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LV 80

LEYBOLD LV 140, LV 80, LV 250 Operating Instructions Manual

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Page 1
Part Numbers
115080V15 / 30 / 35 / 40
115140V15 / 30 / 35 / 40
115250V15 / 30 / 35 / 40
LEYVAC
LV 80, LV 140, LV 250
Dry Compressing Vacuum Pumps
Operating Instructions 300407956_002_C1
Page 2
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Page
0 Important Safety Information 5
Explanation of Warning Symbols 5
0.1 Mechanical Hazards 7
0.2 Electrical Hazards 8
0.3 Thermal Hazards 9
0.4 Hazards Caused by Materials and Substances 10
0.5 Ignition Risk 11
0.6 Noise Hazard 11
0.7 Dangers in Connection with safety-related Measures and Precautions 12
0.8 Danger of Pump Damage 12
1 Description 14
1.1 Pump Module 14
1.2 Supplied Equipment 19
1.3 Technical Data 20
1.4 Ordering Information 22
2 Transport and Storage 23
3 Installation 25
3.1 Ambient Requirements and Placement 25
3.2 Conforming Use 26
3.2.1 Non-conforming Use 26
3.3 Connecting the Intake and Exhaust Lines 28
3.3.1 Intake Lines 28
3.3.2 Exhaust Lines 28
3.4 Connecting Cooling Water 30
3.4.1 Water Quality 30
3.5 Purge Gas Piping 31
3.6 Electrical Connection 32
3.6.1 Standard- and C-Type Pumps 33
3.6.2 CC-Type Pumps 35
3.6.3 Checking the Direction of Rotation 37
3.6.4 Connecting an external Frequency Converter 37
3.7 Mounting Accessories 40
3.7.1 Roots Pump Adapter 40
3.7.2 Non-return Valve and Silencers 42
3.7.4 Gas Ballast Kit (option) 44
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Original installation and operating instructions.
4 Operation 46
4.1 Before Starting 46
4.1.1 Pumping of monoatomic Gas 47
4.2 Stop Pump 48
4.3 Venting 48
4.4 Removing from Service 49
5 Maintenance 51
5.1 Leybold Service 51
5.2 Maintenance Intervals 51
5.3 Exchanging the Lubricant 53
5.4 Exhaust Piping Connector 54
5.5 Pump Inlet Flange 54
5.6 Purge Gas Pressure and Flow Regulator 55
5.7 Cooling Water Piping 55
5.8 Coolant Level 55
6 Troubleshooting 56
6.1 Pump Malfunctions 56
6.1.1 Malfunctions with CC-type Pumps 56
6.2 Malfunctions with Frequency Converter Operations (option) 56
7 Waste Disposal 59
EC Declaration of Conformity 60
Declaration of Contamination 61
Page
Page 4
Safety Information
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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.
The Leybold LEYVAC 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 condi-
tion and under the conditions described in the Operating Instructions. It must be operated and maintaine d 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.
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.
NOTE
DANGER
WARNING
CAUTION
NOTICE
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Safety Information
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0 Important Safety Information
Explanation of Warning Symbols
Toxic gases
Danger of explosion
Fire danger
Reactive or corrosive media
Contaminated parts
The pump must be leaktight. When the pump has been used to pump hazardous gases before, introduce appropriate safety pre­cautions before opening it. Before opening the pump, purge it for a longer period of time with an inert gas. If necessary, wear gloves, breathing protection or protection clothing.
Hazardous Voltage
Disconnect power before opening. Contact causes electrical shock.
High Leakage Current
Earth connection essential before connecting supply.
Electrical Hazards
Danger of residual voltage for up to 5 min after disconnecting power supply. Connect and disconnect the mains plug only in deenergized condition.
Hot Surface
Do not touch. Allow this area to cool before servicing.
Burn hazard
Hot Surface inside. Do not touch, wear protective equipment.
Page 6
Safety Information
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Purge gas
Check compatibility with applications
Overpressure in the discharge line
Components can be thrown in all directions. The pressure in the discharge line must not exceed atmospheric
pressure by 300 mbar max. The discharge line must not be blocked or restricted.
Pumps with wheels
must only be placed and moved on levelled horizontal surfaces!
Vacuum
Avoid exposing any part of the human body to the vacuum.
Machinery starts automatically
Connect the pump so that it not will restart automatically after a mains power failure, once the power returns.
Overhead load
Transport the pump only secured with a forklift. Only qualified personnel are allowed to unload and lift the pump. When elevating the pump, no personnel should be under the object.
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Safety Information
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0.1 Mechanical Hazards
1 In order to avoid the destruction of systems and injury to operating
personnel we urgently recommend to observe the information and installation information provided in these Operating Instructions.
2 Avoid exposing any part of the human body to the vacuum.
3 Do not operate the pump with an opened intake port. There exists the
risk of suffering injury.
4 The pump is intended for generating a vacuum only. If an overpres-
sure can occur in the pump and the system then they must be pro­tected against such an overpressure by an overpressure safety valve, for example.
5 The maximum permissible discharge pressure for the LEYVAC is
1.3 bar abs.
We recommend to operate the pump with a silencer or a connected discharge line. The pressure in the discharge line must not exceed atmospheric pressure by 300 mbar max.
Make sure that the gas flow at the discharge is not blocked or restrict­ed in any way, even when the pumped out gases need to be collected or contained.
No shutoff devices are required in the discharge line for pump opera­tion. If shutoff devices are installed, open them before starting the pump.
In the case of processes involving much condensate, we recommend the installation of a condensate separator in the discharge line.
6 Protect the purge gas supply so that in the event of a malfunction or
power interruption no overpressure can occur within the pump system.
7 We recommend to design the discharge line in consideration of a pos-
sible overpressure of 5 bar. In the event of a malfunction, such a pres­sure can occur briefly.
8 For transporting the pump use only suitable transport means.
When selecting the lifting and transport means take note of the total weight before transporting the pump.
Only the qualified personnel are allowed to unload and lift the pump. When elevating the pump, no personnel should be under the object.
As standard the pump has been equipped with a single crane eye. When transporting the pump with a forklift or similar, ensure that the pump has been secured on the forks or on a suitable pallet. Alternatively use two nylon slings as hoisting devices.
Be careful not to overturn the pump when pushing or pulling the pump sideways.
WARNING
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Safety Information
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9 Select the location where the pump is installed so that all controls can
be easily accessed. Place the pump only on a floor which is level. It can topple when it is tilted by more than 10° with respect to the verti­cal axis.
For pumps on castors only
Because of the fitted castors, the pump must only be placed on a level floor capable of supporting the pump’s weight, as otherwise there exists the risk of the pump rolling away. Moreover, the pump may only be moved on a level floor! Moving the pump along sloping paths or ramps is prohibited! The pump must only be transported with a forklift or a crane! At the installation location, screw down the adjustable feet.
10 Before beginning with any maintenance and servicing work always
ensure that no gas can flow backwards through the pump since then the rotors might turn against the normal direction of rotation. For this reason vent the vacuum chamber to the discharge pressure level or ensure through suitable valves that the vacuum chamber and the lines are reliably separated from the pump. When connecting several pump systems, pressure differences between inlet and discharge can give rise to uncontrolled turning of the pump’s shafts.
11 During operation, the cooling water circuit must not be shut off. A
cooling water discharge which has been blocked can cause the for­mation of gas bubbles and result in excessively high pressures.
12 Lay electric feed and cooling water lines so that there is no risk of trip-
ping over these.
13 When changing the oil remove any escaped oil as otherwise there is
the risk of slipping.
14 Before doing installation work on the pump system make sure that no
vacuum is present in the pump and that all media connections have been depressurised.
15 Before disassembling any cooling water lines, leave the pump to cool
down, shut off the feed line.
0.2 Electrical Hazards
1 The electrical connection must only be provided by a trained person.
Observe the national regulations in the country of use like EN 50110-1 for Europe, for example.
2 Potentially lethal voltages are present at the mains connections. Before
beginning with any maintenance or service work on the pump, discon­nect the pump from all power supplies (lockout/tagout).
3 Install a device for a safe disconnection from the power supply.
4 High electric voltages! When touching parts at high electric voltages,
there is the risk of suffering severe injuries by an electric shock! Covers marked with this symbol must only be opened by trained electricians after having reliably deenergised (lockout/tagout) the equipment.
5 Always operate the pump with a properly connected protective earth
conductor and make sure that the motor casing is closed.
DANGER
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Safety Information
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6 The pump must only be operated at the frequency specified for the
motor.
7 After having connected the motor and each time after having made
changes to the wiring, check the motor’s direction of rotation. A wrong direction of rotation can cause a pressure buildup on the intake side. Moreover, the pump may suffer severe damage.
8 Install a suitable motor protection for the electric motor before starting
up for the first time. Note the information in these Operating Instructions and on the nameplate.
9 Before starting, check to ensure that the junction box is undamaged,
run a visual inspection on on the seals.
10 Install add-on parts (pressure switches, for example) without any
mechanical tensions and protect these against being damaged by impacts, for example.
11 Lay the connecting lines so that these cannot be damaged. Protect
the lines against humidity and contact with water. Avoid thermally stressing the lines by unfavourable laying. Comply with the required standards when designing and laying the electrical connections.
12 Provide strain relief for the connecting lines so that the plugs and the
line connectors are not subjected to excessively high mechanical stresses.
13 Lay electric feed lines so that there is no risk of tripping over these.
14 The pump must be integrated in the system control arrangement so
that it can not run-up automatically after it has been shut down due to overtemperature. This applies equally to emergency shut-down arrange ments. After having determined the fault cause, the pump should be switched on manually again.
0.3 Thermal Hazards
1 Under certain ambient conditions parts of the the pump may attain
temperatures over 80 °C. There then exists the risk of suffering burns. Note the danger symbols on the pump and in the case of a hot pump wear the required protection equipment. All work on a pump which is “still warm from operation” should be done only whilst wearing protec­tive gloves.
2 Handle the pump only while vented and after having let it cool down.
3 Before disassembling any cooling water lines, leave the pump to cool
down, shut off the feed line.
4 When uninstalling the cooling water lines, take note of splashing water.
Heated water can cause burns.
5 Never remove the oil-fill or oil-drain plugs while the pump is running.
There exists the risk of suffering burns. Always wear protective gloves and protective goggles also for protection against the oil.
CAUTION
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Safety Information
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6 Operating the pump with less than the specified amount of cooling
water will result in excessively high surface temperatures. Moreover, there exists the risk of suffering burns.
0.4 Hazards Caused by Materials and Substances
1 The vacuum line must be leaktight. Hazardous process gases may
escape or the pumped gases can react with air or atmospheric humid­ity. After installation of the pump and after servicing work on the vacu­um system, a leak search will always be necessary.
