Contents
Mounting instructions
Doc-ID: 5040 / MA / EN
Prior to installing the VacuStar WR and putting it into operation you must have read and understood
VacuStar WR 2500 / WR 3100 / WR 4000
Release: Rev. 03 / 13/09/2017
these instructions. These instr u ctions are only valid together with the operating instructions, they do
not replace them!
2
Translation of the Original Assembly Instructions
© CVS engineering GmbH
Großmattstraße 14
79618 Rheinfelden / Germany
Phone: +49 (0)7623 71741-0
Customer service: +49 (0)7623 71741-0
E-Mail: info@cvs-eng.de
Internet: www.cvs-eng.de
3
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Contents
1 General .................................................................................... 5
1.1 Information on the assembly instructions ...................... 5
1.2 Pictogram explanation ................................................... 6
1.3 Limitation of Liability ...................................................... 7
1.4 Copyright protection ....................................................... 7
1.5 Spare parts .................................................................... 7
1.6 Warranty conditions ....................................................... 7
1.7 Customer Service .......................................................... 7
1.8 Declaration of Incorporation ........................................... 7
1.9 ATEX Declaration of Conformity .................................... 7
2 Safety ...................................................................................... 8
2.1 Intended use .................................................................. 8
2.2 Proper operation ............................................................ 9
2.3 Acceptance and monitoring ........................................... 9
2.4 Operator's responsibility ................................................ 9
2.5 Requirements placed upon the specialised staff ........... 9
2.6 Personal protective equipment .................................... 10
2.7 Occupational safety and special risks ......................... 10
3 Technical data ...................................................................... 11
3.1 Dimensions of VacuStar WR 2500 / WR 3100 ............ 11
3.2 Dimensions of VacuStar WR 4000 .............................. 12
3.3 Connection variants for suction and pressure line....... 12
3.4 Technical data.............................................................. 14
4 Design and function............................................................. 17
4.1 Design .......................................................................... 17
4.2 Function ....................................................................... 17
5 Transport and storage ......................................................... 21
5.1 Safety notes for transport ............................................ 21
5.2 Transport ...................................................................... 21
5.3 Storage ........................................................................ 22
6 Installation and assembly ................................................... 23
6.1 Safety ........................................................................... 23
6.2 Installation example ..................................................... 24
6.3 Necessary work ........................................................... 25
6.4 Assembly of the VacuStar WR .................................... 25
6.5 Compensators.............................................................. 26
6.6 38B38BLines and containers ....................................... 26
6.7 Safety equipment ......................................................... 28
6.7.1 Safety valve .................................................. 28
6.7.2 49B49BMonitoring the end temperature ...... 29
6.7.3 Non-return valve ........................................... 29
6.7.4 Vacuum suction filter .................................... 29
6.7.5 Protection against contact ............................ 29
6.7.6 Cell ventilation valve ..................................... 30
6.7.7 Display and monitoring equipment ............... 32
6.8 40B40BAdditional components of the system ............. 33
6.8.1 Safety tank.................................................... 33
6.9 Safety dome ................................................................. 33
6.10 Cooling water system .................................................. 33
6.11 Drive 35
6.11.1 V belt drive.................................................... 35
6.11.2 Articulated shaft drive ................................... 36
6.11.3 Drive via flexible coupling and hydraulic
motor ............................................................ 36
4
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Contents
7 Start-up ..................................................................................37
7.1 Safety during start-up ...................................................37
7.2 Start-up ........................................................................38
7.3 Switching off .................................................................40
7.4 Inspections to be performed ........................................40
8 EC Declaration of Incorporation .........................................41
9 Declaration of Conformity ...................................................42
Index ..............................................................................................43
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
1 General
1.1 Information on the assembly instructions
These assembly instructions provide important information about
installation and start-up of the VacuStar WR. A precondition for
safe operation is the observance of all specified safety and
handling instructions.
Furthermore, all local accident prevention regulations and general
safety regulations valid for the application area of the VacuStar WR
must be observed.
You must have read and understood the mounting instructions
before you start installing the machine and put it into operation! It is
a product component and must be kept in direct proximity of the
VacuStar WR, well accessible to the personnel at all times. All
safety instructions of the operating instructions must additionally be
observed.
General
6
Warning notes
Warning notes are characterised by pictograms in these mounting
Hints and recommendations
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
1.2 Pictogram explanation
instructions. The warning notes are marked by signal words
expressing 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 immediately dangerous situation, which
can lead to death or serious injuries if it is not
avoided.
WARNING!
... points to an immediately dangerous situation,
which can lead to death or serious injuries if it is not
avoided.
CAUTION!
... points to a potentially dangerous situation, which
can lead to minor or light injuries if it is not avoided.
ATTENTION!
... points to a potentially dangerous situation, which
may lead to property damage if it is not avoided.
Safety note ATEX!
Only for VacuStar WR with Ex-approval.
This icon shows the special conditions that must be
observed according to the approvals when
conveying explosive gases and gas mixtures.
NOTE!
… highlights useful hints and recommendations as
well as information for an efficient and trouble-free
operation.
7
1.3 Limitation of Liability
1.4 Copyright protection
1.5 Spare parts
1.6 Warranty conditions
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
See operating instructions "VacuStar WR 2500 / WR 3100 / WR
4000" for information about limitation of liability.
