AirTech 3AL Manual

Operating and Maintenance Instructions
3AL Vacuum Systems - Standard Design

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INSTALLATION & OPERATING MANUAL
3AL VACUUM SYSTEMS
Table of Contents
Section: Page Number:
1.0 Safety 3
2.0 Intended Use 4
3.0 Prohibited Uses 5
4.0 Technical Data 6
5.0 Transportation & Handling 8
6.0 Installation 8
7.0 Start-Up 11
8.0 Shut-Down 12
9.0 Operation 13
10.0 Long Term Shut-Down 13
11.0 Servicing 14
12.0 Maintenance 14
Maintenance Chart 15
Troubleshooting Chart 17
Exploded-View Drawings & Parts Lists for
Standard 3AL Models 22
Exploded-View Drawings & Parts Lists for
Food-Grade 3AL Models 36
Warranty Statement 50

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1.0 Safety
Safe operation of the 3AL vacuum system requires strict adherence to all local
and national codes. In addition to these requirements, specific dangers are
identified within this manual and should be considered when installing and
operating your Airtech vacuum system.
1.1Severity
1.1.1 Danger means an immediately hazardous situation that will result in
serious injury or death if the recommended actions are not taken.
1.1.2 Warning means a hazardous situation that could result in serious injury or
death if the recommended actions are not taken.
1.1.3 Caution means a hazardous situation that may result in minor or moderate
injury if the recommended actions are not taken.
1.1.4 Caution – Damage indicates a situation that could result in property
damage if the recommended actions are not taken.
1.1.5 Note indicates a recommendation for better operation of the equipment.
1.2General Safety Precautions
1.2.1 Improper operation or installation of the equipment could result in serious
injury or death. These instructions should be read and understood before
attempting to install or operate the equipment.
1.2.2 The system must be operated within the stated limits in this manual to
avoid serious damage to the equipment.
1.2.3 This system consists of rotating equipment that could cause injury
including loss of limb or severe cutting if normal safety precautions are not
followed. Only personnel trained in proper installation and operating
procedures should attempt to operate this equipment.
1.2.4 Hair and clothing can be pulled into this equipment during start-up and
precautions should be taken to prevent same.
1.2.5 This equipment is designed to work on 3 Phase, 200-230/380-460 Volt,
50/60Hz AC current. Appropriate caution must be taken, including
ensuring that the power is off and locked out prior to connecting or
disconnecting the motor or making other electrical adjustments.

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1.2.6 Only a trained electrician should attempt to connect this equipment to the
power source.
1.2.7 Surfaces within the 3AL vacuum system can be cause burns or scalding.
Do not touch internal surfaces within the system.
1.2.8 The 3AL can produce vacuums to 29 inches Hg vacuum. Be sure that the
vacuum has been vented to atmosphere before working on the 3AL
system.
1.2.9 Only operate the system if the inlet piping is fully connected. The vacuum
produced by the system can cause injury, especially to the eyes if looking
into the system inlet when the system is energized.
2.0 Intended Use
2.1 The 3AL vacuum system is intended to be used to produce a vacuum. Do
not use as a compressor system.
2.2 The 3AL vacuum system contains a Speck liquid ring vacuum pump as
indicated in table 2-1.
Table 2-1 Pump Identification
Airtech Model Number Speck Pump Model
3AL2041 V-30
3AL2061 V-55
3AL2101 V-95
3AL2241 V-130
3AL2251 V-155
3AL2281 V-255
3AL2341 V-330
3AL2430 V-430
2.3 Standard 3AL systems are designed to handle non-aggressive and non-
explosive vapor or gas mixtures. When handling corrosive, explosive or
aggressive gases, please contact Airtech for assistance.

