Installation

Instructions

AQUALINE

1200

T-EA-5100-1-GB-07-08

1.

1.1

1.2

1.3

1.4

1.5

2.

Technical data . . . . . . . . . . . . . . . . . . . . . 7

Machine data . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Location of lubricating points . . . . . . . . . . . . . 9

Operating fluid . . . . . . . . . . . . . . . . . . . . . . . . 9

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety instructions and hazard alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Use for intended purpose. . . . . . . . . . . . . . . 11

Acceptance and monitoring . . . . . . . . . . . . . 11

Hazard alerts and symbols . . . . . . . . . . . . . 11

Safe working . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1

2.2

2.3

2.4

3.

3.1

3.2

3.3

4.

Installation . . . . . . . . . . . . . . . . . . . . . . . 15

4.1

4.2

4.3

System setup with cooler in main flow . . . . . 15

System setup with cooler in side flow . . . . . 16

Point of installation and fastening . . . . . . . . 18

4.4

4.5

Connections and piping . . . . . . . . . . . . . . . . 18

Protection against intake of dirt and residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.1

Suction line . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.2

Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.3

Safety dome . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.4

Safety bowl . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.6

Safety and monitoring instruments . . . . . . . 19

4.6.1

Vacuum gauge . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.2

Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.3

Non-return valve . . . . . . . . . . . . . . . . . . . . . 20

4.6.4

Thermometer . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.5

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.6

Pressure gauge . . . . . . . . . . . . . . . . . . . . . . 20

4.6.7

Hand guard . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.8

Bellows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.6.9

Speed monitor . . . . . . . . . . . . . . . . . . . . . . . 21

4.7

Operating fluid . . . . . . . . . . . . . . . . . . . . . . . 21

4.7.1

Operating water back-cooling and storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.7.2

Cell Ventilation . . . . . . . . . . . . . . . . . . . . . . . 21

4.8

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.8.1

Drive by hydromotor. . . . . . . . . . . . . . . . . . . 22

4.8.2

Drive by flexible clutch . . . . . . . . . . . . . . . . . 22

4.8.3

Drive by Prop. shaft . . . . . . . . . . . . . . . . . . . 22

4.8.4

Drive by Vee belt . . . . . . . . . . . . . . . . . . . . . 23

5.

Transport . . . . . . . . . . . . . . . . . . . . . . . . 13

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Scope of delivery . . . . . . . . . . . . . . . . . . . . . 13

6.

7.

Start-up / Operation / Maintenance /

Spare parts . . . . . . . . . . . . . . . . . . . . . . . 25

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

T-EA-5100-1-GB-07-08 3

Table of contents

Table of contents

4 T-EA-5100-1-GB-07-08

your new Liquid Ring Pump is the outcome of intensive development based on decades of experience as a supplier of vacuum pumps and compressors to the suction vehicle market. Advanced manufacturing methods in combination with highest quality standards and extensive testing ensure reliability, a high degree of availability and long life of your machine.

You will appreciate that this machine requires expert attention, especially in severe conditions. Commissioning, operation and maintenance therefore require trained and authorized personnel.

These Operating Instructions contain all required information and have been written for those in charge of the unit. The machine will give smooth service for a long time provided these Instructions are followed. The Operating Instructions are a component part of the product and must be kept available for the operating personnel. You will appreciate that we cannot be held responsible for any damage caused due to non-compliance with these Instructions.

Please note that repairs should only be undertaken by authorized repair centres using original parts. Otherwise our guarantee will be void.

We wish you success with your Liquid ring pump from

Gardner Denver. If you have any questions for which you do not find an answer in this booklet, please call us.

Sincerely yours,

Gardner Denver Drum

Preface

T-EA-5100-1-GB-07-08 5

Mode of operation, Design versions

Design versions

Liquid compressor vacuum pumps, like rotary compressor vacuum pumps, work on the displacement principle, providing uniform, low-pulsation flow.

Single-shaft liquid ring machines have a housing with cylindrical bore and an eccentrically mounted bucket wheel. The housing is partly filled with liquid, which the rotation of the bucket wheel forms into a rotating liquid ring in contact with the housing. Together with the hub of the eccentrically mounted bucket wheel, it forms a sickle-shape working space divided by the vanes of the bucket wheel.

The rotation of the rotor causes the cell volume to become large at the intake side. This causes a vacuum which sucks air into the cell, which is open towards the air intake. As the rotation continues, the cell closes and the cell volume becomes smaller. As a result of this, the enclosed air is compressed and pushed out of the pressure outlet.

The cells are charged and drained through openings in the housing cover located on the bucket wheel faces.

This functional principle causes the machine to work nearly at isothermal compression due to internal cooling.

