Samson TRUCK MASTER 3400 User manual

DOC9055M
INSTRUCTION MANUAL FOR SAMSON LIQUID RING PUMP
TRUCK MASTER 3400
TRUCK MASTER® 3400
INSTRUCTION MANUAL
LIQUID RING PUMP
• Technical data
• Design of a system
• Installation and start-up
• Service
• Troubleshooting
• Spare parts
HPR
The English version of the instruction manual is the legally binding version.

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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 Vacuum .................................................................................................................................. 8
2.3.2 Pressure.................................................................................................................................. 8
2.3.3 Correction factor - Temperature ............................................................................................. 9
2.3.4 Correction factor - Wet and dry gas......................................................................................... 9
2.4 Handling and transport ......................................................................................................... 10
2.5 Pump storage and draining procedure................................................................................... 11
3 Design of a system ..............................................................................................................12
3.1 Function and design of a liquid separator.............................................................................. 13
3.2 Air cooling with fan cooler .................................................................................................... 14
3.3 Fan cooler ............................................................................................................................. 15
3.4 Water consumption ............................................................................................................... 16
3.5 Dome valve system ............................................................................................................... 16
3.6 Cavitation ............................................................................................................................. 17
3.7 Water requirement ................................................................................................................ 17
4 Installation and start-up...................................................................................................18
4.1 Securing the pump................................................................................................................ 18
4.2 Connections to the pump ...................................................................................................... 18
4.3 Connecting the water ............................................................................................................ 19
4.4 Transmission ........................................................................................................................ 19
4.5 Prior to start-up.................................................................................................................... 20
4.6 Direction of rotation ............................................................................................................. 20

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5 Service, operation, maintenance and inspection intervals............................................. 21
5.1 Draining the liquid separator and the pump .......................................................................... 21
5.2 Check grease cartridges ....................................................................................................... 21
5.3 Winterization......................................................................................................................... 21
5.4 Lubrication of bearings ......................................................................................................... 22
5.5 Inspection and cleaning of water supply pipe ........................................................................ 22
5.6 Inspection and cleaning of internal channels ........................................................................ 22
6 Troubleshooting ...................................................................................................................23
7 Spare parts and tools..........................................................................................................24
7.1 Marking and identification..................................................................................................... 24
7.2 How to order......................................................................................................................... 25
7.3 Spare parts - GENERATION 1 ................................................................................................. 26
7.4 Spare parts - GENERATION 2 ................................................................................................. 30
7.5 Adaptor................................................................................................................................. 34
7.6 Gasket set............................................................................................................................. 35
7.7 Special tool set...................................................................................................................... 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,02.12.2020________________________________________
JanS.Christiansen–Manager,Technicaldept.

1 INTRODUCTION
1.1 Declaration of conformity
DOC4044B

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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 water 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 control valve (optional)

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2.1 Dimensions
2 TECHNICAL DATA
DOC1627468_1
140
315
737 319
773
1234
Ø32
M16x2
Ø210
Ø125
G3/8"
Ø60 k6
578
280
380
663
G1"
G3/8"
DOC1627468_1

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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, water - 60°C
Water pipe connection, dimension 1¼” -
Water pipe connection, length - 6 m
Noise level - 80 dB(A)
Water volume - 52 L
Maximum radial load on drive shaft - 14000 N
Heat input for cooler calculation
1100 rpm 48 kW -
1200 rpm 57 kW -
1300 rpm 68 kW -
1400 rpm 80 kW -
Revolutions 1100 rpm 1400 rpm
Pressure 150 mbar abs. 0,75 bar(g)
Lubricating grease
Type of grease SKF LGWA2
Automatic lubrication SKF LAGD 125/WA2
Weight 531 kg
A failure to meet these specifications may result in damage to the pump

