have been so arranged
that the spare and exchange parts they contain cover
any servicing work which might be required.

Each set comes with brief instructions in which the
necessary work is detailed.This very much simplifies the
servicing or repair work.

Given in the following is a brief description of the indivi­dual kits and how to use these (in connection with the
TRIVAC D 10 E, other pumps are similar)

Maintenance Kit 1

This kit is recommended for maintenance after an ope­rating period of one year. It contains the gaskets for the
oil box, the internal demister which separates the oil from
the gas (for contents see page 27, Fig. 11).

Repair Kit 1

This kit is used for the seal on the side of the motor. It
contains the gaskets for the side of the motor, the shaft
sealing ring as well as the following wearing parts: cou­pling sleeves and compression spring for the oil pump
(for contents see page 27, Fig. 12).

Repair Kit 2

This set will only be required in those cases where the
pump is not capable of attaining its ultimate pressure.
This kit contains the valves, the internal demister which
separates the oil from the gas as well as the gaskets for
the oil box (for contents see page 28, Fig.13).

Maintenance Kit 2 / Repair Kit 3

These kits are identical. They contain all wearing parts,
all gaskets and the internal demister which separates the
oil from the gas.

They are used as follows:

1. Maintenance after three years of operation

2. Complete repair
(for contents see pages 27, 28 and 29, Fig.12, 13 and 14).

27

GA 01.600/10.02 - 07/01

Maintenance Kits and Repair Sets

Fig. 12 Repair kit 1

B

G

0

1

2

3

TRIVAC

OUT

IN

OUT

IN

OIL

Fig. 11 Maintenance kit 1

Key to Fig. 11

1 Oil drain plug
2 Gasket
3 Oil box
4 Hex. socket screw
5 Washer
6 Gasket
7 Oil fill plug
8 Oil box seal
9 Spring clip
10 Guide panel
11 Sealing strip for guide panel (D 16 E only)
12 Holding frame for demister
13 Demister
14 O-ring
15 Dirt trap

- parts contained in the maintenance kit

1

10

2

3

4

5

6

7

8

9

11

12

13

14

15

OIL

1

2

4

5

8

6

10

11

12

13

14

3

7

15

9

Sectional view of the flange for

the shaft sealing ring and

orientation of the shaft

sealing ring

Key to Fig. 12

1 Coupling/Oil pump
2 Coupling bushing (2x)
3 Flange for the shaft sealing ring
4 O-ringe (4x)
5 Bolt (4x)
6 Fan cowl
7 Tie rods (4x)
8 A-bearing plate
9 O - ring
10 Stopper
11 Compression spring
12 HV-bearing piece
13 Base
14 Hex. socket bolt (4x)
15 Shaft sealing ring

- parts included in the repair kit

28

GA 01.600/10.02 - 07/01

Maintenance Kits and Repair Sets

20 21 22 23 24 25

19

Fig. 13 Repair kit 2

1

2

3

4

5

6*

7

8

9

10

11

13 14 15 16 17

26

27

28

29

30

31

32

34

36

33

Key to Fig. 13

1 Hex. socket bolt
2 Washer
3 Gasket
4 Oil fill plug
5 Guide panel
6 Sealing strip for guide panel*
7 Oil or gas ballast pipe
8 Spring clip
9 Rubber insert (4x)
10 Holding frame for demister
11 Demister
12 HV bearing piece
13 Hex. socket bolt

14 Flat gasket
15 Gas ballast valve - cap
16 Gas ballast valve
17 Flat gasket
18 Forevacuum pot
19 Hex. socket bolt
20 Valve holder
21 Restrictor
22 Compression spring
23 Sealing element
24 Valve bracket
25 Bypass valve
26 End disk

27 Compression spring
28 Non-return valve
29 Gas ballast orifice
30 O-ring
31 Diaphragm valve
32 Hex. socket bolt
33 Oil box seal
34 Oil box
35 Gasket
36 Oil drain plug
37 Gasket

* D 16 E only

- parts contained in the repair kit

12

18

35

A

C

B

- Option -

Gas ballast valve
Model with knurled screw

37

29

GA 01.600/10.02 - 07/01

Maintenance Kits and Repair Sets

Fig. 14 Complete kit

Key to Fig. 14

1 End plate
2 O-ring
3 Forevacuum pot
4 Sealing nipple
5 Rotor
6 Shaft sealing ring
7 Flat seal
8 Tandem valve
9 Compression spring
10 Intake port

11 O-ring
12 High vacuum bearing piece
13 Oil guiding panel
14 Position/shaft sealing ring
15 Vane (HV)
16 Compression spring
17 Guide pin
18 Vane (FV)
19 Hex. socket bolt

- Parts included in the complete kit

1

3

5

10

12

13

14

2

4

6

7

8

9

11

15

15

16

18

18

17

19

Enlarged view F

Position of the HV vanes

View ”G”

Oil pump Nozzel

G

30

GA 01.600/10.02 - 07/01

Maintenance Kits and Repair Sets

5.1 Ordering Information for the Maintenance Kits
and the Repair Sets

The use of the Maintenance Kits and the Repair Sets is detailed in the Tables 4 - Troubleshooting and 5 - Maintenance Plan.