When pumping toxic, corrosive and reactive gases we recommend a leak search on a regular basis. Leaks in the pump cannot be ruled out under all circumstances. When pumping hazardous gases, the opera­tor must ensure that that leaks at the pump will not be a hazard.
2 Before commissioning the pump, 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 If required additional monitoring of the purge gas quantities is neces-
sary from the side of the operator when a well-defined and ensured dilution is necessary from the side of the process.
The type of protection depends on the specific process and needs to be assessed by of the customer.
4 The cooling water from the return is not of drinking water quality and
should not be used for this purpose.
After having operated the pump, the cooling water lines may suffer from microbiological contamination. Take appropriate safety precau­tions.
5 Before operating the pump with a gas ballast or a purge gas check the
compatibility of the gas with the pumped media so as to avoid danger­ous conditions during operation.
6 Secure the purge gas supply so that in the event of a malfunction no
overpressure can occur in the system.
7 When the pump has been used to pump hazardous gases before,
introduce appropriate safety precautions before opening the intake or the discharge connections. Before opening the pump, purge it for a longer period of time with an inert gas. If necessary, wear gloves, breathing protection or protection clothing and work under a fume hood. Firmly seal off the pump. When shipping the decontaminated pump for servicing please also indicate the type of hazard. For this see Section 5.1 Service at Leybold.
8 Leybold is not in a position to perform servicing (repairs) and waste
disposal of radioactively contaminated pumps. Both needs to be ensured from the side of the user.
DANGER
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Safety Information
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9 When disposing of the pump, used lubricants and used oil filters
observe the applicable environment regulations.
10 When pumping hazardous gases you must assume the presence of
hazardous residues in the pump.
11 If the pump has been contaminated by the process or through envi-
ronmental influences, it must be decontaminated professionally.
Contaminated parts can be detrimental to health and the environment. Before beginning with any repair and maintenance work inform yourself about any possible contamination. When handling contaminated parts observe the pertinent regulations and comply with the necessary pro­tection measures.
When shipping contaminated pumps which require approval by the authorities, note the applicable regulations regarding packaging and shipping.
12 Some pumps use perfluoropolyether (PFPE) as lubricant.
When handling PFPE you should observe the following: During thermal decomposition at temperatures over 290 °C toxic and corrosive gases are released. When handling PFPE keep it way from open fires. Do not smoke with PFPE on your fingers. Touch the inner sections of the pumps only while wearing clean gloves, and use clean tools; do the necessary work in clean and dry rooms; after having removed the pump from its packaging, start it up as quickly as possible; as cleaning agents solvents based on hydrofluorether compounds may be used.
13 Fluoropolymers are used as sealants (FKM) and as lubricants (PFPE) in
the pumps. In case the pump suffers a severe mechanical failure, or is misused, or was exposed in a fire, the possibility of hazardous sub­stances being released owing to their thermal decomposition cannot be excluded. Do not touch or inhale these thermal breakdown prod­ucts of fluorinated materials.
0.5 Ignition Risk
The standard version of the pump must not be used to pump potentially flammable atmospheres and is not suited for operation in explosion hazard areas. Contact us before planning to use the pump under such circum­stances.
0.6 Noise Hazard
The noise level of the pump during ultimate pressure operation with silenc­er or connected discharge line corresponds to the values stated in the Technical Data. In other operating modes and with other equipment, higher values must be expected. Make sure that suitable protection measures are taken to protect your hearing. We recommend to wear hearing protectors (earmuffs), if local noise levels exceed mandatory limits.
DANGER
CAUTION
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Safety Information
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0.7 Dangers in Connection with safety-related Measures and Precautions
Take note of the warning information on the casing surface. If this warning information was removed, covered or obstructed, then provide corre­sponding additional warning information.
0.8 Danger of Pump Damage
1 Select an installation site for the pump so that all controls are easily
accessible.
2 The pumps are supplied filled with PFPE (LVO 410) or synthetic oil
(LVO 210). For this reason they should, while being transported or shipped, not be subjected to tilting by more than 10° with respect to the horizontal axis. Store the pumps only horizontally standing on their feet.
3 When pumping dust containing media, install a dust filter in the pro-
cess gas flow upstream with respect to the pump.
4 When connecting the pump, provide a suitable valve on the intake side
for the purpose of shutting off the intake line so as to prevent the pump from turning backwards in the event of a power failure. Otherwise the pump may suffer damage or oil may contaminate the pump chamber.
5 Lines and other vacuum connections should be clean and free of oil.
Special attention must be paid here when oil-sealed pumps have been used on the vacuum side. Check the conditions before initial commis­sioning. In the case of deviations, the pump can suffer contamination with oil residues.
6 The pressure within a pump which has been switched off will increase
to ambient pressure within a few seconds. In such a case the pump is vented through the discharge. We recommend to fit a nonreturn dis-
charge valve.
7 The discharge line should be laid so that it slopes down and away
from the pump so as to prevent condensed vapours from backstream­ing into the pump.
8 In the case of wet processes we recommend the installation of liquid
separators, upstream and downstream of the pump so as to avoid the influx of liquid into the pump.
CAUTION
NOTICE
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Safety Information
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9 During installation work on the intake and discharge lines do not sub-
ject flanges to any stresses. Check the rubber elements of the pump’s feet as to any deformation.
10 Before pumping condensable vapours the pump should be at oper-
ating temperature. If a gas ballast is present, then it should be opened. The pump will attain its operating temperature approximately 120 min­utes after having started the pump. During this warm-up phase, the pump should be left separated from the process by a valve in the intake line, for example.
11 If condensable vapours have been pumped, the pump should before
switching off be purged with an inert gas or air (depending on the spe­cific application). This process should also be run before cleaning the pump chamber.
12 For shutting down the pump let the pump operate idle for at least 30
minutes. Disconnect the pump from the mains power. Place desiccant into the intake flange and into the discharge flange and blank off the flanges with a piece of foil. When storing the pump for a longer period of time, drain out the oil first. Package the pump airtight in polyethylene foil.
13 Improper maintenance or repair work can have an influence on the
service life and the performance of the pump and will void any warran­ty claims.
14 Maximum cooling water pressure: 7 bar. When exceeded, there is
the risk of leaks.
Pressures given in bar or mbar are absolute values. If exceptionally a gauge pressure is meant, a “g” is added (bar(g)).
Page 14
Description
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1 Description
1.1 Pump Module
Members of the LEYVAC vacuum pump family are of the dry compressing single stage screw vacuum pump type. All LV models are positive displace­ment rotary pumps. During operating, the pump rotors are not in contact to each other; therefore, there is no need of grease for lubricating or for sealing the vacuum chamber. Thus, concerns in respect to oil dust backflows are not applicable.
The pumps are water cooled and they are lubricated with PFPE (LVO 410) or synthetic oil (LVO 210). Their purge gas system is equipped with a 24V-operated magnetic valve for both rotor purge and shaft seal purge, with an additional manually operated valve fitted to the rotor purge line. There are three different model types to be distinguished: The uncovered LEYVACs, the C-type pumps with a cover installed, and the CC-type, equipped with covers and an additional controller box.
Fig. 1.1 LEYVAC LV 80; LEYVAC LV 140 and LV 250 similar
Page 15
Description
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2524
23
22
21
1918171615
14
13
12
11
10
123456789
Fig. 1.2 LEYVAC LV 80 Pump Configuration; LEYVAC LV 140 and LV 250 similar
1. Castor
2. Expansion Vessel
3. Oil Level Indicator
4. Gear Box Cooler
5. Pump Outlet (Side)
6. Cooler
7. Casing Temperature Sensor
8. Shock-absorping Pad
9. Height-adjustment Foot
10. Pump Frame
11. Oil Level Indicator
12. Oil Box
13. Casing
14. Pump Inlet
15. Main Cooler
16. High Pressure Side Plate
Fig. 1.3 Cooling Water System
17. Gear Box
18. Motor
19. Front Panel
21. Cooling Water Inlet
22. Cooling Water Outlet
23. N2 Gas Inlet
24. N2 Pressure Regulator
25. N2 Pressure Gauge
1. Cooling Water Inlet
2. Cooling Water Inlet of Motor
3. Cooling Water Outlet of Motor
4. Cooling Water Inlet of Gear Box Cooler
5. Cooling Water Outlet of Gear Box Cooler
6. Cooling Water Inlet of Main Cooler
7. Cooling Water Outlet of Main Cooler
8. Cooling Water Outlet
Page 16
Description
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Cooling Water System
Fig. 1.3 shows the flow path entering at water inlet 1, cooling down the motor (2 -> 3), the gear box (4 -> 5), the casing and the high pressure side plate. Then it enters the main cooler (6 -> 7). After passing the main cooler at 7 the cooling water exits at outlet 8. Casing and high pressure side plate are both cooled down by the coolant in the water jacket (indirect cooling).
There is another line between main cooler and expansion vessel, to resupply the coolant. The expansion vessel has another pipe to balance its pressure.
There are thermal switches on motor and casing to protect the pump.
Connect the thermal switches of motor and casing to the protection circuit of your equipment, or it might cause pump damage. With the LEYVAC CC versions both temperature switches are connected to the CC controller. If the CC pump is not sufficiently cooled, the pump will be switch off auto­matically to protect it from damage.
NOTICE
Purge Gas System
Operate the pump with purge gas at all times.
The pressurized purge gas comes into the pump via the inlet. Adjust the reg­ulation pressure (by pressure regulator) to the specified value, and supply the correct amount of purge gas to the pump. The pressure is shown at the pressure gauge. The purge gas piping can be divided into two sets of pipe lines.
LEYVAC LV 80 / 140
Purge Gas
Rotor Purge
Shaft Seal Purge
24 V DC
Fig. 1.4b Purge Gas System (schematic)
LEYVAC LV 80 / 140 / 250
NOTICE
Fig. 1.4a Purge Gas System
Rotor Purge (A) -->
24 VDC Valve
Shaft Seal Purge (B) -->
Page 17
Description
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Front Panel
The connectors for cooling water (outlet over inlet) are RC3/8"; the connector for the purge gas inlet is Swagelok 1/4". The maximum pressure for the purge gas regulator is 2 bar (0.2 MPa), and the pressure is indicated at the pressure gauge. Refer to the Technical Data Section for adjusting process­dependent purge gas pressures.
CC-type pumps are additionally equipped with an EMO at the controller box to enable the user to turn off the pump in case of an emergency.
Fig. 1.5 Front Panel Layouts
1 2
3
4 5
LEYVAC LV 80 CLEYVAC LV 140 C
123
4 5
1. Pressure Gauge
2. Pressure Regulator
3. Purge Gas Inlet
4. Cooling Water Outlet
5. Cooling Water Inlet
LEYVAC LV 80 C / 250 C
LEYVAC LV 140 C
Gas line (rotor purge): The main purpose is to decrease the partial pres­sure of the process gas in the pump, to reduce corrosion due to process gas, and to retard the accumulation of reaction byproducts. The amount of purge gas can be adjusted by the flow regulator, and the non-return valve can prevent the process gases from getting into the purge gas pipe line.
