CVS VacuStar WR 2500 Operating Instructions Manual
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CVS VacuStar WR 2500 Operating Instructions Manual

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Operating instructions
VacuStar WR 2500 / WR 3100 / WR 4000
Doc-ID: 5041 / BA / EN
Release: Rev. 04 / 28/03/2023
The operating instructions must be read by the VacuStar WR operator before start-up!

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Summary of Contents for CVS VacuStar WR 2500

  • Page 1 Contents Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Doc-ID: 5041 / BA / EN Release: Rev. 04 / 28/03/2023 The operating instructions must be read by the VacuStar WR operator before start-up!
  • Page 2 Translation of the original operating manual © 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

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Contents General ..................4 Information regarding the operating instructions ... 4 Pictogram explanation ........... 5 Limitation of Liability ............6 Copyright protection ............6 Spare parts ..............7 Warranty conditions ............7 Customer Service ............

  • Page 4: General

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 1 General 1.1 Information regarding the operating instructions These operating instructions provide important information on how to deal with the VacuStar WR. A precondition for safe operation is the observance of all specified safety and handling instructions.

  • Page 5: Pictogram Explanation

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

  • Page 6: Limitation Of Liability

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 1.3 Limitation of Liability All specifications and notes in these operating instructions were compiled with consideration to the valid standards and regulations, the state of the art as well as to our long-standing knowledge and experience.

  • Page 7: Spare Parts

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 General 1.5 Spare parts WARNING! Risk of injury by incorrect spare parts! Incorrect or defective spare parts can result in damage, malfunctions or total failure and also impair safety.

  • Page 8: Safety

    Operating 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 series are exclusively intended for the compression or extraction of air or filtered water vapour saturated air.

  • Page 9: Acceptance And Monitoring

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety Only use VacuStar WR for the intended use. All specifications in these 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.

  • Page 10: Operating Personnel

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety In addition, it is the operator's responsibility to ensure that:  the machine is always in a technically perfect condition.  the machine is maintained in accordance with specified maintenance intervals.

  • Page 11: Occupational Safety And Special Risks

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety 2.7 Occupational safety and special risks The remaining risks that result from the hazard analysis are specified in the following section. Observe the safety notes listed here and the warning notes in the other chapters of these instructions to reduce health hazards and to avoid dangerous situations.
  • Page 12 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety Hazard notes and occupational safety For your own safety and that of the machine, the following information must be observed and complied with: Improper operation DANGER! Danger due to improper operation! –...
  • Page 13 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety Moving components WARNING! Risk of injury by moving components! Powered rotating components can cause the most serious injuries! Therefore during operation: – It is absolutely forbidden for persons to stay in the hazard area or in the immediate vicinity! –...
  • Page 14 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety Signposting WARNING! Risk of injury by illegible pictograms! Labels and signs can become dirty or unrecognisable in the course of time. Therefore: – Always keep safety, warning and operating instructions in a well legible condition.
  • Page 15 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety 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. Therefore: – Have all work during initial operation exclusively...
  • Page 16 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Safety Maintenance and troubleshooting WARNING! Risk of injury due to improper maintenance and troubleshooting! Improper maintenance and troubleshooting can lead to serious bodily injuries or property damage. Therefore: – Maintenance work and troubleshooting work may only be carried out by sufficiently qualified and instructed personnel.

  • Page 17: Technical Data

    Weight without water filling [kg] Permissible inclination in longitudinal direction [°] – Process liquid Water-glycol mixture 1) Consult CVS for suction temperature and/or altitudes outside the permissible working range. Tab. 1: General data Permissible working range Unit WR 2500 WR 3100 WR 4000...
  • Page 18 Operating 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 Maximum intake volume flow...

  • Page 19: Design And Function

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function 4 Design and function 4.1 Design Fig. 1: Design Drive shaft Rating plate Connection process water Rotation arrow Cell ventilation connection Thread for eye bolt Connecting flange for pressure or suction...
  • Page 20 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function Fig. 2: Functional principle Lubrication All moving parts are without contact. The lubrication of the VacuStar WR is limited to the impeller bearing. The bearings are fitted with a permanent grease filling.

  • Page 21: Control And Display Elements

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Design and function Process water consumption Fig. 3: Process water delivery Fig. 3 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.

