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CVS VacuStar WR 2500 Mounting Instructions

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Mounting instructions
VacuStar WR 2500 / WR 3100 / WR 4000
Doc-ID: 5040 / MA / EN
Release: Rev. 03 / 13/09/2017
Prior to installing the VacuStar WR and putting it into operation you must have read and understood
these instructions. These instructions are only valid together with the operating instructions, they do
not replace them!

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Summary of Contents for CVS VacuStar WR 2500

  • Page 1 Contents Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Doc-ID: 5040 / MA / EN Release: Rev. 03 / 13/09/2017 Prior to installing the VacuStar WR and putting it into operation you must have read and understood these instructions.
  • Page 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...

  • Page 3: Table Of Contents

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Contents General ..................5 Information on the assembly instructions ...... 5 Pictogram explanation ........... 6 Limitation of Liability ............7 Copyright protection ............7 Spare parts ..............7 Warranty conditions ............7 Customer Service ............
  • Page 4 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Contents Start-up ..................37 Safety during start-up ...........37 Start-up ................38 Switching off ..............40 Inspections to be performed ........40 EC Declaration of Incorporation .........41 Declaration of Conformity ...........42 Index ....................43...

  • Page 5: General

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 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.

  • Page 6: Pictogram Explanation

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 1.2 Pictogram explanation Warning notes are characterised by pictograms in these mounting Warning notes instructions. The warning notes are marked by signal words expressing the extent of the hazard.

  • Page 7: Limitation Of Liability

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 1.3 Limitation of Liability See operating instructions "VacuStar WR 2500 / WR 3100 / WR 4000" for information about limitation of liability. 1.4 Copyright protection See operating instructions "VacuStar WR 2500 / WR 3100 / WR 4000"...

  • Page 8: Safety

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety 2 Safety 2.1 Intended use The liquid-ring compressor vacuum pumps of the VacuStar WR 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.

  • Page 9: Proper Operation

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety 2.2 Proper operation The intended use is chiefly defined by the data in "Tab. 1: General data Tab. 1" (page 14). If explosive gases and gas mixtures are conveyed, the following guidelines must be observed: –...

  • Page 10: Personal Protective Equipment

    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...

  • Page 11: Technical Data

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Technical data 3 Technical data 3.1 Dimensions of VacuStar WR 2500 / WR 3100 Fig. 1: Dimensions of VacuStar WR 2500 / WR 3100, shown here is WR 3100 VacuStar WR 2500 VacuStar WR 3100 Foot arrangement "outward"...

  • Page 12: Dimensions Of Vacustar Wr 4000

    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 Foot arrangement "outward" WR 4000 Cell ventilation connection G2" Foot arrangement "inward" Process water connection G1 ½"...
  • Page 13 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Technical data The horizontal and vertical flange arrangements can be combined with each other. B-side A-side WR2500 WR2500 WR4000 WR4000 WR3100 WR3100 Pressure connection Suction connection R: 950 080-00...

  • Page 14: Technical Data

    Maximum final overpressure with V-belt drive [bar] 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...
  • Page 15 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Technical data VacuStar WR performance data vacuum Unit WR 2500 WR 3100 WR 4000 operation 1), 2) Suction pressure: 400 mbar Speed [1/min] 1600 1300 1), 2), 3) Maximum intake volume flow...
  • Page 16 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Technical data VacuStar WR process water circulation Unit WR 2500 WR 3100 WR 4000 200 / 400 mbar 48 / 42 60 / 52 81 / 72 at speed...

  • Page 17: Design And Function

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function 4 Design and function 4.1 Design Fig. 5: Design Drive shaft Rating plate Connection process water Rotation arrow Cell ventilation connection Thread for eye bolt Connecting flange for pressure or suction...
  • Page 18 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function Fig. 6: Functional principle All moving parts are without contact. The lubrication of the Lubrication VacuStar WR is limited to the impeller bearing. The bearings are fitted with a permanent grease filling.
  • Page 19 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function The VacuStar WR can be powered via: Drive Articulated shaft  V-belt  Flexible coupling  See page 35. In addition to the drive and the suction and pressure lines, other...
  • Page 20 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function Process water loss 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.