See operating instructions "VacuStar WR 2500 / WR 3100 / WR
4000" for information about limitation of liability.
See operating instructions "VacuStar WR 2500 / WR 3100 / WR
4000" for information about limitation of liability.
The warranty conditions are included in the sales documentation
as a separate document.
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, E-mail or via the Internet at any time, refer to
manufacturer's address on page 2.
1.8 Declaration of Incorporation
Declaration of incorporation (pursuant to EC Machinery Directive
2006/42/EC,
Part 1, Section B, Annex II) see page 41.
1.9 ATEX Declaration of Conformity
Declaration of conformity (pursuant to ATEX-directive 2014/34/EU)
see page 42.
8
The liquid-ring compressor vacuum pumps of the VacuStar WR
The VacuStar WR in the explosion proof design complies with
II 2G c k IIB T5 (i),
Device category, temperature class and explosion group of all
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
2 Safety
2.1 Intended use
model range have been developed for installation in a
superordinate system. The manufacturer of the overall system
must assess the new risks resulting from the installation. These
risks must be included in the operating instructions of the system.
The VacuStar WR is exclusively intended for the compression or
extraction of air or filtered water vapour saturated air.
Directive 2014/34/EU (ATEX) and is suitable for conveying
explosive gases and gas mixtures of explosion group IIB,
temperature class T5 from explosive zone 1 and zone 2 areas.
No explosive atmosphere is allowed in the area around the
VacuStar WR. The VacuStar WR may only be opened when it is
stopped and when there is no explosive atmosphere around it.
Marking of the VacuStar WR:
no potentially explosive external atmosphere.
In temperature class T5, the gas temperature is
limited to 95 °C, and must be secured.
attachments that are not contained in the scope of delivery of
CVS engineering GmbH (such as temperature sensors and
pressure switches) must comply with the requirements of the
Directive 2014/34/EU.
9
If explosive gases and gas mixtures are conveyed, the
following guidelines must be
2.2 Proper operation
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
The intended use is chiefly defined by the data in "Tab. 1: General
data Tab. 1" (page 14).
All specifications in these installation and operating instructions
have to be strictly complied with (technical data, ATEX regulations,
etc.)
All types of claims due to damage arising from improper use are
excluded. The operator alone shall be responsible for any damage
arising from improper use.
2.3 Acceptance and monitoring
The VacuStar WR itself is not subject to any acceptance and
monitoring obligation.
2.4 Operator's responsibility
See operating instructions "VacuStar WR 2500 / WR 3100 / WR
4000" for information about the responsibility of the operating
company.
– 2014/34/EC
observed:
Devices and protection systems for the proper
use in explosive environments
– 99/92/EC
Health protection and safety of the employees in
potentially explosive areas
2.5 Requirements placed upon the specialised staff
The mounting instructions specify the following qualification
requirements for the different fields of activity:
Specialists
are due to their technical training, knowledge and experience
and their knowledge of the pertinent regulations able to carry
out the work assigned to them and to independently recognize
potential hazards.
Electrical specialists
are, due to their technical training, knowledge and experiences
and their knowledge of the relevant standards and regulations,
able to work on electrical systems and to independently
recognize possible hazards.
10
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
2.6 Personal protective equipment
See "VacuStar WR 2500 / WR 3100 / WR 4000" operating
instructions for information about personal protective equipment.
2.7 Occupational safety and special risks
Observe all safety instructions in the operating instructions
"VacuStar WR 2500 / WR 3100 / WR 4000", Chapter
"Occupational safety and special risks".
11
a VacuStar WR 2500 b VacuStar WR 3100
1 Foot arrangement "outward" 3 Cell ventilation connection G1 ½"
1 2 3
5
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
3 Technical data
3.1 Dimensions of VacuStar WR 2500 / WR 3100
Technical data
Fig. 1: Dimensions of VacuStar WR 2500 / WR 3100, shown here is WR 3100
2 Foot arrangement "inward" 5 Process water connection G1 ½"
12
WR 2500/3100
WR 4000
WR 2500/3100
WR 4000
2
1 4 5
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
3.2 Dimensions of VacuStar WR 4000
Fig. 2: Dimensions of VacuStar WR 4000
1 Foot arrangement "outward" 4 WR 4000 Cell ventilation connection G2"
2 Foot arrangement "inward" 5 Process water connection G1 ½"
3.3 Connection variants for suction and pressure line
CVS engineering offers the following connecting flanges:
Model 1
950075-00
Fig. 3: Connecting flanges
950076-00
950080-00
Model 2
950081-00
13
B-side
A-side
WR2500
WR2500
R: 950 080-00
950081-00
R: 950 080-00
950081-00
R: 950 075-00
950076-00
R: 950 075-00
950076-00
R: 950 075-00
950076-00
R: 950 075-00
950076-00
R: 950 080-00
950081-00
R: 950 080-00
950081-00
Fig. 4: Connection variants for suction and pressure line
Example:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
The horizontal and vertical flange arrangements can be combined
with each other.
