GD AQUALINE 1100, AQUALINE1600, AQUALINE 2700, AQUALINE2100 Installation & Operating Instructions Manual

AQUALINE
1100/1600/2100/2700

Installation
Operating &
Maintenance
Instructions

4990671000
February 2008

Contents

4990671000 February 2008 2

Contents

Contents

1. Technical data . . . . . . . . . . . . . . . . . . . . . 5

1.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.2.1 Connection versions. . . . . . . . . . . . . . . . . . . . 7

1.3 Location of lubricating points . . . . . . . . . . . . . 8

1.4 Operating fluid . . . . . . . . . . . . . . . . . . . . . . . .8

1.5 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2. Safety instructions and hazard alerts . . 9

2.1 Use for intended purpose. . . . . . . . . . . . . . . .9

2.2 Acceptance and monitoring . . . . . . . . . . . . . . 9

2.3 Hazard alerts and symbols. . . . . . . . . . . . . . . 9

2.4 Safe working . . . . . . . . . . . . . . . . . . . . . . . . .9

3. Transport, Storage and Scope of

delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . 11

4. Installation . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 System setup with cooler in main flow . . . . .12

4.2 System setup with cooler in side flow . . . . .13

4.3 Point of installation and fastening . . . . . . . .15

4.4 Connections and piping . . . . . . . . . . . . . . . . 15

4.5 Protection against intake of dirt and

residue . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.5.1 Suction line. . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.2 Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . .16

4.5.3 Safety dome . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.4 Safety bowl. . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.6 Safety and monitoring instruments. . . . . . . . 16

4.6.1 Vacuum gauge . . . . . . . . . . . . . . . . . . . . . . . 17

4.6.2 Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . .17

4.6.3 Non-return valve. . . . . . . . . . . . . . . . . . . . . . 17

4.6.4 Thermometer . . . . . . . . . . . . . . . . . . . . . . . . 17

4.6.5 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.6.6 Pressure gauge . . . . . . . . . . . . . . . . . . . . . .17

4.6.7 Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.6.8 Bellows. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.6.9 Speed monitor . . . . . . . . . . . . . . . . . . . . . . .18

4.7 Operating fluid . . . . . . . . . . . . . . . . . . . . . . .18

4.7.1 Operating water back-cooling and

storage tank . . . . . . . . . . . . . . . . . . . . . . . . .18

4.7.2 Cell Ventilation . . . . . . . . . . . . . . . . . . . . . . .19

4.8 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.8.1 Drive by hydraulic motor . . . . . . . . . . . . . . .19

4.8.2 Drive by flexible clutch . . . . . . . . . . . . . . . . .19

4.8.3 Drive by propeller shaft . . . . . . . . . . . . . . . .19

4.9 Drive by Vee belt . . . . . . . . . . . . . . . . . . . . .20

5. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.1 Testing the system . . . . . . . . . . . . . . . . . . . . 22

5.2 Operating liquid . . . . . . . . . . . . . . . . . . . . . . 22

5.3 Stop slide and shut-off valves . . . . . . . . . . .22

5.4 Direction of rotation . . . . . . . . . . . . . . . . . . . 22

5.5 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5.6 Inspection of speed, vacuum and pressure .22

5.6.1 Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5.6.2 Vacuum and vacuum gauge . . . . . . . . . . . .22

5.6.3 Pressure at pressure gauge. . . . . . . . . . . . .22

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

6.2 Regular inspections . . . . . . . . . . . . . . . . . . . 23

6.2.1 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.2.2 Water stop valve . . . . . . . . . . . . . . . . . . . . .23

6.2.3 Inspection intervals . . . . . . . . . . . . . . . . . . .24

6.3 Operating the liquid ring pump . . . . . . . . . . . 24

6.3.1 Operating water consumption and control . .24

6.4 Possible faults by the operator . . . . . . . . . . .25

6.5 Extended period of non-use . . . . . . . . . . . .25

6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . .26

7. Maintenance . . . . . . . . . . . . . . . . . . . . . 28

7.1 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . .28

7.2 Maintenance, maintenance

schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

7.2.1 Water back-cooling with air . . . . . . . . . . . . .28

7.2.2 Liquid ring pump . . . . . . . . . . . . . . . . . . . . . .28

7.2.3 Vacuum filter (GDD types) . . . . . . . . . . . . . .28

7.2.4 Vee belts and Vee belt tension. . . . . . . . . . .29

7.2.5 Non-return valve . . . . . . . . . . . . . . . . . . . . . .29

7.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .29

7.3.1 Antifriction bearings . . . . . . . . . . . . . . . . . . .29

7.3.2 Shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . .30

8. Spare parts . . . . . . . . . . . . . . . . . . . . . . 31

8.1 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . .31

9.

Preface

4990671000 February 2008 3

Preface

Dear customer,

Your new Water 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.

This machine requires proper handling, especially un­der severe operating conditions. Startup, operation
and maintenance must must therefore be performed
only by trained and authorised 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 over a long
period 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 water ring pump from
Gardner Denver Drum. If you have any questions
which are not answered in this manual, please call us.

