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RUTA Fore Vacuum Pump Systems ■ with Roots Pumps and with oil sealed ■ Rotary Vane Pumps ■ Rotary Piston Pumps
Operating Instructions 17200207_002_C0
Contents
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Page0 Important Safety Information 5
0.1 Mechanical Hazards 5
0.2 Electrical Hazards 7
0.3 Thermal Hazards 8
0.4 Hazards Caused by Materials and Substances 9
0.5 Ignition Risk 11
0.6 Noise Hazard 11
0.7 Dangers in Connection with Safety-related Measures and Precautions 11
0.8 Danger of Pump Damage 11
1 Description 13
1.1 Design 13
1.1.1 Pumps Systems in a Frame 13
1.1.2 Pump Systems without Base Frame (Adapter Version) 14
1.1.3 Cooling 14
1.1.4 Pressure Switch / Bypass Line 14
1.1.5 Vacuum Protection 15
1.1.6 Principle of Operation 15
1.2 Supplied Equipment 15
1.3 Lubricants 16
2 Transport and Storing 17
3 Installation 18
3.1 Placement 18
3.1.1 Filling Oil into the Pumps 18
3.2 Conforming Utilization 19
3.3 Ambient Conditions 19
3.4 Connecting the Intake and Exhaust Lines 20
3.4.1 Connecting Bellows 20
3.4.2 Intake Line 21
3.4.3 Exhaust Line 22
3.5 Connecting Cooling Water 23
3.5.1 Water Quality 23
3.6 Connecting Compressed Air or Purge Gas 24
3.7 Electrical Connection 24
3.8 Leak Detection after Installation 25
Contents
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Described in these Operating Instructions is the general use of forevacuum pump systems from Leybold equipped with oil sealed backing pumps. These Operating Instructions apply to all pump systems equipped with such pump combinations.
For the specific description of your pump system please refer to the special Operating Instructions for your pump system and the enclosed Operating Instructions for the individual components.
These are the original operating instructions.
4 Operation 26
4.1 Media Compatibility 26
4.2 Start-up 26
4.3 Operation 27
4.4 Shut-off and Venting 29
4.4.1 Shut Down after Pumping Condensable Gases and Vapours 29
4.4.2 Shut Down after Pumping Aggressive or Corrosive Media and Storing 30
5 Maintenance 31
5.1 Leybold Service 31
5.2 Maintenance Intervals 31
5.3 Replacing Individual Pumps in the Pump System 32
5.4 Oil Change 32
5.5 Cleaning the Dirt Trap 33
6 Wearing Parts 34
7 Waste Disposal 34
8 Troubleshooting 35
Safety Information
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Obligation to Provide Information Before installing and commissioning the pump system, carefully read these Operating Instructions and the Operating Instructions for the individual components and follow the information so as to ensure optimum and safe working right from the start.
The Leybold RUTA pump system 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 system must only be operated in the prop-er condition and under the conditions described in the Operating Instructions. It must be operated and maintained by trained personnel only. Consult local, state, and national agencies regarding specific requirements and regulations. Address any further safety, operation and/or maintenance questions to our nearest office.
DANGER indicates an imminently hazardous situation which, if not avoid-ed, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to notify users of installation, operation, programming or 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.
NOTICE
DANGER
WARNING
CAUTION
NOTICE
Safety Information
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0 Important Safety Information
0.1 Mechanical Hazards1 Avoid exposing any part of the human body to the vacuum.
2 Do not operate the pump with an opened intake port. There exists the risk of suffering injury. At valves or flange openings there is the risk of crushing your fingers. Take care of your fingers.
3 The pump is intended for generating a vacuum only. If an overpres sure can occur in the process the pumps and the system must be pro-tected against such an overpressure by an overpressure safety valve, for example.
4 Never connect the intake port of the pump to a device where pres-sures exceeding that of atmospheric pressure can be expected. Design exhaust lines so that the pressure cannot rise above 1.15 bar abs. (0.15 bar (g)).
Make sure that the gas flow at the discharge is not blocked or restrict-ed 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 opera-tion. If shutoff devices are installed, open them before starting the pump.
In the case of processes involving condensate, we recommend the installation of a condensate separator in the discharge line.
5 When using purge gas or gas ballast gas from pressurised cylinders protect the supply so that in the event of a malfunction or a power cut no overpressure can occur in the pump system.
6 For transporting the pump use only suitable transport means.
When selecting the lifting and transport means take note of the total weight and the center of gravity before transporting the pump.
Usually, the pump system has been equipped with four crane eyes.
Use lifting straps possibly with a crane traverse to move pump sys-tems which are not equipped with crane eyes. When lifting the system do not allow it to slip out of control.
Move pumps with an oil filling only in the vertical position. There is the risk of slipping on escaped oil.
Parts can drop off from the pump system. Wear the required protec-tion equipment: safety shoes, safety helmet, safety gloves.
WARNING
Safety Information
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7 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. Only open the pump system provided it is at atmospheric pressure.
8 During operation, the cooling water circuit must not be shut off. A cool ing water discharge which has been blocked can cause the for-mation of gas bubbles and result in excessively high pressures.
9 Lay electric feed and cooling water lines so that there is no risk of trip-ping over these.
10 When changing the oil remove any escaped oil as otherwise there is the risk of slipping.
11 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.
12 Before disassembling any cooling water lines, leave the pump to cool down, shut off the feed line.
13 Align the bellows. Do not overstress the bellows. Too much stress on the bellows will cause premature failing of the bellows and thus leaks in the system.
14 Should malfunctions affect the Roots pump, seized impellers in parti-cular owing to hard deposits or foreign objects, the occurrence of leaks affecting the housing cannot be ruled out. When pumping hazar-dous gases the operator must ensure that the possibility of such an incident is excluded, respectively that leaks at the pump casing will not pose a hazard.
15 When installing the pump system do not exceed the maximum permis-sible ceiling load.
16 When bellows have been fitted, considerable forces are transferred during evacuation. In order to absorb these, mount the pump system and the piping in a suitable way.
Safety Information
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0.2 Electrical Hazards1 The electrical connection must only be provided by a trained person.
Please 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). In addi-tion, there is the danger of residual voltage for up to 5 min after dis-connection.
3 Install a device for a safe disconnection from the power supply.
4 Note the information on the IP type of protection.
5 Always operate the pump with a properly connected protective earth conductor and make sure that the motor casing is closed
6 Observe the manufacturer’s information and operating instructions for the respective frequency converter.
7 The pump must only be operated at the frequency specified for the motor. Use only the Leybold frequency converter.
8 Install add-on parts (pressure switches, for example) without any mechanical tensions and protect these against being damaged by impacts, for example.
9 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. In particular lay the lines at a distance with respect to the discharge. Comply with the required standards when designing and laying the electrical connections.
10 Provide strain relief for the connecting lines so that the plugs and the line connectors are not subjected to excessively high mechanical stresses.
11 Lay electric feed lines so that there is no risk of tripping over these.
12 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.
13 Provide an adequate earth connection for the pump system to avoid charging it with static electricity.
DANGER
Safety Information
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0.3 Thermal Hazards1 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 protec-tive 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.