WR3100
WR4000
WR3100
Pressure connection Suction connection
L: 950 075-00
950076-00
L: 950 075-00
Suction connection Pressure connection
L: 950 080-00
950081-00
L: 950 080-00
Pressure connection Suction connection
L: 950 080-00
950081-00
L: 950 080-00
Suction connection Pressure connection
L: 950 075-00
950076-00
L: 950 075-00
A Drive side
B Opposite side
R Sense of rotation, viewed on the drive shaft right (clockwise)
L Sense of rotation, viewed on the drive shaft left (anticlockwise)
WR4000
950076-00
950081-00
950081-00
950076-00
VacuStar WR rotating clockwise (R)
A-side:
Suction connection vertical → No. 950 075-00
B-side:
Pressure connection horizontal → No. 950 080-00
14
General data
Unit
WR 2500
WR 3100
WR 4000
Permissible working range
Unit
WR 2500
WR 3100
WR 4000
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
3.4 Technical data
Nominal operating vacuum 1) [mbar] 400
Angular momentum on the drive shaft [kgm2] 1.40 1.80 3.9
Weight without water filling [kg] 175 192 298
Permissible inclination to the side [°] 22 (see Fig. 1, Fig. 2)
Permissible inclination in longitudinal direction [°] 5
Process liquid – Water-glycol mixture
Tab. 1: General data
Input speed [1/min]
800 to 1600
800 to 1300
Suction temperature 1) [°C] -20…+60
Outlet temperature [°C] max. 65
Geodetic height 1) [m] 0…1000
Maximum operating vacuum 4) [mbar] 130
Maximum final overpressure with direct drive 3) [bar] 1.5 1.5 1.0
Maximum final overpressure with V-belt drive 3) [bar] 1.0 0.5 0.5
1) Consult CVS for suction temperature and/or altitudes outside the permissible working range.
2) Excess pressure = 0 bar, suction and ambient temperature = 20 °C
3) Vacuum = 0 mbar, suction and ambient temperature = 20 °C
4) Process water temperature = 20 °C
Tab. 2: Permissible working range
15
VacuStar WR performance data vacuum
1), 2)
1), 2), 3)
1), 2), 3)
1), 2)
1), 2)
VacuStar WR performance data
1), 2)
operation
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
Unit WR 2500 WR 3100 WR 4000
Suction pressure: 400 mbar
Speed [1/min] 1600 1300
Maximum intake volume flow
Coupling power
Intake volume flow
Coupling power
[kW] 73 88 117
[m3/h] 2016 2427 3521
[kW] 61 76 107.5
Sound pressure level at 7 m distance at
400 mbar
1) Excess pressure = 0 bar, suction and ambient temperature = 20 °C
2) Process water temperature = 20 °C
3) Water vapour saturated air = 55 °C
[m3/h] 2500 3100 4063
[dB(A)] 70 72 73
Tab. 3: Performance data vacuum operation
pressure operation
Excess pressure: 0.5 bar
Unit WR 2500 WR 3100 WR 4000
Coupling power [kW] 77 94 131.5
Intake volume flow [m3/h] 1936 2469 3496
Sound pressure level at 7 m distance
at 0.5 bar excess pressure
1) Vacuum = 0 mbar, suction and ambient tempe rat ure = 20 °C
2) Process water temperature = 20 °C
[dB(A)] 70 72 73
Tab. 4: Performance data pressure operation
16
VacuStar WR process water circulation
Unit
WR 2500
WR 3100
WR 4000
3)
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
200 / 400 mbar
Dissipated heat in vacuum
operation
1), 4)
at speed
200 / 400 mbar
at speed
0.5 / 1.5 barg
Dissipated heat in
pressure operation
2), 4)
at speed
0.5 / 1.5 barg
at speed
Maximum process water inlet temperature
VacuStar WR
[kW]
[kW]
[°C] 55
48 / 42
1500 1/min
55 / 47
1600 1/min
41 / 80
1500 1/min
46 / 90
1600 1/min
60 / 52
1500 1/min
68 / 59
1600 1/min
50 / 92
1500 1/min
56 / 103
1600 1/min
pH value – 5…8
Pipe dimension [inch] R1 ½
Radiator surface A
Water supply volume in the reservoir min. [l]
Total volume water reservoir min. [l]
[m2] 0.16 0.32 0.43
radiator
approximate
ly 300
approximate
ly 450
approximate
ly 400
approximate
ly 600
81 / 72
1200 1/min
95 / 84
1300 1/min
66 / 100
1200 1/min
79 / 128
1300 1/min
approximate
ly 550
approximate
ly 800
Process water circulating quantity
in vacuum operation at 400 mbar 1)
1) Excess pressure 0 bar
2) Vacuum 0 mbar
3) Based on a radiator of a specific cooling capacity P
P
Heat to be dissipated for oper atio n wit h water vapour saturate d air on re que st
spec = Pab
/ [(t
water
− t
air in
) • A
radiator
]
= 3.5 kW / (m² • °C)
spec
Tab. 5: Process water circulation
[l/min] 70…90 70…90 70…90
17
VacuStar WR
The liquid ring pump works according to the positive displacement
4 Design and function
4.1 Design
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
Fig. 5: Design
1 Drive shaft
2 Connection process water
3 Cell ventilation connection
4 Connecting flange for pressure or suction
connection (flange DIN 28459)
5 Process water draining
4.2 Function
principle. At a sufficiently high speed, a rotating liquid ring is
formed in the casing. In conjunction with the impeller, cells form
that are separated from each other and steadily grow (sucking) or
shrink (compressing) with each revolution.