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2.4 Operating liquid should be tap water with a pH of 6 to 9, free of solids in the
approximate quantity shown in table 2-2. Do not use de-ionized or distilled
water, tap water is best.
Table 2-2 Operating Liquid Sump Capacity
Airtech Model Number Water Capacity
US gal/liters
3AL2041 4.0/15.1
3AL2061 5.5/20.8
3AL2101 5.5/20.8
3AL2241 16.3/61.7
3AL2251 16.3/61.7
3AL2281 16.3/61.7
3AL2341 16.3/61.7
3AL2430 16.3/61.7
2.4.1 Care must be taken to ensure that the operating liquid is not exposed to
freezing conditions during periods of inactivity. Addition of up to 30 percent
ethylene or propylene glycol by volume is acceptable and will protect from
freezing at temperatures as low as 0 F.
3.0 Prohibited uses
3.1 The 3AL should not be used in an environment where explosive gases may
exist in the environment. Special modifications of the system may allow
operation in these environments, but the standard design is not intended for this
purpose and should not be used.
3.2 Do not use the 3AL on process gas environments, which would result in
significant build up of corrosive chemicals in the system. Special material
versions should be selected for these types of applications.
3.3 Do not use the 3AL on lethal gases. The 3AL is not gas tight and is not
intended for these applications.
3.4 Do not operate the 3AL out of its design range.
3.5 Do not operate the 3AL to extract or compress chemicals unless it has been
specifically designed for this purpose. Contact Airtech, Inc. for assistance if you
are unsure of its applicability to your specific application.
3.6 Maintenance or repair work outside the scope of this manual should only be
preformed under the direction of an Airtech authorized service center.

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4.0 Technical Data
4.1 Weight
Model Weight (empty)
lbs/Kg
Weight Filled with Water
lbs/Kg
3AL2041 105/47.7 138.4/62.9
3AL2061 150/68.2 195.9/89.1
3AL2101 190/86.4 235.9/107.2
3AL2241 360/163.6 495.9/225.4
3AL2251 380/172.7 515.9/234.5
3AL2281 470/213.6 605.9/275.4
3AL2341 580/263.6 715.9/325.4
3AL2430 620/281 785/356.07
4.2 Quantity of Anti-liming Agent
Use granulated citric acid or 10% ethanoic acid in the quantity shown in the
operating liquid sump filled with the normal amount of water as noted in
Table 2-2.
Model Granulated Citric
Acid
lbs/Kgs
10% Ethanoic Acid
(US Gal/Liter)
3AL2041 4.4/2 0.16/0.6
3AL2061 8.8/4 0.26/1.0
3AL2101 8.8/4 0.26/1.0
3AL2241 17.6/8 1.4/5.5
3AL2251 17.6/8 1.4/5.5
3AL2281 17.6/8 1.7/6.3
3AL2341 17.6/8 1.85/7
3AL2430 17.6/8 1.85/7
4.3 Quantity of Corrosion Protection Agent
Use ethylene glycol without additives. Run the system briefly on the glycol water
mixture to ensure all areas of the system are exposed to the glycol.
Model Approximate Amount
US Gal/Liters
3AL2041 0.16/0.6
3AL2061 0.26/1.0
3AL2101 0.26/1.0
3AL2241 1.4/5.5

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3AL2251 1.4/5.5
3AL2281 1.7/6.3
3AL2341 1.85/7
3AL2430 1.85/7
4.4 The 3AL is an air cooled unit and therefore sufficient space as noted in this
table must be allowed around the unit to ensure adequate air flow for cooling and
proper operation. Front refers to the air inlet through the heat exchanger; back
refers to the air outlet through the perforated metal grid and side refers to any
other side of the unit.
Model Front
ft/m
Back
ft/m
Side
ft/m
3AL2041 1.3/0.4 1.3/0.4 1/0.3
3AL2061 1.3/0.4 1.3/0.4 1/0.3
3AL2101 1.3/0.4 1.3/0.4 1/0.3
3AL2241 1.3/0.4 1.3/0.4 1/0.3
3AL2251 1.3/0.4 1.3/0.4 1/0.3
3AL2281 1.3/0.4 1.3/0.4 1/0.3
3AL2341 1.3/0.4 1.3/0.4 1/0.3
3AL2430 1.3/0.4 1.3/0.4 1/0.3
4.5 Approximate noise level of the 3AL unit is described below for a system with
the inlet and outlet piped to a remote location and corrected for local conditions
to a free field value. Measurement is taken at 3 feet (1 meter) from any surface
of the unit. Readings are taken at 60 Hz operation, units operating at 50 Hz will
be approximately 3 dBA less in all cases.
Model Sound Pressure Level
(dBA) maximum
3AL2041 66
3AL2061 70
3AL2101 74
3AL2241 74
3AL2251 71
3AL2281 73
3AL2341 76
3AL2430 76
4.6 Electrical rating of the units is noted on a data plate located on the front of the
unit.