6 Operating the pump with less than the specified amount of cooling water will result in excessively high surface temperatures which can damage the pump. Moreover, there exists the risk of suffering burns.
7 Note the warning information on the housing surface. If these warning notices have been removed, covered or obstructed, include corre-sponding additional warning notices.
CAUTION
Fig. 0.1 RUTA WSU 501/D 65 BCS/G
Safety Information
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0.4 Hazards Caused by Materials and Substances1 The vacuum and exhaust lines must be leaktight. Hazardous process
gases may escape or the pumped gases can react with air or atmo-spheric humidity. After installation of the pump and after servicing work on the vacuum system, a leak detection will always be necessary.
When pumping toxic, corrosive and reactive gases we recommend a leak detection 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 and in the vacuum system 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 hazard-ous situations. All relevant safety standards and regulations must be observed.
3 Standard pump systems are not suited for pumping oxygen at con-centrations above the oxygen concentration (21%) in the atmosphere.
4 When pumping toxic, chemically active, radioactive and corrosive gases as well as pyrophorus materials, the operator is committed to comply with the national and international safety regulations and guidelines. As to the suitability of the pump for special applications in which such substances shall be pumped, please consult Leybold first for advice.
5 We recommend urgently to connect an exhaust line so that no danger-ous gases and no oil mist at all may enter into the room. The cross-section of the exhaust line must at least match the inside diameter of the connection.
6 The type of protection will depend on the process and needs to be assessed by the operator so that additional purge gas quantity checks may be necessary, for example.
7 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 precau-tions.
8 Before operating the pump with a gas ballast and/or a purge gas (option) check the compatibility of the gas with the pumped media so as to avoid dangerous conditions during operation.
9 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. Should this not be possible, evacuate the pump system using a separate pump (through a leak detection connection, for example) and purge 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 Service at Leybold.
DANGER
Safety Information
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10 When cleaning a system in which a RUTA system has been integrated, parts in contact with the pumped medium must be compatible with the cleaning agent so as to prevent the occurrence of a chemical reac-tion. Avoid cleaning agent residues in the pump system.
11 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.
12 When pumping hazardous gases you must assume the presence of hazardous residues in the pump.
13 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 pro-tection measures.
When shipping contaminated pumps which require approval by the authorities, note the applicable regulations regarding packaging and shipping.
14 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.
15 All points which are opened on the pump or the vacuum system need to be reliably sealed immediately after having run the maintenance work.
16 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.
Safety Information
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0.5 Ignition Risk1 The standard version of the pump is not suited for operation in explo-
sion hazard areas. Contact us before planning to use the pump under such circumstances.
0.6 Noise Hazard1 The noise level of the pump during ultimate pressure operation with an
appropriate discharge line corresponds to the values stated in the Technical Data. In other operating modes and with other equipment, higher values may occur. 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.
0.7 Dangers in Connection with Safety-related Measures and Precautions1 The pump is not equipped with an emergency shutdown facility.
2 The following applies to pumps being operated with a frequency con-verter: after a mains power failure the pump will automatically start up again once the power returns, as long as a start command from the system control is present.
3 Take note of the warning information on the casing surface. If this warning information was removed, covered or obstructed, then pro-vide corresponding additional warning information.
0.8 Danger of Pump Damage1 Select an installation site for the pump so that all controls are easily
accessible.
2 With the pump filled with oil it must be placed such that it will deviate by no more than 2° from the vertical axis as otherwise oil can enter into the sealing system. Before filling the pump with oil, align it.
3 Do not allow the ingestion of any objects (screws, welding beads, nuts, washers, pieces of wire, etc.) through the intake port of the pump.
In case the pump is operated without intake screen the operator has to make sure that no objects can enter the pump through the intake port. Objects falling into the pump can cause severe damage at the pump including leaks to atmosphere.
The intake screen does not replace a filter. Prevent the intake of parti-cles from the side of the process by fitting suitable filters. Upstream fil-ters protect the pump against damage to the pump chamber.
4 The pump system is not suited for applications in which abrasive or cohesive substances or condensable vapours are produced which may form sticky deposits or deposits which are hard to remove. Please contact our Sales or Service when planning to pump vapours other then water vapour.
DANGER
CAUTION
CAUTION
NOTICE
Safety Information
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5 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.
6 The discharge line should be laid so that it slopes down and away from the pump so as to prevent condensed vapors from backstream-ing into the pump.
7 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.
8 Reliably prevent any condensation of vapors within the pump and in the exhaust volume through purging with nitrogen, operating the pump thereby warming it or heating the exhaust, for example. In the case of wet processes we recommend the installation of an upstream and downstream liquid separator as well as the use of the gas ballast.
9 Prevent the ingress of particles and liquids.
10 With the pump warm from operation do not clean it from the outside with water. There is the risk of a rotor crash due to shock cooling.
11 For shutting down the pump purge the pump with nitrogen for at least 30 minutes. Disconnect the pump from the mains power. Place desic-cant 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 and the water first. Package the pump airtight in polyethylene foil.
12 Improper maintenance or repair work can have an influence on the service life and the performance of the pump and will void any warran-ty claims.
13 Maximum cooling water pressure: 6 bar (5 bar (g)). When exceeded, there is the risk of leaks.
14 Starting up without oil or operation with the wrong direction of rotation can destroy the pump.
15 Never reuse disassembled gaskets. Always fit new gaskets.
Pressures given in bar or mbar are absolute values. If exceptionally a gauge pressure is meant, a “g” is added (bar(g)).
Description
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1 DescriptionRUTA pump systems consist of a combination of Roots pumps and backing pumps.
Described in these Operating Instructions is the operation of 2, 3 and 4 stage RUTA pump systems using backing pumps.
Various types of pump may be used in the pump system:
Roots pump: RUVAC WA/WAU RUVAC WS/WSU RUVAC WH/WHU RUVAC RA
Backing pump: TRIVAC B/BCS (two-stage) SOGEVAC SV (single-stage or two-stage) Rotary piston pumps E (single-stage) Rotary piston pumps DK (two-stage)
For a special description on the pumps used in each case please refer to the Operating Instructions for the particular pumps.
1.1 DesignThe pump systems form compact, pre-assembled units normally ready for transportation, which may be easily installed and operated.
The standard models consist of pumps installed on top of each other.
Two-stage pump systems 1 Roots pump + 1 single-stage backing pump
Three-stage pump systems 2 Roots pumps + 1 single-stage backing pump or 1 Roots pump + two-stage backing pumps
Four-stage pump systems: 2 Roots pumps + two-stage backing pumps
1.1.1 Pumps Systems in a FrameThe entire assembly may be lifted by a crane at the crane eyes if provided at the frame.
The pump system is normally equipped with four floor mounting panels.
The Roots pump has been fitted within the frame without any elastic suspen-sion. The RA pumps are so mounted that the casing may expand thermally without restriction.
Roots pump and backing pump are linked by bellows made of stainless steel or an adapter.
The backing pump is elastically suspended on a console/panel for low vibra-tion operation of the pump system. Using a fork lifter, the backing pump may be removed without having to disassemble the Roots pump.