Gas line (shaft seal purge): The main purpose is to prevent process gas from entering the gear box through the high pressure side plate. The purge gas will come into the rotating shaft in the high pressure side plate through the non-return valve.
Page 18
Description
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Fig. 1.6 Pumping Speed Curves for LEYVAC LV 80
0.0
1.0
2.0
3.0
4.0
5.0
0
25
50
75
100
0.001 0.01 0.1 1 10 100
[mbar]
60 Hz Pump Speed Air 50 Hz Pump Speed Air
50 Hz Power Air 60 Hz Power Air
[m
/h]
Power Consumption [kW]
Pumping Speed
Inlet Pressure
LEYVAC LV 80
Fig. 1.7 Pumping Speed Curves for LEYVAC LV 140
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
0
25
50
75
100
125
150
0.001 0.01 0.1 1 10 100
60 Hz Pump Speed Air 50 Hz Pump Speed Air
50 Hz Power Air 60 Hz Power Air
Power Consumption [kW]
Pumping Speed [m
3
/h]
Inlet Pressure [mbar]
LEYVAC LV 140
Page 19
Description
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1.2 Supplied Equipment
Check if all the parts attached are complete. When there is any damage, or when components are missing, contact us immediately. All LEYBOLD vacu­um pumps are equipped with:
■
Operating Instructions
■
Purge Gas Swagelok Connector
■
Lubricants (already filled in)
Fig. 1.8 Pumping Speed Curves for LEYVAC LV 250
0
0.001
300
200
100
250
150
50
1
60 Hz Pump Speed Air 50 Hz Pump Speed Air
50 Hz Power Air 60 Hz Power Air
Power Consumption [kW]
Pumping Speed [m
3
/h]
Inlet Pressure [mbar]
LEYVAC LV 250
0.01 0.1 10 100 1000
14
2
8
12
10
6
4
0
Fig. 1.8a Permissible gas inlet temperature as function of the inlet pressure
Gas inlet temperature (°C)
Inlet pressure (mbar)
Page 20
Description
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1.3 Technical Data
LEYVAC LV 80 140 250 Tolerance
Maximum pumping speed (50 / 60 Hz) (w/o gas ballast) 80 / 96 m3/h 125 / 145 m3/h 250 / 300 m3/h ±10 %
Ultimate partial pressure 1 x 10-2 mbar
Max. perm. inlet pressure 1050 mbar 50 Hz: 1050 mbar
60 Hz: 1050 mbar
(temporarily);
perm.: 400 mbar
Max. perm. discharge pressure (absolute) 1300 mbar
Integral leak rate 1 x 10-5 mbarl/s
Water vapour tolerance w/gas ballast 80 slm 50 / 60 Hz 20 / 30 mbar 125 / 160 mbar 30 / 37 mbar
(at 150 slm)
Water vapour capacity w/ gas ballast 80 slm 50 / 60 Hz 1.24 / 2.3 kg/h 11.5 / 18 kg/h 6.0 / 6.3 kg/h
(at 150 slm)
Perm. ambient temperature +5 to +45 °C
Storage temperature -10 to +60 °C
Noise level with silencer, at ultimate pressure (acc. to DIN EN ISO 2151)
< 75 dB(A)
Noise level with rigid exhaust pipe, at ultimate pressure (acc. to DIN EN ISO 2151)
< 65 dB(A) < 72 dB(A)
Relative atmospheric humidity < 95% RH non-condensing
Installation location up to 2,500 m
Cooling Water / Glycol
Mains voltage (50 Hz) Δ200 - 220 V (Standard- & C-Version, only) / Y380 - 420 V ±10 %
Mains voltage (60 Hz) Δ200 - 220 V (Standard- & C-Version, only) / Y440 - 460 V ±10 %
Frequency 50 / 60 Hz
Phases 3-ph
Rated power at 50 / 60 Hz 4.1 kW 5.5 kW 8 kW
Rated current at 50 / 60 Hz 12 A (200 V)
6 A (400 V)
16 A (200 V)
8 A (400 V)
28 A (200 V)
16 A (400 V)
Power consumption at ultimate pressure (50 / 60 Hz) 2.9 / 3.2 kW 3.9 / 4.3 kW 4.2 / 4.7 kW
Power factor cos w (400 V; 50 / 60 Hz)
0.9 / 0.92 0.89 / 0.92 0.87 / 0.93
Max. permissible speed 4,200 rpm 3,600 rpm
Min. permissible speed 1,200 rpm
IP Code IP 54
Lubricant filling LVO 210 / LVO 410
Total lubricant quantity (low pressure side / high pressure side)
0.8 l
(0.2 / 0.6 l)
Intake flange DN 63 ISO-K
Discharge flange DN 40 KF
Materials (components in contact with gas in the pump chamber)
grey cast iron / steel / stainless steel / FPM
Weight, approx. 280 kg
300 kg (C & CC)
300 kg
320 kg (C & CC)
320 kg
340 kg (C & CC)
Dimensions in mm (L x W x H) 814×375×550 895×400×567 1051×425×537
Water
Water connection RC 3/8"
Water temperature +15 – 30 °C
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Description
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LEYVAC LV 80 140 250 Tolerance
Maximum supply pressure 2 – 7 bar (g)
Nominal flow 15 – 25 °C 25 – 30 °C
3 – 7 Nl/m
5 Nl/m 7 Nl/m
Materials in the cooling circuit of the pump copper, stainless steel, brass
Purge gas
Allowed purge gas N2 / Ar / dry clean air
Connection Swagelok 1/4"
Rotor purge gas flow shaft seal rotor purge
7 Nl / min
0 – 100 Nl / min
Permissible purge gas supply pressure 4 – 8 bar (g) (0.4 – 0.8 MPa (g))
Permissible purge gas setting pressure 1.5 – 2 bar (g) (0.15 – 0.2 MPa (g))
Optional Gas ballast (manual or electrical)
Flow (normally ambient air) 80 Nl / min
Fig. 1.9 Dimensional Drawings
C
A
B
H
G
N
P
U
V
W
Fig. 1.10 Dimensions and Exhaust Arrangements
N
Q
S
R
T
R
Modell A B C G (CC-type) H N P Q R S T U V W
LV 80 375 320 550 814 (984) 576 266 335 485 410 341 191 265 402 266
LV 140 400 350 567 895 (1065) 597 257 364 514 439 332 182 297 453 285
LV 250 425 375 537 1051 (1224) 570 230 512 662 587 305 155 420 464 285
Dimensions in mm
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1.4 Ordering Information
Part numbers for pumps
LV 80 115080V15 LV 80 C 115080V30 LV 80 C (LVO 210) 115080V40 LV 80 CC 115080V35
LV 140 115140V15 LV 140 C 115140V30 LV 140 C (LVO 210) 115140V40 LV 140 CC 115140V35
LV 250 115250V15 LV 250 C 115250V30 LV 250 C (LVO 210) 115250V40 LV 250 CC 115250V35
Accessories
Check valve ball type 115005A01 Check valve spring loaded (for noise reduction) 115005A02
RUVAC Adapter for Wx(U)501 and WH700 onto LV 80 / LV 140 115005A03 RUVAC Adapter Disc for WX1001 onto LV 140 115005A04* RUVAC Adapter for Wx(U)501 / WH700 onto LV 250 115005A05 RUVAC Adapter Disc for WX1001 / LV 250 115005A06**
Exhaust Pressure Sensor LV 80 115005A10 Exhaust Pressure Sensor LV 140 115005A11 Exhaust Pressure Sensor LV 250 115005A09
Gas Ballast Kit manual 115005A12 Gas Ballast Kit 24V 115005A13 Purge Gas-Kit EK110003350
Standard Silencer (w/built-in check valve for noise reduction) 115005A20 High Efficiency Silencer 115005A21 Serviceable Silencer 115005A22 Drainable Silencer (w/built-in check valve for noise reduction) 115005A23 Drainable Elbow for Silencer 115005A26
Inlet screen LV 80 / LV 140 / LV 250 115005A28
Earthquake ground fixation LV 80 / LV 140 / LV 250 115005A29
Frequency converter LEYVAC LV 80 400V (incl. mains filter) 115005A30 Frequency converter LEYVAC LV 80 200V (incl. mains filter) 115005A31 Frequency converter LEYVAC LV 140 400V (incl. mains filter) 115005A35 Frequency converter LEYVAC LV 140 200V (incl. mains filter) 115005A36 Frequency converter LEYVAC LV 250 400V (incl. mains filter) 115005A40
LEYBONOL LVO 210 (synthetic oil) 1 litre L21001 LEYBONOL LVO 210 (synthetic oil) 5 litres L21005 LEYBONOL LVO 410 (PFPE) 1 litre L41001
* 115005A03 additionally required ** 115005A05 additionally required
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Transport and Storage
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2 Transport and Storage
Check the specification on the nameplate of the pump and confirm that pump supplied agrees with your purchase.
Observe safety notes 0.1.8 and 0.1.9.
All LEYVAC LVs are equipped with a single crane eye. The pump may be lifted with a forklift. Alternatively use two nylon slings as hoisting devices with a length of 3 m, a width of 50 mm, and a tensile load of min. 2 tons.
Before hoisting, check if the slings are in the position between castors and adjustment feet (cf. Fig. 2.1), to ensure the pump will not slide off. The slings’s eyes must be centre top during hoisting, to avoid a tending to one side. The tension for the slings should be equal at the both sides.
The pumps are supplied filled with PFPE or synthetic oil. For this reason they should, while being transported or shipped, not be subjected to tilting by more than 10° with respect to the horizontal axis. Store the pumps only horizontally standing on their feet.
WARNING
Fig. 2.1 Hoisting the Pump Lifting via Crane Eye
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Transport and Storage
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Pumps with castors
Due to the castors which have been fitted, the LEYVAC must only be installed on a level surface capable of carrying the weight of the pump as otherwise there exists the danger of the pump rolling away. The pump must also only be moved on level surfaces.
Moving the pump on slopes or ramps is not allowed!
The pump must only be transported using a crane.
At the installation site, use all four adjustable feet for aligning thereby securing the unit from rolling away and thus taking away the load from the castors.
Storage
Store the pumps only horizontally standing on their feet.
When storing the pump for a longer period of time (> 2 weeks) the flanges should be sealed off with a piece of foil. Place a bag with desiccant in the pump chamber, if required. Before operating the pump once more do not forget to remove this bag first.
Due to the PFPE filling pumps should be sealed off in a gas-tight manner and vented with nitrogen.
The cooling jacket is filled with a water glycol mixture, which is cold resist­ant up to -10 °C.
