CVS WR Operating Manual 2500 3100 4000
Contents
1. A Process water outlet temperature 30 C Water loss Liter h per 100 m3 h intake volume flow O m CO A Ci OQO N O CO sa 200 300 400 500 600 700 800 900 1000 Intake pressure mbar Fig 2 Process water delivery Fig 2 shows the process water delivery from the reservoir for an intake volume flow of 100 m h as a function of intake pressure and process water temperature Typical process water loss calculation amp Type WR 3100 Intake pressure 400 mbar Intake volume flow according to Tab 3 2427 m h Process water outlet temperature 50 C Water loss for intake pressure and process water outlet temperature according to Fig 2 2 1 l h pro 100 m h intake air Process water loss 2e etel 50 97 h In operation with cell ventilation the process water loss is increased as a function of the additional air throughput 20 Operating instructions Liquid ring compressor vacuum pump VacuStar WR j Le j i IL AV Ta ST al ME Manufacturing Design and function 4 3 Control and display elements Depending on the installation situation different display elements Such as pressure gauge temperature gauge and negative pressure display are mounted 21 j Operating instructions Liquid ring compressor vacuum pump VacuStar WR Manufacturing 1 p rs ET s yl t Transport and storage 5 Transpo2. Therefore Before starting any work first depressurise pressurised components Pay attention to accumulators Accumulator pressure must also be completely relieved Do not change pressure settings beyond the maximum values WARNING Risk of injury by illegible signs or labels Labels and signs can become dirty or unrecognisable in the course of time Therefore Always keep safety warning and operation instructions in a well legible condition Immediately replace damaged or obliterated signs or labels 14 i Ez i TR iS ICA I I Im if fT Al AN j Vx AES D A ee p x NOS Manufacturing Improper transport Start up operation Er A Operating instructions Liquid ring compressor vacuum pump VacuStar WR A Safety Danger Danger by falling down or tilting of the machine The weight of the machine may injure a person and cause serious bruising Therefore Depending on the dead weight and size of the machine use a pallet on which the machine can be moved by means of a fork lift For lifting the machine use suitable lifting gear sling etc that is designed for the weight of the machine When putting the slings in position take care to avoid putting stress on individual components Only use eye bolts provided for that purpose See page 19 Fig 1 Pos 8 WARNING Risk of injury due to improper start up and operation Improper start up and op
3. 1 min 1600 1300 1300 m h 2500 3100 4063 kW 73 88 117 m h 2016 2427 3521 kW 61 76 107 5 kW 77 94 131 5 m h 1936 2469 3496 dB A 70 72 73 17 Operating instructions Liquid ring compressor vacuum pump VacuStar WR Technical Data VacuStar process water circulation unit Unit WR2500 WR 3100 WR 4000 Maximum process water inlet temperature VacuStar C 55 pH value 5 8 Process water circulating quantity in vacuum operation l min 70 90 70 90 70 90 at 400 mbar 1 Excess pressure 0 bar 2 Vacuum 0 mbar 3 Based on a radiator of a specific cooling capacity Pspez 3 5 kW m e P spez Pap i Wasser ein l Luft ein Akunter 4 Heat to be dissipated for operation with water vapour saturated air on request Tab 4 Process water circulation 18 Operating instructions Liquid ring compressor vacuum pump VacuStar WR Design and function 4 Design and function 4 1 Design Fig 1 Design 1 Drive shaft 6 Rating plate 2 Connection process water 7 Rotation arrow 3 Connection cell ventilation 8 Thread for eye bolt 4 Connecting flange for pressure or suction 9 Fixing foot connection flange DIN 28459 125 10 Process water indicator 5 Process water draining 11 Liquid supply for slide ring seals 4 2 Function VacuStar The liquid ring pump works according to the positive displacement principle At a sufficiently high speed a rotating liquid ring is formed in the c
4. p F P al n A F FI 2 AX B Operating instructions Liquid ring compressor vacuum pump VacuStar WR Index J mp p p Manufacturing Switching Off EEE 24 TN aea a ee ener eee 22 T W Technical Data rrrnnnrornnnnoonrnnnnvrnnnnnvnnnnnnnnnnnnre 17 AS Ud E VE 7 8 35 36
5. V belt and V belt tension re tension if necessary Monthly Check fastening screws and tighten if necessary Operator Quarterly Check cell ventilation valve opecialised staff Half yearly Check non return valve of VacuStar opecialised staff 5000 hrs or 3 years Replace permanent grease filling Specialised staff 15 000 hrs 10 000h Replace roller bearings Specialised staff 15 000 hrs 10 000h Replace shaft sealing rings Specialised staff 15 000 hrs 10 000h Replace slide ring seals Specialised staff Values in apply for WR 4000 7 3 Performance of maintenance work Cleaning the VacuStar Carrying out cleaning work 1 Switch off system and secure against restarting 2 Remove soiling appropriately Observe the following E Do not use aggressive cleaning agents m After cleaning work check that all previously opened covers and safety equipment are correctly installed and function correctly Clean process water radiator Clean radiator cooling fins cooling air must have a free flow through the radiator cooling fins Process water circulation Scale all parts carrying process water if necessary Action after lengthy standstill See chapter 6 4 27 Operating instructions Liquid ring compressor vacuum pump VacuStar WR Maintenance P gt Manufacturing Roller bearings lubrication Replace permanent grease filling of the roller bearings either after 5000 hrs or 3 years Prior to a replacement remove old grease and clean bearing