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4.7 The 3AL is a liquid ring vacuum system using ambient air as the coolant.
The reported performance curves of the 3AL assume basic operating parameters
as noted. Should local conditions vary significantly from these values,
performance may be affected.
Condition Value
Ambient Temperature 60 F /15 C
Barometric Pressure 14.7 psia /1013 mbar
Air Humidity 50%
Maximum Operating Liquid Temperature 160 F/ 71C
Minimum Ambient Temperature (if operating
below these temperatures, addition of ethylene
glycol will be required)
40 F/ 5 C
Maximum discharge pressure (if operating above
this range, please consult factory)
5 psig / 0.344 Bar G
5.0 Transportation and Handling
5.1 The 3AL liquid ring vacuum system is designed to be lifted easily by a forklift;
this is the recommended method of transport.
5.2 If lifting the 3AL using a crane, use two lifting belts routed below the system
in the area where the forklift would normally lift the unit. Ensure that the belts are
positioned to avoid tipping the load.
5.3 After transportation, inspect the unit to ensure no damage has occurred.
6.0 Installation
6.1 Install the unit in a location that allows for the consistent maintenance of the
clearances around the unit as noted in Section 4.4 of this manual. Do not install
the unit in areas where these clearances can not be maintained. Do not stack
material in the area immediately around the unit that may restrict cooling air flow
into and out of the unit.
6.2 The system must be installed on a flat level surface that is stationary when
the machine is operating.
6.3 Consult the factory for installations at altitudes above 3000 feet (1000 m)
above mean sea level.
6.4 Ensure that the load bearing capacity of the installation surface will bear the
weight of the unit filled with water as shown in Section 4.1 of this manual.

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6.5 Consider local installation details to minimize vibration. Maximum vibration
allowed is 0.177 inches/sec (4.5 mm/sec). Consult a vibration expert if this value
is exceeded. For most applications, a special foundation or base plate is not
required to achieve this level of vibration and the unit can simply be bolted to the
floor.
6.5.1 Any suitable fastener can be used to secure the system to the floor.
6.5.2 Securing the unit to the floor is only necessary when local conditions
require it to ensure operation inside the vibration limits.
6.6 Install the electrical connections in accordance with all local and national
codes.
6.6.1 Only a qualified electrician should electrically install this equipment.
6.6.2 Observe the voltages and frequency data on the nameplate. Ensure that
the power supply is adequate to operate the unit. Voltage variations of plus or
minus 5 percent and frequency variations of plus or minus 2 percent must not be
exceeded.
6.6.3 Use adequately sized, flexible connection cable to install the unit.
6.6.4 Remove the outer metal cover plate of the unit (covers both top and side of
the unit.
6.6.5 Insert the cable so that no strain is possible on the cable. Secure the cable
to the base plate with an electrical tie.
6.6.6 Connect the cable to the terminal box in accordance with the desired
voltage and the motor connection diagram located in the terminal box.
6.6.6.1 The electrical connection must be permanently safe.
6.6.6.2 The electrical connection must not have protruding ends.
6.6.6.3 Clearance between bare live parts and the ground must be maintained at
greater than 0.217 inches (5.5 mm) at a nominal voltage of less than UN690.
6.6.6.4 For terminals with clamping strips, the connections should be inserted so
that the same clamping height results on both sides of the bar. Individual
conductors should therefore be bent into a U shape or connected with a cable
lug.