Description
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For the backing pump, there exists the option of fitting an oil trough under-neath.
The pump system has an exhaust filter which has either been integrated into the backing pump or which is separate. In some cases a separate exhaust filter will not be necessary.
Option: ControllerIf the pump system has been equipped with an electric controller (optional) this controller will be attached to the frame and the pump system will be sup-plied fully wired up. All electric components can be operated.
In such a case the motors have motor protection switches which protect them from being overloaded.
1.1.2 Pump Systems without Base Frame (Adapter Version)The entire assembly may be moved using a fork lifter. For this, the forks of the fork lifter are inserted under the frame of the pump system.
If the pump system is to be moved by a crane, the straps must be guided under the frame. Note the centre of gravity!
The pump system has an exhaust filter. It has either been integrated into the backing pump or has been fitted separately. In some cases a separate exhaust filter will not be necessary.
Option: ControllerIf the pump system has been equipped with an electric controller (optional) this controller will be supplied separately.
The pump system‘s wiring needs to be provided by the customer.
1.1.3 CoolingThe pumps of the pump system are air or water cooled. For details refer to the separate Operating Instructions for the respective pumps.
1.1.4 Pressure Switch / Bypass Line
Pump systems with RUVAC WA, WS, WH, RAThe pump system must be equipped with a pressure switch or a pressure sensor the signals of which are monitored accordingly, so that the Roots pump may be switched on while in the permissible pressure range. Depending on the pump ratio the pressure switch may be omitted when a frequency converter is used.
Pumps systems with RUVAC WAU, WSU, WHUIn the case of those pump systems with a Roots pump having a bypass line, the pressure switch will generally not be necessary. For small volumes, the Roots pump can be switched on and off together with the forevacuum pump. In the case of large volumes the pump may suffer from thermal over-loading. In such a case please consult us.
Description
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1.1.5 Vacuum Protection
Pump systems with TRIVAC B/BCS, SOGEVAC backing pumps The pump system and the vacuum chamber are both protected by means of an anti-suckback valve in the backing pump against being vented through the backing pump.
In the case of some backing pumps, a venting valve will have to be electrical-ly connected separately (refer to the Operating Instructions for the pumps).
Pump systems with rotary piston pumps E and DK Usually, both the pump system and the vacuum chamber are protected by a SECUVAC valve against being vented through the backing pump.
1.1.6 Principle of OperationIt is the task of the pump system to mechanically compress the pumped gas from the pressure in the process or the vacuum chamber to atmospheric pressure by means of one or several Roots pumps and an oil-sealed backing pump. The Roots pump compresses the gas to the intake pressure of the backing pump whereby this pressure depends on the magnitude of the vol-ume flow.
Details on the operating principles used by the pumps are provided in the corresponding Operating Instructions.
1.2 Supplied EquipmentThe pump system is supplied as standard without the electric wiring for all installed components.
Prior to delivery, the ports on the intake and exhaust sides have been sealed using caps, foil, rubber diaphragms or pieces of cardboard.
The following items are supplied for connecting the intake of the vacuum sys-tem:
Intake ■ RUVAC WH, WHU Intake screen for use on the inlet side.
■ RUVAC WA, WAU, WS, WSU Gasket with dirt trap, ISO-K collar flange with snap ring and the required number of bolts.
■ RUVAC RA Adapter for connecting ISO-K clamped flanges or DIN connection flange without accessories.
Exhaust Exhaust connection of the backing pump without accessories.
Oil FillingDepending on the type of pump, the operating oil is in the pump or it has
Description
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been drained out and is supplied separately.
Possibly required special oils/special lubricants are not included with the standard deliveries. These operating agents are optionally available.
1.3 Lubricants The standard pump systems are delivered with standard oil LVO 100 except in the case of the SOGEVAC pumps which use LVO 130 as the lubricant. Possible deviations from this are detailed in the special Operating Instructions for the pump system.
Operation with special lubricants is possible, please consult with us.
Also operation with the special lubricant perfluoropolyether (PFPE) is possi-ble, provided the pumps have been prepared correspondingly.
Since mineral oils and PFPE emulsify when mixed, they may only be used in pumps intended for the particular type of lubricant. Conversion to a different kind of lubricant should be left to Leybold.
Conversion from mineral oils to PFPE will only be possible at all after the pump has been thoroughly cleaned by the supplier.
When handling PFPE please observe the following:
■ Touch the inside of the pumps only while wearing clean gloves and with cleaned tools.
■ Work preferably in clean and dry rooms.
■ Put the pump system into service as quickly as possible again.
■ While working do not eat, drink or smoke.
Fig. 1.1 RUTA WAU251/TRIVAC D65 B/A
Transport and Storing
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2 Transport and StoringSome pumps are supplied filled with oil. For this reason during transportation it should not be subjected to any tilting as best possible.
When transporting the pump systems always make use of the crane eyes which are provided on the frame and place the pump system on a dry, level, hard and horizontal underground.
Movable pump systems with castors must only be placed and moved on level, solid, horizontal surfaces. When moving the system, make sure that the moving speed is adequately slow so as to reduce the risk of an accident.
Use sufficiently rated lifting gear. While transporting, do not stand under the lifted system. Note the centre of gravity. Do not exceed the maximum permissible ceiling load.
The pump systems must not be lifted at the crane eyes of the pumps.
StorageStore the pump system only horizontally standing on its feet.
When storing the pump for a longer period of time (> 2 weeks) the flanges should be sealed off with a piece of foil.
In the case of the SOGEVAC pumps the oil should be drained out.
Place a bag with desiccant in the pump chamber, if required. Before operat-ing the pump once more do not forget to remove this bag first.
The pumps should be sealed off in a gas-tight manner and vented with nitro-gen.
Pumps which are being operated with PFPE must immediately be protected against corrosion after having switched the pumps off.
If there is the danger of frost, the cooling water must be drained, see Section 4.4 Shut-off and Venting
You may use a water glycol mixture of up to 30 %.
Temperature (only for storage without cooling water!) –10 °C to +60 °C
Storage site dry
Maximum atmospheric humidity 95 %, non-condensing
If the pump was on stock for a time longer than two years, it should not be connected directly to the power line. If doing so electrical components might be permanently damaged. Consult with Leybold.
WARNING
NOTICE
NOTICE
Installation
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3 Installation
The pump system must only be installed by trained installation personnel.
3.1 PlacementPlace the pump system on a level, horizontal surface. On inclined planes there is the risk of an uncontrolled movement. Do not exceed the maximum permissible ceiling load.
Each pump system with a frame has four points for affixing, or which may be equipped with additional vibration absorbers or elastic components in case this is required.
The floor and the foundations must be level and clean, and capable of with-standing the static and dynamic forces which will occur.
Install the pump system on level foundations free of vibrations. In the case of vibration sensitive ceilings or steel constructions the pump system should be placed on vibration absorbers and it should be bolted to the floor.
Start-up mobile pump systems only with the castors properly arrested.
The pumps, pipes, valves and monitoring facilities may during operation attain high temperatures (> 80 °C), so that there exists the risk of receiving burns. The same also applies to the exhaust line. Protect the hot parts against being touched.