6 Rating plate
7 Rotation arrow
8 Thread for eye bolt
9 Fixing foot
10 Water level indicator
11 Liquid supply for slide ring seal
12 Manuel fill level inspection
18
Lubrication
All moving parts are without contact. The lubrication of the
Cooling
The unit is cooled by the process water and/or the liquid ring. A
Shaft sealing
Maintenance-free slide ring seals separate the working space from
Sense of rotation
The unit is always driven from the A-side. The VacuStar WR is
Connecting flanges
Location (A-side or B-side) and direction (horizontal or vertical) of
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
Fig. 6: Functional principle
VacuStar WR is limited to the impeller bearing. The bearings are
fitted with a permanent grease filling.
radiator in the process water circulation dissipates the heat to the
environment.
the bearings and/or the atmosphere.
optionally available with clockwise or anticlockwise sense of
rotation.
suction and pressure flange are variable. Fig. 4 (page 13) shows a
diagram of the flange allocations.
19
Drive
The VacuStar WR can be powered via:
Process water circulation and cell
In addition to the drive and the suction and pressure lines, other
Typical process water loss calculation:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
Articulated shaft
V-belt
Flexible coupling
See page 35.
ventilation
components are required to operate a liquid ring pump (see
page
24, Fig. 8).
Water circulation with reservoir and radiator.
The air flowing through the VacuStar WR absorbs humidity
from the liquid ring, and is 100% saturated when it exits.
Only the water drops are separated in the reservoir. The
steam component is dissipated to the environment.
Fig. 7: Process water delivery
Fig. 7 shows the process water delivery from the reservoir for an
intake volume flow of 100 m³/h as a function of intake pressure and
process water temperature.
Type : VacuStar WR 3100
Intake pressure: 400 mbar
Intake volume flow according to Tab. 3: 2427 m³/h
Process water output temperature: 50 °C
Water loss for intake pressure and
process water outlet temperature according to Fig. 7:
2.1 l/h per 100 m³/h intake air
20
Process water loss
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
In operation with cell ventilation, the process water loss is
increased as a function of the additional air throughput.
Cell ventilation:
As the vacuum increases, the amount of process water that
is removed from the working space decreases due to the
decreasing air mass.
At a higher vacuum, auxiliary air is fed through a ventilation
line. This maintains a safe operation.
21
Improper transport
For future transports:
5 Transport and storage
5.1 Safety notes for transport
Please also observe all safety instructions in the operating
instructions "VacuStar WR 2500 / WR 3100 / WR 4000", Chapter
5.2 Transport
"Occupational safety and special risks".
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Transport and storage
Danger!
Danger by falling down or tilting of the
VacuStar WR!
The weight of the VacuStar WR may injure a
person and cause serious bruising!
Therefore:
– Depending on the dead weight and size of the
VacuStar WR, use a pallet on which the
VacuStar WR can be moved by means of a fork
lift.
– For lifting the VacuStar WR, use suitable lifting
gear (slings, etc.) that is designed for the weight
of the VacuStar WR.
– When putting the slings in position, take care to
avoid putting stress on individual components.
– Only use the provided attachment points with
eye bolts.
The VacuStar WR fastened on a pallet must be transported by
means of a fork lift or suitable lifting gear. The lifting gear must be
designed for the weight of the VacuStar WR.
Seal all open connections with protective caps
(prevents penetration of dirt and water)
Secure against vibrations
Drain all process and operating media
Securely fasten the VacuStar WR prior to transport (e.g.
screw it onto a pallet)
Transport and put down the VacuStar WR with a fork lift or
secure with straps and lift with suitable lifting gear.
22
Storage of packages
Store packages under the following conditions:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Transport and storage
5.3 Storage
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…+60 °C
Relative humidity: max. 95%, non-condensing
If storage lasts longer than 3 months, regularly check the
general condition of all parts and of the packaging. If
necessary, brush up or recondition the preservation.
23
Safety
Electrical system
Dirt and lying about items
6 Installation and assembly
6.1 Safety
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
WARNING!
Risk of explosion!
Only use components that are suitable for the zone
in which the unit is used when you install the unit in
an explosive atmosphere. An equipotential bonding
must be installed between the equipment and the
vehicle.
The safety equipment described in our mounting
instructions and installation instructions are
mandatory for a safe operation of the VacuStar WR
in explosive areas.
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.
– Only skilled electricians are allowed to carry out
any work on the electric systems, on electric
components and connections.
CAUTION!
Risk of tripping from dirt and objec ts lying
around!
Contamination and discarded items can lead to
slipping and tripping, resulting in substantial
injuries.
Therefore:
– Always keep the working area clean.
– Remove objects that are not required.
– Mark tripping points with yellow-and-black tape.
Please also observe all safety instructions in the operating
instructions "VacuStar WR 2500 / WR 3100 / WR 4000", Chapter
"Occupational safety and special risks".