If there is the danger of frost, the cooling water for the external water cir­cuit must be drained, see Section 4.4 Removing from Service
Temperature -10 to +60 °C
Coolant mixture 30% glycol
Storage site dry
Maximum atmospheric humidity < 95 %, non-condensing
NOTICE
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3 Installation
3.1 Ambient Requirements and Placement
The pump is designed for operation in buildings with a good ventilation. It must not be installed in sites which are highly-polluted, very humid, full of corrosive gases, and metal dust. The pump must not be exposed to direct sunlight or water.
For maintenance purposes the clearance on top and around the pump must be at least 900 mm.
The ambient temperature for the pump should not exceed 45 °C. The install­ing site should not be near boilers or any other equipment that would be heat-radiating.
Ensure a good ventilation and heat dissipation with the pump installed indoors; therefore the location for the vacuum pump should be considered cautiously.
For a convenient installation, four mobile support units, each consisting of a castor and a height-adjustment foot, are attached at the frame of the pump. Before moving the pump, make sure to check the four adjustment feet are already at their highest positions.
The pump should be installed on a floor which can stand the weight of the pump. A shock-absorbing pad should be used between the frame of the pump and the floor for a better ground holding and less impact to avoid vibration.
Place the pump system on a flat and level surface. For proper securing against rolling away, use all four adjustable feet for aligning thus taking away the load from the castors.
Adjust the adjustment feet on the pump frame until the moveable wheels are 3-5 mm off the ground; then tighten the M16 nuts to fix the pump.
Remove covers and blank flanges on the pump only before fitting the pump so that the assembly work can be performed under the cleanest conditions.
The pumps are supplied filled with PFPE (LVO 410) or synthetic oil (LVO 210). Nothing will have to be refilled. Check the oil levels through all oil level glass­es. If one of the oil levels is found to be incorrect, please contact us.
The oil levels of both, the gear box and the low pressure side, should be between 1/2 - 2/3 of the oil level glass. If the level is below 1/2, lubricant should be added. See the Maintenance section for further information.
Fig. 3.1 Adjusting Castors
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3.2 Conforming Use
The LEYVAC dry pumps have been developed to meet the demanding requirements for process pumping solutions in the Coating, Flat panel, Process and Solar industries.
Basically, all LEYVAC pumps are leaktight and may for this reason be utilised for pumping toxic and potentially flammable gases outside their ignition range. For such applications, note the safety information given in Section 0.4. When using the pumps in connection with oxidising or corrosive gases, check media compatibility first. Media compatibility and the therefrom result­ing hazards of each substance used and also of each substance mixture need to be reassessed on a case-by-case basis.
When planning to pump hazardous substances always consult Leybold first.
3.2.1 Non-conforming Use
Non-conforming use for the pump are among others:
■
Operation with limit parameters which are not programmed by Leybold, particularly the maximum speed.
■
Pumping of gases and vapours for which the materials of the pump are not suited, consult Leybold. For a list of materials in contact with the process gases, see Section 1.3 Technical Data.
■
Pumping of substances and mixtures (gases, liquids and solids) which are rated as being explosive.
■
Pumping of condensable vapours without adequately controlling the tem­perature of the pump. Upon compression in the pump, these vapours may condense or form deposits, consult Leybold.
Fig. 3.2 Oil Level Indicators Low Pressure Side
High Oil Level
Low Oil Level
High Oil Level
Low Oil Level
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■
Pumping of dusts and solids without suitable screens and filters, consult Leybold.
■
Pumping of liquids
■
Pumping of ignitable gas mixtures
■
Pumping of process gases which form hard or sticky deposits which may cause the pump to seize.
■
The use of pump and frequency converter in the explosion hazard areas
■
Non-compliance with the described maintenance and service intervals.
■
Use in systems and pump systems in which the exhaust pressure may increase over 1.3 bar abs.
■
Operation with an inadequately affixed pump.
■
Operation at impermissibly high gas temperatures
■
Use in systems where pump, frequency converter and cables are subject­ed to impact stresses.
■
Operation on movable systems or system components (locks or mobile pump systems).
■
Use of pump, fitted ad-on components, drive electronics, flanges and cables to climb onto the system.
■
Removing, covering or obstructing warning notices.
■
Operation outside of buildings.
■
Standstill or storing of pump and drive electronics without suitable sealing and drying. When stored in a humid atmosphere corrosion can occur.
■
Conversions, manipulations and maintenance work by persons not author­ised by Leybold.
■
Accessories which have not been specified by Leybold may only be used after approval by Leybold.
The non-conforming use of pump and accessories may result in severe injury or damage to the components.
WARNING
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3.3 Connecting the Intake and Exhaust Lines
3.3.1 Intake Lines
Pay attention to the following rules when connecting the vacuum pump and the vacuum system:
For the lowest vacuum and the best pumping speed, we suggest to use the shortest pipe, the least elbow, if possible, with the biggest diameter to reduce the pipe line loss.
The intake lines must be clean. Connect the intake line to the pump. We rec­ommend using bellows on the top of the pump for vibration absorption.
Support the intake lines.
Align the bellows. Do not overstress the bellows. Too much stress on the bellows will cause them to drop out untimely and thus leading to leaks in the system.
Check for leaks after installing the pump. A leak may lead to a dangerous discharge of hazardous substances or to unpredictable reactions with air admitted into the pump.
When choosing and installing the vacuum pumps for harsh processes or for processes of special applications, like harsh furnace process, toxic or explo­sive gas process, please check in advance with the engineers of Leybold; when necessary, we suggest installing a trap at the pump inlet or outlet port to prevent any safety accidents.
Ensure that no items like welding beads, bolts, nuts, washers, pieces of wire, for example, enter into the inlet.
3.3.2 Exhaust Lines
Connect the exhaust line to the pump system‘s exhaust connection. Use bel­lows to eliminate tension and vibration in the line. If applicable the exhaust ell­bow can be detached and turned in 90° angels for an exhaust transport
according to customer-specific needs (cf. Fig.1.9). In this case ensure to
retighten the 4 bolts, and to conduct a leak tightness check on the exhaust.
DANGER
NOTICE
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The exhaust line should have the same or larger diameter than the exhaust flange (DN 40 KF) and 2.0 mm min. thickness. The exhaust line must be able to withstand 1.3 bar and 150 °C.
Observe the following when connecting the pump and the exhaust system:
When there is high pressure from the exhaust system, check whether the silencer of the vacuum pump and the exhaust pipes for the facilities are blocked or not.
When using explosive, corrosive or toxic gas for the process, the pump exhaust system must not contact the atmosphere.
The supports must be installed under the exhaust pipe line to avoid any leakage caused by shear strength at the connecting parts of the pipe lines.
A leak check will surely be performed after the installation of the vacuum pump or when finding any leakage. When proceeding with the leak check for the vacuum pump or the vacuum system, please pay attention to check any emission of gas (moisture, residual of organic solvent) which will cause virtual leaks of the vacuum system. The recommended maximum leak rate value for a purge gas leakage test or other ways of test is 1x10
-5
mbarl/s.
Observe Safety Information 0.1.6 to 0.1.8.
Check leak tightness of the exhaust lines on a regular basis! Observe Safety Information 0.4.
Keep the exhaust line free of deposits. If the exhaust flow becomes restrict­ed, deposits could collect in the LEYVACs.
Connect the exhaust line to an abatement system with sufficient throughput, if required by the process. The LEYVAC pumps will not be switched off auto­matically, when the abatement system is too small and there is an overpres­sure. As prevention an optional pressure sensor may be installed; in this case provide an adequate electrical connection; cf. Section 3.7.3.
In order to prevent deposits in the exhaust lines it may be necessary to heat the exhaust lines.
Run the exhaust line only by way of a fixed installation to the outside and/or connected to a silencer.
NOTICE
WARNING
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3.4 Connecting Cooling Water
Observe Safety Information 0.3.3 to 0.3.6. Never stop supplying cooling water during the pump operation, otherwise, the components of the pump will over-heat and can damage the pump.
According to the directions of water inlet and outlet from the pump, connect the male and female quick joints to the front panel.
Ensure that the cooling water discharge is not constricted in any way.
Supply the cooling water and check for any leakage from the joints and the pipe lines.
Do not connect pump cooling water loops in series. Select piping to ensure sufficient and adequate flow through each pump in accordance with the technical data.
The temperature of the discharged cooling water must not exceed 55 °C as otherwise the lines will tend to calcify.
If work on the water cooling system becomes necessary and in the case of a longer standstill or transportation, completely drain out all cooling water and completely dry the lines (with nitrogen, for example).
Block or label the area of the cooling water and exhaust lines to prevent trip­ping.
3.4.1 Water Quality
In order to ensure long trouble-free operation the cooling water must not contain any oils, greases and suspended solids. Moreover, we recommend compliance with the following limit values:
Appearance Clear, free of oils and greases
Suspended matter < 250 mg/l
Particle size < 150 µm
Electrical conductivity < 700 µS/cm
pH value 7.0 to 9.0
Total hardness (total alkaline earths) < 8 °dGH
Aggressive carbon dioxide None, not detectable
Chloride < 100 mg/l
Sulfate < 150 mg/l
Nitrate ≤ 50 mg/l
Iron < 0.2 mg/l
Manganese < 0.1 mg/l
Ammonium < 1.0 mg/l
Free chlorine < 0.2 mg/l
8 °dH (degrees German hardness) = 1.4mmol/l = 10 °e (degrees English hardness) = 14 °f (degrees French hardness)
If there is the danger of frost, you may use a water glycol mixture of up to 30 %.
When using DS water/deionised water (softened or fully desalinated water) check whether cooling system, water and materials used are suitable. For this please con­sult us.
CAUTION
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3.5 Purge Gas Piping
The inlet port for the purge gas is a Swagelok 1/4” stainless connector. Allowed purge gases are N2, Ar, or dry clean air. The pressure of the purge gas can be adjusted by the pressure regulator to a suitable pressure, and the range is 1.5 to 2 bar (g) (0.15 – 0.2 MPa (g)).
As Leybold vacuum pumps can be used for a variety of processes the amount of sediments thus produced will also be different. In order to reduce corrosion due to process gas and retard the accumulation of reaction byproducts, adjust the purge gas pressure and flow to the appropriate val­ues. Please refer to the information given in Section 1.3 Technical Data.
Ensure that the purge gas flow is not obstructed.
The purge gas supply should not be shut off while the pump system is operat ing, above all especially not during shutdown and venting operations.
As the pumps are equipped with a 24V-operated magnetic valve in the purge gas system, provide an adequate electrical connection. Ensure with switching off the pump that the magnetic valve will be closed.