Sincerely yours,

Gardner Denver Drum Ltd.

Mode of operation, Design versions

4990671000 February 2008 4

Mode of operation, Design versions

Mode of operation

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 rotor.
The housing is partly filled with liquid, which the rota­tion of the rotor forms into a rotating liquid ring in con­tact with the housing. Together with the hub of the
eccentrically mounted rotor, it forms a sickle-shape
working space divided by the vanes of the rotor.

The rotation of the rotor causes the cell volume to be­come large at the intake side. This creates 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 covers located on either side of the rotor
faces.

This functional principle causes the machine to work at
nearly 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.

Design versions

The design versions differ in their direction of rotation.

Type code:

AQUALINE 2100 R

Liquid ring pump,
operating

medium: water

1)

1)

Water is the working liquid commonly used by suction vehicles.

Machine size R = CW rotation

L = CCW rotation

Technical data

4990671000 February 2008 5

Technical data

1. Technical data

1.1 Machine data

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

Conveyed medium

Air of maximum intake temperature of 60 °C.

Operating fluid

Water or water-glycol mixture

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.

Liquid ring pump Aqualine

1100

Aqualine

1600

Aqualine

2100

Aqualine

2700

Rated operating vacuum (absolute) mbar 400 400 400 400

Maximum gauge pressure in

compressor operation

1)

barg 1.5 1.5 1.5 0.5

At 400 mbar (absolute) intake pressure

volume flow rate
final gauge pressure
power consumption on shaft

m

3

/h

barg

kW

900

0.0
32

1,300

0.0
46

1,700

0.0

60.5

2,075

0.0
74

At 1,000 mbar (absolute) intake pressure

volume flow rate
final gauge pressure
power consumption on shaft

m

3

/h

barg

kW

840

0.5
33

1,270

0.5
50

1,660

0.5
65

2,100

0.5
84

Possible max. intermitant vacuum (absolute)

approx.

2)

mbar 130 130 130 130

Rated speed

3)

1/min 1,500 1,500 1,500 1,500

Mass moment of inertia, incl. liquid ring kgm

2

0.7 1.0 1.3 1.6

Sound pressure at 7 m distance at 400 mbar
(absolute)

dB(A)66687072

Weight of the basic machine kg 150 165 180 195

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.

2)

Dependant on water temperature.

3)

The permitted speed range from 1,100 to 1,500 rpm must be observed.

Technical data

4990671000 February 2008 6

1.2 Dimensions

Fig. 1.1 Dimensions of Aqualine 1100 to 2700

E

F

G

H

Air

Water

b

590

448

Ø 48

k6

80

270

a

c

M16

26

AB

45°

479

370

157

210

18

200

274

50

122

190

500

52

147,5

C

D

a b c Machine serial no. Connection

for

additional

ventilation

Z

1) 2) 3)

1)

One-side cell venting Z only for connection to the machine numbers in this table.

2)

Second venting lines on opposite side required for machine serial nos. 910 390/.., 910 400/.. et 910 410/.. for housing pipe socket

Z = G 1

1

⁄4" and OD = 28 mm.

3)

If conditions at the installation site require a second cell venting line, the minimum diameter in the table above also applies.

Ø Cell

venting

line I/D

Connection

for liquid
ring fluid

Ø

Operating

water line

Weight

[mm] [mm] [mm]

cw

rotation

ccw

rotation

[mm] [kg]

Aqualine

1100

170 355 630 910 389/.. 910 381/..

Optional

G 1"

or

G 1

1

⁄2"

28

G 1

1

⁄2"R 1

1

⁄2"

150

Aqualine

1600

260 400 720 910 399/.. 910 382/.. 165

Aqualine

2100

350 445 810 910 409/.. 910 383/.. 180

Aqualine

2700

450 495 910 910 439/.. 910 440/.. G 1

1

⁄2" 52 195

A

A-Side
BB-Side
C Connecting flanges with connecting variations (see figure 1.2)
D Drain for the liquid ring fluid G 3/4"
E Connection for an additional ventilation Z

F Drain for an additional ventilation G 3/4"
G Connection for the liquid ring fluid G 11/2";

Operating water inflow duct – drain

H Covered on A-side and B-Side

Technical data

4990671000 February 2008 7

1.2.1 Connection versions

Fig. 1.2 Connection sizes for Aqualine 1100 to 2700 versions (in mm)

Version I Version II Version III Version IV Version V Version VI

DEDEDEDEDEDE

Aqualine 1100 335 670 263 526 373 746 263 526 297 594 297 594

Aqualine 1600 380 760 308 616 418 836 308 616 342 684 342 684

Aqualine 2100 425 850 353 706 463 926 353 706 387 774 387 774

Aqualine 2700 475 950 403 806 513 1026 403 806 437 874 437 874

Version I

E

D

506

Part number
910 423 00

Version II

E

D

E

D

E

D

E

D

E

D

577

504

616

504

540238

28

Part number
910 423 00

Version II

8 x Ø14

Flange in acc. with
DIN 28 459 – DN125

Flange in acc. with
DIN 28 459 – DN125

Version I

Version III

Version IV

Version IVVersion III

Version V

Version VI

Version VIVersion V

Ø204

Ø204

Ø176

Ø176

Ø125

Ø125

105

105

105

105

Part number

910 424 00

Part number
910 427 00

Part number
910 427 00

Part number

910 424 00

Technical data

4990671000 February 2008 8

1.3 Location of lubricating points

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

From the vehicle engine:

• by auxiliary drive and propeller shaft

• by Vee belt, whereby the Vee belt pulley is installed

on the free shaft end

• by hydraulic drive

From other engine, electric or hydraulic motor:

• by flexible coupling

• by Vee belt, whereby the Vee belt pulley is installed

on the free shaft end

• For more details, see Installation section.

