CVS VacuStar WR 2500 User manual

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!

2
Translation of the original operating manual
© CVS engineering GmbH
Großmattstraße 14
79618 Rheinfelden / Germany
Phone: [phone]
Customer service: [phone]
E-Mail: [email protected]
Internet: www.cvs-eng.de

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Contents
3
1General....................................................................................4
1.1 Information regarding the operating instructions ...........4
1.2 Pictogram explanation ...................................................5
1.3 Limitation of Liability ......................................................6
1.4 Copyright protection.......................................................6
1.5 Spare parts ....................................................................7
1.6 Warranty conditions.......................................................7
1.7 Customer Service ..........................................................7
2Safety ......................................................................................8
2.1 Intended use..................................................................8
2.2 Proper operation............................................................8
2.3 Acceptance and monitoring...........................................9
2.4 Operator's responsibility ................................................9
2.5 Operating personnel ....................................................10
2.5.1 Requirements...............................................10
2.6 Personal protective equipment....................................10
2.7 Occupational safety and special risks .........................11
3Technical data ......................................................................17
4Design and function.............................................................19
4.1 Design..........................................................................19
4.2 Function.......................................................................19
4.3 Control and display elements ......................................21
5Transport and storage.........................................................22
5.1 Safety notes for transport ............................................22
5.2 Transport......................................................................22
5.3 Storage ........................................................................22
6Start-up and operation ........................................................23
6.1 Safety...........................................................................23
6.2 Start-up........................................................................23
6.3 Switching off.................................................................25
6.4 Inspections to be performed at standstill.....................25
7Maintenance .........................................................................27
7.1 Safety...........................................................................27
7.2 Maintenance schedule.................................................27
7.3 Performance of maintenance work..............................29
8Malfunctions.........................................................................32
8.1 Safety...........................................................................32
8.2 Recommissioning after corrective action.....................33
8.3 Malfunction table..........................................................33
9Spare parts ...........................................................................36
10 Decommissioning and disposal.........................................37
Index..............................................................................................38

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
4
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.
Furthermore, all local accident prevention regulations and general
safety regulations valid for the application area of the VacuStar WR
must be observed.
Carefully read the operating instructions before starting any work! It
is a product component and must be kept in direct proximity of the
VacuStar WR, well accessible to the personnel at all times.
When passing the VacuStar WR on to third parties, the operating
instructions must also be handed over.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
5
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.
It is absolutely essential to observe the notes and to proceed with
caution in order to prevent accidents as well as bodily injuries and
property damage.
DANGER!
points to an immediately dangerous situation, which
can lead to death or serious injuries if it is not
avoided.
WARNING!
... points to an immediately dangerous situation,
which can lead to death or serious injuries if it is not
avoided.
CAUTION!
... points to a potentially dangerous situation, which
can lead to minor or light injuries if it is not avoided.
ATTENTION!
... points to a potentially dangerous situation, which
may lead to property damage if it is not avoided.
Safety note ATEX!
Only for VacuStar WR with Ex-approval.
This pictogram denotes the special conditions that
must be observed according to the approvals when
operating the VacuStar WR in potentially explosive
areas.
Hints and recommendations
NOTE!
… highlights useful hints and recommendations as
well as information for an efficient and trouble-free
operation.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
6
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.
The manufacturer is not liable for damages caused by:
Non-observance of the operating instructions
Improper use
Deployment of non-trained personnel
Arbitrary modifications
Technical changes
Use of non-approved spare and wear parts
The actual scope of supply may differ from the explanations and
illustrations described in this manual in case of special designs, if
additional order options are made use of, or due to latest technical
changes.
Incidentally, the responsibilities agreed upon in the delivery
contract, the general terms and conditions as well as the
manufacturer's conditions of delivery and the statutory provisions
valid at the time of contract conclusion shall apply.
Warranty
The manufacturer guarantees the correct functioning of the applied
process technology and the performance parameters identified.
The warranty period commences on the date the VacuStar WR is
delivered to the customer.
Wear parts
Wear parts are all components coming into immediate contact with
the material to be processed (e.g. bearings, shaft sealing rings,
etc.).
These components are excluded from the warranty and any claims
for defects as far as wear and tear damage is concerned.
1.4 Copyright protection
Surrendering the operating instructions to third parties without
written permission of the manufacturer is not permitted.
NOTE!
Content details, texts, drawings, pictures and other
illustrations are protected by copyright and are
subject to industrial property rights. Any improper
use shall be liable to prosecution.
Any type and form of duplication also of extracts as well as the
exploitation and/or communication of the contents are not
permitted without the manufacturer’s written declaration of consent.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
General
7
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.
Therefore:
–Use only the manufacturer's original spare
parts.
Procure spare parts from authorised dealers or directly from the
manufacturer. Refer to page 2 for address.
A list of spare and wear parts can be found in the enclosure.
1.6 Warranty conditions
The warranty conditions are included in the sales documentation
as a separate document.
1.7 Customer Service
Our customer service can be contacted for any technical advice.
Information about the responsible contact person can be retrieved
by telephone, fax, E-mail or via the Internet at any time, refer to
manufacturer's address on page 2.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
8
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.
The VacuStar WR in the explosion proof design complies with
Directive 2014/34/EU (ATEX) and is suitable for conveying
explosive gases and gas mixtures of explosion group IIB,
temperature class T5 from explosive zone 1 and zone 2 areas.
No explosive atmosphere is allowed in the area around the
VacuStar WR. The VacuStar WR may only be opened when it is
stopped and when there is no explosive atmosphere around it.
Labelling of the VacuStar WR on the rating plate:
II 2G ck IIB T5 (i),
no potentially explosive external atmosphere.
In temperature class T5, the gas temperature is
limited to 95 °C, and must be secured.
2.2 Proper operation
The following criteria in essence define the proper
operation:
–Technical Data in Tab. 2
–Solids may not be sucked into VacuStar WR.
If explosive gases and gas mixtures are conveyed, the
following guidelines must be observed:
–2014/34/EC
Devices and protection systems for the proper
use in explosive environments
–99/92/EC
Health protection and safety of the employees in
potentially explosive areas