6. are collected and disposed of in an environmentally compatible manner The machine may only be opened for Ex maintenance and repair work by specialised staff if the machine is stationary and no potentially explosive atmosphere is present 13 Cs po Fs iTS UN i cS fe Ti FAIT GEN GT Eo EA li I fell pA J j j Ji Operating instructions Liquid ring compressor vacuum pump VacuStar WR Ne UC UC e UU Lour NI ELLA A Safety Moving components Compressed air Signposting A A ET NA A ES Manufacturing WARNING Risk of injury by moving components Powered rotating components can cause the most serious injuries Therefore during operation Itis absolutely forbidden for persons to stay in the hazard area or in the immediate vicinity Do not put safety devices and or functions out of operation and do not render them inoperative or bypass them Never reach into open outlets and inlets or into running equipment Before entering the hazard area Switch off power supply and secure against restarting Wait for standstill of lagging components Wait for automatic dissipation and or discharge of residual energies compressed air WARNING Risk of injury due to compressed air Pneumatic energies can cause the most serious injuries In case of damage to individual components air can be discharged under high pressure and injure e g the eyes
7. be forfeited in such case The operator alone shall be responsible for any damage arising from improper use 2 2 1 Acceptance and monitoring The VacuStar W itself is not subject to any acceptance and monitoring obligation 2 3 Operator s responsibility The machine is used for industrial purposes The operator of the machine is therefore subject to the legal obligations concerning occupational safety The provisions valid at the place of installation as well as the safety and accident prevention regulations of the Institution for statutory accident insurance and prevention must be observed The operator must in particular E inform himself on the valid industrial safety regulations E determine the additional hazards that arise from the special working conditions at the machine s place of installation by means of a hazard assessment E implement the necessary rules of conduct for operation of the machine at the place of installation by means of user instructions m check at regular intervals during the machine s entire period of use whether the user instructions correspond to the current state of the body of rules and regulations E adapt the operation instructions if necessary to the new regulations standards and operating conditions m clearly regulate the responsibilities for installing operating maintaining and cleaning the device E ensure that all employees working on or with the machine have read and understood the
8. extraction of filtered air or filtered water saturated air The VacuStar WR in the explosion proof design complies with Directive 94 9 EC ATEX and is suitable for conveying explosive gases and gas mixtures of explosion group IIB temperature class 15 from explosive zone 1 and zone 2 areas No explosive atmosphere is allowed in the area around the VacuStar WR The vacuum pump may only be opened when it is stopped and when there is no explosive atmosphere around Labelling of the machine on the rating plate Il 2G ck IIB T5 i Zone 1 and Zone 2 inside no explosive atmosphere outside In temperature class T5 the gas temperature is limited to 95 C and must be secured 2 2 Intended use The following criteria in essence define the proper operation Technical Data in Table 2 Solids may not be sucked into VacuStar If explosive gases or gas mixtures are conveyed the following regulations have to be observed 94 9 E6 ATEX 95 Requirement on equipment 99 92 E6 ATEX 137 Assembly installation and operation of equipment Only use machine for the intended use All specifications in these operating instructions have to be strictly complied with technical data ATEX regulations etc F rT Fi MT GIN i f ear J Vi LG i Operating instructions Liquid ring compressor vacuum pump VacuStar WR 3 EY FE CLA D ILL S STI AR Manufacturing Safety Any warranty claims shall also
9. fabric filter cartridge with detergent Carefully rinse out filter cartridge with fine filter cartridge Check for damage after cleaning Replace defective cartridge Check round sealing ring on casing lid for damage Damaged sealing rings must be replaced After cleaning reassemble the filter in reverse order Fig 3 Suction filter 1 NO Star handle 4 Air inlet soiled air Casing 5 Air outlet filtered air Filter cartridge 29 Operating instructions Liquid ring compressor vacuum pump VacuStar WR p Malfunctions 8 Malfunctions Personal Personal protective equipment Environmental protection Conduct in case of malfunctions s uet i ERR DANTA This chapter describes possible causes of malfunctions and trouble shooting tasks Reduce the maintenance intervals if similar malfunctions occur repeated due to above average intensive use so intervals correspond to the actual load If malfunctions cannot be corrected due to the notes contact the manufacturer 3 p 2 See chapter 2 6 Occupational safety and special risks m The trouble shooting work describes at this point can be carried out by the operator unless otherwise indicated m Some work may only be carried out by specially trained specialised staff or exclusively by the manufacturer himself This is specifically pointed out in the description of the individual malfunctions Only electrical specialists may carry out work on the electrical