3.1.1 Filling Oil into the PumpsThe required type of oil is specified in the special Operating Instructions for the system. Use this type of oil only. Only fill in the oil after having ensured that the pump is at a standstill.
For some RUVAC models, the oil has been supplied separately and must be filled into the gear chambers after having put the system in place. For filling in, see the Operating Instructions for the RUVAC pumps.
The RUVAC WH/WHU has two oil chambers. For this reason the oil needs to be filled in at two separate points.
The RUVAC pumps have been subjected to a test run and contain residual oil quantities. Filling in the wrong type of lubricant can damage the pumps. Therefore use only the oil specified by Leybold. Use clean tools and aids only.
Generally the SOGEVAC pumps are supplied already filled with oil. Check the oil level and correct it if necessary. See Operating Instructions for the individu-al pump.
NOTICE
CAUTION
Installation
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3.2 Conforming UtilizationWith the RUTA pump systems you may pump gases and vapours, and evac-uate vacuum chambers well down into the fine vacuum range.
Standard RUTA pump systems are not suited for pumping of: ■ oxygen at levels exceeding the concentration present in the atmosphere, ■ easily flammable, explosive, hazardous or toxic gases, ■ extremely aggressive or corrosive media ■ liquids ■ or solid materials.
Comply with the maintenance intervals as otherwise damage may be caused or leaks may occur at gaskets, bellows or at the exhaust, for example.
3.3 Ambient ConditionsThe ambient temperature must be between 12 °C and 40 °C. For systems within an enclosure, this temperature range must be maintained within the enclosure.
Generally, elevated temperatures will result in shorter intervals for the oil change and increased wear. In addition, it is possible that elastomeric seals in vacuum pumps could over heat leading to possible leaks and possibly the creation of hazardous decomposition products.
Lower temperatures will hamper running up of the pumps. Low ambient tem-peratures can also result in hazards due to the embrittlement of elastomers such as O rings or the condensation of process by products to form hazard-ous liquids.
The air feed and ejection ducts for the motors and the surfaces of the pumps must remain unobstructed and should be kept free of dust and other depos-its.
The system must not be operated under humid ambient conditions and must never be exposed to drip water, 95% max. relative atmospheric humidity. Maximum installation altitude is 1000 meters above sea level.
There must be enough space to operate and maintain the system inasmuch as each component may be disassembled at its location. Ensure access at all times to a possibly fitted electric controller.
All required kinds of energy should be available to a sufficient extent regard-ing type, quality and quantity.
The sucked off gases and possibly present condensate must be removed in a professional manner. This applies also to the gas ballast and/or purge gas if used. Here all relevant statutory rulings must be observed so as to exclude the possibility of injuring persons and damaging the environment.
When using ambient air for gas ballast purposes, the room where the pump is installed must be sufficiently ventilated so as to avoid the creation of a low pressure.
DANGER
Installation
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When installing the pump system in smaller rooms or if the pump system has been encased, ensure an adequate exchange of air.
If gases at high temperatures shall be pumped, check the thermal load on the pump.
3.4 Connecting the Intake and Exhaust LinesIn order to avoid contaminating the inside of the pump chamber, you should only remove the flange covers immediately prior to installation.
In the case of Roots pumps you need to remove the protective foils on the flanges.
If the pipes from the side of the customer‘s system are not to be connected immediately, all open flanges should be sealed so as to avoid contaminating the inside of the pump chamber.
3.4.1 Connecting BellowsWe recommend to connect the pump systems with bellows and vibration absorbers.
Align the bellows. Do not overstress the bellows. Too much stress on the bellows will cause premature failing of the bellows and thus leaks in the system.
■ The bellows may only be fitted and commissioned by trained installation personnel. Proper and professional mounting is an absolute requirement for safe and reliable operation!
■ The connecting pipes must align as precisely as possible. If possible read-just the lines at their supports.
■ If the bellows are equipped with fixed flanges, then their screw holes must align with the screw holes on the piping. The bellows must not be subject-ed to torsion stress.
■ The amount of expansion must not exceed the specified amount of axial expansion/compression or the stated amount of side displacement. A combination of axial expansion/compression and side displacement is possible. The total percentage of the partial expansions must be less than 100%.
■ When using movable pump systems connected to fixed piping, position the pump system as precisely as possible and then reliably secure it in place.
■ When mounting the bellows make sure that no tensions from the side of the pipe can have a torsional effect on the bellows.
■ When lifting equipment is used to mount the bellows, then such equipment must not be attached to sensitive sections like the actual bellows section itself.
■ Run the pressure and leak detection on the system only after the bellows have been properly mounted. The bellows shall be installed so that an unrestricted visual inspection regarding integrity is possible in regular inter-vals.
DANGER
Installation
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■ In the case of deficiencies like indentations, cracks, corrosion, discoloura-tion or irregular deformations, replace the bellows.
■ Insulation must only be attached to the bellows after prior consultation.
■ Avoid pressure bursts in the system.
3.4.2 Intake Line
Do not allow the ingestion of any objects (screws, welding beads, nuts, washers, pieces of wire, etc.) through the intake port of the pump. Objects falling into the pump can cause severe damage at the pump including leaks to atmosphere.
Remove the cap or the protection foil from the intake port. Install the dirt trap at the intake flange of the pump. Connect the intake line using a flexible com-ponent so that it is not subjected to any mechanical stress.
The diameter of the intake line should at least match that of the intake port. An intake line which is too narrow with throttle the pump.
The intake line must be clean. Deposits in the intake line may degas and impair the vacuum or when coming loose may damage the pump. The con-necting flanges must be clean and undamaged.
The flanged connections on the intake side must be leak tested. This applies generally to all seals which are provided, changed or renewed by the cus-tomer.
If the pumped medium contains dust, you must install in addition to the pos-sibly supplied dirt trap a dust filter; however, any installations in the intake line will reduce the pumping speed of the pump system.
When pumping vapours we recommend that you install a condensate sepa-rator on the intake side and also on the exhaust side. Please contact us for more detailed information on this.
NOTICE
Installation
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3.4.3 Exhaust LineRemove the protection cap from the exhaust flange.
Connect the exhaust port to the exhaust line using a flexible component or a flexible hose to ensure that the equipment is not subjected to strain.
The diameter of the exhaust line should at least match that of the exhaust flange. The exhaust line must not be clogged by deposits or blocked. If blocking components are used in the exhaust line, you must ensure that the pump system can not be started up as long as the line remains blocked.
If condensate collects in the exhaust line, then this must be professionally discharged. Ensure that no condensate can flow back from the exhaust line into the pump system.
An exhaust line the cross-section of which is too narrow, can generate overpressures within the backing pump. The possible consequences are damage to the pump, and in extreme cases the pump or the connected lines are endangered by bursting.
The pressure in the exhaust line must be at pressures between 50 mbar below and 200 mbar above atmospheric pressure. If required, suitable pro-tection means need to be provided.
Lay the exhaust line so that it slopes down and away from the pump in order to prevent the entry of condensate into the pump. If this is not possible, install a condensate separator.