Overview of Rotor Purge Gas Throughput
Refer to the following table for the relationship between pressure regulator turns and purge gas throughput (cf. Fig. 1.4):
at End Pressure
Knob turns 0.15 MPa
0 0
0.5 16
1 37
1.5 59
2 84
2.5 95
3 100
(all values in slm; ±3 slm)
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3.6 Electrical Connection
Observe Safety Information 0.2.
Customers must make sure that the grounding wire is connected, and the grounding function meets the electric rules (cf. Fig. 3.4 LHS).
Check if the voltage of the power supply is correct; and the rated current of the NFB (No Fuse Breaker) at the customer’s site meets the values in the table listed below.
With all types of LV pumps, too, a short-circuit protection must be installed at the connection side.
Refer to the national and local electrical regulations, and decide the proper specification for the wire and NFB to ensure the safety of electricity usage.
Recommended rated current of main fuse and cable sizes
The voltage for the power supply should be kept within ±10% of the rating voltage.
DANGER
Δ200 – 220V Y380 – 460V (50/60 Hz)
Main fuse Cable Size (mm
2
) Relay (A) Main fuse Cable Size (mm2) Relay (A)
LV 80 20A 4 16 15A 2.5 10
LV 140 30A 6 24 20A 4 15
LV 250 40A 6 28 30A 4 16A
Thermal switch casing;
SW85 - white
Thermal switch
motor;
SW90 - black
PT1000 - white
Fig. 3.3 Thermal switch positions
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3.6.1 Standard- and C-Type Pumps
Figure 3.4 (RHS) shows the mains connecting methods for different voltages. The terminal is designed for voltage ranges of 200 – 220V (cf. upper array), or 380 – 420V (50 Hz) and 420 – 460V (60 Hz) (cf. lower array).
The LEYVAC has no switching devices of its own. Install an adequate motor protection switch for the equipment. The pumps are equipped with two ther­mal switches for motor and casing protection, and a Pt1000 sensing device for measuring the motor’s temperature (cf. Fig. 3.3).
The motor must only be operated with an overprotection circuitry in place.
Connect the factory-integrated Pt 1000 temperature sensor, and the ther­mal switch of the casing (SW85) to the protection circuit of the equipment, to prevent pump damage.
The Pt1000 serves the purpose of thermally monitoring the water-cooled motor. It is recommended to set a warning and a shut down at temperatu­res of 85 °C and 100 °C, respectiviely, to protect the pump in case of unsufficient cooling water qualities or flow rates. The thermal switch of the motor (SW90) can be used as an alternative to the Pt 1000, if fresh water with sufficient pressure is used as coolant.
Refer to the table below for the trigger temperatures.
Electric Device (cable) Status Action Temperatures Reset Temperatures
Motor Thermal Switch (black) NC 90 °C 50 – 60 °C
Casing Thermal Switch (white) NC 85 °C 45 – 65 °C
NOTICE
Fig. 3.4 Electrical connections: PE grounding, Thermal switch (motor) and PT 1000, and motor wiring
PE
200V
400V
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LEYVAC LV 80 / 140 / 250
Control Unit
prov. by
customer
>>
>>
>>
F 2 F 1
L 2
L 1
L 3
Exhaust Pressure Sensor (optional)
p
=
Purge Gas
24V DC
Thermal Switch Casing (white)
M
3
Pump
24V DC
85V AC min. 50mA
250V AC max. 2.5A
24V DC
85V AC
min. 50mA
PT1000 (white)
+
–
ϑ
Output 1 -5V
Supply 9 - 30V
< 5mA
24V DC
85V AC min. 50mA
250V AC max. 2.5A
Thermal Switch Motor (black)
Fig. 3.5 Main and Control Circuit Wiring (without frequency converter; non-CC-pumps)
PT1000 processing
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Fig. 3.6 Mains wiring for CC-type pumps
Input voltage
Transformer TR1
Mains feed
Motor protection switch
GND
3.6.2 CC-Type Pumps
Loosen the 2 screw on each side of the terminal box (cf. Fig. 3.6). Then remove the box cover. Connect the mains as depicted. Re-attach the cover and tighten the screws. CC-type pumps are designed for 380 – 460V cur­rents only.
CC-type pumps are equipped with an EMO to enable the user to turn off the pump in case of an emergency. The EMO signal may be accessed via the potential-free contact EMO-2 (cf. circuit diagram, Fig. 3.7) for further use within the customer provided control unit.
The CC pump’s thermal switches are monitored by the integrated protection circuit cutting off the motor in case of overheating. There is no need for rewir­ing, as the motor protection switch has already been pre-configured. By trig­gering the motor protection switch or the EMO the pump will be deenergised and must be restarted after troubleshooting.
The factory-integrated Pt 1000 temperature sensor (white cable) represents an additional means for the operator to monitor the pump (recommended warning at 85 °C; shut down at 100 °C; cf. Fig. 3.5).
CC-type pumps are equipped with a regulating transformer for dual voltages. Select the corresponding feed terminals A1 at the regulating transformer TR1 depending on the voltage range used: 380 – 420V: terminal 415V; 420 – 460V: terminal 380V.
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Fig. 3.7 Main and Control Circuit Wiring (CC versions only)
* For pump operation in 460 V / 60 Hz nets the input connection of Transformer (A1) has to be changed by trained staff from 415 V to 460 V. Output connection of Transformer (A2) stays unchanged.
*
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3.6.3 Checking the Direction of Rotation
The rotational direction is correct, when there is pressure at the exhaust and the attached plastic cap fixed to the exhaust is blown off, after the pump has been test-switched on.
3.6.4 Connecting an external Frequency Converter
Observe Safety Information 0.2.
Take note of the information provided in the manufacturer’s Operating Instructions enclosed with the frequency converter Read these Operating Instructions and make yourself comfortable with the contents before install­ing and operating the frequency converter or before doing maintenance work on it. The frequency converter must be installed in agreement with the information given in these Operating Instructions and in agreement with the locally applicable regulations. Non-compliance with the safety informa­tion can result in severe or even deadly injuries or may damage the prod­ucts or facilities and systems operated in connection with the product.
Enclosed with the frequency converters delivered by Leybold is a copy of the instructions for commisioning the Yaskawa V1000. This frequency converter shows an integrated mains filter and perfectly matches the pump.
P/N. for LEYVAC
115005A30 LV 80, 4.1 kW, 400 V
115005A31 LV 80, 4.1 kW, 200 V
115005A35 LV 140, 5.5 kW, 400 V
115005A36 LV 140, 5.5 kW, 200 V
115005A40 LV 250, 11 kW, 400 V
■
Connect the pump to the correct mains voltage through the connections in the junction box (cf. Fig. 3.3).
■
Do not connect the electric control circuitry to the power circuitry of the frequency converter.
■
Use fuses recommended in Main Circuit only, cf. the section Technical Data.
Connect both thermal switches as shown in Fig. 3.8 to ensure that the pump is shut down as soon as one of the monitoring facilities responds:
■
Connect the casing’s thermal switch (nc; trigger 85°C) to inputs S2-SC and
■
the motor’s thermal switch (nc; trigger 90°C) to inputs S3-SC of the FC.
Shielded types of cable must be used for the motor power supply line.
The max. length for the cable between external frequency converter and motor is 30 m.
WARNING
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Fig. 3.8 Wiring of the main and control circuits for LEYVACs w/ external frequency converter
<1> Connected using sequence input signal (S1 to S6) from NPN transistor. Default: sink mode (0V com).
Fault reset*
PTC
Digital Output Warning*
Digital Output Failure*
Baseblock
Thermal switch casing
Thermal switch motor
Do not use the “Hardware Baseblock“ input for any functional safety in ac­cordance to IEC 61508 or ISO/EN 13849 on your machine. For details contact Leybold.
<2> Use only the +24V internal power supply in sinking mode. The source mode requires an external power supply.
DIP switch S4 changes the functio­nality of analog input A2. When DIP switch S4 is set to “P“ the function is PTC input. When DIP switch S4 is set to “M“ the function of analog input A2 is multi-function input.
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Fig. 3.9 Establishing the potential equalisation at the pump casing
Washer
Lock washer
Hexagon socket screw M 10
Copper strap, for example
In the case of FC operation considerable electromagnetic interference occurs. Here the limits specified in the pertinent standards and guidelines need to be complied with under all circumstances by the installer. In order to reduce the level of electromagnetic interference, shielded motor cables, shielded cable feedthroughs, mains filters and EMC compliant ground connections are required between frequency converter and pump.
In order to protect the pump, current limits in the frequency converter as a function of the frequency must be taken into account.
Permissible frequencies range
The permissible frequencies range for LEYVAC pumps is between 20 Hz to max. 70 Hz, except for the LV 250 it is between 20 Hz and 60 Hz.
Establishing Potential Equalisation
In the case of operation with a frequency converter and ground leakage­currents of over 3.5 mA, the protective ground conductor must have across-section of the least 10 mm2. Or a further protective ground conduc­tor having at least the same cross-section as the connection cable must be provided.
A M10 thread is provided at the motor casing for connecting the external potential equalisation cable.
The potential equalisation conductor must be connected as depicted in Fig. 3.9.
After connecting the motor and every time you alter the wiring, check the direction of rotation (cf. Section 3.6.3 for more information).
NOTICE
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Cover
Transport Block
Fig. 3.10 Preps for Mounting a RUVAC
3.7 Mounting Accessories
C- and CC-type pumps only show a detachable cover on the housing lid. For mounting a RUVAC remove this cover first, and then the lid. With this modification the transport block does not have to be removed.
Fig. 3.11 RUVAC Adapter for Wx(U) 501 and WH 700 similar
3.7.1 Roots Pump Adapter
The adapter serves as a connecting component when fitting a RUVAC onto the LV models. The use of other pump types or other connection compo­nents is not permissible. The adapter for the RUVAC weighs approximately
6kg.
Before the adapter can be mounted the stainless steel pump inlet must be removed. Keep this gasket and the 4 screws for re-use. The RUVAC adapter comes with 4 substitute screws; the RUVAC comes completely with bolts, washers, nuts and gasket.
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Fig. 3.12 LEYVAC with RUVAC WH 700 on top
Installation
Make sure that no items like welding beads, screws, nuts, washers, small pieces of wire, for example, enter through the inlet into the pump. Carefully handle the sealing surfaces and keep them clean.
We recommend that two fitters fit the adapter.
The Roots vacuum pump must only be fitted as depicted. Other orientations are not allowed as otherwise stability is endangered.
Supplied Equipment
■
Adapter
■
4 hexagon socket screws M 8x25
■
O-ring 80x5, 4 stud bolts M 12x50, 8 washers A 13, 8 nuts M 12 (for fas­tening the RUVAC)
NOTICE
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Mounting the adapter on the LEYVAC
C- and CC-type pumps: Firstly remove the cover and the housing lid.
When fitting the adapter onto the LEYVAC, ensure that the O-ring will not slip.
