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Related Manuals for SAMSON PUMPS TRUCK MASTER 600
Summary of Contents for SAMSON PUMPS TRUCK MASTER 600
- Page 1 LIQUID RING PUMP ATEX APPROVED Zone 1 Internal / Zone 1 External TRUCK MASTER ® INSTRUCTION MANUAL FOR SAMSON LIQUID RING PUMP TRUCK MASTER 600 • Installation and start-up • Technical data • Design of a system • Service • System layout •...
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Page 2: Table Of Contents
CONTENTS Introduction ..........................4 Declaration of conformity ......................4 Explanation of warning symbols ....................5 Disposal ..........................5 ATEX Directive 2014/34/EU ....................6 Field of application ........................7 Technical data .......................... 8 Dimensions ..........................8 Specifications .......................... 9 Power consumption and output ..................... 10 2.3.1 Vacuum .......................... - Page 3 Inspection and cleaning of internal channels ................ 30 5.11 Winterization ......................... 30 Troubleshooting ........................31 Spare parts and tools ......................32 Marking and identification ..................... 32 How to order ......................... 33 Spare parts ..........................34 Gasket set ..........................38 Special tool set ........................39 Truck Master 600...
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Page 4: Introduction
Explosive atmospheres - Explosion prevention and protection - part 1: Basic concepts and methodology DS/EN ISO 80079-36:2016 Explosive atmospheres - Part 36: Non-electrical equipment for explosive atmospheres - Basic method and requirements DS/EN ISO 80079-37:2016 Explosive atmospheres - Part 37: Non-electrical equipment for explosive atmospheres - Non-electrical type of protection constructional safety "c", control of ignition sources "b", liquid immersion "k" The standard above only applies 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. ATEX Conformity Certificate Number ExVeritas 19 ATEX 0582 Viborg, 28.04.2020 ________________________________________ Jan S. Christiansen – Manager, Technical dept. DOC4047F DOC4047F E-Mail info@samson-pumps.com Samson Pumps A/S Petersmindevej 21 www.samson-pumps.com Phone | +45 87 50 95 70 DK-8800 Viborg... -
Page 5: Explanation Of Warning Symbols
1.3 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). -
Page 6: Atex Directive 2014/34/Eu
1.4 ATEX Directive 2014/34/EU The pump may be incorporated into a larger system, if the internal atmosphere has an area classification of: Zone 1 (for ATEX category 2 pumps) These systems will be certified in accordance with the ATEX Directive 2014/34/EU For the certification to be valid, the pump must be installed as described in this manual. -
Page 7: Field Of Application
Do not operate the pump so that cavitation can occur! 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. -
Page 8: Technical Data
2 TECHNICAL DATA 2.1 Dimensions G3/8" Ø16 Ø18 Ø50 G1" Ø125 DOC1627363_1B DOC1627363_1B... -
Page 9: Specifications
Automatic lubrication SKF LAGD 125/WA2 Weight 117 kg It is required to install liquid separator to ensure the pump is supplied as much water as needed. See System layout Zone 1/1. Zone 1/1 - Optional. Automatic lubrication Truck Master 600... -
Page 10: Power Consumption And Output
2.3 Power consumption and output 2.3.1 Vacuum Vacuum Flow [m³/h] Flow 1500 [rpm] Consumption [kW] Torque [Nm] Flow [m³/h] Flow 1600 [rpm] Consumption [kW] Torque [Nm] Flow [m³/h] Flow 1700 [rpm] Consumption [kW] Torque [Nm] Flow [m³/h] Flow 1800 [rpm] Consumption [kW] Torque... -
Page 11: Correction Factor - Temperature
50°C 100% saturated and service liquid temperature of 15°C. Suction pressure % Vacuum Correction factor wet gas K 1,34 1,28 1,15 1,13 1,09 1,08 1,07 The performance of the pump can thereby be calculated as: Truck Master 600... -
Page 12: Handling And Transport
2.4 Handling and transport The pump must not be used if it is damaged or the identification plate is missing ATEX marking must correspond to the area the pump is operating in The pump must be transported in such way that it is not exposed to vibrations and impacts that can overload the bearings. -