If several pumps are connected to a common exhaust line, each pump should be equipped with a non-return flap at its exhaust.
Make sure that the cross section of the common exhaust line is sufficiently large.
The pump systems are usually equipped with exhaust filters which are capa-ble of reliably separating the oil mist even at high throughputs and which will guarantee an exhaust gas which is free of oil mist. In case the exhaust filters get clogged, an overpressure valve will open so that the filters are then bypassed. This will increase the share of oil in the exhaust gas, and oil con-sumption of the pump will increase. Volatile substances may pass through the filter.
WARNING
Installation
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3.5 Connecting Cooling WaterThe pumps are in part supplied by way of a water-cooled version. The cool-ing water connection needs to be done in accordance with the information provided in the individual Operating Instructions. Before commissioning, pos-sibly present gas coolers/condensers must be connected to the cooling water supply and discharge facility.
We recommend the installation of a monitoring facility in the cooling water cir-cuit.
We recommend the use of cooling water of boiler feed water grade (corre-sponding to a hardness of 2 °d). When using cooling water having a hard-ness in excess of 2 °d, you will have to expect at cooling water temperatures over 70 °C a calcification of the heat exchanger.
We also recommend the installation of a dirt sieve in the water feed line and to clean this sieve regularly.
Depending on local regulations, the necessary cooling water must not be taken from the drinking water supply.
Before working on any cooling water lines, it needs to be ensured that these have been depressurised. For this, relief valves need to be provided both in the cooling water feed and also in the cooling water discharge lines.
In order to avoid scalding, let the system to cool down first before starting with any work on the system.
The SOGEVAC pumps have been equipped with thermostatic valves for con-trolling the cooling water quantity. To set up, see the Operating Instructionsfor the SOGEVAC pumps.
3.5.1 Water QualityIn 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 °dH
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
Installation
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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 %.
DS water (softened or fully desalinated water) can be used for cooling the system, if the pH value corresponds to the range indicated above.
3.6 Connecting Compressed Air or Purge GasConnect compressed air or purge gas if required, see Operating Instructions for the individual component.
3.7 Electrical Connection
Note the safety information given in Section 0.2. Disconnect the mains power before doing work on the electrical system. Operate the pumps only at the mains voltage and mains frequency stated on the nameplate of the pump. Lay connecting lines so that they cannot be damaged. Protect the lines against humidity and contact with water.
See enclosed electrical wiring diagrams.
As standard, the pump systems are supplied with a three-phase motor, but without any accessories for the electrical connection. For proper connection in line with the regulations it is required to install a suitable motor protection switch. The setting of this motor protection switch must match the data pro-vided on the name plate of the motor in each case. For details on this please refer to the corresponding Operating Instructions.
After having connected the motor and each time after having made any changes to the wiring check the direction of rotation. See direction indicating arrow on the pump’s housing or at the motor.
In the case of the WS pumps you can not determine the direction of rotation by referring to the rotational direction of the fan.
We recommend the use of a phase sequence tester. If such a phase sequence tester is not at hand you may check the direction of rotation as detailed in the following. During this check the intake should be open.
Risk of suffering injury at the open intake port. Do not reach in to the pump. In case the direction of rotation is wrong, oil may be ejected from the intake of the backing pump and this oil may then enter the Roots pump or the environment.
To check the motor, switch it on only briefly (less than one second). In case it turns in the wrong direction switch the motor off immediately, disconnect the mains supply and interchange two phases at the mains power terminals of the motor.
Prolonged operation with a wrong direction of rotation will result in damage within the vacuum pump.
DANGER
CAUTION
NOTICE
Installation
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Rotary piston pumps E, DKA reverse rotation lock will prevent the pump from running with the wrong direction of rotation.
3.8 Leak Detection after InstallationAfter having completed the installation work we recommend a leak search on the entire pump system. For this we shall be pleased to provide our consult-ing service.
Fig. 3.1 RUTA WAU251/SV100B/A/E
Operation
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4 Operation
Observe Safety Information 0.6.
The pump system must only be operated by duly trained operating personnel.
4.1 Media CompatibilityRUTA pump systems are capable of pumping gases and vapours.
When pumping vapours, the use of the gas ballast facility is mandatory. The quantities of vapour which can be pumped are limited by the vapour toler-ance of the backing pumps. Depending on the type of gases and vapours which need to be pumped, the use of a purge gas will be required.
Standard RUTA pump systems are not suited for pumping of: ■ oxygen at levels exceeding the concentration present in the atmosphere, ■ easily flammable, explosive, hazardous or toxic gases, ■ extremely aggressive or corrosive media ■ liquids ■ or solid materials.
4.2 Start-up
Checks before every Start-up ■ Check the oil level of all pumps: Setpoint between the min. and max. marks.
■ Visually check the oil quality. The oil should be clear.
■ Check if the pump system is leak tight.
You must never switch on a pump system where the pumps are in the overheated state. Upon starting up, the gas in the pumps gets even hotter due to compression. This may mechanically damage the pumps, and the oil or the pumped medium may ignite.
Overheated pumps may be identified through the following: ■ the overtemperature switch has responded ■ dark oil ■ discoloured paint on the pump ■ the motor protection switch has responded
Before switching on again, you must in any case remove the cause for over-heating and let the pump cool down first.
Check the oil level and the condition of the oil, see Operating Instructions for the pumps.
NOTICE
DANGER
NOTICE
Operation
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Open any valves which are blocking the exhaust line. Never operate the pump system with a shut-off exhaust line.
If required switch on the cooling water.
Depending on the type of pump the Roots pump must only be switched on after the backing pump has evacuated the vacuum chamber down to the cut-in pressure.
The maximum cut-in pressure is stated in the individual Operating Instructions.
The pressure switch which possibly has also been supplied, has been set by the manufacturer to the correct pressure. Ensure that this pressure switch has been properly connected. Before starting up, check the operation of the pressure switch.
4.3 Operation
The pumps, pipes, valves and monitoring facilities may during operation attain high temperatures (> 80 °C), so that there exists the risk of receiving burns. The same also applies to the exhaust line.
Pumping of Non-condensable Gases In the case of excess quantities of permanent gases the pump systems may be operated without gas ballast, provided the saturation vapour pressure at the pump‘s operating temperature is not exceeded during the compression cycle.
If the composition of the gases is not known and the possibility of condensa-tion in the pump system can not be excluded, we recommend that you oper-ate the backing pump of the pump system with its gas ballast valve open.
Pumping of Condensable Gases and VapoursWith the gas ballast valve open and at operating temperature, the pump sys-tems are capable of pumping pure water vapour up to the levels given in the technical data (see Operating Instructions for the backing pump).
Here the pressure ahead of the backing pump must be observed. The per-missible pressure ahead of the Roots pump is lower.
If the vapour pressure rises above the permissible value, the vapour will con-dense in the pump‘s oil of the backing pump or already on the discharge side of the Roots pump. A sign for the condensation of vapours in the pump is a rising oil level in the backing pump while it is running.
