SAMSON PUMPS OCEAN MASTER 1000 User manual

DOC9063L
INSTRUCTION MANUAL FOR SAMSON LIQUID RING PUMP
OCEAN MASTER 1000
OCEAN MASTER 1000
INSTRUCTION MANUAL
LIQUID RING PUMP
• Technical data
• Design of a system
• Installation and start-up
• Service
• Troubleshooting
• Spare parts
The English version of the instruction manual is the legally binding version.

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Ocean Master 1000
CONTENTS
1 Introduction .............................................................................................................................. 4
1.1 Declaration of conformity........................................................................................................ 4
1.2 Explanation of warning symbols.............................................................................................. 5
1.3 Field of application.................................................................................................................. 5
1.4 Disposal.................................................................................................................................. 5
2 Technical data.......................................................................................................................... 6
2.1 Dimensions............................................................................................................................. 6
2.2 Specifications.......................................................................................................................... 7
2.3 Power consumption and output............................................................................................... 8
2.3.1 Performance ........................................................................................................................... 8
2.3.2 Consumption .......................................................................................................................... 9
2.4 Handling and transport ......................................................................................................... 10
2.5 Pump storage and draining procedure................................................................................... 11
3 Design of a system ..............................................................................................................12
3.1 Piping ................................................................................................................................... 13
3.2 Service liquid adjustment - Pressure method......................................................................... 13
3.3 Service liquid pump............................................................................................................... 14
3.4 Pump performance................................................................................................................ 14
3.5 Pressure drop........................................................................................................................ 15
3.6 Service liquid requirement..................................................................................................... 16
4 Installation and start-up...................................................................................................17
4.1 Securing the pump................................................................................................................ 17
4.2 Connections to the pump ...................................................................................................... 17
4.3 Connecting the service liquid ................................................................................................ 17
4.4 Drive..................................................................................................................................... 18
4.4.1 Direct drive .......................................................................................................................... 18
4.4.2 Belt drive............................................................................................................................... 18
4.5 Prior to start-up.................................................................................................................... 19
4.6 Direction of rotation ............................................................................................................. 19

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5 Service, operation, maintenance and inspection intervals............................................. 20
5.1 Check grease cartridges - Only belt drive.............................................................................. 20
5.2 Winterization......................................................................................................................... 20
5.3 Lubrication of bearings - Only belt drive ............................................................................... 20
5.4 Inspection and cleaning of service liquid’s supply pipe.......................................................... 20
6 Troubleshooting ...................................................................................................................21
7 Spare parts and tools..........................................................................................................22
7.1 Marking and identification..................................................................................................... 22
7.2 How to order......................................................................................................................... 23
7.3 Spare parts - GENERATION 0 ................................................................................................. 24
7.4 Spare parts - GENERATION 2 ................................................................................................. 28
7.5 Gasket set - GENERATION 0 .................................................................................................. 32
7.6 Gasket set - GENERATION 2 .................................................................................................. 33
7.7 Adaptor - GENERATION 2 ...................................................................................................... 34
7.8 Special tool set - GENERATION 0 ........................................................................................... 35
7.9 Special tool set - GENERATION 2 ........................................................................................... 36

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E-Mail
[email protected] Samson Pumps A/S Petersmindevej 21
Web www.samson-pumps.com Phone | [phone] DK-8800 Viborg
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I hereby declare that the liquid ring pumps are in conformity with the following harmonized standards:
DS/EN ISO 12100:2011 Safety of machinery - General principles for design - Risk assessment and risk
reduction
DS/EN 1012-2 + A1:2009 Compressors and Pumps - Safety requirements - Part 2: Vacuum pumps
The standards above only apply 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.
Viborg,05.12.2019________________________________________
JanS.Christiansen–Manager,Technicaldept.