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
9
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. The operator alone shall be responsible for any damage
arising from improper use.
2.3 Acceptance and monitoring
The VacuStar WR itself is not subject to any acceptance and
monitoring obligation.
2.4 Operator's responsibility
The VacuStar WR is used for industrial purposes. The operator of
the VacuStar WR is therefore subject to the legal obligations
concerning occupational safety.
The provisions valid at the place of installation as well as the safety
and accident prevention regulations of the Institution for statutory
accident insurance and prevention must be observed. The operator
must in particular:
inform himself on the valid industrial safety regulations.
determine the additional hazards that arise from the special
working conditions at the VacuStar WR's place of installation by
means of a hazard assessment.
implement the necessary rules of conduct for operation of the
VacuStar WR at the place of installation by means of user
instructions.
check at regular intervals during the VacuStar WR's entire
period of use whether the user instructions correspond to the
current state of the body of rules and regulations.
adapt the operation instructions, if necessary, to the new
regulations, standards, and operating conditions .
clearly regulate the responsibilities for installing, operating,
maintaining and cleaning the VacuStar WR.
ensure that all employees working on or with the VacuStar WR
have read and understood the operating instructions. In addition
he must at regular intervals train the employees in how to deal
with the VacuStar WR and inform them about potential hazards.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
10
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.
all safety equipment is regularly checked for completeness and
correct functioning.
2.5 Operating personnel
2.5.1 Requirements
WARNING!
Risk of injury in case of inadequate
qualification!
Improper handling can lead to considerable bodily
injuries and property damage.
Therefore:
–Have any activities only carried out by the
individuals designated for that purpose.
The operating instructions specify the following qualification
requirements for the different fields of activity:
Instructed persons
have been instructed during instructions provided by the
operator with regard to the work assigned to them and possible
hazards arising from improper conduct.
Specialists
are due to their technical training, knowledge and experience
and their knowledge of the pertinent regulations able to carry
out the work assigned to them and to independently recognize
potential hazards.
2.6 Personal protective equipment
When handling the VacuStar WR, it is necessary to wear personal
protective equipment, in order to minimise health hazards.
Before carrying out any work, properly don the necessary
protective equipment such as gloves, safety goggles, etc. and
wear during work.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
11
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.
Assembly of the VacuStar WR
The relevant dangerous spots on the VacuStar WR are identified
by these pictograms:
DANGER!
General danger pictogram!
… denotes general dangerous situations for
individuals. Non-observance of the safety
instructions can result in severe injuries or
death.
DANGER!
Explosion protection pictogram!
… denotes regulations and information that need to
be observed in potentially explosive areas.
Explosion protection class, temperature ranges
, etc. must be observed!
DANGER!
Danger of burns!
… denotes the presence of a hot surface.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
12
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!
–Only use VacuStar WR in a perfect technical
condition. Malfunctions that are relevant for
safety have to be promptly eliminated.
–Conversions of the VacuStar WR are not
permissible and can impair safety.
–Never bridge any safety equipment or put it out
of operation.
–Any work on the VacuStar WR and/or on
electrical equipment must be carried out by
specialised staff.
–Repair and maintenance work may only be
carried out when the VacuStar WR is stationary.
For this, the VacuStar WR must be secured
against restarting!
–The VacuStar WR may not be under pressure
or in a state of vacuum while work is being
carried out on it.
Close shut-off valve on the vehicle side and
vent the pipe between VacuStar WR and shut-
off valve or manually relieve excess pressure at
safety valve. Observe pressure gauge!
–The drive's protective equipment may only be
removed when the VacuStar WR is stationary
and has to be correctly refitted after completion
of work.
–Only dismantle accidental contact protection
after VacuStar WR and pressure pipe have
cooled down.
–It is an environmental protection requirement
that any liquids arising during maintenance work
(e.g. cooling oil, cooling water, etc.) are
collected and disposed of in an environmentally
compatible manner.
–The machine may only be opened for
maintenance and repair work by specialised
staff if the VacuStar WR is stationary and no
potentially explosive atmosphere is present.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
13
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!
–Do not put safety devices and/or functions out
of operation and do not render them inoperative
or bypass them.
–Never reach into open outlets and inlets or into
running equipment.
Before entering the hazard area:
–Switch off power supply and secure against
restarting.
–Wait for standstill of lagging components.
–Wait for automatic dissipation and/or discharge
of residual energies (compressed air).
Compressed air
WARNING!
Risk of injury due to compressed air!
Pneumatic energies can cause the most serious
injuries.
In the case of damage to individual components,
air can be discharged under high pressure and
injure e.g. the eyes.
Therefore:
–Before starting any work, first depressurise
pressurised components. Pay attention to
accumulators. Accumulator pressure must also
be completely relieved.
–Do not change pressure settings beyond the
maximum values.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
14
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.
–Immediately replace damaged or obliterated
signs or labels.
Improper transport
Danger!
Danger by falling down or tilting of the
VacuStar WR!
The weight of the VacuStar WR may injure a
person and cause serious bruising!
Therefore:
–Depending on the dead weight and size of the
VacuStar WR, use a pallet on which the
VacuStar WR can be moved by means of a fork
lift.
–For lifting the VacuStar WR, use suitable lifting
gear (slings, etc.) that is designed for the weight
of the VacuStar WR.
–When putting the slings in position, take care to
avoid putting stress on individual components.
–Only use eye bolts provided for that purpose.
See page 19, Fig. 1, pos. 8