24
1 VacuStar WR
11 Vacuum meter
18 Process water cooling in the
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
6.2 Installation example
2 Dehydration
3 Compensator
4 Pressure gauge
5 Thermometer / temperature
switch
6 Safety valve
7 Non-return valve for
VacuStar WR
8 Process water reservoir
9 Changeover four-way cock
10 Safety tank
Fig. 8: Typical installation
12 Vacuum suction filter
13 Safety dome with float valve
14 Vehicle tank
15 Cell ventilation from
atmosphere
15.1 Cell ventilation valve
15.2 Muffler
15.3 Air filter
15.4 Cell ventilation valve
17 Process water radiator
control line
NOTE!
Fig. 8 shows the example of a complete system
with ideal design.
bypass flow
18.1 Reservoir pipe – radiator
18.2 Circulating pump
18.3 Radiator pipe – reservoir
18.4 Reservoir pipe –
VacuStar WR
20 Water stop valve
21 T-piece to fill the
VacuStar WR with process
water
25
Installation requires the following activities:
Fixing options for the VacuStar WR
Four screws at the feet of the VacuStar WR secure the
Checking the function before the
Check the rotor shaft function. Rotating the rotor shaft with
Requirements
The attachment points on the vehicle must feature a
Requirements
Protected against dirt, gravel impact and splashing water.
Assembly
Use the following screws for securing the VacuStar WR:
Model
Screw
Solidity
Torque
6.3 Necessary work
Installing all components on the vehicle side.
Installing VacuStar WR with suction and pressure lines.
Installing safety and monitoring equipment.
Connecting the VacuStar WR with the process water
Connecting the drive with VacuStar WR. Observe sense of
6.4 Assembly of the VacuStar WR
To adjust the unit in the best possible way to the installation
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
circulation.
rotation and speed range.
VacuStar WR to the vehicle.
conditions, the feet of the VacuStar WR can be rotated
clockwise or anticlockwise by one screw pitch. See page 11,
Fig. 1 and page 12, Fig. 2
installation
placed upon installation point
and attachment
upon the installation location
your hand must be possible.
sufficient load capacity and rigidness.
The attachment points for the feet of the VacuStar WR must
be on the same level.
offer sufficient space for accidental contact protection.
offer sufficient space for the connections of the suction and
pressure lines.
ensure good legibility of the instruments.
Accessible for maintenance and repair work (e.g. for
replacing the air filter, or for checking the safety and nonreturn valve).
WR 2500 / 3100 M16 8.8 190 Nm
WR 4000 M24 8.8 680 Nm
Tab. 6: Fastening screws
26
Compensators in
Vacuum- and pressure-proof compensators must be installed in
Suction and pressure line
As required, the suction line and the pressure line can be installed
VacuStar WR
DN suction and pressure line
Process water line
Depending on the pipe routing, a line cross-section of R1/2“…R2“
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
6.5 Compensators
suction and pressure lines
the suction and pressure lines to delimit the socket forces and to
isolate the impact sound. Selection according to the protection
pressure and - with ATEX - the explosion pressure shock
resistance. Temperature resistance up to 100 °C.
6.6 38B38BLines and containers
at the A-side or at the pressure side and in vertical or horizontal
direction (see page
Fig. 4 (Page 13) shows the allocations of the flanges for all
possible combinations.
The lines must satisfy the following requirements:
Corrosion-proof
Pressure resistance or explosion pressure shock resistance
Nominal diameter according to the following table:
WR 2500 DN 125 (5“)
11, Fig. 1 and page 12, Fig. 2).
for ATEX
WR 3100 DN 125 (5“)
WR 4000 DN 150 (6“)
Tab. 7: DN suction and pressure line
The lines must not have any reaction force on the
VacuStar WR. Support the lines adequately.
Place suction lines rising towards the VacuStar WR. The
condensate must be able to be drained.
Remove dirt, welding remainders, rust,. etc. before you put
the unit into operation.
results.
To avoid overfilling the VacuStar WR, a solenoid valve (flow when
the VacuStar WR is started, stop when it is switched off) is
installed in the process water inlet.
27
Cell ventilation
See page 24, chapter 6.2.
VacuStar WR
Inside diameter cell ventilation line
Reservoir
There must always be a water supply available in the VacuStar WR.
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
The cell ventilation line is fed via the cell ventilation valve from
the atmosphere. Installing a sound absorber is necessary to
reduce the flow noise. An air filter prevents the penetration of
dirt.
up to a line length of 2.5 m
WR 2500 min 27 mm
WR 3100 min 52 mm
WR 4000 min 68 mm
Tab. 8: Inside diameter
This is required for generating the liquid ring during the start and to
ensure the lubrication of the slide ring seal.
Variant I (see page 24, chapter 6.2): The liquid level is above the line
connection of the VacuStar WR.
At minimum water content in the reservoir and open process
water line, the water level must not be below the connection of
the VacuStar WR lines.
A water stop valve must be installed in the process water inlet
to avoid overfilling the VacuStar WR at standstill.
Variant II: The liquid level is below the line connection of the
VacuStar WR.
Depending on the line routing, installing a water circulation
pump in the process water line may be necessary to support
the circulation. Please contact CVS for the rating of the pump.
ATTENTION!
The slide ring seal will be damaged when the
machine runs dry, without liquid. Before it is started,
the liquid ring pump must always be filled
approximately half with liquid.