Place the O-ring on the inlet of the LEYVAC and bolt the adapter onto the pump, tightening torque 50 ± 5 Nm.
C- and CC-type pumps: Re-fit the housing lid, before mounting the RUVAC.
Mounting the RUVAC
When fitting the RUVAC onto the adapter, ensure that the gasket will not slip.
Place the O-ring in the adapter groove and attach the RUVAC to the adapter, Push the studs through the flanges and secure both ends with the nuts, tightening torque 50 ± 5 Nm.
After fitting the adapter, we recommend conducting a leak search. For com­missioning the pump combination please note the information given in the Operating Instruction for the RUVAC.
3.7.2 Non-return Valve and Silencers
The non-return valve is a fitting for shutting off which is attached to the ex haust flange for the LEYVAC. It prevents gas from flowing back into the pump.
If the pump is to be connected directly to the exhaust piping, we recommend the use of a spring-loaded valve which can be mounted in either direction.
For extremely dusty processes, we recommend the use of a self-cleaning ball-type valve. This must only be mounted vertically.
The standard silencer comes with a built-in non-return valve which operates both vertically and horizontally.
For processes involving much condensate there are two options for fitting the silencer. All silencers may be fitted vertically only in combination with a drain­able elbow (cf. Section 1.4). With a horizontal version the supplied elbow can be used; in this case the serviceable silencer must be attached, to ensure that the ball valve is the lowest point of the exhaust system.
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Installation
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Fig. 3.13 LEYVAC 80 with optional exhaust pressure sensor Fig. 3.14 Position of the orifice plate to be inserted
3.7.3 Exhaust Pressure Sensor (option)
An exhaust pressure sensor may be installed optionally above the elbow. This sensor is purge gas protected; the connection is provided by the customer. At a pressure of 0 bar (g) the output voltage is 1 VDC; with a pressure of 1 bar (g) it is 5 VDC. For more information on connecting the sensor refer to the manufacturer’s specs. The pump must be turned off with an exhaust pressure of 0.3 bar (g).
Before starting any installation work on the pump, shut down the system and leave it to cool down. In particular observe Safety Information 0.3 and 0.4. Retrofitting must only be carried out by duly trained personnel. The electri­cal connection must only be provided by a trained person.
The conversion kit consists of the exhaust pressure sensor as well as all nec­essary pipes, T-pieces, and fittings.
Only C-an CC-type pumps: Remove the top and side covers.
Remove the plug above the elbow and screw in the corresponding threaded connector of the exhaust pressure sensor kit. Use Loctite 542 to ensure for leak tightness. At the upper tee remove the blank flange from the shaft seal purge gas pipe. Connect all pipes and tees as shown above. Make sure to insert the orifice plate into the riser of the lower tee.
DANGER
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Installation
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Provide an adequate electrical connection for the sensor; refer to the wiring schematics in the Section “Checking the Direction of Rotation”.
Systematically check for leaks after the installation, and before starting the pump system.
Only C- and CC-type: Conduct a leak test before re-fitting the covers.
3.7.4 Gas Ballast Kit (option)
As options, LEYVACs can be retrofitted with an electrically (24 VDC) or a manually operated gas ballast system. These conversion kits modify the con­ventional rotor purge gas line (A). Via these systems ambient air as the gas ballast can be supplied at a fairly high throughput of up to 80 Nl/m. The 24 VDC valve is nc.
With the LEYVAC LV 250 with installed gas ballast kit pumped / process gas can leak into the pump’s surrounding area via the gas ballast port. Due to the high compression inside the pump this is the case with inlet pres­sures >150 mbar. When pumping dangerous, flammable, or toxic gases the gas ballast kit of the LEYVAC LV 250 must not be used!
The gas ballast conversion kit contains all of the necessary modification parts.
Only C- and CC-type pumps: Remove the side cover.
Fig. 3.16 LEYVAC with gas ballast kit installed (24 V)Fig. 3.15 Purge gas lines
Rotor Purge (A)
Purge (B)
WARNING
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Installation
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Conversion to manually operated system
Remove the purge gas pipe between the lower T-piece connection and the manual valve. Blank-flange (included) the T-piece (cf. arrow in Fig. 3.15).
Conversion to 24 VDC system
Remove the purge gas line (A) between the lower T-piece connection and the threaded connector at the purge gas entry (rotor). Blank-flange (included) the T-piece, to ensure for a continuous purge gas flow to the shaft (line B).
Install the gas ballast kit, as depicted. Use Loctite 542 to ensure for leak tightness.
Provide an adequate electrical connection for the valve (cf. to the wiring schematics).
Check the compatibility with the media being pumped.
Systematically check for leaks after the installation, and before starting the pump system.
Only C- and CC-type: Conduct a leak test before re-fitting the cover.
Check the gas ballast filter contamination on a regular basis.
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Operation
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4 Operation
Observe Safety Information 0.6.
4.1 Before Starting
Proceed with the following items before connecting the vacuum pump with the power cable.
■
Check if the vacuum pump is in its position, and the adjustment feet are fixed.
■
Turn on the cooling water flow, and check piping for water leaks.
■
Operate the pump with purge gas at all times. For purge gas operations: Check that the pressure regulator on the front panel is closed, i.e. the pressure adjustment knob is fully counterclockwise. Turn on purge gas supply. Adjust the pressure slowly to 1.5 bar (0.15 MPa), then lock the knob. The manometer might be damaged while the purge gas supply pressure is too large.
NOTICE
Fig. 4.1 CC-type pump’s main switches
ON
EMO
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Operation
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■
Check the exhaust piping. If there is any valve closed on the exhaust pip­ing, open it.
■
Check that the 24V valve is opened before starting to ensure a shaft seal purge flow.
■
Check that the manual rotor purge is opened or closed, depending on the requirements of your applicaiton.
■
Check if the inlet port of the pump and the vacuum system are connected properly.
■
Check the connection between the thermal switches of motor and casing to the protection circuit of the whole equipment.
■
Check that the voltage of the power supply is correct; turn on power.
■
CC-types only:
Push the ON button, to start the pump; unlock the EMO first, if applicable.
■
Adjust the flow regulator in the N2 piping, until the flow is suitable.
If the water flow is too low, the temperatures of the pump body and the motor will rise, and may cause rotor contact and other problems.
If the purge gas flow is too low, it can cause oil backstream, pump corro­siveness and byproducts.
CC-types only: CC-type pumps are equipped with an EMO to enable the user to turn off the pump in case of an emergency. The EMO signal may be accessed via the potential-free contact EMO-2 (cf. circuit diagram, Fig. 3.7) for further use within the customer provided control unit.
The EMO is not intented to be used as a regular switch for turning off the pump !
4.1.1 Pumping of monoatomic Gas
Due to the higher adiabatic exponent K with monoatomic gases (e.g. argon) and resulting higher compression temperatures please consult with the corre­sponding customer service before pumping these gases to evaluate your application.
CAUTION
NOTE
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Operation
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4.2 Stop Pump
When operation is finished switch off the pump. Proceed as follows:
Isolate the pump from the chamber but keep it running.
In order to prevent any corrosive gases or byproducts inside the pump, do not stop the pump until after at least 30 minutes after stopping the flow of process gases.
Switch off the pump.
In order to prevent any residual process gas inside the pump, purge with N2 gas for at least one hour after the pump stops.
Low purge gas flow during shut-off may damage the pump.
The pump must only be vented such that atmospheric pressure is never exceeded.
If the pump has previously pumped hazard ous gases observe Safety Information in Section 0.4.
In order to prevent a scald accident, it is strictly forbidden to touch the pump body, the exhaust piping and the hot N2 piping before they are cold down completely.
Keep cooling the pump with the cooling water for at least ten minutes; after that, stop supplying the cooling water, to prevent condensation on the surface.
4.3 Venting
Open the vacuum system only in completely vented state and only as short as possible. Otherwise humidity will collect on the inner surfaces. This will then, during subsequent evacuation, result in significantly longer pump down times until attaining the desired ultimate pressure.
If during longer downtimes the system shall remain conditioned for a rapid pumpdown, we recommend to vent the system with dry nitrogen to atmos­pheric pressure and maintain it in this condition without opening it.
DANGER
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Operation
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Process pump recovery after pump failure
In the event of a process pump stopping during a process step there is risk that the pump could contain hazardous materials, the following procedure should be followed in order to minimise the risk to people and property.
If the pump has previously pumped hazard ous gases observe Safety Information in Section 0.4.
■
Interlock the process valve to close when the process pump stops.
■
Vent the system with dry purge gas to atmospheric pressure.
■
Shut off the purge.
■
Disconnect the pump exhaust and fit a metal ISO / NW blanking plate.
■
Disconnect the pump inlet and fit a metal ISO / NW blanking plate.
■
Disconnect the purge gas supply and seal.
■
The pump can now be removed to a workshop for decontamination and repair.
4.4 Removing from Service
Shut off and vent the pump system as described above.
Clean the pump system of any substances which may lead to corrosion. (e.g. by extended purge).
Flood it with nitrogen or dry purge gas, add desiccant and seal it.
Remove the cooling water from the pump system.
Remove the cooling water hoses from the pump and drain the cool ing water. Blow out the cooling water coils with compressed air or Nitrogen (max. 4 bar). Blow into the cooling water inlet port only.
Drain the lubricant (PFPE or synthetic oil) out of the pump (cf. Fig. 5.1).
DANGER
Drain cooling water
Drain lubricant
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Operation
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If the lubricant is drained out of pumps which have already been operated on the process, then it may have suffered contamina tion. You must deter­mine the nature of the hazard and take the appropriate safety precautions before draining the lubricant. Precautions can include the use of appropri­ate personal protective equipment (PPE) such as gloves, respirator and/or protective clothing, working under an exhaust hood, etc. Comply with all safety regulations. Label the lubricant containers according to the type of contamina tion.
Loosen the drain plug somewhat, hold drain through and bucket against the pump. Unscrew the drain plug. Tools and bucket must be clean so as not to further contaminate the lubricant.
Screw the drain plug with the sealing ring back in, wipe off any dripped lubri­cant from the casing.
DANGER
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Maintenance
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5 Maintenance
5.1 Leybold Service
Whenever you send us in equipment, indicate whether the equipment is con­taminated or is free of substances which could pose a health hazard. If it is contaminated, specify exactly which substances are involved. You must use the form we have prepared for this purpose.
A copy of the form has been reproduced at the end of these Operating Instructions: “Declaration of Contamination for Compressors, Vacuum Pumps and Components”. Another suitable form is available from www.leybold.com/ -> Documents -> Download Documents.
Attach the form to each pump. This statement detailing the type of contamination is required to satisfy legal requirements and for the protection of our employees. We must return to the sender any equipment which is not accompanied by a contamination statement.