Fig. 1.3 Lubrication fittings and venting valve

X

Air

Water

X 2:1

0

Cover the lubrication fit­tings and the venting valve
when final painting!

Safety instructions and hazard alerts

4990671000 February 2008 9

Safety instructions and hazard alerts

2. 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, catagory 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.

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 to be used in a potentially explosive
atmosphere.

This symbol indicates information of particular
importance to the operator of the machine.

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 good working 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 agreed with the manufacturer.

• The machine must only be used with delivery and
intake lines connected.

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

• 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 start­ing work. It may be too late to refer to these
Instructions when work has already started!

• Operation and maintenance of the machine must
only be carried out when the machine is not run­ning.

Safety instructions and hazard alerts

4990671000 February 2008 10

• 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.
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 safety 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, cooling oil
or lubricant residue, are collected and dis­posed of as prescribed.

Transport

4990671000 February 2008 11

Transpor t

3. Transport

Symbols on the packaging:

Top

Fragile

Keep dry

3.1 Transport

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

Attach lifting equipment only at the firmly
installed eye bolts (see figure 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 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

Installation

4990671000 February 2008 12

Installation

4. 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

Fig. 4.1 Components of a system with liquid ring pump – Cooler in main flow

6

min

max

7 1 8 3 4 9 1a 5 19 12 11

10141518182171314155

16

15

20

For details of shaded area see page 14

1 +1a Vent line
2 Vacuum filter
3 Liquid ring pump
4 Non-return valve
5Bellows
6 Safety valve

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
16 Safety bowl with float valve
17 Flexible mounting

18 Vacuum gauge
19 Float switch
20 Water inlet for filling system

* For dimensions of the vent line, see table page 6

Installation

4990671000 February 2008 13

4.2 System setup with cooler in side flow

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.

• Lift the machine using only the 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.

Fig. 4.2 Components of a system with liquid ring pump – Cooler in side flow

54

Z

min

max

1 6 8 1a 7 5 3 14 19 9 12 11

101415171320

21

18182

16

15

15

For details of shaded area see page 14

1+1a V

ent line
2 Vacuum filter
3 Liquid ring pump
4 Non-return valve
5Bellows
6 Safety valve

7P

ressure gauge
8 Thermometer
9 Operating water tank
10 Four-way directional control

valve

11 Safety dome and float valve

12 Vehicl

e tan

k

13 Operating water cooler
14 Water stop valve
15 Drain valves
16 Safety bowl with float valve
17 Flexible mounting

18 V

acuum gauge
19 Float switch
20 Pump
21 Water inlet for filling system

* For dimensions of the vent line, see table page 6

Installation

4990671000 February 2008 14

Details of figure 4.1

Details of figure 4.2

15a Drain valve for the

liquid ring fluid

15b Drain valve in

cell venting line

15c Drain valve after

water stop valve

15d Drain valve for the

operating water cooler

Fig. 4.3 Components of a system with liquid ring pump – Cooler in main flow (detail)

Z

15b

15a

15c

15d

15a Drain valve for the

liquid ring fluid

15b Drain valve in

cell venting line

15c Drain valve after

water stop valve

15d Drain valve for the

operating water cooler

Fig. 4.4 Components of a system with liquid ring pump – Cooler in side flow (detail)

15b

15c

15a

15d

Installation

4990671000 February 2008 15

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
water splash.

• 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 (M16 tapped holes).
The machine can be fastened directly onto a suitable
frame. The minimum depth of thread engagement is
23 mm.

Framework must be of sufficient strength to support
machine in operation and while vehicle is driven.

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

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

The machine must be adequately earthed.
An equipotential earth bonding strap should
be securely fastened between the machine
body and a suitable point on the vehicle
frame.

Ensure that the machine and all ancilliaries
are earthed in accordance with BS5958 Pt1:
1991;

'Control of undesirable Static Electricity'.

4.4 Connections and piping

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

The various possibilities of the suction and pressure
line connections are illustrated in figure 4.5 for ma­chines of clockwise and counterclockwise rotation.

The suction and pressure line, respectively, can either
be connected on the A side or B side. 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.

Fig. 4.5 Aqualine 1100 to 2700 connection versions

Aqualine 1100 1600 2100 2700

Suction line DN 125

(5")

DN 125

(5")

DN 125

(5")

DN 125

(5")

Pressure line DN 125

(5")

DN 125

(5")

DN 125

(5")

DN 125

(5")

Top view

clock wise Operation

Suction side

connection on one

flange optional

Pressure side

connection on one

flange optional

Top view

counter clock wise Operation

Suction side

connection on one

flange optional

Pressure side

connection on one

flange optional

Installation

4990671000 February 2008 16

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. 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 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 of the vehicle tank. The
splash guard prevents liquid splash into the system.