10. operating instructions In addition he must at regular intervals train the employees in how to deal with the machine and inform them about potential hazards In addition it is the operator s responsibility to ensure that E the machine is always in a technically perfect condition m the machine is maintained in accordance with specified maintenance intervals E all safety equipment is regularly checked for completeness and correct functioning 10 Sas A aS I P T ff i f i i Pa i AN j iif Fj i J i j i E l i ri Operating instructions Liquid ring compressor vacuum pump VacuStar WR Safety mmm ms f Manufacturing 2 4 Operating personnel 2 4 1 Requirements WARNING Risk of injury in case of inadequate qualification Improper handling can lead to considerable bodily injuries and property damage Therefore Have any activities only carried out by the individuals designated for that purpose The operating instructions specify the following qualification requirements for the different fields of activity E Instructed persons have been instructed during instructions provided by the operator with regard to the work assigned to them and possible hazards arising from improper conduct E Specialised staff is due to its technical training knowledge and experience as well as due to its knowledge of the pertinent regulations able to carry out the work assigned to it and
11. PIRUINLANID Est 1957 Manufacturing Operating instructions Liquid ring compressor vacuum pump VacuStar WR 2500 WR 3100 WR 4000 Doc ID 5041 01 11 10 2010 BA EN Release 10 2010 The operating instructions must be read by the machine operator prior to start up Fruitand Manufacturing www fruitlandmanufacturing com 905 662 6552 1 800 663 9003 324 Leaside Ave Stoney Creek Ontario Canada L8E 2N7 Fruitland Manufacturing 324 Leaside Ave Stoney Creek Ontario Canada L8E 2N7 Toll Free 1 800 663 9003 Telephone 905 662 6552 Email sales fruitland mfg com Website www fruitlandmanufacturing com CVS engineering GmbH Grossmattstrafse 14 D 79618 Rheinfelden Germany Phone 49 0 7623 71741 0 Customer service 49 0 7623 71741 31 E mail info cvs engineering de Internet www cvs eng de il en dr ak al as c TTS FS RM P FS Haj i 1 f iia i ff FAN F Li Pr a tn f Pi i L LA L Hi ror wd UN Manufacturing or XT J E I E 1 er Operating instructions Liquid ring compressor vacuum pump VacuStar WR Contents Contents ce 3 1 Bee 5 1 1 Information regarding the operating instructions 5 1 2 Pictogram explanation rrnrnnnnrnnnnnnrvrnnnnrennnnnenvnnenennnn 6 3 Limitation PADI Lassen 7 4 oem NR 7 15 Spare PAUS e 8 1 6 Warranty terms rrrrnnnnvnrnnnrvrvnnnnrvvnnnnrrnnnnrenvnnrrennnnenennnnn 8 1 7 Customer SEIVICE vitiiicccasin
12. Remove emerging used or excessive grease at all lubricating points that are manually supplied with lubricant and dispose of in accordance with valid local regulations The following describes the maintenance work that is necessary for an optimum trouble free operation Maintenance intervals must be observed If increased wear of individual components or functional groups is determined during regular inspections the operator has to reduce the required maintenance intervals on the basis of the actual signs of wear Changes compared to the normal operation increased power consumption temperatures vibrations noises etc or respond of monitoring systems lead to the assumption that the functions are impaired These then have to be subjected to an inspection by specialised staff In case of queries regarding the maintenance work and intervals contact the manufacturer service address page 2 For maintenance schedule refer to next page 26 All JE l A M i LE j i IL fel bt Air Manufacturing Fy 4 ERI a M N li TE A p IA Ji D Operating instructions Liquid ring compressor vacuum pump VacuStar WR JE Manufactuniig Maintenance hu Table Maintenance schedule Interval Maintenance work To be carried out by Check safety valve Check water stop valve Clean cooling unit process water cooler Weekly Clean VacuStar Operator Clean vacuum filter Clean cell ventilating filter replace if damaged Check
13. Ventilating valve A ventilating valve can be installed on the suction side to secure the installation When the set vacuum is reached the ventilating valve opens and admits atmospheric auxiliary air into the system Non return valve in the suction line The non return valve is maintenance free but is subject to wear of the VacuStar like all other moving parts We recommend a visual control every 6 months In this connection the non return valve must be dismantled cleaned freed of deposits and checked for freedom of motion Worn out non return valves must be replaced Inspection of cell ventilation For a save operation the VacuStar must be equipped with cell ventilation see Page 19 Fig 1 Pos 3 If there is ventilation from the atmosphere the suction filter sucks fresh air The filter must be cleaned weekly and replaced in case of visible damage Inspection of the VacuStar drive For this observe the instructions of the installer regarding the drives in use e g hydraulic motor V belt drive 25 Operating instructions Liquid ring compressor vacuum pump VacuStar WR p Maintenance 7 Maintenance 7 1 Safety Personal protective equipment Environmental protection 7 2 Maintenance schedule r Er i j I W he s uet i ERR DANTA See chapter 2 6 Occupational safety and special risks See chapter 2 5 Observe the following information with regard to environmental protection during maintenance E