TRIVAC D 5 E 2 D 10 E 2 D 16 E 2

Maintenance Kit 1 200 40 023 200 40 023 200 40 044
Maintenance Kit 2 E 100 000 348 E 100 000 349 E 100 000 350

Repair-Set 1 E 100 000 352 E 100 000 352 200 40 043
Repair-Set 2 200 40 054 200 40 054 200 40 056
Repair-Set 3 E 100 000 348 E 100 000 349 E 100 000 350

5.2 Ordering Information for the Special Tools

TRIVAC D 5 E 2 D 10 E 2 D 16 E 2

Special tool for 200 02 760
the tie rods

31

GA 01.600/10.02 - 07/01

Troubleshooting

6 Troubleshooting

Fault Possible cause Remedy Repair*

Pump does not start
up.

Pump does not
attain its ultimate
pressure.

Faulty wiring.
Motor protection switch not set correctly.
(three-phase motors only)
Power supply voltage does not match the rating of the motor.
Motor faulty.
Oil temperature less than 12 °C.
Oil is too thick.
Exhaust filter or exhaust line is clogged.
Pump has seized (Sign: blocked pump).

Check the wiring and repair it.
Properly set up the motor protection switch.

Exchange the motor.
Exchange the motor.
Warm up the pump and the oil of the pump or use a different oil.
Change the oil.
Exchange the filter or clean the exhaust line.
Repair the pump.

-

2.3.2

3.5

3.5

2.5.3/3.2

3.2

­Service

Method of measurement or measuring instrument not suitable.

External leak

1

).
Dirty internal demister.
Faulty exhaust valve.
Unsuitable oil.
Intake line dirty or leaky.
Pump too small.

Use the right method of measurement or measuring instrument.
Measure the pressure directly at the intake port of the pump.
Repair the pump.
Perform maintenance.
Repair the valve.
Change the oil (possibly degas it).
Clean or exchange the intake line.
Check process data, possibly change the pump.

­Service

Main.kit1/2.3.5
Rep.-Set 2

3.2

-

-

Pumping speed of
the pump is too low.

Dirt trap in the intake line is clogged.
Clogged exhaust filter.

Connection lines too narrow or too long.

Clean the dirt trap.
Preventive action:install a dust filter in the intake line.
Exchange the filter element.
Use sufficiently wide and short intake lines.

3.3

-

2.2

Pump gets hotter
than previously
observed.

Supply of cooling air is obstructed.
Ambient temperature is too high.
Process gas is too hot.
Not enough oil.
Unsuitable oil.
Oil circulation is obstructed.
Clogged exhaust filter or exhaust line.
Exhaust valve faulty.
Deviating mains supply voltage.

Properly install the pump.
Properly install the pump.
Change the process.
Fill in oil.
Change the oil.
Clean or repair the oil channels.
Change the exhaust filter, clean the exhaust line.
Repair the valve.
Check power supply rating of the motor and the mains supply.

Oil is turbid. Condensation. Degas the oil or change the oil and clean the pump.

Preventive action:open the gas ballast valve or fit a separator.

2.5.2/3.2

2.1

2.1/2.5.3

-

Service

­Rep.Set 2

The pump is extre­mely loud.

Oil level is much too low (oil is no longer visible).
Intake pressure is too high.
Clogged internal demister.
Coupling bushings worn out.
Damaged vanes or bearings.
Faulty motor bearing.

Top up some oil.
Reduce the intake pressure.
Clean or replace the internal demister.
Replace the coupling bushings.
Repair the pump.
Exchange the motor bearing.

3.2

-

3.4/Maint.Kit 1
Rep.Set 1
Service
Service

After switching the
pump off the pressu­re in the system
increases to fast.

System has a leak.
Faulty tandem valve.
Inner shaft seal is faulty.
Faulty exhaust or bypass valve.

Check the system.
Repair the valve.
Exchange the shaft seal.
Repair the valve(s).

­Rep.Set 3
Rep.Set 3
Rep.Set 2

Oil in the intake line
or the vacuum
chamber.

Oil coming from the system.
Blocked tandem valve.

Check the system.
Clean the valve or repair it.

­Rep.Set 3

1

) Bubble test:The warm pump with degassed oil is running without gas ballast with the intake blanked off. The exhaust line is lead into a vessel containing water.If an

evenly spaced row of bubbles appears, then the pump has developed an external leak.

Oil leak at the side
of the motor

Outer shaft seal damaged or worn out.

Exchange the shaft seal.

Rep.Set 1

*Descriptions relating to the repairs or maintenance work have been included with the respective maintenance kits or repair sets.For ordering information please refer

to Section 5.1.

32

GA 01.600/10.02 - 07/01

We - Leybold Vacuum GmbH - herewith declare that the
products defined below meet the basic requirements
regarding safety and health of the relevant EC directives
by design, type and versions which are brought into cir­culation by us.

In case of any product changes made without our appro­val, this declaration will be void.