4.5.4 Safety bowl

The safety bowl (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.

To inspect the function of the optimized gravity sepa­rator illustrated in figure 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 figure 4.1
and figure 4.2).

All items of safety equipment must be
inspected for proper function at regular inter­vals (see manufacturer’s technical instruc­tions).
It is forbidden to change, block or render safety
guards ineffective in any way.

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

At the suction side:

• Vacuum gauge

• Vacuum filter

• Non-return valve

• Bellows

At the pressure side:

• Safety valve

Fig. 4.6 Safety bowl

1

2

3

4

5

6

1 Intake bend
2 Baffle plate
3 Double perforated plate

4Drain cock
5 Two floating balls
6 Four guide rods

Installation

4990671000 February 2008 17

• Thermometer

• Pressure gauge

• Bellows

Operating water supply line:

• Solenoid valve for opening or closing the operating
water supply

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 is
to be installed downstream the non-return valve at the
suction side.

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

4.6.2 Vacuum filter

The vacuum filter protects the machine from coarse
mechanical impurities. The vacuum filter must be in­stalled in the suction line.

Note on installation the flow direction and required
space for replacing the filter insert.

4.6.3 Non-return valve

The non-return valve prevents the entry of water from
the pump to 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, install
the thermometer in the pressure line directly down-

stream 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 0 to
100 °C.

4.6.5 Safety valve

A non-shutting off safety valve shall be installed down­stream every compressor. 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 elements
(especially shutoff valve),

• the component marking and seal must be visible.

• 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

Provides pressure readings during normal machine
service. Measuring range in accordance with the oper­ating pressure. Install directly downstream the pres­sure connection.

Installation

4990671000 February 2008 18

4.6.7 Guard

The drive of the machine and the hot pressure lines
must be protected by guards.

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

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 must be installed.

At the same time, the bellows isolate 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 4.8
“Drive”.

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 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 covers of the machine have a G 1

1

/4" connec­tion (only one operating water supply connection is
needed, i.e. either on the A side or B side).

If the piping has sufficiently low resistance (feeding line
diameter R1

1

/2" to R2", depending on pipeline length
and layout) no recirculation pump may be needed for
the operating water supply provided the arrangement
of the liquid ring pump is such that 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 be­provided 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 to ensure sufficient operating hours of the
system, a combined operating water storage and sep­arating tank is needed. For minimum sizes, refer to the
table below.

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.

Aqualine

1100 1600 2100 2700

Amount of heat
to be
dissipated

at 1.5 bar

(g)

at 0.5 bar

(g)

at 400 mbar
at 200 mbar

kW 50

25
29
33

65
32
39
48

78
39
48
57

50
58
67

Recom­mended pipe
diameter oper­ating water line

R1

1

/2"R11/2"R11/2"R11/2"

Recom­mended mini­mum tank size

ltr 250 350 450 600

Recom­mended water
volume in the
tank

ltr 150 225 300 400

Installation

4990671000 February 2008 19

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 on the A-side and B-side housing covers
(see figure 1.1 connection socket “Z”).

Aqualine models 1100/1600/2100 need a ventilation
line with a pipe internal diameter Øi = 28 mm. Aqualine
model 2700 required pipe internal diameter Øi =
52 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 the entrained air line is the correct
size. Ensure 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 a closed intake line. If a loud noise
is heard, the entrained air 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 both water drains (see figure 1.1).

4.8 Drive

The direction of rotation must agree with the
direction of the arrow on the liquid ring pump.

Permitted speed range: 1,100 to 1,500 rpm

Ensure the drive speed increasing or reducing
ratios are observed (belt drive, auxiliary drive
of vehicle, ...)

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

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 power requirement 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 M16 thread.
Do not use a hammer or other impact device to
install the drive components on the rotor shafts

A coupling guard must be fitted as appropriate.

4.8.1 Drive by hydraulic motor

The selection and installation of the hydraulic motor is
the responsibility of the installation firms.

We can supply a matching flange and coupling.

After mounting the flange, the motor side coupling hub
must not transfer axial thrust onto the liquid ring pump.

4.8.2 Drive by flexible coupling

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

Align the coupling exactly as prescribed by the
manufacturer.

4.8.3 Drive by propeller shaft

The propeller shaft drive must

• incorporate a splined shaft,

• be balanced,

• have smallest possible angles and be as short as

possible.

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

Installation

4990671000 February 2008 20

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

Bolt the propeller shaft to the mounting flange of the
liquid ring pump shaft.

The resulting angle of bend must not exceed 15° at
1,500 rpm speed.

Ensure propshaft spline is correctly engaged.
Observe marking.

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".

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

Installation of the Vee belt drive

• The axis of the driving and driven machines should

be parallel.

• The grooves of the belt pulleys must be inline.