1 INTRODUCTION
1.1 Declaration of conformity
DOC4045A

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1.2 Explanation of warning symbols
To be used with all safety instructions that must be followed. A failure to follow the
instructions may result in injuries and/or incorrect machine operation
Important technical and safety instructions are shown by symbols. If the instructions are not performed
correctly, it can lead to personnel injuries or incorrect function of the pump.
1.3 Field of application
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.
For other operating data, see specifications.
• The pump must only be used with media that is not aggressive to the pump's materials. See section 7
for components and materials.
Inlet of foreign objects can damage the pump
The pump is designed exclusively to pump gases, including atmospheric air
1.4 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).
These components must be disposed of in accordance with national regulations.
WARNING!
Avoid cavitation of the pump! For further information, see instruction manual for the
Samson Pumps vacuum limiter

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2.1 Dimensions
2 TECHNICAL DATA
DOC1619221A
524
86
901
249
472
320
295
455
Ø80
45 k6
598 195
Ø162,5
Ø13,5
ABCEF
D
DOC1619221A
Pos. Description Size
AWater inlet hose stud Ø20 G 3/4”
B, F Drain plug G 3/4”
C, E Housing plug G 1/2”
DShell plug G 3/8”

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2.2 Specifications
Description Minimum Maximum
Ambient temperature, operation Below 0°C - see chapter 5.3 -20°C 55°C
Ambient temperature, storage -20°C 55°C
Humidity - 100%
Intake temperature, suction side - 60°C
Intake temperature, service liquid - 60°C
Service liquid pipe connection, dimension ¾” -
Service liquid pipe connection, length - 6 m
Noise level (measured 7 m from pump) - 80 dB(A)
Water volume - 52 L
Maximum radial load on drive shaft
Belt drive* - 4800 N
Direct drive* - -
Revolutions 800 rpm 1800 rpm
Pressure 150 mbar abs. 3 bar(g)
Lubricating grease (Only belt drive)*
Type of grease SKF LGWA2
Automatic lubrication SKF LAGD 125/WA2
Weight
Without branch pipes 253 kg
With branch pipes 280 kg
A failure to meet these specifications may result in damage to the pump
* -See section 7.1 for identification of pump. (Belt drive or direct drive)

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OCEAN MASTER 1000
DISCHARGE HEIGHT
SUCTION DEPTH
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
2,50
5,00
7,50
10,00
12,50
15,00
17,50
20,00
22,50
25,00
27,50
30,00
100
200
300
400
500
600
700
800
900
1000
1100
800 RPM
800 RPM
1200 RPM
1200 RPM
1500 RPM
1500 RPM
1650 RPM
1650 RPM
1800 RPM
1800 RPM
- 9,00
- 8,00
- 7,00
- 6,00
- 5,00
- 4,00
- 3,00
- 2,00
- 1,00
0 m
FISH
m3/h
POWER
kW
1100 1000 900 800 700 600 500 400 300 200 100
PERFORMANCE
m3/h
m3/h
kW
kW
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
DOC11582
2.3 Power consumption and output
2.3.1 Performance

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DOC11582
OCEAN MASTER 1000
DISCHARGE HEIGHT
SUCTION DEPTH
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
2,50
5,00
7,50
10,00
12,50
15,00
17,50
20,00
22,50
25,00
27,50
30,00
100
200
300
400
500
600
700
800
900
1000
1100
800 RPM
800 RPM
1200 RPM
1200 RPM
1500 RPM
1500 RPM
1650 RPM
1650 RPM
1800 RPM
1800 RPM
- 9,00
- 8,00
- 7,00
- 6,00
- 5,00
- 4,00
- 3,00
- 2,00
- 1,00
0 m
FISH
m3/h
POWER
kW
1100 1000 900 800 700 600 500 400 300 200 100
PERFORMANCE
m3/h
m3/h
kW
kW
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
2.3.2 Consumption

10 DOC9063L |
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DOC1627542A
DOC1627542A
The pump must not be used if it is damaged or the identification plate is missing
2.4 Handling and transport
The pump must be transported in such way that it
is not exposed to vibrations and impacts that can
overload the bearings.
The pump must be inspected for damages upon
delivery. If the pump is damaged, it must not be used
and the damage must be reported to the manufacturer.
Ensure that the pump’s identification plate is intact and
that the marking of the pump corresponds to its use.
The pump must only be handled using approved
lifting eyes, in accordance with nationally applicable
regulations and only in a vertical motion.
The pump can be transported in the following
ways:
DOC11093A