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2.3 Power consumption and output
2.3.1 Vacuum
Vacuum [%] 80 70 60 50 40 30 20
1100 [rpm]
Flow Wet [m³/h] 2292 2706 2740 2839 2736 2572 2514
Flow Dry 1711 2114 2383 2512 2510 2382 2350
Consumption [kW] 64
Torque [Nm] 556
1200 [rpm]
Flow Wet [m³/h] 2434 2964 2993 3078 2888 2837 2840
Flow Dry 1816 2316 2603 2725 2650 2627 2654
Consumption [kW] 77
Torque [Nm] 613
1300 [rpm]
Flow Wet [m³/h] 2482 3196 3230 3347 3111 3069 3019
Flow Dry 1852 2497 2808 2962 2855 2841 2822
Consumption [kW] 92
Torque [Nm] 676
1400 [rpm]
Flow Wet [m³/h] 2476 3415 3357 3323 3286 3304 3243
Flow Dry 1848 2669 2919 2940 3015 3059 3031
Consumption [kW] 108
Torque [Nm] 737
2.3.2 Pressure
Pressure [bar(g)] 0 0.25 0.5 0.75
1100 [rpm]
Flow [m³/h] 2102 1974 1871 1787
Consumption [kW] 56 65 72 82
Torque [Nm] 486 564 625 712
1200 [rpm]
Flow [m³/h] 2387 2197 2133 2068
Consumption [kW] 74 80 89 98
Torque [Nm] 589 637 708 780
1300 [rpm]
Flow [m³/h] 2560 2441 2351 2281
Consumption [kW] 90 96 105 117
Torque [Nm] 661 705 771 860
1400 [rpm]
Flow [m³/h] 2766 2623 2570 2502
Consumption [kW] 104 110 123 133
Torque [Nm] 709 750 839 907
The data FlowDry is based on the following parameters:
• Air temperature 20°C
• Water temperature 15°C
• Test performed with dry air and 1,013 mbar absolute pressure
• Tolerance ±10%

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2.3.3 Correction factor - Temperature
DOC1628005_1A
2.3.4 Correction factor - Wet and dry gas
Normal atmospheric air contains water vapor. In this case water will condense inside the pump and will
create a higher flow.
Below you can find a correction factor table for the performance based on condensing gas with an inlet
temperature of 50°C 100% saturated and service liquid temperature of 15°C.
Suction pressure % Vacuum 80 70 60 50 40 30 20
Correction factor wet gas KWet 1,34 1,28 1,15 1,13 1,09 1,08 1,07
The performance of the pump can thereby be calculated as:
VWet= VDry xKWet
When the temperature of the water exceeds 15°C,
the pump’s capacity will be affected with respect
to the specified values.
To determine the output at a higher temperature,
the correction factor can be used.
Capacity at water temperature higher than 15°C :
Qt>15= Q15 xK1

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DOC1627511
DOC1627511
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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DOC1627512
D1
A
C1
B
D2
C2
B A
D3 D4
DOC1627512
A failure to comply with the requirements for storing the pump may result in internal
damage to the device
If the temperature is below freezing point of the water, it could damage the pump.
Under these conditions, the pump must be drained completely
All plugs and protective covers must be fitted during storage
2.5 Pump storage and draining procedure
The pump’s water 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 water must be drained, and
the water supply to the pump must be shut off.
When emptying the pump, it is important that all chambers inside the pump are emptied.
To empty the correct chambers (X) depends on the rotation of the pump (CW or CCW). See table below.
The pump can be fitted with valves in the draining connections. See below.
Chamber
Rotation
A B C1or C2D1 or D2 or D3 or D4
CW X X X
CCW X X X
Draining during normal operation, see chapter 5.

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3 DESIGN OF A SYSTEM
DOC1627390
Pos. Description
1Liquid ring pump
2Non return valve
34-way valve
4Vacuum control valve
5Water control valve
6Fan cooler
7Liquid separator
8Dome valve

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Together with the air there will be a water flow out of the pump up to 6 m3/h.
The water will be separated from the air in the liquid separator.
Depending of the size of particles, water will be carried with the water when the air velocity is more than
3-4 m/s.
The inlet speed to the separator can be more than 50 m/s and this must be reduced to 3 m/s.
Below you find an illustration showing how to reduce the speed and control that no water will be in contact
with the high velocity air stream. The round velocity reducer can be placed inside any tank geometry.
3.1 Function and design of a liquid separator
DOC1627391
Air flow [m³/h] øD minimum [mm]
3400 600
3300 590
3200 580
3100 570
3000 560
2900 550
øD so the velocity is below 3 m/s
H=4 to 6*d depending on the geometry. A smooth diameter conversion will give a low factor.