The first digit of the references to illustrations in these Operating Instructions refers to the chapter in which you find the illustration. The illustrations within each chapter are numbered consecutively. The last number of an illustration reference denotes the position number of the item in the references illustration.

For example, the reference (7.2 / 3): second illustration in chapter 7, item number 3.

This symbol precedes information that refers to units used in a potentially explosive atmosphere.

The design versions differ in their sense of rotation.

Type code:

AQUALINE 1200 R

Liquid ring pump, operating medium: water

1)

Machine size R = CW rotation

L = CCW rotation

1)

Water is the working liquid commonly used by suction vehicles.

6 T-EA-5100-1-GB-07-08

Technical data

1.1

Machine data

Operating fluid

Water or water-glycol mixture

Liquid ring pumps of the Aqualine series use water as operating fluid.

Conveyed medium

Air of maximum intake temperature of 60 °C.

Maximum outlet temperature

The temperature at the outlet of the liquid compressor vacuum pump should be restricted to maximum 65 °C.

The machine number and other important machine data are given on the machine’s nameplate.

Technical data

Liquid ring pump

Rated operating vacuum (absolute)

Maximum gauge pressure in compressor operation

1)

At 400 mbar (absolute) intake pressure volume flow rate final gauge pressure power consumption on shaft

At 1,000 mbar (absolute) intake pressure volume flow rate final gauge pressure power consumption on shaft

Possible maximum vacuum approx. (absolute)

Permissible speed range

Mass moment of inertia, incl. liquid ring

Sound pressure at 7 m distance at 400 mbar

(absolute)

Weight of the basic machine mbar barg m

3

/h barg kW m

3

/h barg kW mbar

1/min kgm

2 dB(A) at 1000 min -1

650

0.0

18 at 1000 min -1

600

0.5

19

Aqualine 1200

400

1.5

at 1500 min -1

1,050

0.0

38 at 1500 min -1

980

0.5

38.5

130

1,000...1,800

0.75

66 at 1800 min -1

1,220

0.0

57 at 1800 min -1

1,150

0.5

58 kg 120

All data relate to water at 20 °C inlet temperature as the operating fluid and intake temperature of

20 °C.

Operating fluids other than water or water-glycol mixture require prior consultation with the manufacturer.

The data and illustrations reflect the current state. The right of modifications is reserved.

1)

Secure by providing a safety valve

T-EA-5100-1-GB-07-08 7

Technical data

1.2

Dimensions

[3,543]

[4,843]

123

[2,028]

51,5

[2,520]

64

[0,551]

14

] )

0,001

)

0,018

+

( +0

+

( +0,002

Ø 48k6

[

1,890k6

Fig. 1.1

Dimensions of Aqualine 1200

[21,122]

536,5

[10,787]

274 90

Ø

[3,543]

[7,874]

200

8 T-EA-5100-1-GB-07-08

1.3

Location of lubricating points

View shaft top-down View shaft bottom-up Back-View

Technical data

1

3

2

2

1

Cover the lubrication fitting, the venting valves and the silencer for final painting!

Two lubrication fittings, venting valves and silencers are provided!

3

Fig. 1.2

Lubrication fittings (1), venting valve (2) and silencer (3)

1.4

Operating fluid

The operating fluid is water or water-glycol mixture.

Operating fluids other than water or water-glycol mixture require prior consultation with the manufacturer.

1.5

Drive

By the vehicle engine:

■ by auxiliary drive and prop. shaft

■ by Vee belt, whereby the Vee belt pulley is installed on the free shaft end

■ by pneumatic clutch

By hydromotor:

■ by diesel engine or electric motor

■ by flexible clutch

For more details, see Installation instructions.

T-EA-5100-1-GB-07-08 9

Technical data

10 T-EA-5100-1-GB-07-08

Safety instructions and hazard alerts

2.1

Use for intended purpose

The intended purpose of the liquid ring pump is to convey and compress filtered air. The entrainment of small amounts of water in the air is possible. Any use other than or beyond that described above is contrary to the intended purpose.

Following the operating data and the specified maintenance are also part of the use for the intended purpose.

Liquid ring pumps of the Aqualine series comply with the requirements of directive 94/9/EC

(ATEX) and belong to equipment group II, category 2, temperature class T4 (135 °C maximum surface temperature), zone 1,2 (gas atmosphere).

Changes and repairs must only be made with the manufacturer’s written permission. Units of the Aqualine series are designed for integration in a higher-level machine. The new risks created by the integration must be assessed by the manufacturer of the new machine.

2.2

Acceptance and monitoring

The liquid ring pump as a unit is not subject to any acceptance or monitoring requirements.