• Vee belt lenghts should be the same to ensure uni-

form belt tension.

• The Vee belt tension is correct when the

installed and tensioned belt can be deflected by
the pressure of the thumb by 16 to 20 mm for
every 1000 mm axial distance.

Ensure the bending moment exerted by the
belt drive on the shaft of the driving machine is
within the limits recommended by the manufac­turer.

Installing the Vee belt pulley with taper lock bush

1. Clean and degrease all blank faces. Place the pul-

ley 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. 4.7 Mounting the propeller shaft

Aqualine 1100 1600 2100 2700

Belt profile XPB XPB XPB XPB

Belt pulley
minimum

diameter D

W

1)

1)

Consult the manufacturer if smaller pulleys are to be used.

mm 280 280 280 280

Max. gauge
pressure with
Vee belt drive

bar

ü

1.5 1.5 0.5 0.5

Number of belts
in pressure
service

4555

Number of belts
in vacuum
service

4455

max. 15
at 1500 [1/min]

1

2

4

3

2

1 To liquid ring pump
2 Keyed shaft

3 Marking on splined joint
4From drive

Fig. 4.8 Correct Vee belt tensioning

1000 mm

16…20 mm

Dw

1

2

1 Vee belt deflection (16 to

20 mm for every 1.000 mm
distance)

2 Axial distance

DWVee belt pulley diameter,

min. 280 mm

Installation

4990671000 February 2008 21

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. 4.9 Installing the Vee belt pulleys

1

2

Fig. 4.10 Removing the Vee belt pulley

1

2

Installation

4990671000 February 2008 22

2. Remove the slack pulley assembly by hand; do not
use a hammer as this may damage the machine.

Fig. 4.11 Removing the Vee belt pulley

Start-up

4990671000 February 2008 23

Start-up

5. Start-up

5.1 Testing the system

The correct initial commissioning and start-up after ex­tended standstill (more than 4 weeks) is essential for
the optimum function of the liquid ring pump.

We recommend that you allow adequate time to com­mission the system. The liquid ring pump may be dam­aged if the correct procedure is not followed.

Damage as a result of incorrect commissioning
is not covered by our warranty!

Before start-up

• Inspect the liquid ring pump (for damage in transit,
incorrect installation),

• Inspect the drive guard and the safety guard on the
pressure side for damage,

• Instruct the operators,

• Instruct others who need to know the operation
and maintenance of the water ring pump,

• Make certain that the rotor shaft can be rotated by
hand.

5.2 Operating liquid

Make certain of the following points to ensure that the
liquid ring pump is supplied with operating liquid:

• Completely fill the operating water system, fill only
up to the maximum mark in the combined operat­ing water and separating vessel.

• Fill the liquid ring pump up to shaft centre, it may
be necessary to observe a closed automatic water
stop valve (also see chapter 6.2.4 "Operating the
liquid ring pump").

• Check the function of the automatic water stop
valve.

• Make sure that the pressure line is not blocked.

If sub-zero temperatures are likely, mix anti­freeze as specified by the manufacturer (usu­ally 33%). Alternatively drain the operating
water system completely if the machine is not
used.

5.3 Stop slide and shut-off valves

• Inspect the installation direction of the non-return
valve (see arrowed direction)

• Open all manual stop slide and shut-off valves.

Switch over the four-way directional control
valve to extreme position, an intermediate
position is not allowed.
(If the valve is set to an intermediate position,
the temperature of the operating water rises
and more water is lost.)

5.4 Direction of rotation

When starting the system for the first time, briefly
switch on the drive to check the rotation. Observe the
arrowed direction on the machine housing.

5.5 Drive

Switch on the drive and check if pressure or vacuum
are produced.

5.6 Check speed, vacuum and pressure

5.6.1 Speed

Permitted speed range: 1,100 to 1,500 min-1

5.6.2 Vacuum and vacuum gauge

Permitted minimum suction pressure see nameplate

5.6.3 Pressure at pressure gauge

The maximum pressure indicated on the nameplate is
permitted (also see chapter 1.1 "Machine data").

Make certain that the safety valve blows off.

Operation

4990671000 February 2008 24

Operation

6. Operation

6.1 Start-up

For normal setting the liquid ring pump (referred to as
the “machine”), follow chapter 5. "Start-up".

6.2 Regular inspections

In pressure service

Check the operating gauge pressure at the pressure
gauge (for permitted pressure, see machine name­plate)

In vacuum service

Check the operating vacuum at the vacuum gauge (for
permitted vacuum, see machine nameplate)

Operating water inlet temperature

Recommended max. inlet temperature: 55 °C

pH

5 < pH < 8

Speed

Permitted speed range: 1,100 to 1,500 min

-1

Check the operating speed

6.2.1 Safety valve

Every compressor must be fitted with a safety valve in
the pressure line that cannot be shut off. The valve
should be set so that the highest permitted operating
pressure cannot be exceeded by more than 10%.

The setting of the valve must be guarded
against tampering.

The safety valve must not be blocked or manip­ulated.

Avoid blowing the full volume flow through the
safety valve with the pressure line closed. This
can produce harmful vibration.