14. asing In conjunction with the impeller cells form that are separated from each other and steadily grow sucking or shrink compressing with each revolution Lubrication All moving parts are without contact The lubrication of the machine is limited to the impeller bearing The bearings are fitted with permanent grease Cooling The unit is cooled by the process water and or the liquid ring A radiator in the process water circulation dissipates the heat to the environment EET PITCH RITT Operating instructions Liquid ring compressor vacuum pump VacuStar WR Sem USG DV bat VER i 1 Ns Manufacturing Design and function Shaft sealing Maintenance free slide ring seals separate the working space from the bearings and or the atmosphere Sense of rotation oee rotation arrow Page 19 Fig 1 Pos 7 Process water circulation and cell The air flowing through the VacuStar absorbs humidity from the ventilation liquid ring and is 10096 saturated when it exits Only the water drops are separated in the reservoir The steam component is dissipated to the environment Process water consumption Intake conditions 17 Air intake temperature 20 C relative humidity of air 60 15 H gt Process water outlet temperature 70 C 14 O Process water outlet temperature 60 C 13 i Process water outlet temperature 50 C LL Process water outlet temperature 40 C
15. ausnanavadoundsvaredcevanwneiaaavadetenienns 8 2 DUM E Mem 9 27 DE 216 10 kok RE E FUNIS 9 2 2 Jjntended USG nccsicsievescise sannneaunnnwoueiidvansineusnaceecnceeanneesiecesenton 9 2 2 1 Acceptance and monitoring 10 2 3 Operators responsibility ssesuusse 10 2 4 Operating personnel eeeeesesseeeeenreeeeneee 11 2 4 1 Requirements eeeeseesreeenneee nn 11 2 5 Protective Equipment eeeeeeesssesees 11 2 6 Occupational safety and special dangers 12 3 Technical Data sessiones iuda vise iacitaucU vidt Dnizec Dati ne 17 Design and function eeeeeeeee eene nne 19 XA D D o a 19 que FN 19 4 3 Control and display elements 21 5 Transport and Storage rannunnnnennnnnnnnnnnnnnnnnnnnnnennnnennnnnnnnennnr 22 5 1 Safety notes for the transport 22 B MEMNIC c o mRTT 22 SS SO NOTET 22 6 Start up and operation sse 23 EL NN 23 Dr NN 23 63 NT 24 6 4 Inspections to be performed at standstill 25 7 lice UNIT 26 G Eee 26 7 2 Maintenance schedule rarrarranennarnernanerrnunennnnnennenene 26 7 3 Performance of maintenance work 27 Operating instructi
16. d operation ANS Manufacturing LJ Inspection during operation The following inspections have to be carried out during operation m During operation the liquid level must not fall below the minimum mark in the reservoir m Always turn he four way cock until it hits the stop Intermediate positions are not permitted m Pay attention to abnormal noise and leaks during operation owitch off the machine if necessary E Check function of installed cell ventilation the machine must run smoothly when the suction valve is closed Checking the operating data E Rotation speed has to be between 800 1600 min WR 2500 WR 3000 resp 800 1300 min WR 4000 m The cooling water temperature return flow to the cooler must not exceed 60 C m Check positive working pressure at the pressure gauge permissible pressure refer to rating plate E Operating vacuum at the vacuum meter permissible vacuum refer to rating plate Inspections if explosive gases and DANGER gas mixtures are conveyed There is mortal danger in case of insufficient inspections The following points must be observed when explosive gases and gas mixtures are conveyed Prior to every machine start and during operation Check process liquid levels VacuStar and reservoir Check system for leaks Listen for abnormal noise during the suction process Switch off the machine if necessary Check the machine at regular interva
17. d with consideration to the valid standards and regulations the state of the art as well as to our long standing knowledge and experience The manufacturer is not liable for damages caused by Non observance of the operating instructions Improper use Deployment of non trained personnel Arbitrary modifications Technical changes Use of non approved spare and wear parts The actual scope of supply may differ from the explanations and illustrations described in this manual in case of special designs if additional order options are made use of or due to latest technical changes Incidentally the responsibilities agreed upon in the delivery contract the general terms and conditions as well as the manufacturer s conditions of delivery and the statutory provisions valid at the time of contract conclusion shall apply Warranty The manufacture guarantees the correct functioning of the applied process technology and the performance parameters identified The warranty period commences on the date the machine is delivered to the customer 1 4 Copyright Surrendering the operating instructions to third parties without written permission of the manufacturer is not permitted NOTE Content details texts drawings pictures and other illustrations are protected by copyright are subject to industrial property rights Any improper use shall be liable to prosecution Any type and form of duplication also of extracts as well as the expl
18. eration can lead to serious bodily injuries or property damage Therefore Have all work during initial operation exclusively performed by the manufacturer s employees or by his authorized representatives or by trained personnel Start up and operation may only be performed by adequately qualified personnel that has been authorised and instructed by the operator Before the start of any work ensure that all covers and protective devices are correctly installed and function correctly Never override any protective equipment during operation Pay attention to tidiness and cleanliness in the working area Loosely stacked or scattered components and tools are accident sources 15 Operating instructions Liquid ring compressor vacuum pump VacuStar WR Eh sa Safety Electrical system Maintenance and trouble shooting A A det Fu TE n k io n I fi d BE 4 FAIT a E d ES EA li I i ft eat keg ET NA A ES Manufacturing DANGER Mortal danger due to electric current There is mortal danger in case of contact with live components Activated electrically driven components can start to move uncontrolled and cause severest injuries Therefore Switch off the electric power supply before commencing any work and secure against restarting Work on the electrical system on individual electrical components and on the connections may only be car