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A failure to comply with the requirements for storing the pump may result in internal
damage to the device
2.5 Pump storage and draining procedure
The pump’s service liquid is drained on delivery, and the pump can be immediately stored in accordance
with the technical specifications.
After operation, the pump can be stored for 30 days without further action.
If the pump remains out of operation for a longer period of time after use, its service liquid must be
drained, and the liquid supply to the pump must be shut off.
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.
After use with sea water it is recommended to drain and flush the pump with fresh water.
If the temperature is below freezing point of the service liquid, it could damage the pump
Under these conditions, the pump must be drained completely
All plugs and protective covers must be fitted during storage
DOC1627543A
DOC1627543A

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3 DESIGN OF A SYSTEM
DOC1627418_1
Pos. Description
1Liquid ring pump
24-way valve
3Pressure gauge
4Regulating valve
5Water pump
6Pipe connection - Critical pipe
7Stop valve

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Ocean Master 1000
In a fish handling system, where the pump is working without liquid separator, the piping can be critical.
The pipe pos 6 will be a combination of a discharge and a suction pipe and the design of this pipe is very
important.
Figure below shows a standard setup. When the pump is discharging, the tank pipe pos 6 will carry a
mixture of air and water, which is the sealing water supplied to the pump. When the 4 way valve pos 2
change position this pipe becomes the suction pipe and water that is in the pipe will enter the pump. In
normal situation a small vibration will follow when the pump is injected with water on the suction side.
It is important to keep a high velocity > 30 m/s in this pipe and design it as short as possible without
“water traps”. The velocity can be calculated based on the nominel flow and the pipe diameter.
Another and safer solution is to place the 4 way valve closer to the fish tank as illustrated below.
3.1 Piping
DOC1627418_2
3.2 Service liquid adjustment - Pressure method
In order to get the correct water pressure to the pump it is recommended to build the supply line as
illustrated below. For correct service liquid supply, the pressure needs to be adjusted to between 0,6 and
0,8 bar(g) when the pump is running unloaded.
DOC1627418_3

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3.4 Pump performance
The pump performance can easily be found using the performance curves.
• Plot in the lifting height and add the calculated pressure drop in meter water column.
• Follow a horizontal line till you meet the performance curve.
• Go vertical down and read the performance.
For practical design it is important that the speed in the pipe system etc. is verified against a fish handling
perspective.
Note: 1 meter water column = 0,1 bar = 100 mbar
DOC1627419_1
3.3 Service liquid pump
The water pump must be able to have a flow on 3000 l/h at a pressure at 1 bar(g) in order to get the full
performance of the liquid ring pump.

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3.5 Pressure drop
The pressure drop in the system depends on the flow and on the other side the flow will depend on the
pressure drop.
It is a mathematical iteration process, therefore in practice we need to start the calculation with a guess.
As a start value for the flow it will be recommended to use the flow corresponding to the static lift + 1
meter corresponding to 0,1 bar or 100 mbar.
DOC1627419_2
It is possible to calculate the pressure drop manually, but there is a lot of free programs for download.
Use the system data to evaluate the pressure drop used as start value.
The calculated value can be used to find out if the start value is too low or too high.
Example
If the calculated pressure drop is far below the start value (100mbar) make a new calculation with the flow
based on for example 50 mbar. Start with the static pressure + 50 mbar and find the flow from the curve.
If the calculated pressure drop is far above the start value (100 mbar), make a new calculation with the
flow based on for example 200 mbar. Start with the static pressure + 200 mbar and find the flow from the
curve.
NOTE: Pressure drop above 100 mbar indicates that your pipe diameter is too small for the pump you are
using.