On Initial installation and at weekly intervals
check the function of the safety valve by actu­ating the manual vent while the machine is run­ning.

6.2.2 Water stop valve

Check for proper function.

Operation

4990671000 February 2008 25

6.2.3 Inspection intervals

6.2.4 Operating the liquid ring pump

The volumes of operating water required for proper op­eration of the liquid ring pump are given in the table be­low:

Note that the actual operating water requirement var­ies widely as a function of the operating vacuum / op­erating pressure.

6.2.5 Operating water consumption and
control

While passing through the liquid ring pump, the con­veyed medium (air) comes into close contact with the
operating medium (water). This causes the relative hu­midity of the conveyed medium to be, as a rule, 100%
at the discharge side. Even if all water droplets were
separated in the water storage tank or in a cyclone, the
steam in the exhaust air will always cause a certain
consumption of operating fluid.

The specific water discharge as a function of the oper­ating pressure and the operating water temperature
can be seen in Fig. 6.1.

It follows that for Aqualine 2100 at 400 mbar operating
pressure and operating water temperature of 40 °C the
water loss due to steam is

1,700 [m

3

/h] x 0.016 [kg/m3] = 25.6 kg/h

That is roughly 26 [ltr/h]

In actual pump service, therefore, the following points
should be noted:

• The loss of water due to steam can cause a rise in
the concentration of pollutants in the operating
water tank, which depends on the conveyed
medium; this again can change the pH of the oper­ating water.

• To avoid operating water pH outside the permitted
range of 5 < pH < 8, the pH should be checked
regularly (daily or as dictated by experience) and
the operating water changed in regular intervals.
Litmus paper can be used for pH measurement.

• Water can condense in long exhaust lines, espe­cially in cold weather. To prevent the outflow of
condensed operating fluid from the exhaust sys­tem, the installation of an additional separator
(cyclone) at the end of the exhaust line may be
used.

See chapter Every 10 –

20 min while

running

Weekly If necessary

Operating speed 6.2

X

Operating pressure / operating
vacuum

Nameplate

X

Operating water feed temperature 6.2 X

Actuate safety valve 6.2.1 X

Water stop valve 6.2.2 X

Replace contaminated operating
water (e.g. pH, abrasive material)

X

Clean compressor and cooling unit X

Operating
liquid level: Inspect the level of the operating liquid before every start and during operation of the
pump.
Bearings: Inspect the housing, housing covers and end covers for symptoms of overheating, abnor­mal

noise or colour daily/regularly.

Aqualine 1100 1600 2100 2700

Operating
water volume
at 400 mbar
in [ltr/min]

50 – 70 60 – 80 70 – 90 80 – 90

Operation

4990671000 February 2008 26

If the water inlet temperature exceeds
55°C. Stop the machine immediately.
Recirculate the water for half an hour or
until the water temperature is below 55°C.

6.3 Possible faults by the operator

Faulty operation can cause failure of the machine.

The following must be avoided:

• Underspeeding and overspeeding (see chapter 6.2
or nameplate)

• Pressure above the permitted limit (see chapter

6.2 or nameplate)

• Blowing off the full volume flow through the safety
valve when the pressure line is closed

• Vacuum below the permitted limit (see chapter 1.1
"Machine data" or nameplate)

• Poor cooling (lack of water, contaminated cooling
unit)

• Poor water quality (e.g. pH, abrasive material, etc.)

• Blocked vacuum filter

• Water stop valve malfunction

• Wrong lubricating grease

Damage due to wrong operation causes forfei­ture of all warranty claims on Gardner Denver.

6.4 Extended period of non-use

Check the operating water, replace if necessary.

Fig. 6.1 Specific loss of water as a function of the operat-

ing water temperature and the operating pressure
(Calculated for air at atmospheric pressure and
60% RH)

0

0

10

20

30

40

50

60

70

80

100 200 300 400 500

Operating pressure [mbar]

Water loss [gr/m

3

]

(Grams per each cubic metre suction volume)

600 700 800 900 1000

Operating water temperature of 50 C

Operating water temperature of 45 C

Operating water temperature of 40 C

Operating water temperature of 30 C

Operating water temperature of 20 C

Operation

4990671000 February 2008 27

6.5 Troubleshooting

The following table can be used for fault diagnosis.

All failures should be repaired without delay.
The machine should not be started until the fail­ure has been repaired.
Repairs must only be carried out by qualified
technical personnel.