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5 kW 10 kW 20 kW
Small liquid separator mounted
external from the truck tank
Water content below 100 L
Small liquid separator inside
slurry tank. Located with only
minor contact to the product
Water content 300 L
Normal liquid separator inside
slurry tank with good contact to
the product
Water content 400 L
With a temperature difference on 20°C it is typical to have a radiator affect in a truck on somewhere
between 5 to 20 kW depending on the construction.
The table below shows truck radiator effect at a temperature difference of 20°C.
3.2 Air cooling with fan cooler
Example:
We have a tank with 300 litres of water corresponding to 300 kg. The heat input is 30 kW.
How long will it take to heat it up from 20°C to 40°C ?
tsec =Cp x m x Δt
Q
tsec =4,2 x 300 x 20 = 840 s = 14 min
30
The temperature will continue to go up until the steel construction can absorb the heat and transfer it to
the surroundings.
tsec =Time in seconds
Cp=Heat capacity of the media. Water= 4,2
Δt =Temperature difference
m=Mass of the media heating up [Kg]
Q=Heat input in [kW] See specifications, chapter 2.2
Compression of air inside the liquid ring pump will create heat that is transferred to the water.
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.
The operation temperature will go up until there is a balance between the heat input and the heat output.
So basically, there are only two things that can lower the operation temperature. Reduce the heat input or
increase the heat output.
The amount of water has no or only a little influence on the final operating temperature. The truck itself
will work as a big radiator and if there is a huge amount of water in the liquid separator and thereby good
contact area between the water and the steel tank, it will give a higher cooling effect. This in combination
with low ambient temperature and short time of operation, could mean that the truck can operate without
any additional cooling.
In general, the time it takes to heat up the water can be calculated from the formula below.

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3.3 Fan cooler
The fan cooler will increase the heat output from the construction and thereby stabilize the temperature
at a lower level. However, this cooler will use the air to cool down the water and therefore we will always
see that the temperature will be stabilized above the ambient temperature. It’s very simple to find the right
cooler based on the curves from the cooler manufacturer. Typically you will find the cooler capacity as kW/
Δt meaning for example 1.5 kW cooler capacity each °C in temperature difference between the water and
the air. Note that the water flow through the cooler will also affect the cooling capacity.
DOC1627392
Typical fan cooler characteristic.
Practical calculation example:
The truck is used mostly to work with an operation pressure around 70% vacuum. From the technical data
sheet, we find the heat input from the pump to be 68 kW.
The liquid separator is built inside the slurry tank with a good contact to the product and a radiator effect
estimated to 20 kW with a temperature difference of 20°C.
The truck will work with ambient temperature up to 28°C during the summer and we will accept a maximum
temperature on 40°C.
First, we have to reduce the radiator effect based on a temperature difference of 12°C.
Qout Truck = 20 x
12 = 12 kW
20
The total cooling effect required is thereby:
Qout Pump - Qout Truck = 68 - 12 = 56 kW