CAUTION!
No gross iron-containing particles (> 0.2 mm) must
be carried into the VacuStar WR via the intake or the
industrial water.
28
The following safety equipment must be installed:
Risk of explosions
Assembly
1. Install the safety valve immediately after the pressure pipe
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
6.7 Safety equipment
Safety valve
Monitoring the compression end temperature
Non-return valve always at the suction side
Vacuum suction filter
6.7.1 Safety valve
Protection against contact.
DANGER!
Risk of injury by explosions!
Explosions can cause severe injuries!
Therefore:
– Install the safety valve as instructed. Observe
the manufacturer's instructions.
– Only use the safety valve for its intended
purpose.
– Never block the safety valve.
The German accident prevention regulations require a nonlockable safety valve to be installed after the VacuStar WR at the
pressure side. This valve must be selected such that it prevents
the pressure to exceed the highest permissible operating pressure
by more than 10 %. It must be identified with a TÜV component
test number and be equipped with a manual venting element.
joint.
2. The nominal opening pressure may not exceed the maximum
permissible final overpressure (refer to Tab. 2) or the
permissible system pressure, provided the latter is lower.
29
A suitable measuring instrument must be installed that switches
Assembly
1. Install the temperature sensor in the line after the pressure
Assembly
Install the vacuum filter into the suction line upstream from the
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
6.7.2 49B49BMonitoring the end temperature
the VacuStar WR off when the maximum permissible temperature
is reached.
pipe joint.
2. Connect the temperature sensor to the superordinate vehicle
controller.
CAUTION!
– The temperature sensor connection must be
– The maximum shutdown temperature is 95 °C
Installation and assembly
intrinsically unbreakable.
6.7.3 Non-return valve
When a vacuum is applied and the VacuStar WR is stopped, the
non-return valve prevents the air and the process water from
flowing back into the suction line.
The non-return valve must be installed immediately before the
suction flange.
6.7.4 Vacuum suction filter
An adequate filter (filter mesh < 0.5 mm) is required to prevent
solid matters from being sucked in.
VacuStar WR. Observe the flow direction.
6.7.5 Protection against contact
CAUTION!
For explosion-proof VacuStar WR, use only filters
that are resistant to the explosion pressure shock.
Such filters can be purchased from CVS for the
VacuStar WR 2500 and WR 3100.
Rotating or hot parts of the system must be equipped with a
protection against contact.
Please note that the German accident prevention regulations do
not allow a maximum surface temperature of 80 °C to be
exceeded.
30
Assembly
The VacuStar WR has been prepared for operation with cell
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
Observe DIN EN ISO 13857, for example, for the distances and
the layout of the protective grid.
6.7.6 Cell ventilation valve
ventilation. The connection is located at the top next to the process
water connection.
Observe the following points during installation:
1. Install cell ventilation valve vertically.
2. Install the fresh air lines between the VacuStar WR and cell
ventilation valve.
3. Install the control line between the connection at the suction
socket and the cell ventilation valve.
4. Set an opening pressure of 200…300 mbar with the
VacuStar WR running at the setting screw.
5. Check the full stroke. Full stroke = 27 mm.
Cell ventilation valve, muffler and suction filter can be purchased
from CVS
ATEX note
When transporting explosive gases and gas
mixtures, the control and fresh air lines must be
explosion and shock-proof (11.6 barg).
31
1 Air filter (installed vertically)
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
Fig. 9: Cell ventilation valve with muffler and air filter
2 Hose adapter
3 Muffler (installed horizontally or vertically)
4 Muffler holder
5 Connection line, max. length 1 m (not included in scope of
delivery)
6 Hose stub
7 Cell ventilation valve (installed vertically)
8 Screw connection, connection control line (recommended pipe
diameter: 10 x 1 mm)
9 Locknut
10 Adjustment nut for the adjustment and tuning of the oil
pressure
11 Spring cage
Caution: Spring is under pressure. Prior to removing the
spring cage, the springs must be completely relaxed with the
set screw.
12 Connection R1 1/2" fresh air line to VacuStar WR,
max. length 300 mm
32
Designation
Monitoring
Place of installation
Measuring range
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
6.7.7 Display and monitoring equipment
Vacuum meter, pressure gauge, temperature sensor, and flow
monitor must be installed for the safety of the VacuStar WR.
The process water supply in the reservoir must also be monitored.
We also recommend the installation of a speed counter.
CAUTION!
All display and monitoring devices in a system that
is used for conveying explosive material must
comply with the Directive 2014/34/EC (ATEX) with
respect to equipment category, temperature class
and explosion group.
parameters
Vacuum meter Operating vacuum
Intended location,
0…1000 mbars
immediate in front of
the inlet
Pressure gauge
Positive working
pressure
Immediately after the
pressure pipe joint of
0…2.0 bars
the VacuStar WR
Temperature sensor
Compression end
temperature
Flow monitor Process water inlet
After the pressure
flange
Water supply line
Up to approximately 120 °C
–
upstream of the
process water
connection of the
VacuStar WR
Water level indicator
Water level in
VacuStar WR at
Exists ex-factory on
both lids
Only for visual inspection
standstill
Speed counter
(option)
Speed Drive shaft
WR 2500 / WR 3100
WR 4000
800…1600 min
800…1300 min
1
−
1
−
Tab. 9: Display and monitoring equipment
33
Requirements
The safety tank protects the VacuStar WR from sucking in liquids.