19. heck re cooling or water Specialised high quantity staff Abnormal noise Machine is out of alignment Align machine accurately Specialised emission staff Bearing defective Replace bearing or have it replaced Speed incorrect Maintain speed Operator Pressure incorrect Maintain nominal pressure Operator Vacuum incorrect Maintain nominal vacuum Operator check exhaust system and clean if necessary Process water temperature too Check re cooling or water Specialised high quantity staff Process water highly Replace process water Specialised contaminated with particles staff Foreign matter in the machine Remove foreign matter Specialised Rinse the machine staff Non return valve rattles Check non return valve Specialised staff Cell ventilating valve does not Check cell ventilating valve Specialised open staff Operating Pressure gauge or vacuum Replace pressure gauge or Specialised pressure or meter indicate incorrectly vacuum meter staff operating vacuum V belts are slipping Check v belt tension and re Operator Is not obtained tension if necessary Four way cock in wrong position Correctly adjust four way cock Operator Process water quantity too small Fill in correct process water Operator quantity 31 mE qs fes fe m HP TIT AN INT Operating instructions Liquid ring compressor vacuum pump VacuStar WR Eh Usa NEN C mI E ru Malfunctions P Ny Manufacturing Malfunction Possible cause Corrective action Execution Cooling
20. ls daily for signs of overheating and exceptional deformations If necessary switch off the machine or do not put into operation 6 3 Switching off To switch off the VacuStar proceed as follows m Switch off the drive to the VacuStar Close the shut off valves if available E Drain the safety tank Tank may not be under pressure then 24 2I HP HE iL HE gm FANN JD Operating instructions Liquid ring compressor vacuum pump VacuStar WR Ira EJ TX Manufacturing Start up and operation N he J 6 4 Inspections to be performed at standstill Process water liquid level The permanent water loss leads to a low process water level in the system Prior to every start check the fill level in the reservoir of the VacuStar Process water pH value E Depending on the conveyed medium the steady water delivery can lead to an increased concentration of harmful substances and thus to a change in the ph value E The permissible pH value of 5 to 8 must be checked at regular intervals e g using litmus papyri according to the operation experience Safety valve The safety valve is no regulating device The operational capability must be checked on start up and later at weekly intervals The safety valve must be secured against maladjustments Blocking or manipulating the safety valve can have penal consequences if it gives rise to an accident Any warranty claims shall also be forfeited in such case
21. nnnnennnnnnnnnnene 14 Emission protection Process water consumption 20 pU Process water delivery e 20 Function 19 Proper operation cccsesceccseeeeeeeeeeeeeeaeeeeseneeees 9 E PAO e 11 22 23 26 30 R Improper operation eeeseeeeerreeeeene 13 l m Roller bearings LUDHCAUOI NE RET EE 28 Cell SPU E m 25 Drive o5 EE 9 28 S Non return valve eeeeeeeeeeeeeeenee 25 eret TET SE a a dates suse l Process water liquid level 25 d Sense of rotation rrrnrrrrrrrrrrrnnnnnrrrrnnrrnnnnnnnnee 20 Process water pH value 25 Shaft sealing rrnnrnnrrannnnnvvvnvrrnnnnnnnnsvnnnnnnnnnnnee 20 Safety VANG M 25 2n SIOEHIDOS LIC OE 14 Ventilating valve eeeeeseeeeess e 25 l l l Spare P SE sug e aq ala arta ever eda ED C rU 8 33 Inspections during operation 24 m l l Specialised staff rrrrnrrnnnrnrrnrnnnnrnornrnnnnnennnnnn 11 Inspections to be performed at standstill 25 l l l l l Standstill lengthier rrrrrrrnrrrerrrnnnrnrvrrrnnnnnvenn 27 Inspections if explosive gases and gas mixtures are conveyed EMEN 24 otart up Trenes 23 Instructed persons o on 11 O E EE EEE 22 34 ii h a i Til LE E
22. oitation and or communication of the contents are not permitted without the manufacturer s written declaration of consent Ae m r FR pP I I at 3 Operating instructions Liquid ring compressor vacuum pump VacuStar WR SL Ir PR a B 1L 259 MIB General LAN Manufacturing 1 5 Spare parts WARNING Risk of injury by incorrect spare parts Incorrect or faulty replacement parts may cause damage faulty function or total breakdown as well as impairing safety Therefore Use only the manufacturer s original spare parts Procure spare parts from authorised dealers or directly from the manufacturer Refer to page 2 for address 1 6 Warranty terms Warranty terms see General Terms of Sale 1 7 Customer service Our customer service can be contacted for any technical advice Information about the responsible contact person can be retrieved by telephone fax email or via the Internet at any time refer to manufacturer s address on page 2 Eon ANT A j FA JJ B FERNI i BESTE Operating instructions Liquid ring compressor vacuum pump VacuStar WR 4 DA Ny Manufacturing Safety J 2 Safety 2 1 Intended use WARNING Risk of explosion The type WR 4000 will be available in explosion proof design from 2011 Therefore Do not use type WR 4000 in explosive atmosphere up to this date The machines of the VacuStar WR series are exclusively intended for the compression or