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6.6.7 Connect the water supply solenoid valve to the motor control circuit so that
the solenoid valve opens when the motor starter is energized and closed when
the motor starter is de-energized (see Figure 1).
Figure1
6.6.8 Use of a properly sized magnetic motor starter with heater is required to
protect the equipment from electrical failure.
6.7 Once the electrical connections are complete, reattach the junction box cover
and then reattach the 3AL metal cover sheets, ensuring that the wire is properly
routed through the cut out in the side sheet near the bottom of the unit.
6.8 Before making the piping connection to the system, briefly jog the system
(<10 sec) by turning it on and off to check direction of rotation. With a piece of
paper, check the direction of air flow through the system. The paper should be
held against the radiator when the system is operating in the proper direction. If
the paper is blown away from the radiator, then the system is operating in the
incorrect direction and two of the leads must be exchanged in the motor terminal
box.
6.8.1 Ensure the power is de-energized before switching leads inside the
terminal box to change motor direction.
6.9 Fill the system with water in the approximate amount as shown in Section
2.4.
6.9.1 Remove the plastic plug in the top of the 3AL water sump.
6.9.2 Add water to the sump through this connection until the level reaches the
level of the overflow on the back of the unit. Do not use high pressure water to
fill

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6.9.3 Check the water level by observing the liquid level sight glass installed near
the operating liquid overflow connection on the back of the unit.
6.9.4 If this is the first time the unit is being installed or run, add water to the inlet
of the system to prime the pump. For the 3AL2041 through 3AL2241 add 0.4
gallons (1.5 liters); for larger systems add 1.3 gallons (7 liters).
6.10 Connect the inlet of the system to the local vacuum header or source
requiring the vacuum production of the unit.
6.10.1 Ensure that no pipe stress is present on the system; application of stress
to the inlet can cause the system to leak, malfunction, or fail.
6.10.1.1 Remove the pipe plug before connecting the inlet. The pipe plug is
inserted prior to shipment to keep foreign bodies out of the operating liquid sump.
6.10.2 A check valve is included with each 3AL system and additional check
valves are not required.
6.11 Connect a ¼inch water supply line to the operating liquid make up and
spray line located on the back of the unit near the bottom of the perforated metal
grid.
6.11.1 Connect a drain hose to the overflow water connection on the back of the
unit. While not required for operation, failure to connect the overflow to a drain
will result in operating liquid spilling onto the floor.
6.12 In most cases, the exhaust air should be allowed to vent freely from the unit.
If installing discharge piping, ensure that the piping is large enough to keep the
operating discharge pressure below 5 psig and that no pipe forces are allowed to
be exerted onto the 3AL system (e.g. adequately support the piping).
6.13 Add accessories as recommended by your Airtech representative. The
following items are available and commonly applied depending on the local
circumstances.
6.13.1 Add an inlet filter if particulates may be present in the inlet gas stream.
6.13.2 Add an electronic level switch if remote monitoring of the liquid level in the
operating liquid sump is desired.
6.13.3 Add a temperature switch if shut-down on high discharge temperature is
required.
6.13.4 Add a temperature gauge if monitoring of the operating liquid sump
temperature is required.

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6.13.5 Add a discharge pressure switch if connecting the system to a
downstream process which could cause excessive back pressure onto the unit.
7.0 Start-up
7.1 Visually check the operating liquid level in the operating sump on the liquid
level gauge on the back of the unit. Add or remove water as necessary to
achieve a level of water just below the level of the overflow connection.
7.2 Ensure the cover plate is mounted and secured properly.
7.3 Turn the power on. The unit should produce a vacuum on the upstream
equipment.
8.0 Shut Down
8.1 In general, the system may be shut down at any operating condition
(pressure, temperature, etc..), but this will obviously affect the dependant
processes.
8.2 To shut the system down, de-energize the power (turn it off).
8.3 If the system is not to be started for a long period of time, please follow the
instructions in Section 9 of this manual.

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9.0 Operation
9.1 Continuous operation at a maximum vacuum is possible. The power
consumption of the vacuum system is at its lowest at this operating condition. In
case of no load operation, we recommend operation at this condition (e.g. with
the inlet blanked off from the process) rather than open flow to atmosphere.
9.2 In the case of liquid loss due to operation on dry air, the make-up water
supply solenoid will replace the water if operating properly. The amount of make-
up water is a constant 0.06 gallons per minute.
9.3 In the case that operating liquid builds up in the separator, the water will flow
out of the overflow connection located on the back of the unit.
10.0 Long term Shut-down
10.1 When shutting down the system for long periods (greater than
approximately one week), the system must be drained and protected from
corrosion.
10.1.1 Remove and lock out the power from the system. Disconnect the power
in such a way to ensure the system can not be accidentally restarted during the
period of storage.
10.1.2 Shut off the water to the ¼inch make-up connection at the bottom of the
unit.
10.1.3 Open the drain valve on the operating liquid sump and remove all of the
water from the sump.
10.1.4. Remove the sheet metal top and side (one or two pieces, depending on
size).
10.1.5 Drain the liquid ring vacuum pump by removing the bottom drain
connections and collecting the water in a suitable container.
10.1.6 Replace the pump drain plugs.
10.1.7 Close the operating water sump drain valve.
10.1.8 Replace the sheet metal top and side.
10.2 If shutting down for very long periods (greater than 4 weeks) additional
precautions must be applied.

