Samson TRUCK MASTER 2500 Instruction Manual
INSTRUCTION MANUAL
HPR
LIQUID RING PUMP
®
TRUCK MASTER
INSTRUCTION MANUAL FOR SAMSON LIQUID RING PUMP
TRUCK MASTER 2500
• Technical data
• Design of a system
• Installation and start-up
• Service
• Troubleshooting
• Spare parts
2500
DOC9056J
CONTENTS
1 Introduction .............................................................................................................................. 4
1.1 Declaration of conformity ........................................................................................................ 4
1.2 Explanation of warning symbols .............................................................................................. 5
1.3 Field of application .................................................................................................................. 5
1.4 Disposal .................................................................................................................................. 5
2 Technical data .......................................................................................................................... 6
2.1 Dimensions ............................................................................................................................. 6
2.2 Specifications .......................................................................................................................... 7
2.3 Power consumption and output ............................................................................................... 8
2.3.1 Vacuum .................................................................................................................................. 8
2.3.2 Pressure .................................................................................................................................. 8
2.3.3 Correction factor - Temperature ............................................................................................. 9
2.3.4 Correction factor - Wet and dry gas ......................................................................................... 9
2.4 Handling and transport ......................................................................................................... 10
2.5 Pump storage and draining procedure ................................................................................... 11
3 Design of a system ..............................................................................................................12
3.1 Function and design of a liquid separator .............................................................................. 13
3.2 Air cooling with fan cooler .................................................................................................... 14
3.3 Fan cooler ............................................................................................................................. 15
3.4 Water consumption ............................................................................................................... 16
3.5 Dome valve system ............................................................................................................... 16
3.6 Cavitation ............................................................................................................................. 17
3.7 Service liquid requirement ..................................................................................................... 17
4 Installation and start-up ...................................................................................................18
4.1 Securing the pump ................................................................................................................ 18
4.2 Connections to the pump ...................................................................................................... 18
4.3 Connecting the service liquid ................................................................................................ 19
4.4 Transmission ........................................................................................................................ 19
4.5 Prior to start-up .................................................................................................................... 20
4.6 Direction of rotation ............................................................................................................. 20
2
5 Service, operation, maintenance and inspection intervals............................................. 21
5.1 Draining the liquid separator ................................................................................................. 21
5.2 Check grease cartridges ....................................................................................................... 21
5.3 Winterization ......................................................................................................................... 21
5.4 Lubrication of bearings ......................................................................................................... 22
5.5 Inspection and cleaning of service liquid’s supply pipe .......................................................... 22
5.6 Inspection and cleaning of internal channels ........................................................................ 22
6 Troubleshooting ...................................................................................................................23
7 Spare parts and tools ..........................................................................................................24
7.1 Marking and identification ..................................................................................................... 24
7.2 How to order ......................................................................................................................... 25
7.3 Spare parts ............................................................................................................................ 26
7.4 Adaptor ................................................................................................................................. 30
7.5 Gasket set ............................................................................................................................. 31
7.6 Special tool set ...................................................................................................................... 32
Truck Master 2500
3
E-Mail
Web www.samson-pumps.com Phone | +45 87 50 95 70 DK-8800 Viborg
1 INTRODUCTION
1.1 Declaration of conformity
Dec
Hereby declares that the following products:
ruck Master 350, Truck Master 600, Truck Master 1600,
T
ruck Master 2500, Truck Master 3400
T
laration of Conformity
Annex IIA
Samson Pumps A/S
Petersmindevej 21
DK-8800 Viborg
Liquid ring pump
Conforms to the directive:
Machinery Directive 2006/42/EC
I hereby declare that the liquid ring pumps are in conformity with the following harmonized standards:
DS/EN ISO 12100:2011 Safety of machinery - General principles for design - Risk assessment and risk
DS/EN 1012-2 + A1:2009 Compressors and Pumps - Safety requirements - Part 2: Vacuum pumps
The standards above only apply to the extent that it is relevant for the purpose of the pump.
The product must not be used before the complete system, which it must be incorporated in, has been conformity
assessed and found to comply with all relevant health and safety requirements of 2006/42/EC and other relevant
directives. The product must be included in the overall risk assessment.
Viborg, 03.10.2018 _______________________
Kelvin Storm Jensen
R&D Manager
Samson Pumps A/S
reduction
DOC4044
DOC4044
info@samson-pumps.com Samson Pumps A/S Petersmindevej 21
4
1.2 Explanation of warning symbols
Important technical and safety instructions are shown by symbols. If the instructions are not performed
correctly, it can lead to personnel injuries or incorrect function of the pump.
To be used with all safety instructions that must be followed. A failure to follow the
instructions may result in injuries and/or incorrect machine operation
1.3 Field of application
Inlet of foreign objects can damage the pump
The pump is designed exclusively to pump gases, including atmospheric air
WARNING!
Avoid cavitation of the pump! For further information, see instruction manual for the
Samson Pumps vacuum limiter
It must be ensured that the inlet gas cannot react with the service liquid and create aggressive bonds that
break down the pump's components.
For other operating data, see specifications.
• The pump must only be used with media that is not aggressive to the pump's materials. See section 7
for components and materials.
1.4 Disposal
Samson’s liquid ring pump is manufactured so that most of the device can be reused/recycled.
Samson Pumps offer users of the company’s pumps the option of returning used pumps to be restored or
scrapped.
Alternatively, the pump must be taken apart and sorted into its separate components, by the customer
(see section 7 for the pump’s material).
These components must be disposed of in accordance with national regulations.