  • Page 21: Transport And Storage

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Transport and storage 5 Transport and storage 5.1 Safety notes for transport Improper transport Danger! Danger by falling down or tilting of the VacuStar WR! The weight of the VacuStar WR may injure a...

  • Page 22: Storage

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Transport and storage 5.3 Storage Store packages under the following conditions: Storage of packages Do not store outdoors.  Store dry and dust free.  Do not expose to aggressive media.

  • Page 23: Installation And Assembly

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6 Installation and assembly 6.1 Safety Safety 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.

  • Page 24: Installation Example

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.2 Installation example Fig. 8: Typical installation VacuStar WR 11 Vacuum meter 18 Process water cooling in the Dehydration 12 Vacuum suction filter bypass flow Compensator 13 Safety dome with float valve 18.1 Reservoir pipe –...

  • Page 25: Necessary Work

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.3 Necessary work Installation requires the following activities: Installing all components on the vehicle side.  Installing VacuStar WR with suction and pressure lines.  Installing safety and monitoring equipment.

  • Page 26: Compensators

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.5 Compensators Vacuum- and pressure-proof compensators must be installed in Compensators in the suction and pressure lines to delimit the socket forces and to suction and pressure lines isolate the impact sound.
  • Page 27 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly See page 24, chapter 6.2. Cell ventilation 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.

  • Page 28: Safety Equipment

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.7 Safety equipment The following safety equipment must be installed: Safety valve  Monitoring the compression end temperature  Non-return valve always at the suction side ...

  • Page 29: 49B49Bmonitoring The End Temperature

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.7.2 49B49BMonitoring the end temperature A suitable measuring instrument must be installed that switches the VacuStar WR off when the maximum permissible temperature is reached. Install the temperature sensor in the line after the pressure Assembly pipe joint.

  • Page 30: Cell Ventilation Valve

    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 The VacuStar WR has been prepared for operation with cell Assembly ventilation.
  • Page 31 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly Fig. 9: Cell ventilation valve with muffler and air filter Air filter (installed vertically) Hose adapter Muffler (installed horizontally or vertically) Muffler holder Connection line, max. length 1 m (not included in scope of...

  • Page 32: Display And Monitoring Equipment

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.7.7 Display and monitoring equipment 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.

  • Page 33: 40B40Badditional Components Of The System

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.8 40B40BAdditional components of the system 6.8.1 Safety tank The safety tank protects the VacuStar WR from sucking in liquids. Requirements It must comply with the following requirements: Passing air must not hit the liquid surface directly ...
  • Page 34 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly The following figure shows a diagram of the radiator arrangement. Also see page 24, Fig. 8. Fig. 10: Radiator arrangement Process water inlet from the reservoir...

  • Page 35: Drive

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Installation and assembly 6.11 Drive 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.

  • Page 36: Articulated Shaft Drive

    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: VacuStar WR V-belt drive Unit WR 2500 WR 3100 WR 4000 V belt profile –...

  • Page 37: Start-Up

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up Start-up 7.1 Safety during start-up Start-up, operation 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.

  • Page 38: Start-Up

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up 7.2 Start-up The following points must be checked prior to initial start-up: Inspection prior to initial start-up Inspect the VacuStar WR and the entire system  Check the pipes for continuity and residues (remove blanks if ...
  • Page 39 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up The following inspections have to be carried out during operation: Inspections during operation The liquid level in the reservoir must not be lower than the  minimum mark during operation.

  • Page 40: Switching Off

    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 ...

  • Page 41: Ec Declaration Of Incorporation

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 EC Declaration of Incorporation 8 EC Declaration of Incorporation...

  • Page 42: Declaration Of Conformity

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Declaration of Conformity 9 Declaration of Conformity...

  • Page 43: Index

    Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Index Index Acceptance ............9 Monitoring equipment .........32 Articulated shaft drive ......... 36 ATEX ........8, 26, 29, 30, 32, 35, 39 Non-return valve ..........29 Cell ventilation design ......... 19 Occupational safety ..........10...
  • Page 44 Warranty ...............7...
  • Page 45 Mounting instructions VacuStar WR 2500 / WR 3100 / WR 4000 Index...

This manual is also suitable for:

Vacustar wr 3100Vacustar wr 4000

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