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10.2.1 Add a small amount of ethylene glycol to the inlet of the pump (see
Section 4.3 of this manual).
10.2.2 Ensure the system is stored in a clean, dry location and is not exposed to
extremes of temperature or weather.
10.3 To re-commission after a long storage period, add the following to the
standard commissioning procedures outlined in Sections 6 and 7 of this manual.
10.3.1 Measure the insulation resistance of the motor (<1kOhm per volt of
nominal voltage, dry winding).
10.3.2 Remove the anti-corrosion agent from the pump by draining it from the
pump casing. Ensure proper disposal of the anti-corrosion agent.
10.3.3 Clean the system by adding water to the operating liquid sump and
priming the pump as described in Section 6.9.
10.3.3.1 Briefly run the system.
10.3.3.2 Shut the system off and drain the system operating water from the
sump.
10.3.3.3 Repeat this procedure until the system is free of debris or foreign matter.
11.0 Servicing
11.1 Do not attempt to service the system without consulting Airtech, Inc. for
assistance. Normally, no service is required and the need for service may
indicate a process problem that must be addressed prior to re-commissioning.
12.0 Maintenance
12.1 If hard water is used to operate the system, then the water should be
softened or the entire unit must be de-calcified at regular intervals. Use the anti-
liming agent recommended in Section 4.2 of this manual.
12.2 Periodically check the hoses and fittings for leaks. If leaks are found, de-
energize the system and tighten or replace the leaking fittings.
12.3 If dirt or other foreign matter enters the system, it must be cleaned regularly
according to the procedure outlined in Section 10.3.3.

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Maintenance Chart
Problem Probable Cause and Solution
Water consumption
increases as
indicated by
reduction of liquid
level in the operating
liquid sump.
Clogged or obstructed cooler.
Clean the cooler by blowing compressed air through it,
taking reasonable and necessary safety precautions.
Ambient air highly
contaminated.
Clogged or obstructed cooler.
Clean the cooling fins with compressed air.
Dirt builds up in the
system due to
introduction with the
suction gas or make-
up water.
Clean the unit as described in Section 10.3.3 of this
manual.
Add an inlet filter or water filter as required.
Sand or other fine
grain particulate
enters system with
make-up liquid.
Clean the system periodically (intervals dependant on
contamination level, but at least once a year) as described
in Section 10.3.3 of this manual.
In addition, you can briefly run the system with the
operating liquid drain closed to flush out any water
existing in the pump. Take care to avoid contact with the
cooling fan during this operation; it is recommended to
reinstall the housing panels prior to operation of the
system.
No vacuum due to
jammed impeller
Turn the shaft by hand to fee up.
Turn off the electrical power supply and lock out power to
the unit.
Remove the sheet metal covers to the unit.
Remove the shroud covering the fan (note: cooler may
need to be removed to remove the shroud).
Turn the fan by hand (do not use leverage).
If the shaft will not come free, the unit must be serviced by
an authorized service center. Please contact Airtech for
assistance.