Possible cause Remedy

Poor pump output

• Vacuum filter soiled

• Suction line leaking

• Instrument leaking

• Underspeed

• Lack of operating water

• High operating water feed temperature

• Clean vacuum filter

• Locate and repair leak

• Replace leaking instrument

• Run at prescribed speed

• Top up operating water to maximum level

• Inspect the operating water cooling system

Abnormal noise

1)

• Poor machine alignment

• Bearings worn

• Operating water grossly contaminated

• Incorrect speed

• Pressure has changed

• Vacuum has changed (higher vacuum needed)

• Vent line blocked

• Operating water temperature high

• Foreign object in the machine

• Re-align machine

• Replace bearings or have them repaired

• Change the operating water

• Keep within speed limit

• Keep within rated pressure

• Keep within rated vacuum / inspect, clean exhaust air
system

• Inspect and/or clean vent line

• Inspect the operating water cooling system

• Remove foreign object immediately and flush the
machine

Operating pressure or operating vacuum cannot be obtained

• Incorrect pressure gauge or vacuum gauge reading

• Vee belt slip

• Directional control valve at wrong position

• Operating water feed disturbed (not enough or no water)

• Replace pressure gauge / vacuum gauge

• Inspect Vee belt tension, re-tension if necessary

• Set directional control valve to correct position

• Ensure sufficient operating water supply

Operating water temperature high (above 55 °C)

• Not enough water in the operating system

• Cooling unit soiled

• Top up operating water & recirculate water until water
temperature is less than

55°C.

• Clean cooling unit

Sludge or liquid has entered the machine

• Vehicle oversucking • Clean the machine; check the operating water, change if
necessary

High power consumption

• Overspeed

• Exceedingly high output pressure

• Pressure gauge reading wrong

• Keep within speed limit

• Keep within rated pressure, actuate/check safety valve

• Replace pressure gauge

Operation

4990671000 February 2008 28

1)The cause of abnormal noise in the machine
can be a foreign object; remove the foreign ob­ject without delay.

If the problem persists, please call our Service depart-

ment.

Safety valve blowing

• Closed valves in pressure line

• Pressure pipework blocked

• Open valves

• Remove blockage

Compressed air exits at shaft end and water leaks

• Seal damaged • Replace shaft seal in end cover or have it repaired

Rubber smell (with Vee belt drive)

• Vee belt slip due to lack of belt tension

• High output pressure

• Check belt tension, re-tension if necessary

• Keep within rated pressure

Vee belts buckling

• Lack of belt tension

•Belt wear

• Belt pulley out of alignment

• Belt pulley wear

• Check belt tension, retension if necessary

• Install new Vee belts

• Align pulley

• Replace pulleys

Possible cause Remedy

Maintenance

4990671000 February 2008 29

Maintenance

7. Maintenance

7.1 Warranty

Damage due to non-compliance with the installation
and operating instructions are not covered by the war­ranty.

Please note that repairs to the liquid ring pump must be
made by an authorized repair centre using original
parts. Otherwise the warranty will be invalid.

7.2 Maintenance, maintenance
schedule

When carrying out maintenance or inspection,
observe the safety instructions (chapter 2.
"Safety instructions and hazard alerts").

Machine failure due to poor or improper maintenance
can result in high repair costs and machine down time.
Regular maintenance is therefore necessary.

The operating, safety and service life of the machine
are largely determined by the level of maintenance un­dertaken.

The table below contains time, type and maintenance
work information for normal service of the liquid ring
pump.

The specified maintenance intervals assume approxi­mately 5 hours of pump service per day. If your service
conditions are different, the maintenance intervals may
be proportionally shorter or longer.

As operating conditions may vary, no forecast can be
made as to how often the necessary wear inspections,
maintenance and general inspections should be made.
Decide on the most suitable arrangement in the light of
your conditions.

Refit all guards properly after completion of any
maintenance work.

Dispose of grease, cleaners and spent compo­nents, e.g., filter cartridges, as prescribed by
the environment laws.

7.2.1 Water back-cooling with air

The flow of cooling air must not be obstructed.

• Remove dust and dirt from the cooler every week.

• Inspect the operating water level in the compensa­tion tank and top up water if necessary.

7.2.2 Liquid ring pump

• Clean the machine every week.

7.2.3 Vacuum filter (GDD types)

Depending on the dust load, daily cleaning may be
necessary; clean at least once every week.

The filter insert consists of either a stainless steel
mesh or a fine filter cartridge.

Maintenance points Type of work See chapter Maintenance interval

1 week 1 month 3 months

Cooling unit/water cooler

clean 7.2.1

X

Liquid ring pump

clean 7.2.2

X

Vacuum filter

clean 7.2.3

X

Safety valve

check 6.2.1

X

Water stop valve

check 6.2.2

X

Vee belts, Vee belt tension inspect,

re-tension

7.2.4

X

Non-return valve

check 7.2.5

X

Shaft seal lubrication

regrease 7.3.2

X

Maintenance

4990671000 February 2008 30

Opening the filter:

Warning!
Only open when the machine is stopped and
de-pressurized.

Slacken or unscrew the tapered handle or star handles
(7.1/2+3). With type SFA, turn the cover (7.1/1) about
15° counterclockwise out of straight pins. With type
SFD, simply lift up the cover.

Cleaning the filter

Caution!
Filter cover is under moderate spring tension.

• Wash out the filter housing with a cold cleaner.

• If the filter insert is stainless steel mesh it can be
washed out with cold cleaner.

• If the filter insert has a fine filter cartridge, it can be
blown out with a steam jet directed from the inside
to the outside. Inspect the fine filter cartridge for
damage. Replace damaged filter insert.

• Inspect the round seal ring or seal for damage.
Replace damaged seal.

Make certain that dirt or cleaning residue does not en­ter the pump when the filter housing is cleaned.