Any special provisions in effect at the site of the liquid ring pump must be observed by the operator.

The safety and accident prevention regulations of the local employer’s association must be followed.

2.3

Hazard alerts and symbols

This hazard alert symbol indicates important safety messages in this booklet. Carefully read the message that follows and act as required.

Make certain that the safety instructions are known to all who need to know them!

“CAUTION” indicates provisions and regulations preventing damage to the machine.

Symbol for potentially explosive atmosphere

Here, the symbol draws attention to provisions or information which must be observed if the machine is used in a potentially explosive atmosphere.

This symbol indicates information of particular importance to the operator of the ma chine.

This symbol indicates that no unauthorized persons must enter this area.

Risk of burning!

This symbol indicates a hot surface.

This symbol indicates that you must wear ear protectors.

This alert symbol indicates that environmental protection requirements must be observed.

2.4

Safe working

The liquid ring pump has been designed and built to good engineering practice and the accepted rules of safety. However, hazardous situations may still arise in using the machine with the possibility of personal injury or death of the operator or other persons and damage of the machine or other objects.

Air is the only conveyed medium.

■ Use the liquid ring pump only in proper technical condition and for the intended purpose. Be alert to possible hazards. Defects impairing safety must be repaired without delay.

■ Modifications, additions and alterations of the liquid ring pump that are likely to impair its safety are forbidden unless after prior consultation with the manufacturer.

■ Never reach with your hands in the open suction or pressure duct.

■ The machine must only be used with connected delivery and intake socket.

■ All warnings on the liquid ring pump must be observed and be complete and legible at all times.

■ Observe all fire alarm and fire fighting possibilities.

■ Work on electrical equipment must be carried out by a trained electrician applying the rules of the trade.

■ All persons carrying out work on the liquid ring pump must have read these Operating Instructions, especially the chapter on safety, before start-

T-EA-5100-1-GB-07-08 11

Safety instructions and hazard alerts ing work. It may be too late to refer to these

Instructions when work has already started!

■ Operation and maintenance at the machine must only be carried out when the machine is not running.

■ Secure the drive against starting before beginning to work on the machine.

■ When work is carried out on the system, the latter must not be under pressure or vacuum. Observe the pressure gauge/vacuum gauge reading.

On the vehicle: Close the stop slide valve. Bleed or vent the pressure line between the system and the stop slide valve.

Relieve elevated pressure manually at the safety valve.

Observe the pressure gauge reading.

■ Remove the drive guard only when the machine is not running.

■ Remove the hand guard only when the machine and the pressure line have cooled down.

■ Before starting the machine, make certain that all guards are installed and in place.

Environmental protection requires that all emerging fluids, e.g., cooling water or lubricant residue, are collected and disposed of as prescribed.

12 T-EA-5100-1-GB-07-08

Transport

Symbols on the packaging:

Top

Fragile

Keep dry

3.1

Transport

Avoid any use of force and load / unload the packages with care.

For transport and installation, attach lifting equipment at the firmly installed eye bolts (see

Fig. 3.1).

Remove transport safeguards, where provided.

3.2

Storage

Store the machine in a dry and heated room until installation. Remove the covers on suction and pressure openings only at the time of actual installation.

3.3

Scope of delivery

The contents of the consignment are described in the delivery note. Check for short delivery and transit damage without delay. Claims for damage in transit and short delivery can only be accepted if made in writing without delay.

Fig. 3.1

Lifting eye bolt

T-EA-5100-1-GB-07-08 13

Transport

14 T-EA-5100-1-GB-07-08

Installation

Figures 4.1 and 4.2 show a typical Aqualine liquid ring pump system completely installed. Other arrangement versions are also possible.

4.1

System setup with cooler in main flow

6 7 3 8 1 4 9 5 19 12 11 max min

20

5 14 15 13 17 15 2 18 18 15 16 14 10

Details see page 17

1 Liquid ring pump

2 Vacuum filter

3 Venting line

4 Non-return valve

5 Bellow

6 Safety valve

Fig. 4.1

Components of a system with liquid ring pump – Cooler in main flow

15

7 Pressure gauge

8 Thermometer

9 Operating water tank

10 Four-way directional control valve

11 Safety dome and float valve

12 Vehicle tank

13 Operating water cooler

14 Water stop valve

15 Drain valves (see Fig. 4.3)

16 Safety bowl with float valve

17 Flexible mounting

18 Vacuum gauge

19 Floating switch

20 Water inlet for filling system

21 Leak water return line

(optional)