23. on Warning notes Warning notes are characterised by pictograms in these operating instructions The warnings are introduced by words which indicate the extent of the hazard It is absolutely essential to observe the notes and to proceed with caution in order to prevent accidents as well as bodily injuries and property damage Danger points to an immediate dangerous situation which will lead to death or serious injuries i fit is not avoided WARNING points to a potentially dangerous situation which may lead to death or serious injuries i fit is not avoided ATTENTION points to a potentially dangerous situation which may lead to minor or light injuries if it is not avoided CAUTION points to a potentially dangerous situation which may lead to property damage it is not avoided SAFETY NOTE ATEX Only for machines with Ex approval This icon shows the special conditions that must be observed adoring to the approvals when conveying explosive gases and gas mixtures Hints and recommendations NOTE highlights useful hints and recommendations as well as information for an efficient and trouble free operation e OG BP BP PB Pen mSPH ARNT nai i iauid ri E NL R NY B Operating instructions Liquid ring compressor vacuum pump VacuStar WR General A Manufacturing eas 1 3 Limitation of liability All specifications and notes in these operating instructions were compile
24. ons Liquid ring compressor vacuum pump VacuStar WR S Manufacturing Contents 8 Malfunctions avavnvnunvnununnnnnnnnnnnnnnnnnunnnnnvnnnnnnnnnnnnnnnnnnnnnnnnvnnn 30 8 1 Recommissioning after corrective action or trouble SOO 0 EN 31 8 2 Malfunction table rrrrrrrnnrrvrrrnnnrnvvvrrnnnrrrnnrnnnenrennnnn 31 9 SPA ene er aren ene eee eens eee 33 10 Decommissioning and disposal 33 PR GY Ua Operating instructions Liquid ring compressor vacuum pump VacuStar WR UN Manufacturing General 1 General 1 1 Information regarding the operating instructions These operating instructions provide important information on how to deal with the machine Prerequisite for safe working is the observance of all specified safety notes and instructions In addition the local accident preventions regulations valid at the machine s area of application and general safety regulations have to be complied with Carefully read the operating instructions before starting any work They are part of the product and must be kept near to the machine and accessible to the personnel at all times When passing the machine on to third parties the operating instructions must also be handed over u 1 n ial J f mE nw EE fj If T Al AN 7 h Operating instructions Liquid ring compressor vacuum pump VacuStar WR Eh Ve V PTUS TIAST P ES Manufacturing General 1 2 Pictogram explanati
25. pressor vacuum pump VacuStar WR 3 m a N Manufacturing Safety Hazard notes and occupational safety For your own safety and that of the machine the following information must be observed and complied with Improper operation DANGER Danger due to improper operation Only use machine in a perfect technical condition Malfunctions that are relevant for safety have to be promptly eliminated Conversions of the machine are not permissible and can impair safety Never bridge any safety equipment or put it out of operation Any work on the machine and or on electrical equipment must be carried out by specialised staff Repair and maintenance work may only be carried out when the machine is stationary Secure the machine against restarting the machine may not be under pressure or negative pressure while work is being carried out on it Close shut off vane on vehicle side and ventilate line between machine and shut off vane or drain excess pressure manually from safety valve Observe pressure gauge indication the driver s protective equipment may only be removed when the machine is stationary and has to be correctly refitted after completion of Work Only dismantle accidental contact protection after machine and pressure pipe have cooled down tis an environmental protection requirement that any liquids arising during maintenance work e g cooling oil cooling water etc
26. ried out by electrical specialists WARNING Risk of injury due to improper maintenance and trouble shooting Improper maintenance and trouble shooting can lead to serious bodily injuries or property damage Therefore Maintenance work and trouble shooting work may only be carried out by sufficiently qualified and instructed personnel Secure machine against restarting switch off drives Before starting any wok provide for sufficient space and freedom of movement during assembly Pay attention to tidiness and cleanliness in the assembly area Loosely stacked or scattered components and tools are accident sources If components must be replaced Pay attention to correct installation of spare parts Properly reassemble all fastening elements Observe screw tightening torques Before restarting ensure that all covers and protective devices are correctly installed and function correctly After completion of maintenance work and trouble shooting check correct function and safety equipment 16 ED r TN fal UT LAND E Ej 4 Se 3 Technical Data Operating instructions Liquid ring compressor vacuum pump VacuStar WR Technical Data General data Unit WR 2500 WR3100 WR 4000 Nominal operating vacuum mbar 400 Weight without water filling kg 175 192 298 Permissible misalignment in longitudinal direction 5 Process liquid Water or water glycol mi