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
15
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
performed by the manufacturer's employees or
by his authorised representatives or by trained
personnel.
–Start-up and operation may only be performed
by adequately qualified personnel that has been
authorised and instructed by the operator.
–Before the start of any work, ensure that all
covers and protective devices are correctly
installed and function correctly.
–Never override any protective equipment during
operation.
–Pay attention to tidiness and cleanliness in the
working area! Loosely stacked or scattered
components and tools are accident sources.
Electrical system
DANGER!
Mortal danger due to electric current!
There is mortal danger in case of contact with live
components.
Activated electrically driven components can start
to move uncontrolled and cause severest injuries.
Therefore:
–Switch off the electric power supply before
commencing any work and secure against
restarting.
–Work on the electrical system, on individual
electrical components and on the connections
may only be carried out by electrical specialists.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Safety
16
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.
–Protect VacuStar WR from being restarted,
switch off drives!
–Before starting any work, provide for sufficient
space and freedom of movement during
assembly.
–Pay attention to tidiness and cleanliness in the
assembly area! Loosely stacked or scattered
components and tools are accident sources.
If components must be replaced:
–Pay attention to correct installation of spare
parts.
–Properly reassemble all fastening elements.
–Observe screw tightening torques.
–Before restarting, ensure that all covers and
protective devices are correctly installed and
function correctly.
–After completion of maintenance work and
troubleshooting, check correct functioning of
safety equipment.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
17
3 Technical data
General data
Unit
WR 2500
WR 3100
WR 4000
Nominal operating vacuum 1)
[mbar]
400
Weight without water filling
[kg]
175
192
298
Permissible inclination in longitudinal direction
[°]
5
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
Input speed
[1/min]
800 to 1600
800 to 1300
Suction temperature 1)
[°C]
-20…+60
Outlet temperature
[°C]
max. 65
Geodetic height 1)
[m]
0…1000
Maximum operating vacuum 4)
[mbar]
130
Maximum final overpressure with direct drive 3)
[bar]
1.5
1.5
1.0
Maximum final overpressure with V-belt drive 3)
[bar]
1.0
0.5
0.5
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
Tab. 2: Permissible working range