Truck Master 2500
5
2 TECHNICAL DATA
498
48 k6Ø
270
20Ø
2.1 Dimensions
300
400
1074
647
100
579
549 312
M16x2
Ø107
Ø180
DOC1627354_1D
6
2.2 Specifications
A failure to meet these specifications may result in damage to the pump
Description Minimum Maximum
Ambient temperature, operation Below 0°C - see chapter 5.3 -20°C 55°C
Ambient temperature, storage -20°C 55°C
Humidity - 100%
Intake temperature, suction side - 60°C
Intake temperature, service liquid - 60°C
Service liquid pipe connection, dimension ¾” -
Service liquid pipe connection, length - 6 m
Noise level - 80 dB(A)
Water volume - 34 L
Maximum radial load on drive shaft - 3480 N
1200 rpm 33 kW -
Heat input for cooler calculation
Revolutions 1200 rpm 1500 rpm
Pressure 150 mbar abs. 1 bar(g)
Lubricating grease
Weight 321 kg
1300 rpm 36 kW -
1400 rpm 41 kW -
1500 rpm 48 kW -
Type of grease SKF LGWA2
Automatic lubrication SKF LAGD 125/WA2
Truck Master 2500
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2.3 Power consumption and output
2.3.1 Vacuum
Vacuum [%] 80 70 60 50 40 30 20
1200 [rpm]
1300 [rpm]
1400 [rpm]
1500 [rpm]
Flow
Flow
Wet
Dry
[m³/h]
1261 1846 1777 1803 1852 1846 1860
941 1442 1545 1596 1699 1709 1738
Consumption [kW] 45
Torque [Nm] 358
Flow
Flow
Wet
Dry
[m³/h]
1522 1941 1914 1963 1972 1980 1965
1136 1517 1665 1737 1809 1833 1837
Consumption [kW] 48
Torque [Nm] 353
Flow
Flow
Wet
Dry
[m³/h]
1655 2126 2055 2159 2137 2205 2075
1235 1661 1787 1910 1960 2042 1939
Consumption [kW] 56
Torque [Nm] 382
Flow
Flow
Wet
Dry
[m³/h]
1962 2389 2361 2423 2445 2465 2322
1464 1866 2053 2144 2243 2282 2170
Consumption [kW] 64
Torque [Nm] 407
2.3.2 Pressure
Pressure [bar(g)] 0 0.25 0.5 0.75 1
Flow [m³/h] 1300 1226 1179 1070 993
1200 [rpm]
1300 [rpm]
1400 [rpm]
1500 [rpm]
The data Flow
• Air temperature 20°C
• Service liquid temperature 15°C
• Test performed with dry air and 1,013 mbar absolute pressure
• Tolerance ±10%
Consumption [kW] 39 43 49 54 59
Torque [Nm] 310 342 390 430 470
Flow [m³/h] 1425 1328 1261 1171 1097
Consumption [kW] 41 49 55 61 67
Torque [Nm] 301 360 404 448 492
Flow [m³/h] 1605 1569 1433 1341 1271
Consumption [kW] 54 55 61 68 74
Torque [Nm] 368 375 416 464 505
Flow [m³/h] 1824 1636 1633 1531 1390
Consumption [kW] 62 64 70 76 82
Torque [Nm] 395 407 446 484 522
is based on the following parameters:
Dry
8
2.3.3 Correction factor - Temperature
When the temperature of the service liquid
exceeds 15°C, the pump’s capacity will be affected
with respect to the specified values.
To determine the output at a higher temperature,
the correction factor can be used.
Capacity at service liquid temperature
higher than 15°C :
= Q
x K
Q
t>15
15
1
DOC1628005_1A
2.3.4 Correction factor - Wet and dry gas
Normal atmospheric air contains water vapor. In this case water will condense inside the pump and will
create a higher flow.
Below you can find a correction factor table for the performance based on condensing gas with an inlet
temperature of 50°C 100% saturated and service liquid temperature of 15°C.
Suction pressure % Vacuum 80 70 60 50 40 30 20
Correction factor wet gas
K
1,34 1,28 1,15 1,13 1,09 1,08 1,07
Wet
The performance of the pump can thereby be calculated as:
V
= V
Dry
x K
Wet
Wet
Truck Master 2500
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2.4 Handling and transport
The pump must not be used if it is damaged or the identification plate is missing
The pump must be transported in such way that
it is not exposed to vibrations and impacts that
can overload the bearings.
The pump must be inspected for damages upon
delivery. If the pump is damaged, it must not be
used and the damage must be reported to the
manufacturer.
Ensure that the pump’s identification plate
is intact and that the marking of the pump
corresponds to its use.
The pump must only be handled using approved
lifting eyes, in accordance with nationally
applicable regulations and only in a vertical
motion.
DOC1627355_1
The pump can be transported in the following
ways:
DOC11093A
10
2.5 Pump storage and draining procedure
A failure to comply with the requirements for storing the pump may result in internal
damage to the device
If the temperature is below freezing point of the service liquid, it could damage the pump
Under these conditions, the pump must be drained completely
All plugs and protective covers must be fitted during storage
The pump’s service liquid is drained on delivery, and the pump can be immediately stored in accordance
with the technical specifications.
After operation, the pump can be stored for 30 days without further action.
If the pump remains out of operation for a longer period of time after use, its service liquid must be
drained, and the liquid supply to the pump must be shut off.
When emptying the pump, it is important that all chambers inside the pump are emptied.
The pump can be fitted with valves in the draining connections. See below.
Truck Master 2500
DOC1627356_1
11
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