Designation of the products: Rotary vane pump

dual stage

Models: TRIVAC E;

D 5 E / D 10 E / D 16 E

Product numbers: 140 030 to 140 055

EC Declaration of Conformity

The products conform to the following directives:

• EC Directive on Machinery (98/37/EG)

• EC Directive on Low-Voltages (73/23)+(93/68/EWG)

• EC EMC Directive (89/336/EWG)
(91/263/EWG) + (92/31/EWG) + (93/68/EWG)

Applied harmonised standards:

• DIN EN 292 Part 1 11.91

• DIN EN 292 Part 2 06.95

• DIN EN 1012 Part 2 07.96

• DIN EN 60 204 Part 1 11.98

• DIN EN 50 081 - Part 1 03.93

• DIN EN 50 081 - Part 2 03.94

• DIN EN 50 082 - Part 1 11.97

• DIN EN 50 082 - Part 2 02.96

Applied national standards and technical
specifications:

• DIN 31 001 April 1983

Cologne, July 07, 2001

—————————————————————
K. Kilian, Business Area Manager LPV
Division Industrial

Cologne, July 07, 2001

—————————————————————
Dr.Bahnen, Head of R&D LPV
Division Industrial

GA 01.600/10.02 - 07/01

33

GA 01.600/10.02 - 07/01

LPV_03276_2001 bicom/OF 07.01

Printed in Germany on chlorine-free bleached paper

LEYBOLD V AKUUM GmbH

Bonner Strasse 498 (Bayenthal)
D-50968 Cologne

Tel.: + 49 (221) 347-0
Fax: + 49 [phone]
http://www.leyboldvac.de
e-mail:[email protected]

USA:

LEYBOLD VACUUM
USA Inc.

5700 Mellon Road
Export, PA 15632-8900
Phone: [phone]
Fax: [phone]
Internet: http://www.
leyboldvacuum.com

Canada:

LEYBOLD Canada Inc.

7050 Telford Way, Unit 5
Mississauga, Ontario
Canada L5S 1V7
Phone: [phone]
Fax: [phone]
e-mail:
[email protected]

AMERICA EUROPE ASIA

Germany:

LEYBOLD VAKUUM GmbH

Bonner Straße 498
D-50968 Köln
Phone: [phone]
Fax: [phone]
Internet:
www.leyboldvac.de
e-mail:
[email protected]

Belgium/Netherlands/
Luxembourg:

LEYBOLD N.V.

Leuvensesteenweg 542, 9A
B-1930 Nossegem-Zaven­tem
Phone: [phone]
Fax: [phone]

LEYBOLD VACUUM
Nederland B.V.

Computerweg 7
NL-3606 AV Maarssen
Phone: [phone]
Fax: [phone]

France:

LEYBOLD VACUUM
France S.A.

7, Avenue du Quebec
Z.A. de Courtaboeuf, B.P. 42
F-91942 Courtaboeuf Cedex
Phone: [phone]
Fax: [phone]
e-mail:
[email protected]

Great Britain/Ireland:

LEYBOLD VACUUM UK Ltd.

Waterside Way,
Plough Lane
GB-London SW 17 0HB
Phone: [phone]
Fax: [phone]
e-mail:
[email protected]

Italy:

LEYBOLD VACUUM
Italia S.p.A.

Via Trasimeno 8
I-20128 Milano
Phone:[phone]
Fax: [phone]

Spain:

LEYBOLD VACUUM
España S.A.

C/. Mataró,
27 Polígono Industrial Les
Grases
E-08980 Sant Feliu de
Llobregat (Barcelona)
Phone: [phone]
Fax: [phone]

Sweden:

LEYBOLD VACUUM
Scandinavia AB

Datavägen 57 B
Box 9084
S-40092 Göteborg
Phone: [phone]
Fax: [phone]

Switzerland/
Liechtenstein:

LEYBOLD VAKUUM
Schweiz AG

Leutschenbachstraße 55
CH-8050 Zürich
Phone: [phone]
Fax: [phone]

P.R. China:

LEYBOLD (Tianjin) VACUUM

Equipment Manufacturing
Co. Ltd.
Beichen Economic Develop­ment Area (BEDA)
Beichen District

Tianjin 300400
Phone: [phone]
Fax: [phone]
e-mail:
[email protected]

Japan:

LEYBOLD VACUUM
Japan Co. Ltd.

Head Office
Tobu AK Bldg. 3-23-3
4th Floor,
Shin-Yokohama
Kohoku-ku, Yokohama-shi
Kanagawa-ken 222
Phone: [phone]
Fax: [phone]

Korea:

Korea Ltd.

4th Fl. Shinahn Bldg., 173-1
Jangchung-Dong 2-Ga,
Chung-Ku
Seoul 100-392
C.P.O. Box 709
South Korea
Phone: [phone]
Fax: [phone]

Singapore:

LEYBOLD
Singapore Pte. Ltd.

1 Tuas South Street 3
Singapore 638043
Phone: [phone]
Fax: [phone]

Taiwan:

LEYBOLD Taiwan Ltd.

2 F, No. 416-1, Section 3
Chung Hsing Road
Chutung HsinChu
Taiwan R.O.C. 310
Phone: [phone]
Fax: [phone]

Sales Net worldwide