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Extreme hard water
used as the
operating and make-
up liquid (Lime
content greater than
15 degrees of
hardness)
Soften the water or clean with 10% ethanoic acid on a
periodic basis.
To clean with ethanoic acid:
Drain and clean the system as described in Sections 10.1
and 10.3.3.
Lock out the power to the unit.
Wear protective gloves (10 percent ethanoic acid can
cause severe burns, handle with care).
Disconnect the pipe/hose from the liquid ring pump to the
top of the cooler at the cooler.
Fill the interior of the unit with 10 percent ethanoic acid,
taking all necessary precautions to avoid skin contact with
the acid. Fill the pump by adding the proscribed amount
(see Section 4.2) of ethanoic acid through the
disconnected supply hose using a plastic funnel.
Let the ethanoic acid sit in the pump for 30 minutes. Do
not allow to sit for more than 45 minutes, as the acid can
damage the seals of the pump.
During the 30 minute period, occasionally turn the impeller
by hand (using the cooling fan to turn the impeller).
Drain the ethanoic acid from the pump by removing the
drain plug and collecting the acid in a suitable container.
Reconnect the drain plug, hose and reassemble the
system.
Fill with water and clean as described in Section 10.3.3.
Re-commission the unit as described in Sections 6.9 to
6.13.
Or
Decalcify the entire system using granular citric acid.
If lime build-up is experienced in the entire system, it may
be necessary to de-calcify the entire system. Do so as
follows:
Add the proscribed amount (Section 4.2) of citric acid to
the sump (dissolve first in water and pour the resulting
solution into the operating liquid sump).
Operate the system for approximately 10 hours on the
citric acid solution.
Drain and clean the system as described in Section
10.3.3, taking care to dispose of the resulting citric acid
solution properly.
Re-commission the unit as described in Sections 6.9 to
6.13.

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Troubleshooting Chart
Fault Cause Remedy Responsible
Party
Motor does
not start, no
noise.
Two or more
power legs
interrupted
Check fuses, terminals, etc.. for
source of interruption and
correct.
Electrician
Motor does
not start,
humming
noise.
One power
supply lead
interrupted
Check fuses, terminals, etc.. for
source of interruption and
correct.
Electrician
Impeller
Jammed
Free by hand (see
Maintenance Chart) or de-
classify unit if procedure is not
successful and contact Airtech
for assistance.
Operator
Trip of motor
starter at
start-up
Incorrect
starter setting
Ensure starter setting is correct
(check current on nameplate)
Electrician
Winding short-
circuit
Megger motor Electrician
Discharge
pressure too
high
Measure discharge pressure if
possible or disconnect any
discharge piping and attempt to
run while discharging into the
room. Unclog piping or
increase discharge piping size
to eliminate pressure drop.
Operator
Impeller
Jammed
Free by hand (see
Maintenance Chart) or de-
classify unit if procedure is not
successful and contact Airtech
for assistance.
Operator
Excessive
Power
Consumption
Lime or other
deposits
Decalcify or clean unit as
required (see Maintenance
Chart)
Operator
No vacuum No operating
liquid
Check liquid level in separator.
Add as required to achieve
proper level.
Operator
Severe leak in
system
Close off pump and run
deadheaded to confirm pump is
operating properly. If so, find
and fix leak in the system.
Operator
Wrong
direction of
rotation
Check air flow direction and
change direction of rotation if
necessary.
Operator
Electrician

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Insufficient
Vacuum
System too
small
Use larger system Operator
Inlet piping too
long or too
small.
Increase pipe diameter to
reduce pressure loss in inlet
piping. Contact Airtech for
assistance in determining
correct pipe size.
Operator
Leak at
connection to
vacuum
system.
Check for leaks and repair if
necessary.
Operator
Operating
liquid flow too
low.
Check flow of water through the
clear hoses. Remove any
clogs or contamination.
Operator
Operating
liquid too
warm
Cooling fins of unit clogged.
Clean with compressed air as
described in the Maintenance
chart.
Operator
Inlet filter
clogged.
Change filter element; remove
clog.
Operator
Vacuum relief
valve
incorrectly set.
Close vacuum relief valve
located on the pump in some
units. Contact Airtech for
assistance.
Operator
Liquid water
being
expelled from
separator
Baffles not
installed.
Check installation of baffles in
the operating liquid sump by
removing the baffle cover plate
and physically verifying their
installation.
Operator
Build up of
water in the
operating
liquid sump.
Check sump level and remove
obstructions from drain. Drain
water off of sump to
recommended level.
Operator
Abnormal
screeching
noise
Pump is
operating in
cavitation
range.
Check cavitation protection
connection and hose for
clogging.
Operator
For additional assistance, please contact Airtech, Inc., 150 South Van Brunt
Street, Englewood, NJ, 07631. Phone [phone] or via fax at 201-569-
1696.