T-EA-5100-1-GB-07-08 15

Installation

4.2

System setup with cooler in side flow

5 4 3 6 8 7 5 1 14 19 9 12 11 max min

21

2 18 15 18 20 13 17 15 14 10

16

Details see page 17

15

1 Liquid ring pump

2 Vacuum filter

3 Venting line

4 Non-return valve

5 Bellow

6 Safety valve

7 Pressure gauge

Fig. 4.2

8 Thermometer

9 Operating water tank

10 Four-way directional control valve

11 Safety dome and float valve

12 Vehicle tank

13 Operating water cooler

14 Water stop valve

15 Drain valves (see Fig. 4.4)

16 Safety bowl with float valve

17 Flexible mounting

18 Vacuum gauge

19 Floating switch

20 Pump

Components of a system with liquid ring pump – Cooler in side flow

21 Water inlet for filling system

22 Leak water return line to suction side (optional)

Notes

■

■

■

Installation and start-up must only be undertaken by trained persons. Damage due to improper handling is not included in the guarantee terms.

The machine is delivered in fully assembled condition. It must not have suffered damage in transit.

Please make certain that the rotor shaft can be rotated by hand. If this is not the case, inform our service staff.

■ For erection and handling, attach the machine only to securely installed eye bolts.

For use in a potentially explosive atmosphere, all parts of the equipment must satisfy the requirements for the zone in which they are used. Note that it may be necessary to provide equipotential bonding between the equipment and the truck.

The safe operation of the vacuum pump in a potentially explosive atmosphere requires that all safety instructions in our operating instructions and complementary instructions are strictly observed.

16 T-EA-5100-1-GB-07-08

Details of Fig. 4.1

Installation

15a1 Drain valve for the liquid ring fluid

15a2 Drain valve for the liquid ring fluid

15b Drain valve for the operating water cooler

15c Optional leak water return line to suction side

R 1/8” connection

15a2

15a1

15c

15b

Fig. 4.3

Components of a system with liquid ring pump – Cooler in main flow (detail)

Details of Fig. 4.2

15a2

15a1

15a1 Drain valve for the liquid ring fluid

15a2 Drain valve for the liquid ring fluid

15b Drain valve for the operating water cooler

15c Optional leak water return line to suction side

R 1/8” connection

15c

15b

Fig. 4.4

Components of a system with liquid ring pump – Cooler in side flow (detail)

T-EA-5100-1-GB-07-08 17

Installation

4.3

Point of installation and fastening

The point of installation on the vehicle must

■ be easy to access,

■ be protected from dirt, the impact of stones and splash water.

■ leave sufficient space for the connection of operating water, the suction and pressure lines and the operating water drain.

■ be accessible for maintenance (for regreasing the grease barrier).

Fasten the machine at the 4 feet (screw-in thread

M16). The machine can be fastened directly on the frame or crossheads. The minimum depth of screwing is 23 mm.

Crossheads on the vehicle frame must be of sufficient strength, slim profiles must not be used.

The four fastening points (machine foot supports) must be in exact alignment.

For dimensions and weights, see chapter 1. "Technical data".

A suitably dimensioned equipotential bonding must be established between the liquid ring pump and the truck.

4.4

Connections and piping

For regular service of the liquid ring pump the suction and pressure lines, the operating water supply and the venting line and the water valve must be connected to the machine.

The various possibilities of the suction and pressure line connections are illustrated in Fig. 4.5 for machines of clockwise and counter clockwise rotation (see also

Fig. 1.1).

The suction and pressure line, respectively, is directly welded to the connecting flanges.

A q ualine 1200 R

Serial No. 910 701 00

Suction side

Connection on one flange

(top or back) optional

Top view counter clock wise Operation

Pressure side

Connection on one flange

(top or back) optional

Side B

A q ualine 1200 L

Serial No. 910 700 00

Pressure side

Connection on one flange

(top or back) optional

Fig. 4.5

Aqualine 1100 to 2700 connection versions

The suction and pressure line, respectively, must be connected on the A side or B side, depending on whether the machine rotates clockwise or counterclockwise. The same applies to the operating water supply, the drain line and the venting line.

As regards piping, the minimum pipe diameters in the table below are recommended.

Aqualine 1200

Suction line

Pressure line

Side B

Side A

Top view clock wise Operation

Side A

Suction side

Connection on one flange

(top or back) optional minimum pipe diameter

DN 100 (4")

DN 100 (4")

For operating water, water drain and venting pipeline dimensions, see data in Fig. 1.1 and chapter 4.7.1

"Operating water back-cooling and storage tank".

18 T-EA-5100-1-GB-07-08

Installation

4.5

Protection against intake of dirt and residue

4.5.1

Suction line

The pipe must be corrosion-resistant inside. Clean the pipe inside before installing it. Remove all welding beads, scale and rust.