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Technical data
18
VacuStar WR performance data vacuum
operation
Unit
WR 2500
WR 3100
WR 4000
Suction pressure: 400 mbar 1), 2)
Speed
[1/min]
1600
1300
Maximum intake volume flow 1), 2), 3)
[m3/h]
2500
3100
4063
Coupling power 1), 2), 3)
[kW]
73
88
117
Intake volume flow 1), 2)
[m3/h]
2016
2427
3521
Coupling power 1), 2)
[kW]
61
76
107.5
Sound pressure level at 7 m distance at
400 mbar
[dB(A)]
70
72
73
1) Excess pressure = 0 bar, suction and ambient temperature = 20 °C
2) Process water temperature = 20 °C
3) Water vapour saturated air = 55 °C
Tab. 3: Performance data vacuum operation
VacuStar WR performance data
pressure operation
Unit
WR 2500
WR 3100
WR 4000
Excess pressure: 0.5 bar 1), 2)
Coupling power
[kW]
77
94
131.5
Intake volume flow
[m3/h]
1936
2469
3496
Sound pressure level at 7 m distance at
0.5 bar excess pressure
[dB(A)]
70
72
73
1) Vacuum = 0 mbar, suction and ambient temperature = 20 °C
2) Process water temperature = 20 °C
Tab. 4: Performance data pressure operation
VacuStar WR process water circulation
Unit
WR 2500
WR 3100
WR 4000
Maximum process water inlet temperature
VacuStar WR
[°C]
55
pH value
–
5…8
Process water circulating quantity
in vacuum operation at 400 mbar 1)
[l/min]
70…90
70…90
70…90
1) Excess pressure 0 bar
2) Vacuum 0 mbar
3) Based on a radiator of a specific cooling capacity Pspec = 3.5 kW / (m²  °C)
Pspec = Pab / [(t water  tair in)  Aradiator]
Heat to be dissipated for operation with water vapour saturated air on request
Tab. 5: Process water circulation

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
19
4 Design and function
4.1 Design
Fig. 1: Design
1 Drive shaft
2 Connection process water
3 Cell ventilation connection
4 Connecting flange for pressure or suction
connection (flange DIN 28459)
5 Process water draining
6 Rating plate
7 Rotation arrow
8 Thread for eye bolt
9 Fixing foot
10 Water level indicator
11 Liquid supply for slide ring seal
12 Manuel fill level inspection
4.2 Function
VacuStar WR
The liquid ring pump works according to the positive displacement
principle. At a sufficiently high speed, a rotating liquid ring is
formed in the casing. In conjunction with the impeller, cells form
that are separated from each other and steadily grow (sucking) or
shrink (compressing) with each revolution.

Operating instructions VacuStar WR 2500 / WR 3100 / WR 4000
Design and function
20
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.
Cooling
The unit is cooled by the process water and/or the liquid ring. A
radiator in the process water circulation dissipates the heat to the
environment.
Shaft sealing
Maintenance-free slide ring seals separate the working space from
the bearings and/or the atmosphere.
Sense of rotation
See rotation arrow page 19, Fig. 1, pos. 7.
Process water circulation and cell
ventilation
The air flowing through the VacuStar WR absorbs humidity from
the liquid ring, and is 100% saturated when it exits the
VacuStar WR. Only the water drops are separated in the reservoir.
The steam component is dissipated to the environment.