5.2 Maintenance Intervals
See the table for the recommended maintenance intervals for the pumps. Periodic and proper maintenance will keep the pump in a normal working condition, and helps avoiding pump breakdowns and failures. Maintenance intervals are process-dependent. In clean processes, you may increase the maintenance intervals; in harsh processes, you may have to decrease them.
We recommend a service contract with Leybold.
We recommend to inspect the pump system and all components after approximately 6 months under the process conditions. The inspection of the components shall let corrosion attacks become apparent at an early stage and indicate possible deposits of process dust. Depending on the findings, changed maintenance and replacement intervals can become necessary for specific components.
Service work Interval
Coolant level in the expansion vessel Monthly
Oil level check Monthly
PFPE level and colour Monthly
Gas ballast filter Yearly
N2 pressure regulator Yearly
N2 flow regulator Yearly
Vacuum pump bearings 5 years
Vacuum pump impeller seals 5 years
LVO 210 change (synthetic oil) Yearly
PFPE change (with clean / medium appli­cation)
5 years
Water glycol mixture 5 years
Contamination
Form
Page 52
Maintenance
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This maintenance plan is a recommendation, adjust it according to your working conditions. With harsh processes intervals should be reduced.
General Notes on Maintenance
Any maintenance work must be performed by qualified personnel. The per­sonnel must be familiar with the safety rules related to the pump, and must use the suitable tools to dismantle and clean the contaminated parts.
In order to prevent any danger, don’t move or disassemble the pump before it has stopped completely; switch off the power supply to the pump before you start maintenance work.
The pump casing, the exhaust piping and the heating piping are extremely hot during operation and remain hot for some time after stopping. Keep the personnel and flammable substances away from the hot area.
Purge the pump with sufficient N2 gas, at least one hour, before removing and cleaning the vacuum lines and exhaust piping.
There might be toxic gases or materials remain in the pump, check that there is nothing remaining before the disassembly.
Don’t reuse any o-ring. Be careful to cleaning all flange surfaces and check they are undamaged. Check for gas leaks after installing and maintaining the piping.
With improper use, malfunctions or exposure to fire the pump may have overheated. Do not touch or inhale thermal breakdown products of fluori­nated materials which are present if the pump has been subject to temper­atures of 260 °C and above. These breakdown products are very danger­ous. Fluorinated materials in the pump may include oils, greases and seals.
Disposal of process byproducts, lubricating oil, vacuum grease and other wastes must be in strict accordance with all local and national environmen­tal and safety regulations. For further info see Section 7 Waste Disposal.
DANGER
Page 53
Maintenance
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5.3 Exchanging the Lubricant
Notice safety information 0.3 to 0.5.
The oil-fill port must be sealed air-tight. In the presence of a vacuum, the entry of air may cause oil-containing gas to enter the pumping chamber via the impeller seals.
When using PFPE as intended, PFPE is not subject to ageing. It must only be changed if it is contaminated by the process gas. It can only be determined individually when PFPE is so contaminated that it must be changed.
Change the lubricant more frequently when pumping corrosive vapours or large amounts of dust or when cycling frequently from atmospheric to work­ing pressure.
Before removing the oil-drain or oil-fill plug always switch off the pump first and vent to atmospheric pressure. When the pump has become warm during operation the casing and the oil temperature may exceed 80 °C. Leave the pump to cool down. Always wear protective gloves also to pro­tect yourself against aggressive residues in the lubricant.
CAUTION
WARNING
Oil ll ports
Oil drain ports
LEYVAC LV 80 LEYVAC LV 140
Fig. 5.1 Positions of Oil Ports for Exchanging Lubricants
Page 54
Maintenance
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The lubricating oil for the vacuum pump is fluorinated lubricant oil (LVO 410) or synthetic oil (LVO 210). Another kind of oil can not be used or replaced; otherwise, it will cause a major damage of the vacuum pump. When replac­ing the oil, the used oil inside the pump must be drained out completely; oth­erwise, it will reduce the lifetime of the new oil. The procedures to replace the oil are listed as follows:
■
Dismantle the oil fill plug at the oil inlet hole.
■
Dismantle the drain plug at the oil outlet hole; drain out the oil of the oil box, or make use of a proper pump to draw out the used oil.
■
Replace all the O-rings. Check the drain plug is tightened. Wipe off any oil residues from the casing.
■
Fill in new oil at a pump temperature of 15 ºC to 25 ºC.
■
Make sure to use the right kind of oil and according to Leybold’s sugges­tion. Only use Leybold authorized vacuum oil and re-supply the new oil.
■
Clean the oil-fill port, reinstall and tighten the plug using a gasket which is in perfect condition. Wipe off any oil residues from the casing.
Observe the correct oil fill levels for the shutdown (standing still) pump.
The oil levels of both, the gear box and the low pressure side, should be between 1/2 – 2/3 of the oil level glass height. If the level drops below 1/2, lubricant should be added (cf. Fig. 3.2). If the oil level is too low, the bearings and gearwheels are not lubricated adequately; if it is too high, oil may enter the pumping chamber. Mineral oils, synthetic oils and PFPE do not mix.
Please consult us if you intend to run the pump with other oils or special lubricants.
The waste oil must be disposed by a professional and qualified waste dis­posal dealer, container with PFPE has to be labelled as such. For further info see Section 7 Waste Disposal.
5.4 Exhaust Piping Connector
A regular leakage check should be performed over all the connecting parts of the piping. It should be included of checking any crack on the pipes. Washers, O-rings and pipes should be replaced according to their condition. All parts should be tightened again or re-sealing if necessary.
5.5 Pump Inlet Flange
Dismantle the pump inlet flange regularly for cleaning the dirt on the mesh and change with a new O-ring.
NOTICE
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Maintenance
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Fig. 5.3 Expension Vessel
Glykoleinfüllstutzen
Fig. 5.2 Fill port for the main cooling circuit
Glycol fill port
5.6 Purge Gas Pressure and Flow Regulator
Check and test regularly that the function of the N2 pressure regulator and the N2 flow regulator are normal. When the pump is running, supply the N2 gas and regulate the flow to check the N2 mass flow works in normal condi­tion.
Check the gas ballast filter contamination in regards to the ambient air on a regular basis, and replace the filter insert as appropiate.
5.7 Cooling Water Piping
After operating for a period of time, the cooling water piping might encounter the problem of a poor cooling effect because of the dirt adhering to the pip­ing. It will cause the pump casing temperature to rise. A regular cleaning job is necessary, and the clean frequency is dependent on the quality of the water. The cooling tower and the filter should also be cleaned often. If the piping has already been adhered with the dirt, the piping should be cleaned with a cleaner or be replaced.
5.8 Coolant Level
Check the coolant level in the expansion vessel regularly. If the coolant is insufficient, re-supply the water-glycol-mixture and keep the level between FULL and LOW. If the level is really low, additionally fill in coolant directly into the main cooling circuit (cf. Fig. 5.2). The capacity of the main cooling circuit and the expansion vessel is approx. 5 litres.
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Troubleshooting
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6 Troubleshooting
6.1 Pump Malfunctions
6.1.1 Malfunctions with CC-type Pumps
Malfunction Remedy
Thermal relay trip Reset trip (cf. Fig. 3.6)
Motor thermal switch trip Let the pump cool down (≤ 59 °C), then press the “ON”
button (CC cover) manually.
Casing thermal switch trip Let the pump cool down (≤ 70 °C ~ 40 °C), then press
the “ON” button (CC cover) manually.
6.2 Malfunctions with Frequency Converter Operations (option)
Faults and alarms indicate problems in the frequency converter or in the pump.
An alarm (warning) is indicated by a code on the data display and the flashing ALM LED. The frequency converter output is not necessarily switched off.
A fault is indicated by a code on the data display and the ALM LED is on. The frequency converter output is always switched off immediately and the motor coast to stop.
To remove an alarm or reset a fault, trace the cause, remove it and reset the frequency converter by pushing the Reset key on the operator or cycling the power supply.
This lists up the most important alarms and faults only.
Malfunction Likely cause Remedy
Current is too high
Exhaust pressure rises.
Pump with noise, and rotors are in contact.
Power supply failure.
Check exhaust piping and silencer.
Replace or overhaul pump.
Check power supply.
Motor temp. high (90 °C)
Insufficient cooling.
Motor failure.
Check water flow and temperature.
Replace the motor.
Casing temp. high (85 °C)
Insufficient cooling.
Insufficient coolant in the water jacket.
Byproduct is clogged.
Check water flow and temperature.
Refill the coolant.
Replace or overhaul pump.
Water flow is too low
Water piping leaks.
Differential pressure is too small
Water piping is clogged.
Outlet / inlet is reverse.
Check the fittings.
Check the inlet and outlet pressure of water piping.
Clean or replace piping.
Connect correctly.
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Troubleshooting
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Error message
Brief Description
AL FLT Possible cause Corrective Action
Base Block
n
The software base block function is assigned to one of the digital inputs and the input is off. The frequency con­verter does not accept Run commands.
Check the digital inputs function selection.
Provide link between SC and S6.
Control Fault The torque limit was reached during
deceleration for longer than 3 sec. when in Open Loop Vector control
• The load inertia is too big.
• The torque limit is too low.
• The motor parameters are wrong.
Check the load.
Set the torque limit to the most appropriate setting (L7-01 through L7-04).
Check the motor parameters.
Control Circuit Fault
n
There is a problem in the frequency converter’s control circuit.
Cycle the frequency converter power supply.
Initialize the frequency converter.
Replace the frequency converter if the fault occurs again.
Control Circuit Fault
n
There is no terminal board connected to the control board.
Check if the terminal board is installed proper­ly.
Uninstall and Reapply the terminal board.
Change the frequency converter.
Cannot Reset
n
Fault reset was input when a Run com­mand was active.
Turn off the Run command and reset the fre­quency converter.
Option External Fault
n n
An external fault was tripped by the upper controller via an option card.
Remove the fault cause, reset the fault and restart the frequency converter.
Check the upper controller program.
External Fault
n
A forward and reverse command were input simultaneously for longer than 500 ms. This alarm stops a running motor.
Check the sequence and make sure that the forward and reverse input are not set at the same time.
to
External Faults
n n
An external fault was triggered by an external device via one of the digital inputs S1 to S6.
EF2: Temperatur limiter (casing rotor) exceeds fault threshold.
EF3: Temperature limiter (motor) exceeds fault threshold.
The digital inputs are set up incorrectly.
Find out why the device tripped the EF. Remove the cause and reset the fault.
Check water cooling.
Check motor load, reduce if required, check water cooling.
Check the functions assigned to the digital inputs.
to
Ground Fault
n
Ground leakage current has exceeded 50% of the frequency converters rated output current.
Cable or motor insulation is broken.
Excessive stray capacitance at frequen­cy converter output.
Check the output wiring and the motor for short circuits or broken insulation. Replace any broken parts.
Reduce the carrier frequency.