The (water) vapour tolerance of the pump system may be increased by:
■ increasing the operating temperature and
■ retrofitting a gas ballast facility at the intake of the pump system.
Condensing vapours can damage the pumps.
NOTICE
CAUTION
NOTICE
Operation
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In the case of periodic processes, you should not shut down the pump sys-tem during the breaks between the individual work phases. When the pump system is running at ultimate pressure, energy consumption will be fairly low. You should leave open the gas ballast valve and seal off the intake, preferably with a valve.
Special Operating ConditionsOperate the pump system only under the conditions it has been designed for. When wanting to operate the pump system under special conditions, like intake temperatures in excess of 40 °C, dusty media or corrosive media, you must equip the pump systems accordingly.
Contact Leybold for more information on this.
Operation at Higher Intake PressuresOperation of the pump system between atmospheric pressure and 200 mbar abs. thermally stresses the backing pump and increases oil consumption.
Oil Level CheckThe oil change intervals are given in the corresponding Operating Instructions. Normally the pump oil LVO 100 is light brown. Darkening of the oil indicates premature ageing due to excessively high temperatures or chem-ical reactions with the condensate.
Ultimate Pressure of the Pump System If the specified ultimate pressure levels are not attained, you should measure the ultimate pressure directly at the intake port of the pump system. For this, separate the pump system from the remaining part of the system.
Only compression vacuum gauges or partial pressure gauges are capable of measuring the ultimate pressure of non-condensable gases, i.e. the partial pressure of air. THERMOVAC and similar vacuum gauges with an electrically operated display measure the total pressure. Precise data can only be obtained from calibrated vacuum gauges.
After commissioning, longer breaks or after having exchanged the oil, the pump system will only be able to attain the specified ultimate pressure after some time. The pump system must be at its operating temperature and the pump‘s oil must have been allowed to degas. It is recommended to initially operate the backing pump with its gas ballast valve open.
The ultimate pressure depends on the pump‘s temperature and the oil used in the pump.
Options If the pump has been equipped with additional options, please read the enclosed Operating Instructions.
Operation
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4.4 Shut-off and VentingFirst separate the pump system from the remaining part of the system by means of a valve. Then first switch off the Roots pump and then after a delay (of approximately 2 minutes) the backing pump. Fitted in the intake of the backing pump is an anti-suckback valve or fitted in the system is a SECUVAC valve which upon switching off the pump seals the intake and vents the backing pump itself. This maintains the vacuum in the pump sys-tem. Backstreaming of oil into the connected system is thus also effectively prevented.
After having switched off the pump in the overheated state, you must never switch the pump on immediately again; see Section 4.2.
Leave the cooling water to run for 30 further minutes and then switch off.
If there is the danger of exposure to frost, completely drain out the cooling water.
Before working on any cooling water lines, depressurise these. For this, relief valves need to be provided both in the cooling water feed and also in the cooling water discharge lines.
In order to avoid scalding, let the system to cool down first before starting with any work on the system.
After switching off, parts of the system remain evacuated. Before doing any work on the system, it needs to be vented first.
4.4.1 Shut Down after Pumping Condensable Gases and Vapours When pumping, vapours may dissolve in the pump’s oil. This will change the properties of the oil and there is the risk of corrosion for the pumps.
For this reason, the pumps should never be shut down immediately after ter-mination of the process. Instead leave the pump system running with the gas ballast valve open and the intake sealed off until the oil has been freed of dis-solved vapours.
After termination of the process we recommend that you leave the pump system running for about 30 minutes.
Then switch the pumps off, leave the cooling water to run for 30 further minutes and then switch off.
NOTICE
CAUTION
Operation
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4.4.2 Shut Down after Pumping Aggressive or Corrosive Media and StoringAfter pumping of aggressive or corrosive media we recommend that you leave the pump running also in the case of long process breaks (overnight, for example) with the intake line sealed off and the gas ballast open. This will avoid the occurrence of corrosion at standstill. If the pump system is to be shut down or stored after having pumped aggressive or corrosive media, then you should proceed as follows:
When having pumped hazardous media, take the necessary safety precau-tions.
Drain the oil; see Section 5.4.
Fill in fresh oil up to the lower oil level mark and let the pumps run for some time. Then drain out the oil once more and fill in fresh oil up to the upper oil level mark.
Let the pumps operate for a short while, then switch them off and close down the cooling water supply. Thereafter purge the pump system with dry nitrogen.
Seal off all the ports. The use of special conservation or anti-corrosion oils is not required.
Before transporting the pump system, drain out the oil. For this see the Operating Instructions for the individual pumps.
When the pump system has been used in the process the used oil is con-taminated. You must determine the nature of the hazard and take the appropriate safety precautions. Observe Safety information 0.4. Label the oil containers according to the type of contamination.
DANGER
DANGER
Maintenance
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5 Maintenance
5.1 Leybold ServiceWhenever you send us in equipment, indicate whether the equipment is con-taminated or is free of substances which could pose a health hazard. If it is con taminated, specify exactly which substances are in volved. You must use the form we have prepared for this purpose.
A copy of this form is reproduced at the end of these Operating Instructions: “Declaration of Contamination of Compressors, Vacuum Pumps and Components”. Moreover, you may download a suitable form from the Internet: www.leybold.com Documents Download Documents.
Attach the form to the equipment or enclose it with the equipment.
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 IntervalsSee the table for the recommended maintenance intervals for the pumps. We recommend a service contract with Leybold.
Normal operation is assumed for the recommended maintenance intervals. Frequent malfunctions causing the pumps to shut down often will result in shorter maintenance intervals.
The intervals stated in the maintenance schedule serve only as a guide when operating the pump normally. Bad ambient conditions or pumping of aggres-sive or dusty media may necessitate more frequent maintenance. The main-tenance schedules for the individual pumps must be observed.
Leybold recommends 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 dust. Depending on the findings, changed maintenance and replacement intervals can become necessary for specific components.
Please note the safety information given in Section 0.
All points which are opened on the pump or the vacuum system need to be reliably sealed immediately after having run the maintenance work.
DANGER
Maintenance
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Maintenance work Interval Remarks
Check oil level. Daily
Check the condition of the oil. Depends very much on the condi-tions of the process.
In cases where the oil ages quickly frequently exchange the oil. Find the cause for premature ageing of the oil and - if possible - remedy the fault cause. You may con-sult us in such cases.
1st oil change. After 100 operating hours. Depending on how much the oil has aged, also earlier.
Further oil changes. 1,000 to 3,000 operating hours, at least once a year.
Also more frequently depending on the oil’s condition; also after the pump system has been stored for a longer period of time.
Check the exhaust filter. 1,000 operating hours. Additionally check operation of the exhaust overpres-sure valve.
Check the cooler, if required decalcify (RA shaft cooling); pumps with water cooling only.
2,000 operating hours. More frequently in the case of very hard water or high thermal stress on the pump.
Check the dirt trap and the intake channel, clean as required.
2,000 operating hours depending very much on the conditions of the process.
In the case of deposits install a dust filter in the intake line.
General revision. Annually Run all maintenance work, check all functions, change the shaft sealing rings, grease the bearings (for this refer to the special Operating Instructions for the pumps used).