  • Page 22: Transport And Storage

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Transport and storage 5 Transport and storage 5.1 Safety notes for transport See chapter 2.7 "Occupational safety and special risks". 5.2 Transport The VacuStar WR fastened on a pallet must be transported by means of a fork lift or suitable lifting gear.

  • Page 23: Start-Up And Operation

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up and operation 6 Start-up and operation 6.1 Safety See chapter 2.7 "Occupational safety and special risks". 6.2 Start-up Works prior to initial start-up The following points must be checked prior to initial start-up or after a lengthier standstill: ...
  • Page 24 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up and operation Inspections during operation The following inspections have to be carried out during operation:  The liquid level in the reservoir must not be lower than the minimum mark during operation.

  • Page 25: Switching Off

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up and operation 6.3 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) ...
  • Page 26 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Start-up and operation Inspection of cell ventilation For a save operation the VacuStar WR must be equipped with a cell ventilation (see page 19, Fig. 1, pos. 3). If there is a ventilation from the atmosphere the suction filter sucks fresh air.

  • Page 27: Maintenance

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Maintenance 7 Maintenance 7.1 Safety See chapter 2.7 "Occupational safety and special risks". Personal protective equipment The following must be worn during all maintenance work:  Safety working clothing ...
  • Page 28 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Maintenance Table maintenance schedule Interval Maintenance work To be carried out by Check safety valve Check water stop valve Clean cooling unit / process water cooler Weekly Clean VacuStar WR...

  • Page 29: Performance Of Maintenance Work

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Maintenance 7.3 Performance of maintenance work Cleaning the VacuStar WR Carrying out cleaning work: Switch off system and secure against restarting. WARNING! Risk of injury due to compressed air! Pneumatic energies can cause the most serious injuries.
  • Page 30 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Maintenance Lubrication of roller bearings Replace permanent grease filling of the roller bearings either after 5,000 hrs or 3 years. Prior to a replacement, remove old grease and clean bearings. If grease is replaced (approx.30g per bearing) fill the bearing entirely, but the free space in the bearing housing only up to approx.30 –...
  • Page 31 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Maintenance Assembly:  Inserting the filter element (4)  Install the washer and the hexagon nut (5). Press the filter element (4) well against the housing (3) and tighten the hexagon nut (5) manually.

  • Page 32: Malfunctions

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Malfunctions 8 Malfunctions This chapter describes possible causes of malfunctions and troubleshooting tasks. Reduce the maintenance intervals if similar malfunctions occur repeatedly due to above-average intensive use so intervals correspond to the actual load.

  • Page 33: Recommissioning After Corrective Action

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Malfunctions 8.2 Recommissioning after corrective action After corrective action or trouble shooting: Reset emergency stops. Acknowledge error message or malfunction at the control system. Ensure that nobody is staying in the hazard area.
  • Page 34 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Malfunctions Malfunction: Possible cause Corrective action Execution Cell ventilating valve does not Check cell ventilating valve Specialised open staff Operating pressure Pressure gauge or vacuum gauge Replace pressure gauge or...
  • Page 35 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Malfunctions Water escapes from Slide ring seal is damaged. Replace seal Specialised the drain borehole staff...

  • Page 36: Spare Parts

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Spare parts 9 Spare parts We recommend stocking a service package as well as a suction filter cartridge. The service package comprises all wear parts that are required for a normal repair.

  • Page 37: Decommissioning And Disposal

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Decommissioning and disposal 10 Decommissioning and disposal A VacuStar WR that is no longer usable should not be recycled as complete unit, but disassembled into individual components and recycled according to material types. Non-recyclable materials have to be disposed of in an environmentally compatible manner.

  • Page 38: Index

    Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Index Index if explosive gases and gas mixtures are Acceptance ............9 conveyed............. 24 ATEX .............. 8, 24 Instructions ............10 Intended use ............8 Cell ventilation............ 20 Cleaning Lengthy standstill ..........29 Cooler .............
  • Page 39 Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000 Index Switching off ............25 Transport.............22 Symbols in the instructions ........5 Warranty ............6, 7 Technical data ............ 17 Wear parts ............6...

This manual is also suitable for:

Vacustar wr 3100Vacustar wr 4000

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