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3.4 Water consumption
It is possible to design the liquid separator so that almost 100% of the water is separated from the air.
However, the air will be heated up and thereby it can content more water. Also, the relative humidity will go
up and end near 100%.
So, the air will flow into the pump with maybe 50% relative humidity at a low temperature and be
discharged at a higher temperature and humidity. Therefore, there will be an evaporation from the system.
Temp.
Vacuum
20°C 30°C 40°C 50°C 55°C
50% 32 50 86 140 220
70% 17 22 43 75 124
80% 12 20 34 56 88
Choose your water temperature
Water consumption Liters per hour
3.5 Dome valve system
The liquid ring pump can handle liquid and particles in the inlet but it is of course
recommendable to avoid this.
A dome valve or floating valve will ensure that the suction will be closed when the liquid
level reaches the top of the tank.
In many situations there will be foam on the liquid surface inside the tank. It can be
difficult to avoid that this will be transported into the suction line before the dome valve
will close.
Therefore, it will be recommended to make a combination of a filter and dome valve as
illustrated below.
The filter will prevent particles lifted by the foam to enter the pump.
DOC1627393
Pump model Description Truck Master 3400
Heat input from technical specifications Qin Pump 68 kW
Ambient temperature tamb 28°C
Maximum Working Temperature of the water.
This is determined by you. The temperature
has influence on the pump performance
top 40°C
Temperature difference ΔttOp- tamb = 12°C
Truck radiator effect based on 20 °C in
temperature difference Qout Truck 20 20 kW
Truck radiator effect based on 12 °C in
temperature difference Qout Truck 12 12/20*20 = 12 kW
Total cooling requirement from fan cooler Qfan cooler Qin Pump-Qout Truck 12 = 68-12 = 56 kW
Summary
We need to find a fan cooler that can transfer 56 kW with a temperature difference on 12°C.
That is 4,6 kW/°C.
If we for example accept a higher temperature, for instance 48°C, we will have full cooling effect from the
truck on 20 kW and a cooling requirement on 48 kW. The fan cooler we need to find is thereby on 48/20 =
2,4 kW/°C and a big difference to the bigger model calculated above.

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3.6 Cavitation
Vacuum 50% 75% 80% 90%
Temperature °C 80 64 59 44
Maximum discharge temperature 70 50 40 30
Note that the temperature of the gas inside the pump will heat up the water and the water surface therefore
will become a higher temperature than the measured temperature on the discharge side of the pump.
Cavitation will therefore start at a lower temperature and the maximum discharge temperature of the water
must be kept lower.
DOC1627513
DOC1627513
Below you find the boiling point of water as a function of the pressure.
When the temperature reaches the boiling point of the water, steam bobbles will be created in the liquid
ring.
These bobbles cannot exist when they enter the discharge side of the pump and therefore they will
collapse. The impact force on the surface of the rotor and flow plate will damage the pump and can lead to
a total breakdown. It is a very harmful situation that must be avoided.
It is the combination of the pressure and the temperature that will lead to the cavitation. Therefore, it is
recommended to install 2 vacuum control valves, see illustration below that shows a clockwise rotating
pump. If counter-clockwise rotating pump, mount in opposite manifold.
3.7 Water requirement
During operation it is normal that small amount of product will enter the pump, or the gas will react with
the water which can become aggressive.
Drain the liquid separator and refill with fresh water, if the water has become aggressive.

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4 INSTALLATION AND START-UP
4.1 Securing the pump
Immediate before connecting the pipes, remove protective covers. Connection of the pump’s suction and
pressure pipe connections must be made with a gasket in between (C).
The M16 bolts must be tightened with 180 Nm (B).
In order to prevent tensions in the pump, the pipe connections (A) must be tensionless while tightening the
bolts.
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
DOC1627514
A A
DOC1627514
DOC1627514_1
AB
C
DOC1627514_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 4 pcs. M16 bolts, 2 pcs. in front and 2 pcs. in back.
The bolts must be tightened to 180 Nm (A).

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4.3 Connecting the water
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. See specifications.
For belt transmission, note the direction of rotation, see illustration below.
DOC1627512_1A
ABCD
DOC1627512_1A
DOC1627416_1
The water must be connected to the pump at the hose connection (C), see illustration below.
If required, the hose nipple can be dismounted from (C) and mounted on desired location (A, B or D).

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4.5 Prior to start-up
• Do not start the pump without water, as this will damage the mechanical shaft seals
• Do not start the pump if it is completely filled with water
• 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)
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
NDE DE
DOC1627468_3
DOC1627468_3
DOC1627515
DOC1627516
DOC1627515 DOC1627516