The suction line should be sufficiently large.

The pipe diameter must at least meet the diameter specifications in chapter 4.4 ‘Connections and piping”. Otherwise the machine will be overloaded

Wrong design of the suction line causes forfeiture of all guarantee claims on Gardner Denver.

4.5.2

Vacuum filter

Install the vacuum filter (Fig. 4.1/2 and 4.2/2) directly upstream the machine. The filter protects the machine from the ingress of impurities and attenuates the suction noise.

Observe the flow direction when installing the filter.

The filter insert shall be removable from the filter for maintenance.

4.5.3

Safety dome

In addition to the float valve, a splash guard must be installed in the safety dome (4.1/11 and 4.2/11)of the vehicle tank. The splash guard prevents that liquid is carried along by splashing.

4.5.4

Safety bowl

The safety bowl (4.1/16 and 4.2/16) (at the lowest point of the suction line) must be so designed that:

■ entering air does not hit the liquid level directly,

■ sufficient calming space is available,

■ the filter element does not dip into the liquid (also filters with non-absorbing texture become saturated due to the capillary action of the liquid).

A filter element in the safety bowl is not required if a vacuum filter type SFA-F is used.

5

1 Intake bend

2 Baffle plate

3 Double perforated plate

Fig. 4.6

Safety bowl

6

4 Drain cock

5 Two floating balls

6 Four guide rods

1

2

3

4

To inspect the function of the optimized gravity separator illustrated in Fig. 4.6 proceed as follows:

■ When the amount of water to be separated is sucked in, that amount must remain in the bowl.

We will be glad to assist you in designing and inspecting your safety bowl.

4.6

Safety and monitoring instruments

The safe operation of the machine (i.e., the operation of the machine without risk) requires the following safety and monitoring equipment (also see Fig. 4.1

and Fig. 4.2).

All items of safety equipment must be inspected for proper function in regular intervals (see manufacturer’s technical instructions).

It is forbidden to change, block or render safety guards ineffective in any other way.

The operating safety of the system (i. e., the safe operation of the machine requires the following safety and monitoring instruments:

Monitoring instruments:

At the intake side:

■ Vacuum gauge

■ Vacuum filter

■ Non-return valve

■ Bellows

At the discharge side:

■ Safety valve

T-EA-5100-1-GB-07-08 19

Installation

■ Thermometer

■ Pressure gauge

■ Bellows

Operating water supply line:

■ Solenoid valve for opening or closing the operating water supply

Hand guard:

■ Protection against rotating parts

Protection of the machine

■ Speed monitor

■ Install drain cocks for the operating fluid to ensure that the complete system can be drained of liquid.

Non-compliance causes forfeiture of all guarantee claims on Gardner Denver.

4.6.1

Vacuum gauge

To monitor the permitted operating vacuum as specified in chapter 1.1 "Machine data", a vacuum gauge

(4.1/18 and 4.2/18) is to be installed downstream the non-return valve (4.1/4 and 4.2/4) at the intake side.

To measure the pressure loss in the filter, we also recommend to install a vacuum gauge upstream the filter.

4.6.2

Vacuum filter

The vacuum-tight filter (4.1/2 and 4.2/2) protects the machine from coarse mechanical impurities. The vacuum filter must be installed in the suction line.

Note for installation: Flow direction, required space for replacing the filter insert.

4.6.3

Non-return valve

The non-return valve (Fig. 4.1/4 and 4.2/4) prevents the entry of water from the pump in the intake line when the machine is not running.

Install the non-return valve in the suction line as near to the machine as possible. Observe the direction of flow through the valve.

4.6.4

Thermometer

To monitor the compression end temperature (Fig. 4.1/

8 and 4.2/8), install the thermometer in the pressure line directly downstream the pressure socket. For this, install a pipe coupling R 1

⁄

2

". The immersion depth of the thermometers must be equivalent to one half the diameter of the pipe.

The indicating range of the thermometers must be 0 to

100°C.

4.6.5

Safety valve

A non-shutting off safety valve (4.1/6 and 4.2/6) shall be installed downstream every vacuum/compressor pump. The valve must be dimensioned and set so that the highest permitted operating pressure cannot be exceeded by more than 10%. The valve must be capable of blowing off the entire volume conveyed by the liquid ring pump. This valve must also be suitable for manual venting.

If the safety valve is handled or located improperly or tampered with, there is RISK OF

EXPLOSION due to pressure and temperature rise!

The following points must be observed when installing the safety valve:

■ Install the valve directly downstream the liquid ring pump, upstream of any other shutoff element

(especially shutoff valve),

■ the setting must correspond to the maximum permitted operating pressure (see chapter 1.1

"Machine data"),

■ the setting must be protected against tampering,

■ the valve must not be blocked,

■ the safety valve must not be used for control of the air volume in compression service.