27. rt and storage 5 1 Safety notes for the transport See chapter 2 6 Occupational safety and special risks Personal protective equipment See chapter 2 5 5 2 Transport The machine fastened on a baseplate must be transported by means of a fork lift or suitable straps The lifting gear must be designed for the weight of the machine For future transports E Seal all open connections with protective caps prevents penetration of dirt and water m Secure against vibrations Drain all process and operating media m Securely fasten machine prior to transport e g screw it onto a pallet E Transport and put down machine with a fork lift or secure with straps and lift with suitable lifting gear 5 3 Storage Storage of packages Store packages under the following conditions Do not store outdoors Store dry and dust free Do not expose to aggressive media Protect against solar irradiation Avoid mechanical vibrations Storage temperature 10 bis 60 C Relative humidity max 95 non condensing Check the general state of all parts and the packaging in regular intervals if storage is longer than 3 months If necessary brush up or recondition the preservation 22 Kids A CE j 1j E F m af i l j H j al i AN j IT Lr i i d L EE 7 l l j i ri L Operating instructions Liquid ring compressor vacuum pump VacuStar WR mmm ms f Manufacturing Start up and operation 6 Star
28. s If grease is replaced approx 309 per bearing fill the bearing entirely but the free space in the bearing housing only up to approx 30 40 Replace roller bearings Replace roller bearings after 15 000 hrs 10 000 hrs for WR 4000 and fill them with grease accordingly if newly installed Shaft sealing rings After 15 000 hrs 10 000 hrs for WR 4000 replace the shaft sealing rings situated between bearings and slide seal rings as well as the shaft sealing ring situated between bearings and drive shaft together with the roller bearings Slide ring sealings Replace slide ring seals together with the bearings after 15 000 hrs 10 000 hrs for WR 4000 Cleaning suction filter Clean the suction filter depending on accumulated dirt and only for WR 2500 WR 3100 specification in the maintenance schedule To open the suction filter 1600 F fine filter and 1600 G coarse filter it is necessary to open a star handle on the suction filter 1600 F D fine filter pressure resistant and 1600 G D coarse filter pressure resistant 5 star handles need to be opened to remove the lid The hexagon nut on the stud bolt must be unscrewed to remove the filter cartridge NOTE Pay attention during cleaning that no liquid dirt or other objects get into the vacuum 28 Operating instructions Liquid ring compressor vacuum pump VacuStar WR Maintenance Cleaning procedure Rinse out filter casing with detergent Rinse out stainless steel
29. system E Components and parts may only be replaced by specialised staff See chapter 2 5 See chapter 7 1 The following basically applies 1 Immediately press emergency stop in case of malfunctions if there is an immediate danger for people or items 2 Switch of all power supplies and secure against restarting 3 Reform responsible on site 4 Depending on the kind of malfunction authorised specialised staff must find it out and correct the cause 30 All F l A M i LE d i a p E mmt Air Manufacturing Ir 4 NGU EL iT f fT HAY IR U VT ER ry u UU LL V tt DET Operating instructions Liquid ring compressor vacuum pump VacuStar WR Malfunctions SULCIS TR 8 1 Recommissioning after corrective action or trouble shooting After corrective action or trouble shooting 1 Reset emergency stops Acknowledge error or malfunction message on the control 2 3 Make sure that there is no person in the dangerous area 4 Start according to the notes in chapter Start up 8 2 Malfunction table Malfunction Possible cause Corrective action Execution VacuStar delivery Vacuum filter soiled Clean vacuum filter Operator rate decreases Leaky suction line fitting Look for leaky spots and Specialised eliminate leak Staff Speed too low Correct speed Operator Process water quantity too small Fill process water up to max Operator filling rate Process water temperature too C
30. t up and operation 6 1 Safety See chapter 2 6 Occupational safety and special risks Personal protective equipment See chapter 2 5 6 2 Start up Prior to initial start up The following points must be checked prior to initial start up or after lengthier standstill E Fill in process water clean drinking water up to the maximum mark on the reservoir Ventilate process water circulation Add antifreeze according to manufacturer s specifications E Fill process water directly at the VacuStar up to half full half shaft see Page 19 Fig 1 Pos 10 Process water indicator The water stop valves in process water inlets avoid filling the VacuStar from the process water reservoir m Make sure that the line cross sections of suction and pressure lines are free inside Caution Risk of damaging the slide ring seal The slide ring seal will be damaged when the machine runs dry without liquid Therefore Before the unit is started the liquid ring pump must always be approximately half full shaft centre with liquid see page 19 Fig 1 Pos 10 Start up Proceed as follows during start up E Open shut off devices if available m Start the VacuStar drive 23 i7 Cx Sa mg Sai M y 23 I fi on I i Operating instructions Liquid ring compressor vacuum pump VacuStar WR Noni m DUI P e im ENT i Li ii en iy a T al AA n i L B i LA m wa f i Start up an
31. to disposal E The machine has to be disposed of in accordance with the respective country specific regulations 33 ru rM oo rad u ma 7 i I Fal IF Si PU i y I A J I j J Operating instructions Liquid ring compressor vacuum pump VacuStar WR Ix zm E F Index o Manufacturing Index A MENE USE ve 9 Acceptance rrnnnnnnnnnnnnnnvnnnnnnennnnnnrnnnnnnrnnnnenennnnn 10 L ATEN 2 9 24 Liability 7 C ET og og 1 0 EE EEE 19 Cell ventilation eeeeeeseeeeeeee 20 M Cleaning Vireusiisiars iare RET 26 PACINO EEE 27 Maintenance schedule eene 26 SUCTION filter 28 Maintenance work 21 VacuStar mm 27 VALE Ur PT e3 16 d Iz RETO 30 Contact person 8 Moving components 14 Si 19 O COPYNON tc T 7 Occupational safety sene 12 Customer service 8 Operating instructions eeeneenneen gt D Operating personnel rrrrrrrrrnnnnnrnnrnnnnrnnnnnnnee 11 Danger of burns 12 Operator s responsibility enne 10 Danger pictogram ranrnnnnnnnrvvnnnnrennnnnnennnnnnnennnnn 12 P Danger pictograms eee 12 Personnel Trouble shooting 30 PAN TEE ETT 12 Pictogram explanation in the operating HE UCO Mem 6 Decommissioning ccena 33 E Pneumatik rarrrnnrronnnnronnnnrnnnnennannen