Page 13: Pump Storage And Draining Procedure
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. DOC1627365 Truck Master 600 DOC1627365... -
Page 14: Design Of A System
3 DESIGN OF A SYSTEM DOC1627390 Pos. Description Liquid ring pump Non return valve 4-way valve Vacuum limiter Service liquid valve Fan cooler Liquid separator Dome valve... -
Page 15: Function And Design Of A Liquid Separator
The round velocity reducer can be placed inside any tank geometry. Air flow [m³/h] øD minimum [mm] DOC1627391 øD so the velocity is below 3 m/s H=4 to 6*Ød depending on the geometry. A smooth diameter conversion will give a low factor. Truck Master 600... -
Page 16: Air Cooling With Fan Cooler
3.2 Air cooling with fan cooler Compression of air inside the liquid ring pump will create heat that is transferred to the service liquid. Therefore, it can be necessary to install a fan cooler depending on the expected use, the climate etc. The time it takes to heat up the water also depends on for example ambient temperature, suction pressure, amount of water and the cooling effect in the truck itself. -
Page 17: Fan Cooler
First, we have to reduce the radiator effect based on a temperature difference of 12°C. = 10 = 6 kW out Truck The total cooling effect required is thereby: 11 - 6 = 5 kW out Pump out Truck Truck Master 600... -
Page 18: Water Consumption
Summary Pump model Description Truck Master 600 Heat input from technical specifications 11 kW in Pump Ambient temperature 28°C Maximum Working Temperature of the water. This is determined by you. The temperature 40°C has influence on the pump performance Temperature difference Δ... -
Page 19: System Layout (Zone 1/1)
Float valve SD Stop valve Drain valve Service liquid connection Level transmitter SD 1638149 Pos. Description Vacuum pump Liquid separator Float valve SD Stop valve Drain valve Service liquid connection Plate heat exchanger Level transmitter SD 1638151 Truck Master 600... -
Page 20: Liquid Separator
3.7 Liquid separator Liquid separator must be mounted in such way that the minimum level of service liquid is minimum 0,5 m above the pump´s shaft When operating the drain valves, the outlet may contain explosive gases, corresponding to the classification of the pump´s suction side The liquid separator must be located in immediate proximity to the pump, so that the length of the outlet pipe from the pump is minimised. -
Page 21: Cavitation
Due to economical aspect it is more efficient to drain the liquid separator and refill with fresh water instead of protecting with glycol and drain the separator more rarely. Truck Master 600... -
Page 22: Pipe System
3.10 Pipe system The exhaust from the liquid separator will have the same zone classification as the pump’s suction side The pipes that are connected to the pump’s suction and outlet sides must be at least the same dimension as the pump. The length of the pipe system affects the pump’s capacity and should be calculated to account for pressure drop in longer pipe installations. -
Page 23: Installation And Start-Up
(C). The M12 bolts must be tightened with 60 Nm (B). In order to prevent tensions in the pump, the pipe connections (A) must be tensionless while tightening the bolts. DOC1627367_2 DOC1627367_2 Truck Master 600... -
Page 24: Connecting The Service Liquid
4.3 Connecting the service liquid The service liquid must be connected to the pump at the hose connection, see illustration below. DOC1627365_1 DOC1627365_1 4.4 Transmission The pump can be connected direct or through belt transmission. For belt transmission, it must be ensured that the permissible radial force is not exceeded. -
Page 25: Earth Connection Requirements
The pump must be protected from the creation of sparks in connection with static electricity, in accordance with the applicable regulations for use in the current categories. The pump is prepared for earth connection with an M8 bolt. DOC1627448_1A DOC1627448_1A Truck Master 600... -
Page 26: Prior To Start-Up