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Troubleshooting
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Error message
Brief Description
AL FLT Possible cause Corrective Action
to
Output Phase Loss
n
Output cable is disconnected or the motor winding is damaged.
Loose wires at the frequency converter output.
Motor is too small (less than 5% of fre­quency converter current).
Check the motor wiring.
Make sure all terminal screws in the frequency converter and motor are properly tightened.
Check the motor and frequency converter capacity.
to
Overcurrent
n
Short circuit or ground fault on the fre­quency converter output side
The load is too heavy.
The accel./decel. times are too short.
Wrong motor data or V/f pattern set­tings.
A magnetic contactor was switched at the output.
Check the output wiring and the motor for short circuits or broken insulation. Replace the broken parts.
Check the machine for damages (gears, etc.) and repair any broken parts.
Check the frequency converter parameter set­tings.
Check the output contactor sequence.
to
or
Heatsink Overheat
n n
Surrounding temperature is too high.
The cooling fan has stopped.
The heatsink is dirty.
The airflow to the heatsink is restricted.
Check the surrounding temperature and install cooling devices if necessary.
Check the frequency converter cooling fan.
Clean the heatsink.
Check the airflow around the heatsink.
to
or
Motor Overload
n
The motor load is too heavy.
The motor is operated at low speed with heavy load.
Cycle times of accel./ decel. are too short.
Incorrect motor rated current has been set.
Reduce the motor load.
Use a motor with external cooling and set the correct motor in parameter L1-01
Check the sequence.
Check the rated current setting.
Drive Overload
n
The load is too heavy.
Too much torque at low speed.
Check the load.
The overload capability is reduced at low speeds. Reduce the load or increase the fre­quency converter size.
Page 59
Waste Disposal
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7 Waste Disposal
The equipment may have been contaminated by the process or by environ­mental influences. In this case the equipment must be decontaminated in accordance with the relevant regulations. We offer this service at fixed prices. Further details are available on request.
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.
Separate clean components according to their materials, and dispose of these accordingly. We offer this service. Further details are available on request.
When sending us any equipment, observe the regulations given in Section
5.1 Leybold service.
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.
PFPE from vacuum pumps may be regenerated, if required, and provided the quantities are large enough. For this, please contact us for assistance.
Contamination
WARNING
Page 60
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EC Declaration of Conformity
Page 61
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17200001_002_C0
© Leybold
Declaration of Contamination of Compressors, Vacuum Pumps and Components
The repair and / or servicing of compressors, va cuum pumps and components will be carried out only if a correctly completed declaration has been submitted. Non-completion will result in delay
. The manufacturer can refuse to accept any equipment without a declaration.
A separate declaration has to be completed for each single component.
This declaration may be completed and signed only by authorized and qualified staff.
Customer/Dep./Institute : Reason for return: applicable please mark Address : Repair: chargeable warranty
Exchange: chargeable warranty
Exchange already arranged / received
Person to contact: Return only: rent loan for credit Phone : Fax: Calibration: DKD Factory-calibr.
End user: Quality test certificate DIN 55350-18-4.2.1
A. Description of the Leybold product:
Failure description:
Material description : Catalog number: Additional parts: Serial number: Application-Tool: Type of oil (ForeVacuum-Pumps) : Application- Process:
B. Condition of the equipment
No1) Yes No Contamination : No1) Yes
11.
. Has the equipment been used
toxic
2. Drained (Product/service fluid)
corrosive
3. All openings sealed airtight
flammable
4. Purged
explosive 2)
If yes, which cleaning agent
radioactive
2)
and which method of cleaning
microbiological
2)
1)
If answered with “No”, go to D. other harmful substances
C. Description of processed substances (Please fill in absolutely)
1. What substances have come into contact with the equipment ?
Trade name and / or chemical term of service fluids and substances processed, properties of the substances According to safety data sheet (e.g. toxic, inflammable, corrosive, radioactive)
X Tradename: Chemical name:
a) b) c) d)
No Yes
2. Are these substances harmful ?
3. Dangerous decomposition products when heated ? If yes, which ?
2)
Components contaminated by microbiological, explosive or radioactive products/substances will not be accepted without written
evidence of decontamination.
D. Legally binding declaration I / we hereby declare that the information supplied on this form is accurate and sufficient to judge any contamination level.
Name of authorized person (block letters) :
Date signature of authorized person
firm stamp
Declaration of Contamination
Page 62
Headquarter Leybold GmbH
Bonner Strasse 498 D-50968 Cologne T: +49-(0)221-347-0 F: +49-(0)221-347-1250 [email protected]
Germany
Leybold GmbH
Sales, Service, Support Center (3SC) Bonner Strasse 498 D-50968 Cologne T: +49-(0)221-347 1234 F: +49-(0)221-347 31234 [email protected] www.leybold.com
Leybold GmbH Sales Area North
Branch Office Berlin Industriestrasse 10b D-12099 Berlin T: +49-(0)30-435 609 0 F: +49-(0)30-435 609 10 [email protected]
Leybold GmbH Sales Office South
Branch Office Munich Karl-Hammerschmidt-Strasse 34 D-85609 Aschheim-Dornach T: +49-(0)89-357 33 9-10 F: +49-(0)89-357 33 9-33 [email protected] [email protected]
Leybold Dresden GmbH Service Competence Center
Zur Wetterwarte 50, Haus 304 D-01109 Dresden Service: T: +49-(0)351-88 55 00 F: +49-(0)351-88 55 041 [email protected]
Europe
Belgium
Leybold Nederland B.V. Belgisch bijkantoor
Leuvensesteenweg 542-9A B-1930 Zaventem Sales: T: +32-2-711 00 83 F: +32-2-720 83 38 [email protected] Service: T: +32-2-711 00 82 F: +32-2-720 83 38 [email protected]
France
Leybold France S.A.S.
Parc du Technopolis, Bâtiment Beta 3, Avenue du Canada F-91940 Les Ulis cedex Sales and Service: T: +33-1-69 82 48 00 F: +33-1-69 07 57 38 [email protected] [email protected]
Leybold France S.A.S.
Valence Factory 640, Rue A. Bergès B.P. 107 F-26501 Bourg-lès-Valence Cedex T: +33-4-75 82 33 00 F: +33-4-75 82 92 69 [email protected]
Great Britain
Leybold UK LTD.
Unit 9 Silverglade Business Park Leatherhead Road Chessington Surrey (London) KT9 2QL Sales: T: +44-13-7273 7300 F: +44-13-7273 7301 [email protected] Service: T: +44-13-7273 7320 F: +44-13-7273 7303 [email protected]
Italy
Leybold Italia S.r.l.
Via Trasimeno 8 I-20128 Mailand Sales: T: +39-02-27 22 31 F: +39-02-27 20 96 41 [email protected] Service: T: +39-02-27 22 31 F: +39-02-27 22 32 17 [email protected]
Netherlands
Leybold Nederland B.V.
Floridadreef 102 NL-3565 AM Utrecht Sales and Service: T: +31-(30) 242 63 30 F: +31-(30) 242 63 31 [email protected] [email protected]
Switzerland
Leybold Schweiz AG, Pfäffikon
Churerstrasse 120 CH-8808 Pfäffikon Warehouse and shipping address: Riedthofstrasse 214 CH-8105 Regensdorf Sales: T: +41-44-308 40 50 F: +41-44-302 43 73 [email protected] Service: T: +41-44-308 40 62 F: +41-44-308 40 60 [email protected]
Spain
Leybold Hispánica, S.A.
C/. Huelva, 7 E-08940 Cornellá de Llobregat (Barcelona) Sales: T: +34-93-666 43 11 F: +34-93-666 43 70 [email protected] Service: T: +34-93-666 46 11 F: +34-93-685 43 70 [email protected]
America
USA
Leybold USA Inc.
5700 Mellon Road USA-Export, PA 15632 T: +1-724-327-5700 F: +1-724-325-3577 [email protected] Sales: T: +1-724-327-5700 F: +1-724-333-1217 Service: T: +1-724-327-5700 F: +1-724-325-3577
Brazil
Leybold do Brasil
Rod. Vice-Prefeito Hermenegildo Tonolli, nº. 4413 - 6B Distrito Industrial Jundiaí - SP CEP 13.213-086 Sales and Service: T: +55 11 3395 3180 F: +55 11 99467 5934 [email protected] [email protected]
Asia
P. R. China
Leybold (Tianjin) International Trade Co. Ltd.
Beichen Economic Development Area (BEDA), No. 8 Western Shuangchen Road Tianjin 300400 China Sales and Service: T: +86-22-2697 0808 F: +86-22-2697 4061 F: +86-22-2697 2017 [email protected] [email protected]
India
Leybold India Pvt Ltd.
No. 82(P), 4th Phase K.I.A.D.B. Plot Bommasandra Industrial Area Bangalore - 560 099 Indien Sales and Service: T: +91-80-2783 9925 F: +91-80-2783 9926 [email protected] [email protected]
Japan
Leybold Japan Co., Ltd.
Headquarters Shin-Yokohama A.K.Bldg., 4th floor 3-23-3, Shin-Yokohama Kohoku-ku, Yokohama-shi Kanagawa-ken 222-0033 Japan Sales: T: +81-45-471-3330 F: +81-45-471-3323 [email protected]
Leybold Japan Co., Ltd.
Tsukuba Technical Service Center 1959, Kami-yokoba Tsukuba-shi, Ibaraki-shi 305-0854 Japan Service: T: +81-29 839 5480 F: +81-29 839 5485 [email protected]
Malaysia
Leybold Malaysia Leybold Singapore Pte Ltd.
No. 1 Jalan Hi-Tech 2/6 Kulim Hi-Tech Park Kulim, Kedah Darul Aman 09000 Malaysia Sales and Service: T: +604 4020 222 F: +604 4020 221 [email protected] [email protected]
South Korea
Leybold Korea Ltd.
3F. Jellzone 2 Tower Jeongja-dong 159-4 Bundang-gu Sungnam-si Gyeonggi-do Bundang 463-384, Korea Sales: T: +82-31 785 1367 F: +82-31 785 1359 [email protected] Service: 623-7, Upsung-Dong Cheonan-Si Chungcheongnam-Do Korea 330-290 T: +82-41 589 3035 F: +82-41 588 0166 [email protected]
Singapore
Leybold Singapore Pte Ltd.
8 Commonwealth Lane #01-01 Singapore 149555 Singapore Sales and Service: T: +65-6303 7030 F: +65-6773 0039 [email protected] [email protected]
Taiwan
Leybold Taiwan Ltd.
No 416-1, Sec. 3 Chunghsin Rd., Chutung Hsinchu County 310 Taiwan, R.O.C. Sales and Service: T: +886-3-500 1688 F: +886-3-583 3999 [email protected] [email protected]
Sales and Service
LV_20168_2017 01.17
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