5.3 Replacing Individual Pumps in the Pump SystemBasically the RUVAC or the backing pump can be changed individually.
We will provide disassembly and assembly information for the individual pumps upon request.
5.4 Oil Change For this always shut down the pump system first and vent it.
Change the oil always while the pump system is still warm and off.
If, due to the type of process there is the danger of oil polymerisation, then you must exchange the oil immediately after shutting down.
Hazardous substances may escape from the pumps and the oil. Take sui-table safety precautions: wear gloves, face protection or breathing protec-tion, for example. Observe the safety regulations.
Unalloyed oil of viscosity class ISO VG 100 (formerly SAE 30) must be used for the pumps. The type of oil required for your pump system is specified in the individual Operating Instructions.
When planning to operate the pumps with other kinds of oil or special lubri-cants please consult us first.
The precise way in which to proceed during an oil change is described in the individual Instructions for the pumps.
DANGER
Maintenance
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5.5 Cleaning the Dirt Trap A wire-mesh sieve is usually located in the intake port of the pump system to collect foreign objects. It should be kept clean in order to avoid a reduction of the pumping speed.
To do so, take off the intake line. Remove the dirt trap from the intake flange and rinse it using a suitable solvent. Then thoroughly dry it with compressed air.
If the dirt trap is damaged, replace it.
While blowing out with compressed air, where protective goggles.
All further maintenance work specifically relates to the individual pumps and is detailed in the corresponding Operating Instructions for the pumps.
For further information or troubleshooting please refer to the Operating Instructions for the installed pumps.
WARNING
Fig. 5.1 RUTA WA 2001/DK 200/G/E with electric controller, mobile
Wearing Parts / Disposal
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6 Wearing PartsRefer to the Operating Instructions and Spare Parts Lists for the individual pumps.
7 Waste DisposalThe equipment may have been contaminated by the process or by environ-mental influences. In this case the equipment must be professionally decon-taminated. 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 precau tions when handling contaminated parts.
Separate clean pump components according to their materials, and dispose of these accordingly. We offer this service. Further details are available on request.
When sending us a pump, observe the regulations given in Section “Leybold Service”.
Disposal of Waste OilOwners 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.
WARNING
Troubleshooting
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8 Troubleshooting
Symptom Possible cause Remedy
Pump of the pump system will not start.
Motor not connected correctly; wrong mains volt-age
Faulty motor or PTC.
Faulty pressure switch (Roots pump).
Oil is too thick, pump is too cold.
Clogged exhaust filter or exhaust line.
Pump has seized; faulty vanes, bearings or toothed wheels.
Connect the motor correctly.
Have the motor repaired or exchanged.
Exchange the pressure switch.
Change the oil or warm up the oil and the pump.
Change the filter and have the overpressure valves repaired. Clean the exhaust line.
Service.
Pump system will not attain its pump-ing speed and its ultimate pressure.
Clogged dirt trap in the intake.
Motor not connected correctly.
Faulty motor.
Leak in the pump or the pump system.
Play of the impellers is too big (Roots pump).
Faulty bearing.
Unsuited or contaminated oil in the backing pump.
Gas ballast valve is open.
Unsuitable method of measurement or vacuum gauge.
Clean the dirt trap.
Connect the motor correctly.
Have the motor repaired or exchanged.
Search the leak and seal it.
Service.
Service.
Change the oil.
Close the gas ballast valve, if possible.
Use correct method of measurement and vacuum gauge.
Pumpdown time of the pump system is too long.
Clogged dirt trap in the intake.
Vacuum lines too narrow or too long.
Too much evaporating liquid in the system.
Clean the dirt trap. Precaution: install a dust filter in the intake line.
Use sufficiently wide and short intake lines.
Check and modify the plant and the process as required.
Pump(s) is/are get-ting hotter than pre-viously observed.
Cooling water not connected, cooling water pres-sure is too low or water feed temperature is to high.
Cooling air supply to the motor is obstructed.
Ambient temperature is too high.
Process gas is too hot.
Unsuited or contaminated oil in the backing pump.
Clogged exhaust filter or exhaust line.
Calcified cooler.
Obstructed oil or cooling water circuit.
Faulty pump.
Oil level too high or too low.
Clean the system, ensure an adequate supply of cool-ing water.
Install the pump properly, clean the cooling fins.
Install the pump properly.
Modify the process.
Change the oil.
Change the exhaust filter, have the overpressure valves repaired, clean the exhaust line.
Decalcify the cooler.
Have the pump repaired.
Have the pump repaired.
Drain or top up oil as required.
Roots pump is get-ting hotter than pre-viously observed.
Pressure differential is too high.
Clearance between casing and rotor reduced by - contamination, - flexing the pump.
Check the pressure levels in the system, set up the pressure switch.
Clean the pump chamber. Install and connect the pump so that it is not mechani-cally strained.
Troubleshooting
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Symptom Possible cause Remedy
Power consumption of the motor is too high.
Like symptom “Pump gets too hot”.
Wrong mains voltage for the motor.
Faulty motor.
Oil too thick, pump too cold.
Like symptom “Pump gets too hot”.
Connect the motor to the correct mains supply.
Have the motor repaired or exchange it.
Change the oil or warm up the oil and the pump.
After shutting down the pump system while evacuated, the pressure in the con-nected system will rise too quickly.
Leak in your system.
Dirty or faulty anti-suckback valve of the backing pump.
Too much evaporating liquid in the system.
Check your system.
Clean the valve or repair it.
Check and if necessary modify your system and the process.
Pump is too loud. Oil level much too low, oil level is no longer visible.
Faulty pump.
Top up oil.
Service, shut the pump down immediately.
Roots pump is too loud.
Clearance between casing and rotor reduced by: - contamination, - flexing the pump.
Damaged bearing or gear.
Impellers hit the casing.
Rotor is unbalanced.
Clean the pump chamber. Install and connect the pump so that it is not mechani-cally strained.
Service, shut the pump down immediately.
Service, shut the pump down immediately.
Service, shut the pump down immediately.
Oil in the intake line or the vacuum chamber.
Oil is coming from your system.
Dirty or faulty anti-suckback valve of the backing pump.
Motor is turning in the wrong direction.
Oil level is too high.
Faulty switching action when operating several pump systems in parallel.
Check your system.
Clean the valve or have it repaired.
Interchange two mains phases on the motor.
Drain out excess oil.
Switch pump systems running in parallel on and off together or separate these by valves.
Oil in the pump chamber of the Roots pump.
Oil level too high.
Pump has an outward leak.
Pump has not been placed horizontally.
Oil is coming from the application.
Pump has an inward leak (failed piston ring seals, for example)
Drain out oil until the oil level is correct.
Check to see if the oil fill plugs are properly seated and exchange the gaskets as required.
Install the pump correctly.
Check the application.
Service.
Oil is turbid or dark. Oil has worn out.
Condensation or particles or chemical reactions in the oil.
Condensation due to a dirty inlet filter of the gas ballast.
Pump gets too hot.
Change the oil.