4.6 Prior to start-up • Do not start the pump without service liquid, as this will damage the mechanical shaft seals • Do not start the pump if it is completely filled with service liquid • Do not start the pump before the grease cartridges have been activated, as this can damage the pump (if equipped) •... -
Page 27: Service, Operation, Maintenance And Inspection Intervals
The pump and pipe system around the pump must be inspected for leakage once a week. The inspection must be performed when the pump is both operating and idle. Any leaks must be repaired before operation may continue. Truck Master 600... -
Page 28: Draining The Liquid Separator
5.3 Draining the liquid separator While the pump is stopped, the liquid separator must be drained to remove contaminants. 5.4 Check grease cartridges (Category 2 pumps with grease cartridges) To prevent electrostatic discharge in hazardous areas, only wet cleaning is permitted Appropriate measures must be taken to prevent electric discharge If the pump is equipped with an automatic lubrication feature. -
Page 29: Inspection Of Atex Safety Device
The pump may not be started before the instruments have been re-installed. 5.9 Overhaul of pump The pump must be serviced after 10,000 duty hours. This is done by sending the pump to Samson Pumps, or approved and certified partner, upon agreement. The pump must be cleaned before shipment. -
Page 30: Inspection And Cleaning Of Internal Channels
5.10 Inspection and cleaning of internal channels The pump is designed with internal water channels for lubrication of the mechanical shaft seals. Remove the plug as illustrated below and clean the channel using a ø5 mm 150 mm long screw driver or similar. -
Page 31: Troubleshooting
Leakage from the • Damaged shaft seal • Bearings may become • Stop the pump bearing housing’s drain damaged and contact the manufacturer holes • Potential risk of explosive gas leak Truck Master 600... -
Page 32: Spare Parts And Tools
7 SPARE PARTS AND TOOLS 7.1 Marking and identification The pump is equipped with an identification plate as shown below. CERTIFICATE NO. Ex MARKING NOTIFIED BODY NO. CE CONFORMITY MARK ORDER CONFIRMATION NO. / A NO. MANUFACTURING DATE / SERIAL NO. PRODUCT CODE Configuration example: TM 600 R 0 S S B 1 0 T X1... -
Page 33: How To Order
Pump housing: Cast iron EN-GJL-250; EN1561 Shell: Cast iron EN-GJL-250; EN1561 Flow plates: Stainless steel AISI 316 Generation of pump: 1 or 2 Gaskets: Oakenstrong Colour: Grey primer Truck Master Orange On request Documentation: ATEX Zone 0 Truck Master 600... -
Page 34: Spare Parts
7.3 Spare parts... - Page 35 * - Included in gasket set. DOC1623099 Truck Master 600...
- Page 36 Cast iron EN-GJL-250, EN 1561 1623062 Bearing cover DE Cast iron EN-GJL-250, EN 1561 930000081 Ball bearing Chrome steel W.Nr. 1.3505 1601003 Gasket set Truck Master 600 1601003 Gasket set Truck Master 600 Direction arrow Aluminum 915000197 Grease nipple Steel VFZ...
- Page 37 1623027 Spacer for ball guide SS W.Nr. 1.4401 47** 915000217 Plastic pipe 0,3 m Plastic PA6 48** 915000217 Plastic pipe 0,3 m Plastic PA6 * -See section 7.1 for identification of pump. **-Optional. Not equipped as standard. Truck Master 600...
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Page 38: Gasket Set
7.4 Gasket set DOC11592 Pos. Part number Description Qty. Material 922200051 Radial shaft seal 45x65x8 Rubber NBR DIN 3760A 922200036 Radial shaft seal 40x55x7 Rubber NBR DIN 3760A 1623022 Gasket for shell / flow plate 0,4 mm Paper Oakenstrong 1623055 Gasket for shell / flow plate 0,8 mm Paper Oakenstrong 1623023... -
Page 39: Special Tool Set
Mandrel mechanical shaft ring Plastic POM 1629194 Guide pin M8 SS AISI 316 910300428 Socket set screw SS DIN 916 1629193 Bearing mounting tool Plastic / Aluminum 1629079 Assembly bush Plastic POM 1629195 Mandrel radial shaft seal Ø35 Plastic POM Truck Master 600... - Page 40 Notes:...
- Page 41 Notes: Truck Master 600...
- Page 42 Notes:...
- Page 43 Notes: Truck Master 600...
- Page 44 SAMSON PUMPS Samson Pumps is the only company in the world to specialise exclusively in liquid ring vacuum pumps. Samson pumps are made in Denmark and used around the globe. We offer worldwide delivery, and we export to more than 80 countries around the world.
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