Make a weekly check of the function of the safety valve by actuating the manual vent while the machine is running.

4.6.6

Pressure gauge

The pressure gauge (Fig. 4.1/7 and 4.2/7) provides pressure readings during normal machine service.

Measuring range in accordance with the operating pressure. Install directly downstream the pressure connection.

4.6.7

Hand guard

The drive of the machine and the hot pressure line must be protected by a hand guard.

20 T-EA-5100-1-GB-07-08

It must not be possible to touch rotating or reciprocating machine parts accidentally.

The surface temperature must not exceed 80°C.

4.6.8

Bellows

To limit the connection forces in the suction and pressure line of the liquid ring pump, vacuum-tight and pressure-tight bellows (Fig. 4.1/5 and 4.2/5) must be installed.

At the same time, the bellows cause separation of the solid-borne noise of the suction and pressure lines.

4.6.9

Speed monitor

Speed control of the liquid ring pump and a speed indicator in the operating area of the machine are recommended. For permitted speed range, see chapter 1.1

"Machine data".

4.7

Operating fluid

For start-up, the liquid ring pump requires an amount of water sufficient to form the liquid ring.

Therefore, when installing the pump, make certain that the water tank is located so that when the operating water feed valve is open and the tank contains a minimum of water, the liquid ring pump fills with water up to the middle (also see Operating Instructions). If this is not ensured there may be problems in starting the pump (no conveyed medium flow).

If the water tank is located so that the liquid level is above the middle of the liquid ring pump, an automatic water stop valve (Fig. 4.1/14 and 4.2/14) must be installed in the operating water supply line. This valve must open when the pump starts and close when it is stopped to prevent inundation of the pump.

If the liquid ring pump is installed above the water level in the tank, a pump is required to ensure the operating water supply. The design of that pump must be such that the liquid ring pump is supplied with sufficient operating fluid. We will be glad to assist you in selecting the right pump.

Because liquid is removed from the working space and also because heat must be dissipated, the liquid ring pump requires a constant supply of operating fluid. For this, the casing cover of the machine have a connection (see dimension sheet).

If the piping has sufficiently low resistance (depending on pipeline length and layout) no re-circulation pump may be needed for the operating water supply provided the arrangement of the liquid ring pump is such that

Installation the middle of the pump is at a lower level than the minimum liquid level in the storage tank.

A level control of the operating liquid must be provided if the machine is operating in a potentially explosive atmosphere.

4.7.1

Operating water back-cooling and storage tank

A circulation cooling system is required for back-cooling the operating water. The circulation cooling must be able to handle the following amounts of heat.

To reduce the loss of liquid by the exhaust air to a minimum and also to ensure a sufficient number of operating hours of the system, a combined operating water storage and separating tank (Fig. 4.1/9 and 4.2/9) is needed. For minimum sizes, refer to the table below.

Aqualine 1200

Amount of heat to be dissipated at 1.5 bar

(g) at 0.5 bar

(g) at 400 mbar at 200 mbar kW kW kW kW at 1000 min

-1

26

11

15

16 at 1500 min

-1

48

23

30

35 at 1800 min

-1

72

35

45

52

Recommended pipe diameter operating water line

Recommended minimum tank size ltr

Recommended water volume in the tank ltr

R1 1 /

250

150

2 "

The above minimum water storage figures relate to systems with water back-cooling.

Systems without water back-cooling require substantially larger storage tanks to ensure sufficient operating hours of the liquid ring pump without running the risk that the recommended limit temperature of 55 °C the operating water inflow is exceeded.

Suction dramatically reduces at higher temperatures.

4.7.2

Cell Ventilation

The cell ventilation is required to ensure the proper operation of the liquid ring pump at low intake pressure down to total residual pressure. The ventilation line is connected housing covers (see figure 1.1 ‘Dimensions of Aqualine 1200” ).

T-EA-5100-1-GB-07-08 21

Installation

The ventilation line needs a pipe internal diameter of

Øi = 28 mm. The specified cross sections refer to about 2.5 meters line length. The ventilation line must be installed at an upward gradient and the connection is made on the “clean side” of the water separation vessel.

Make sure of the correct size of the entrained ventilation line. Check if sufficient fresh air can enter the work space of the liquid pump via the ventilation line. This is done by running the liquid pump with closed intake line. If a loud noise is heard, the entrained ventilation flow rate is insufficient. In this case a larger ventilation line must be installed.

If you want to drain all operating fluid from the liquid ring pump, open all water drains (see Fig. 1.1).