Assembling the filter

• Install the filter cartridge.

• Place the round seal ring /seal in the cover and fil­ter cage (type SFD) (7.1/1). Install washers to the
tapered handles or star handles (7.1/2+3).

• Push the cover (7.1/1) in the housing (with type
SFA; turn cover clockwise into the straight pins
(7.1/6)).

• Tighten the cover with tapered handles or star han­dles (7.1/2+3).

7.2.4 Vee belts and Vee belt tension

Remove the Vee belts and Vee belt/ drive
guards only when the machine is stopped and
the vehicle engine is stopped.

Inspect the Vee belts and the Vee belt tension every
week and re-tension or replace the belts if necessary,
see installation section 4.

Always replace damaged Vee belts as a complete set
of length matched belts.

7.2.5 Non-return valve

The non-return valve needs maintenance every
3months.

We recommend a first inspection after 300 operating
hours.

7.3 Lubrication

7.3.1 Antifriction bearings

The antifriction bearings of the liquid ring pump are
pre-lubrication with enough grease for 5,000 operating
hours.

The special lubricating grease ensures outstanding
wear protection, excellent resistance to water and de­bris, good corrosion protection, good ageing resist­ance and an especially high resistance to
tribocorrosion.

The grease is available from Gardner Denver in 400g
cartridges (Part No. TW53105000).

Work on the antifriction bearings must only be

carried out by trained personnel with knowl­edge of the equipment and the potential risks.

The lubrication of the anti-friction bearings
must be replaced, at the latest, after 5,000
operating hours, or three years. Remove all old
lubricant and clean the bearings before filling
with new lubricant. Use only lubricant certified
by the manufacturer (GDD Part No.
TW53105000).

Remove the bearings and install new bearings
(GDD Part No. TW41123100) at the latest after
15,000 operating hours.

Fig. 7.1 Vacuum filters SFA and SFD

1

2

3

1

1Cover
2 Tapered handle (type SFA)

3 Star handle (type SFD)

Maintenance

4990671000 February 2008 31

7.3.2 Shaft seal

The Aqualine series is equipped with a combination of
seals with grease barriers especially developed for this
application.

The grease barrier of this seal needs regreasing with
the above special lubricating grease in regular inter­vals of 200 – 300 operating hours. The lubricating nip­ples are located on the bearing caps on both faces of
the liquid ring pump.

Regrease the machine when it is cold; apply grease
until it emerges from the vent valve (see figure 1.3).
The amount of grease is approx. 10 – 15 grams on
each side. If access to the lubricating nipples is diffi­cult, an extension of the lubricating line by maximum

0.5 m and 6 – 8 mm diameter may provide easier ac-

cess.

If the operating water has a high pollutant content (es­pecially solvents) regreasing may be required more of­ten. The actual intervals are determined by experience.

Caution!
Connecting the Aqualine lubrication to the cen­tral lubrication of the vehicle is not allowed!

A mixture of grease-water vapour can emerge
from the grease nipple at fist start-up or after
extended downtime, occasionally steam in nor­mal operation.

8. Spare parts

8.1 Spare parts

Keeping a sufficient stock of major spares (mainte­nance and wearing parts) at the site of the machine is
an important to ensure the constant availability of the
liquid ring pump.

Please order spare parts from the list below.

Our warranty is only for original parts supplied by us.

Any installation or attachment of spare parts or extra
units not supplied by us is not included in the Gardner
Denver warranty. Please note that that specific manu­facturing and delivery specifications may apply to parts
made by us or OEM suppliers. All parts delivered by us
are of latest engineering standard and satisfy latest
mandatory regulations.

For ordering spare parts, please specify the data in the
spare parts list...

Repairs and maintenance must only be carried out by
qualified technical personnel.

Use only original parts from Gardner Denver.

Repairs and maintenance must only be carried

out by qualified technical personnel.

Repairs must be carried out or parts ex­changed only outside a potentially explosive
atmosphere.

Use only original parts from Gardner Denver.

8.2 Wearing parts

We recommend to keep a stock of the following parts

Item

No.

Order No. for type Quantity Part name

Aqualine

1100

Aqualine

1600

Aqualine

2100

Aqualine

2700

9

⇒
⇒
⇒

TW46530900
TW46530700
TW46531000

TW46530900
TW46530700
TW46531000

⇐
⇐
⇐

2

Housing seal
481 / 471 x 0.5 mm
481 / 471 x 0.75 mm
481 / 471 x 1.0 mm

11 ⇒

TW42438700 TW42438700

⇐

2 Sealing bush

14 ⇒

TW91044400 TW91044400

⇐

2 Seal

⇒

TW53105000 TW53105000

⇐

400 g Bearing grease

For additional information, contact your local

representative or

Gardner Denver Drum Ltd

PO Box 178,

Springmill Street,

Bradford,

West Yorkshire, UK

BD5 7YH

Tel: [phone]

Fax: [phone]

Email: [e-mail]

Web: www.gardnerdenverproducts.com

© 2008 Gardner Denver Drum Ltd.

Specifications subject to change.

4990671000 February 2008