Assembly
Install the safety tank at the deepest point of the system.
Functional check
The functional check of the safety tank must satisfy the following
Requirement
The safety dome on the vehicle tank must be equipped with a float
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
6.8 40B40BAdditional components of the system
6.8.1 Safety tank
It must comply with the following requirements:
Passing air must not hit the liquid surface directly
Sufficiently large settling chamber
Drain cock at the deepest point of the tank
requirements:
The separated water must remain in the safety tank during
suction operation.
In atmospheric suction (pressure operation), the liquid ring
pump must not suck in more than 1 litre of liquid per hour.
Installation and assembly
6.9 Safety dome
6.10 Cooling water system
valve and a baffle.
The baffle prevents the liquid from being entrained when the liquid
sloshes.
ATTENTION!
– The maximum permissible cooling water
temperature is 60 °C.
– When dimensioning the components, you must
take extreme temperatures in the summer and
coolant additives into account. See page 16,
Tab. 5.
34
The following figure shows a diagram of the radiator
1 Process water inlet from the reservoir
Assembly
Observe the following points during installation:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
arrangement. Also see page 24, Fig. 8.
2 Process water outlet to the reservoir
Fig. 10: Radiator arrangement
Operate the radiator in the bypass flow if possible.
Ask CVS engineering for the circulating cooling water
quantity
Install the radiator stress-free on rubber elements.
Install the cooling water pump at the lowest point.
Use hoses that are temperature-resistant up to 100 °C.
Add antifreeze compound for ambient temperatures below
0 °C.
Recommended delivery rate of the water pump 5,200 l/h at
0.2 bar pressure loss
NOTE!
In order to prevent introduction of deposits or dirt
particles into the VacuStar WR with the industrial
water, we recommend installing a coarser filter
depending on the chosen cooler.
35
The VacuStar WR is driven via:
6.11 Drive
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
CAUTION!
Drive and coupling of a system that is used for
conveying explosive material must comply with the
Directive 2014/34/EC (ATEX) with respect to
equipment category, temperature class and
explosion group.
ATTENTION!
– Selection and design are within the
responsibility of the system builder.
– Do not route axial forces into the VacuStar WR
shaft when installing drive components.
– Do not tap couplings or other connection
components onto the shaft, but slide them on.
– Always slide additional components such as V
belt pulleys as far onto the shaft of the
VacuStar WR as possible.
– Check the torque and the sense of rotation.
6.11.1 V belt drive
V-belt
Articulated shaft
Flexible coupling
where drives such as lorry P.T.O, electric motors, hydraulic motors
or diesel engine are possible.
ATTENTION!
The maximum permitted transverse force (FQ) at
the drive shaft due to the belt pull must not exceed
the following values:
VacuStar WR 2500 / WR 3100 FQ= 9300 N
VacuStar WR 4000 FQ= 12500 N
Observe the design, installation and inspection
instructions of the manufacturer.
36
VacuStar WR V-belt drive
Unit
WR 2500
WR 3100
WR 4000
Assembly
Select V-belt drive according to Table (Tab. 10).
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Installation and assembly
The following belt pulleys can directly be installed on the shaft end
of the VacuStar WR:
V belt profile – XPB
Smallest pulley diameter [mm] 280 315
Number of belts in pressure operation – 5 5 6
Permissible final overpressure in pressure
operation
[bar] 1.0 0.5 0.5
Number of belts in vacuum operation – 5 5 6
Tab. 10: Belt pulleys
Align the V belt pulleys accurately to each other.
Install V-belt pulleys (e.g. with Taper-Lock clamping bushes)
and V-belt with pretension according to the manufacturer
specifications.
6.11.2 Articulated shaft drive
ATTENTION!
Observe the design, installation and inspection
instructions of the manufacturer.
Keep the bending radius of the articulated shafts as small as
possible. Observe the specifications of the manufacturer of the
articulated shafts.
6.11.3 Drive via flexible coupling and hydraulic motor
ATTENTION!
Observe the design, installation and inspection
instructions of the manufacturer.
The hydraulic motor is installed to the VacuStar WR via an
intermediate flange. The power is transmitted via a flexible
coupling.
Components that match the VacuStar WR type can be ordered
from CVS.
37
Start-up, operation
7 Start-up
7.1 Safety during start-up
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Start-up
WARNING!
Risk of injury due to improper start-up and
operation
Improper start-up and operation 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 authorised 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.
Please also observe all safety instructions in the operating
instructions "VacuStar WR 2500 / WR 3100 / WR 4000", Chapter
"Occupational safety and special risks".
38
Inspection prior to initial start-up
The following points must be checked prior to initial start-up:
Start-up
Proceed as follows during start-up:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Start-up
7.2 Start-up
Inspect the VacuStar WR and the entire system
Check the pipes for continuity and residues (remove blanks if
there are any)
Check the operating data on the rating plate.
Check whether the rotor shaft can be rotated by hand.
Check the function of the water stop valve (water supply
and/or cell ventilation).