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3.6 Service liquid requirement
If sea water is used as sealing water, it is recommended to flush the pump with fresh water (inlet A or B)
after use and drain the pump (outlet C) afterwards. See illustration below.
Before the pump is started again, remember to fill the pump to about shaft height before start up.
Otherwise the pump will be started with dry run of the mechanical shaft seals, which will shorten the
lifetime.
DOC1627543_2A
A
B
C
DOC1627543_2A

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4 INSTALLATION AND START-UP
4.1 Securing the pump
4.2 Connections to the pump
• Check for foreign objects in the pump and physical damage on pump
• Gaskets to be handeled with highest degree of caution
• Gasket and sealing surfaces must be cleaned before assembly
DOC1627544
AA
DOC1627544
DOC1627544_1
A
B
DOC1627544_1
Installation requirements must be observed, otherwise there is a risk of damage
The pump must be installed on a stable foundation, which must
be level and stable, so that the pump is not twisted or exposed
to a profile distortion.
The pump must be installed with M16 bolts on all four legs,
which must be tightened to 180 Nm (A).
Immediate before connecting the pipes, remove protective covers.
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.
4.3 Connecting the service liquid
The service liquid must be connected to the pump at the hose connection, see
illustration.
DOC1627543_1A
DOC1627543_1A

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4.4 Drive
The pump can be connected through direct or belt drive.
The unit (pump & motor) must be installed on a stable foundation, which
must be level and stable, so that the unit is not twisted or exposed to a
profile distortion.
Misalignemt tolerances must be complied. See illustration to the right
for misalignment types.
4.4.1 Direct drive
4.4.2 Belt drive
DOC1611500_1
DOC1611500_1
DOC1611501_1
DOC1611501_1
For belt drive, it must be ensured that the permissible radial force is not exceeded. See specifications.
DOC11754
Offset misalignment
Angular misalignment
Angular misalignment : 0,08 mm / 100 mm
Offset misalignment : 0,1 mm
Angular misalignment : 0,87 mm / 100 mm
Offset misalignment : 0,1 mm

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4.5 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)
• Stop the pump immediately if the rotational direction does not correspond to the
directional arrow
• A failure to follow the above guidelines may result in damage to the pump
4.6 Direction of rotation
Check the direction of rotation by briefly starting the pump.
The direction of rotation of the rotor must correspond to the direction arrow!
Below left, a right-side pump is shown which has a clockwise direction of rotation (CW)
Below right, a left-side pump is shown which has a counter-clockwise direction of rotation (CCW)
Activating the grease cartridges (Accessories and only belt drive)
Turn the handle in NDE clockwise to position 12.
Turn the handle in DE clockwise to position 12.
The pump has been lubricated from factory and is ready to start.
DOC3707
DOC1619221_1
DE
NDE
DOC1619221_1
DOC1627545
DOC1627545_1
DOC1627545 DOC1627545_1

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5 SERVICE, OPERATION, MAINTENANCE AND
INSPECTION INTERVALS
A failure to observe the inspection intervals described in table below may result in
damage to the pump
Section Operation Interval
5.1 Check grease cartridges (if equipped) - Only belt drive Weekly
5.2 Winterization When below 0°C
5.3 Lubrication of bearings - Only belt drive Per 500 duty hours
5.4 Inspection and cleaning of service liquid’s supply pipe Monthly
5.5 Inspection and cleaning of internal channels Monthly
5.1 Check grease cartridges - Only belt drive
DOC3707
5.2 Winterization
If the pump needs to be used at a temperature below freezing point of the service liquid, it is necessary to
protect the liquid from freezing by adding anti freeze liquid.
If the pump is equipped with an automatic lubrication feature. It must be inspected and
replaced as needed.
When the pump is commissioned for the first time, the cartridges must be activated by
turning the arrow in the clockwise direction.
The cartridge is set to 12, which corresponds to an emptying time of 12 months.
The cartridge must be replaced when empty.
It is only allowed to use automatic lubricator of type LAGD 125/WA2.
The pipe connection between the liquid separator and pump must be inspected at least once a month, and
any contaminants must be removed.
5.4 Inspection and cleaning of service liquid’s supply pipe
Over-lubrication of bearings may result in bearing damage! Do NOT exceed the
amount of grease specified below!
5.3 Lubrication of bearings - Only belt drive
The bearings must be lubricated with grease of type SKF LGWA2, per 500 duty hours.
It is recommended to lubricate the bearings while pump is running.
DOC1619221_2
DE
NDE
DOC1619221_2
Lubrication interval per 500 duty hours
Drive end (DE) 16 g
Non drive end (NDE) 8 g