4.8

Drive

The sense of rotation must agree with the direction of the arrow on the liquid ring p ump

Permissible speed range see chapter 1.1 "Machine data". The speed range must not be exceeded.

Make absolutely certain to observe the drive speed increasing or reducing ratios (belt drive, auxiliary drive of vehicle, ...)

We recommend a speed monitor at the liquid ring pump with an indicator in the operating area.

At any rate, check the speed after installing the liquid ring pump and put up a note for the operator of the vehicle.

If the machine is powered by a combustion engine, the engine must have speed control which limits the speed to a permitted level if the engine power drops.

The axial thrust of the drive must not be transferred to the rotor shaft.

Install the drive components on the rotor shaft using the available thread M16.

Do not attempt to install the drive components on the rotor shafts with blows.

A hand guard and a clutch guard must be provided in any case.

4.8.1

Drive by hydromotor

The selection and installation of the hydromotor is the responsibility of the installation firms.

Gardner Denver can supply a matching flange and a clutch.

We have already installed the half clutch on the compression side. After mounting the flange, the half clutch on the motor side must not transfer axial thrust on the liquid ring pump.

4.8.2

Drive by flexible clutch

If the pump is coupled directly to the drive (e.g. diesel engine) a torsionally flexible clutch that compensates most of the drive irregularities must be selected according to the specifications of the engine maker.

Align the clutch exactly as prescribed by the manufacturer.

4.8.3

Drive by prop. shaft

The prop. shaft drive must be

■ designed as a splined shaft,

■ balanced,

■ have smallest possible angles and be as short as possible.

The centre axes of the prop. shaft flanges must be parallel with each other.

The mounting flange of the prop. shaft must be installed on the drive shaft of the compressor.

1 max. 15 at 1500 [1/min]

2 3 2

1 To liquid ring pump

2 Splined shaft

Fig. 4.7

Mounting the prop. shaft

3 Marking

4 From drive

4

Bolt the splined portion of the prop. shaft to the mounting flange of the liquid ring pump shaft.

The resulting angle of bend must not exceed 15° at

1,500 min

-1

speed.

Do not install prop. shaft with the wrong end up.

Observe marking.

22 T-EA-5100-1-GB-07-08

4.8.4

Drive by Vee belt

If the engine speed must be raised or reduced, Vee belt drive is recommended. Observe the rated speeds in chapter 1.1 "Machine data".

Installation

The belt pulleys in the table below can directly be installed on the free shaft end.

Aqualine 1200

Pressure range

Vacuum service

200...10000 mbar

Belt profile

Belt pulley minimum diameter D

W

1)

XPB

212 mm

Number of belts in pressure service 4

1)

Consult the manufacturer if smaller pulleys are to be used.

Note:

The permitted total belt pulling force is max. 7000N to 0.5 bar g

XPB

212 mm

4

Pressure service

0.5 ... 1.0 bar g

XPB

1,0 ... 1,5 bar

ü

XPB

280 mm 280 mm

4 5

Installation of the Vee belt drive

■ Exactly and carefully align in parallel the axes in all planes of the driving and the driven shafts.

■ The grooves of the belt pulleys must not be offset.

■ Select the Vee belts according to length to ensure uniform belt tension.

■ The Vee belt tension is correct when the ready installed and tensioned belt can be deflected by the pressure of the thumb by 16 to 20 mm for every

1000 mm axial distance.

Vee belt drive with electric motor is not allowed because of tilting moment.

D w

16…20 mm

1000 mm

1

2

1 Vee belt deflection (16 to

20 mm for every 1.000 mm distance)

2 Axial distance

Fig. 4.8

D

Correct Vee belt tensioning

W

Vee belt pulley diameter, min. 280 mm

T-EA-5100-1-GB-07-08 23

Installation

The distance of 5 ... 8 mm between the Vee belt pulleys and the end cover must be maintained (see Fig.

4.9)

5 - 8 mm

1

2

Fig. 4.9

Distance between first Vee belt pulley and housing

Installing the Vee belt pulley with taper lock

1. Clean and degrease all blank faces. Place the pulley and the bush one in the other. Bring holes in alignment with each other and install screws loosely.

2. Push the pulley with the bush on the shaft, align and uniformly tighten the screws.

Fig. 4.11

Removing the Vee belt pulley

2. Remove the slack pulley assembly by hand; do not apply blows or damage the machine.

1

2

Fig. 4.10

Installing the Vee belt pulleys

Removal

1. Take out the screws, install one as a forcing screw in the half-thread hole in the bush and tighten. This slackens the taper lock bush.