Check the sense of rotation (switch briefly on/off). Observe the
arrow for the sense of rotation.
Fill in process water (clean drinking water) up to the
maximum mark on the reservoir. Bleed the circuit. Add
antifreeze according to manufacturer's specifications.
Check the function of the safety valve (see page 28 ff,
chapter 6.7.1.).
Check the attachment screws.
(see page 25, chapter 6.4.)
ATTENTION!
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 (refer to page 17, Fig. 5,
pos. 10).
Open shut-off devices (if installed).
Start the VacuStar WR drive.
Check the operating data.
Check the function of the installed cell ventilation.
The VacuStar WR must run smoothly when the suction valve
is closed.
39
Inspections during operation
The following inspections have to be carried out during operation:
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Start-up
The liquid level in the reservoir must not be lower than the
minimum mark during operation.
Always turn the four-way cock until it hits the stop.
Intermediate positions are not permitted
Check whether pressure or vacuum builds up.
Pay attention to abnormal noises and leaks during operation.
If necessary, switch off VacuStar WR.
Drain the condensate at the safety trap. Vessel may not be
in a state of vacuum when condensate is drained.
Checking the operating data:
The speed must be between:
800…1600 min
800…1300 min
The cooling water outlet temperature (return flow to radiator)
may be max. 60 °C.
Check the positive working pressure at the pressure gauge
(permissible pressure see Tab. 4, page 15).
Check the operating vacuum at the vacuum meter
(permissible vacuum see Tab. 3, page 15).
-1
(WR 2500 / WR 3000) or
-1
(WR 4000).
CAUTION!
The following points must be observed when
explosive gases and gas mixtures are conveyed:
– Prior to every start of the VacuStar WR and
during operation:
– Check the process liquid levels
(VacuStar WR and reservoir).
– Check for leaks
– Listen for abnormal noise during the suction
process. Switch off the VacuStar WR if
necessary.
– Check the VacuStar WR at regular intervals
(daily) for signs of overheating and exceptional
deformations. If necessary, switch off the
VacuStar WR or do not put it into operation.
40
pH value of the process water
Depending on the conveyed medium, the steady water
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Start-up
7.3 Switching off
To switch off the VacuStar WR, proceed as follows:
Switch off drive for the VacuStar WR
Close the shut-off valves (if installed)
Drain the safety tank. Vessel may not be in a state of vacuum
when condensate is drained.
7.4 Inspections to be performed
delivery can lead to an increased concentration of harmful
substances and thus to a change in the pH value.
The permissible pH value (see page 16, Tab. 5) must be
checked (using litmus paper, for example) at regular
intervals according to the operation experience.
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
8 EC Declaration of Incorporation
EC Declaration of Incorporation
9 Declaration of Conformity
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Declaration of Conformity
43
Index
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Index
A
Acceptance ........................................................... 9
Articulated shaft drive ......................................... 36
ATEX ................................8, 26, 29, 30, 32, 35, 39
C
Cell ventilation design ......................................... 19
Cell ventilation installation .................................. 27
Cell ventilation valve ........................................... 30
Compensators .................................................... 26
Connecting flanges ............................................. 18
Contact person ..................................................... 7
Cooling................................................................ 18
Cooling water system ......................................... 33
Copyright protection ............................................. 7
Customer Service ................................................. 7
D
Danger pictograms ............................................. 10
Dangers .............................................................. 10
Declaration of Conformity ................................... 42
Declaration of Incorporation ................................. 7
Design ................................................................. 17
Dimensions ......................................................... 11
Dirt ...................................................................... 23
Display equipment .............................................. 32
Drive ................................................................... 35
E
EC Declaration of Incorporation ......................... 41
Electrical specialist ............................................... 9
F
Function .............................................................. 17
I
Inspection
during operation .............................................. 39
Lubricating oil .................................................. 40
prior to initial start-up ...................................... 38
Installation and assembly ................................... 23
Installing VacuStar WR ....................................... 25
Intended use ......................................................... 8
L
Liability .................................................................. 7
Lubrication .......................................................... 18
M
Monitoring equipment .........................................32
N
Non-return valve .................................................29
O
Occupational safety ............................................10
Operating instructions ........................................... 5
Operator ................................................................ 9
P
Personnel ..............................................................
9
Pressure line ................................................ 12, 26
Process water circulation ....................................19
Process water delivery ........................................19
Process water line ..............................................26
Proper operation ................................................... 9
Protection against contact ..................................29
Protective equipment ..........................................10
R
Reservoir.............................................................27
S
Safety .................................................................... 8
Safety dome ........................................................33
Safety equipment ................................................28
Safety tank ..........................................................33
Safety valve ........................................................28
Shaft sealing .......................................................18
Sound absorber - oil separator ...........................33
Spare parts ........................................................... 7
Specialised staff .................................................... 9
Start-up ...............................................................37
Start-up ...............................................................38
Storage ...............................................................22
Suction line .................................................. 12, 26
Switching off........................................................40
Symbols in the instructions ................................... 6
T
Technical data ............................................. 11, 14
Transport.............................................................21
Typical installation ..............................................24
V
V belt drive ..........................................................35
Vacuum suction filter ..........................................29
44
W
Warranty ...............................................................7
45
Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000
Index
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