32. to independently recognise potential hazards 2 5 Protective Equipment lt is necessary to wear personal protective equipment when dealing with the machine so as to minimise health hazards m Before carrying out any work properly don the necessary protective equipment such as gloves safety goggles etc and wear during work 11 Operating instructions Liquid ring compressor vacuum pump VacuStar WR 3 MN Ir lr UL ii EN NY LY Safety Sorry AV iAP b QI Manufacturing 2 6 Occupational safety and special dangers The remaining risks which result from hazard analysis are specified in the following section Observe the safety notes listed here and the warning notes in the other chapters of these instructions to reduce health hazards and to avoid dangerous situations Danger pictograms on the device The relevant dangerous spots on the machine are identified by these pictograms DANGER General danger pictogram denotes general dangerous situations for individuals Non observance of the safety instructions can result in severe injuries or death DANGER Explosion protection pictogram denotes regulations and information that need to be observed in potentially explosive areas Explosion protection class temperature ranges etc must be observed DANGER Danger of burns denotes the presence of a hot surface 12 ex ER 1 Wig A IN Ju B Operating instructions Liquid ring com
33. vacuum pump VacuStar WR Spare parts Find the spare and wear parts which are necessary for normal repair in the table below Part Quantity Article number Bearing grease 400 g 530 010 00 Roller bearings 2 411 126 01 Slide ring seal 2 461 315 00 Shaft sealing ring AS 55x72x8 1 461 105 00 Shaft sealing ring AS 80x100x10 2 461 161 00 Filter cartridge for suction filter 1 432 020 00 1600 F Filter cartridge for suction filter 1 432 021 00 1600 G Part Quantity Article number Bearing grease 400 g 530 010 00 Roller bearings 2 411 133 00 Slide ring seal 2 461 319 00 Shaft sealing ring AS 65x90x10 1 461 133 00 Shaft sealing ring AS 100x120x12 2 461 182 00 Customer service In case of queries regarding the product spare part orders repairs replacement machines and dispatch of fitters please contact our customer service Tel 49 0 7623 71741 31 10 Decommissioning and disposal A VacuStar unit that is no longer usable should not be recycled as complete unit but disassembled into individual components and recycled according to material types Non recyclable materials have to be disposed of in an environmentally compatible manner m Prior to decommissioning and disposal of the machine it must be completely separated from the surrounding units m The disassembly and disposal of the machine may only be carried out by specialised staff m f hazardous or poisonous material were conveyed the machine must be decontaminated prior
34. water Too little process water in the Fill process water Operator temperature system exceeds 65 C Radiator soiled process water Clean radiator clean cooling Operator chambers in the VacuStar are water chambers in the silty VacuStar Process water quantity too low Fill in correct process water Operator quantity Silt foreign matter Foreign matter has been sucked VacuStar clean lines Operator in the machine over into the machine Change process water Power requirement Speed too high Maintain speed range Operator too high Final pressure too high Maintain nominal pressure Operator check safety valve Pressure gauge indicates Replace pressure gauge Operator incorrectly Safety valve blows Closed valves in the pressure Open valves Operator off line Clogging in pressure system Eliminate clogging Operator Pressure gauge indicates Replace pressure gauge Operator incorrectly Ventilating valve Closed valves in the suction line Open valves Operator responds Suction filter clogged Clean suction filter if Operator necessary replace filter cartridge Vacuum meter indicates Replace vacuum meter Specialised incorrectly Staff Water escapes Slide ring seal is damaged Replace seal Specialised from the drain staff borehole 32 S en ER brt D n Im HH I A IR AY Vil D EN ii a if n Li d M ANI Pp X EE 9 Spare parts Spare and wear parts WR 2500 WR 3100 Spare and wear parts WR 4000 Operating instructions Liquid ring compressor
35. xture 1 Consult CVS for suction temperature and or altitudes outside the permissible working range Tab 1 General data Permissible working range Input speed Suction temperature Outlet temperature Geodetic height Maximum operating vacuum Maximum final overpressure with direct drive gt Maximum final overpressure with V belt drive 1 Consult CVS for suction temperature and or altitudes outside the permissible working area 2 Excess pressure 0 bar suction and ambient temperature 20 3 Vacuum 0 mbar suction and ambient temperature 20 C 4 Process water temperature 20 Tab 2 Permissible working range VacuStar performance characteristics Vacuum operation suction pressure 400 mbar gt Rotation speed Maximum intake volume flow Coupling power 9 Intake volume flow gt Coupling power Pressure operation excess pressure 0 5 bar Coupling power Intake volume flow Sound pressure level at 7 m distance at 400 mbar 0 5 bar excess pressure 1 Excess pressure 0 bar suction and ambient temperature 20 C 2 Vacuum 0 mbar suction and ambient temperature 20 3 Process water temperature 20 4 Water vapour saturated air 55 C Tab 3 Performance characteristics Unit WR2500 WR3100 WR 4000 1 min 800 1600 800 1300 C 20 60 C max 65 m 0 1000 mbar 130 bar 155 155 1 0 bar 1 0 0 5 0 5 Unit WR2500 WR3100 WR 4000
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