Fig. 4.12

Taking off the Vee belt pulleys

24 T-EA-5100-1-GB-07-08

Information on start-up, operation, maintenance and replacement parts lists have been compiled in a separate operator manual.

Start-up / Operation / Maintenance / Spare parts

T-EA-5100-1-GB-07-08 25

Start-up / Operation / Maintenance / Spare parts

26 T-EA-5100-1-GB-07-08

Index

A

Acceptance ......................................................... 11

Air connection ...................................................... 8

Aufbau der Anlage ........................................ 15 , 16

B

Bellows .............................................................. 21

Belt profile ......................................................... 23

Belt pulley .......................................................... 23

Bucket wheel ........................................................ 6

C

Cell ...................................................................... 6

Cell Ventilation ................................................... 21

Cell volume .......................................................... 6

Connection versions ............................................ 18

Connections ........................................................ 18

Conveyed medium ................................................. 7

Cooler in main flow ............................................. 15

Cooler in side flow .............................................. 16

D

Design versions ..................................................... 6

Dimensions ........................................................... 8

Displacement principle .......................................... 6

Distance between first Vee belt pulley and housing ............................................................... 23

Drive .............................................................. 9 , 22

Drive by flexible clutch ........................................ 22

Drive by hydromotor ........................................... 22

Drive by Prop. shaft ............................................. 22

Drive by Vee belt ................................................ 23

E

Environmental protection ..................................... 12

F

Fasten ................................................................. 18

Fastening ............................................................ 18

Filter .................................................................. 19

Filter insert ......................................................... 19

Final gauge pressure .............................................. 7

Functional principle ............................................... 6

H

Hand guard ......................................................... 20

Hazard alerts ....................................................... 11

Hazard alerts and symbols .................................... 11

Heat to be dissipated ............................................ 21

I

Installation .......................................................... 15

Installation of the Vee belt drive ........................... 23

Intake ................................................................. 19

Intake pressure ...................................................... 7

Intended purpose ................................................. 11

Isothermal ............................................................. 6

L

Liquid ring machines ............................................. 6

Liquid Ring Pump ................................................. 5

Lubricating points .................................................. 9

Lubrication fittings ................................................ 9

M

Mass moment of inertia .......................................... 7

Max. pressure ........................................................ 7

Maximum outlet temperature .................................. 7

Mode of operation ................................................. 6

Monitoring .......................................................... 11

Monitoring instruments ........................................ 19

N

Non-return valve ................................................. 20

Number of belts ................................................... 23

O

Operating fluid ............................................7

, 9 , 21

Operating water ................................................... 21

Operating water supply line .................................. 20

P

Permissible speed range ......................................... 7

Piping ................................................................. 18

Point of installation .............................................. 18

Power consumption ............................................... 7

Pressure gauge .................................................... 20

Pressure line ........................................................ 18

Prop. shaft .......................................................... 22

R

Rated operating vacuum ......................................... 7

References to illustrations ....................................... 6

Rotary compressor vacuum pumps .......................... 6

Rotor .................................................................... 6

S

Safe working ....................................................... 11

Safety ................................................................. 19

Safety bowl ......................................................... 19

Safety dome ........................................................ 19

Schmiernippel ....................................................... 9

Scope of delivery ................................................. 13

Sicherheitstopf .................................................... 19

Silencer ................................................................ 9

Sound pressure ...................................................... 7

Speed monitor ..................................................... 21

Storage ............................................................... 13

Storage tank ........................................................ 21

Suction line ................................................... 18 , 19

T-EA-5100-1-GB-07-08 27

Index

T

Technical data ....................................................... 7

Transport ............................................................ 13

Transport safeguards ............................................ 13

Type code ............................................................. 6

U

Use for intended purpose ...................................... 11

V

Vacuum ................................................................ 7

Vacuum filter ................................................ 19 , 20

Vacuum gauge .................................................... 20

Vee belt .............................................................. 23

Vee belt tensioning .............................................. 23 venting valve ......................................................... 9

Volume flow rate ................................................... 7

W

Weight ........................................................... 7 , 18

Working space ...................................................... 6

28 T-EA-5100-1-GB-07-08

T-EA-5100-1-GB-07-08 29

Index

Technical specifications are subject to change: T-EA-5100-1-GB-07-08

For additional information, contact your local representative or

Gardner Denver Drum Ltd

PO Box 178,

Springmill Street,

Bradford,

West Yorkshire, UK

BD5 7YH

Tel: +44 (0)1274 718100

Fax: +44 (0)1274 718101

Email: [email protected]

Web: www.gardnerdenverproducts.com

© 2008 Gardner Denver Drum Ltd.

T-EA-5100-1-GB-07-08 31

32 T-EA-5100-1-GB-07-08