Degas the oil or change the oil and clean the pump. Precaution: open the gas ballast valve, gas ballast facility for the fine vacuum stage, install separators and/or suitable filters.
Clean the inlet filter of the gas ballast, degas or change the oil.
See symptom “Pump gets too warm” and after having remedied the fault change the oil.
Troubleshooting
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Symptom Possible cause Remedy
Rising oil level in the backing pump.
Oil or other liquids are coming from the applica-tion.
Condensation in the backing pump or in the Roots pump.
Reverse flow of condensate in the exhaust line.
Installed condensate separators are overfilled.
Faulty switching action when operating several pump systems in parallel.
Valves in the intake line open too rapidly.
Leaky cooler.
Check the application.
Degas the oil or change the oil and clean the pump. Precaution: open the gas ballast valve, gas ballast facility for the fine vacuum stage and/or install separa-tors or condensers. Check the process.
Lay the exhaust line so that it slopes down and away or install a condensate separator.
Empty the condensate separator.
Switch pump systems running in parallel on and off together or separate these by valves.
When pumping large quantities of vapour, open the valves in the intake line slowly.
Have the cooler repaired.
Fig. 6.1 RUTA WAU 2001/DK 200/G/E
Notes
38 17200207_002_C0 - 09/2016 - © Leybold
3917200207_002_C0 - 09/2016 - © Leybold17200001_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 hasbeen 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 markAddress : 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 Yes2. 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 declarationI / 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
HeadquarterLeybold GmbHBonner Strasse 498D-50968 CologneT: +49-(0)221-347-0F: +49-(0)[email protected]
GermanyLeybold GmbHSales, Service, Support Center (3SC)Bonner Strasse 498D-50968 CologneT: +49-(0)221-347 1234F: +49-(0)221-347 [email protected]
Leybold GmbHSales Area NorthBranch Office BerlinIndustriestrasse 10bD-12099 BerlinT: +49-(0)30-435 609 0F: +49-(0)30-435 609 [email protected]
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Leybold Dresden GmbHService Competence CenterZur Wetterwarte 50, Haus 304D-01109 DresdenService:T: +49-(0)351-88 55 00F: +49-(0)351-88 55 [email protected]
Europe
Belgium
Leybold Nederland B.V.Belgisch bijkantoorLeuvensesteenweg 542-9AB-1930 ZaventemSales:T: +32-2-711 00 83F: +32-2-720 83 [email protected]:T: +32-2-711 00 82F: +32-2-720 83 [email protected]
France
Leybold France S.A.S.Parc du Technopolis, Bâtiment Beta3, Avenue du CanadaF-91940 Les Ulis cedexSales and Service:T: +33-1-69 82 48 00F: +33-1-69 07 57 [email protected]@leybold.com
Leybold France S.A.S.Valence Factory640, Rue A. BergèsB.P. 107F-26501 Bourg-lès-Valence CedexT: +33-4-75 82 33 00F: +33-4-75 82 92 [email protected]
Great Britain
Leybold UK LTD.Unit 9Silverglade Business ParkLeatherhead RoadChessingtonSurrey (London)KT9 2QLSales:T: +44-13-7273 7300F: +44-13-7273 [email protected]:T: +44-13-7273 7320F: +44-13-7273 [email protected]
Italy
Leybold Italia S.r.l.Via Trasimeno 8I-20128 MailandSales:T: +39-02-27 22 31F: +39-02-27 20 96 [email protected]:T: +39-02-27 22 31F: +39-02-27 22 32 [email protected]
Netherlands
Leybold Nederland B.V.Floridadreef 102NL-3565 AM UtrechtSales and Service:T: +31-(30) 242 63 30F: +31-(30) 242 63 [email protected]@leybold.com
Switzerland
Leybold Schweiz AG, PfäffikonChurerstrasse 120CH-8808 PfäffikonWarehouse and shipping address:Riedthofstrasse 214CH-8105 RegensdorfSales:T: +41-44-308 40 50F: +41-44-302 43 [email protected]:T: +41-44-308 40 62F: +41-44-308 40 [email protected]
Spain
Leybold Spain, S.A.C/. Huelva, 7E-08940 Cornellà de Llobregat(Barcelona)Sales:T: +34-93-666 43 11F: +34-93-666 43 [email protected]:T: +34-93-666 46 11F: +34-93-685 43 [email protected]
AmericaUSA
Leybold USA Inc.5700 Mellon RoadUSA-Export, PA 15632T: +1-724-327-5700F: [email protected]:T: +1-724-327-5700F: +1-724-333-1217Service:T: +1-724-327-5700F: +1-724-325-3577
Brazil
Leybold do BrasilRod. Vice-Prefeito Hermenegildo Tonolli,nº. 4413 - 6BDistrito IndustrialJundiaí - SPCEP 13.213-086Sales and Service:T: +55 11 3395 3180F: +55 11 99467 [email protected]@leybold.com
AsiaP. R. China
Leybold (Tianjin)International Trade Co. Ltd.Beichen EconomicDevelopment Area (BEDA),No. 8 Western Shuangchen RoadTianjin 300400ChinaSales and Service:T: +86-22-2697 0808F: +86-22-2697 4061F: +86-22-2697 [email protected]@leybold.com
India
Leybold India Pvt Ltd.No. 82(P), 4th PhaseK.I.A.D.B. PlotBommasandra Industrial AreaBangalore - 560 099IndienSales and Service:T: +91-80-2783 9925F: +91-80-2783 [email protected]@leybold.com
Japan
Leybold Japan Co., Ltd.HeadquartersShin-Yokohama A.K.Bldg., 4th floor3-23-3, Shin-YokohamaKohoku-ku, Yokohama-shiKanawaga 222-0033JapanSales:T: +81-45-471-3330F: [email protected]
Leybold Japan Co., Ltd.Tsukuba Technical Service Center1959, Kami-yokobaTsukuba-shi, Ibaraki-shi 305-0854JapanService:T: +81-29 839 5480F: +81-29 839 [email protected]
Malaysia
Leybold MalaysiaLeybold Singapore Pte Ltd.No. 1 Jalan Hi-Tech 2/6Kulim Hi-Tech ParkKulim, Kedah DarulAman 09000MalaysiaSales and Service:T: +604 4020 222F: +604 4020 [email protected]@leybold.com
South Korea
Leybold Korea Ltd.3F. Jellzone 2 TowerJeongja-dong 159-4Bundang-gu Sungnam-siGyeonggi-doBundang 463-384, KoreaSales:T: +82-31 785 1367F: +82-31 785 [email protected]:623-7, Upsung-DongCheonan-SiChungcheongnam-DoKorea 330-290T: +82-41 589 3035F: +82-41 588 [email protected]
Singapore
Leybold Singapore Pte Ltd.8 Commonwealth Lane #01-01Singapore 149555SingaporeSales and Service:T: +65-6303 7030F: +65-6773 [email protected]@leybold.com
Taiwan
Leybold Taiwan Ltd.No 416-1, Sec. 3Chunghsin Rd., ChutungHsinchu County 310Taiwan, R.O.C.Sales and Service:T: +886-3-500 1688F: +886-3-583 [email protected]@leybold.com
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