SAMSON PUMPS OCEAN MASTER 1000, Instruction Manual

Page 1: ...G 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 ...

Page 2: ... 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...

Page 3: ...ive 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 ...

Page 4: ...directive M Ma ac ch hi in ne er ry y D Di ir re ec ct ti iv ve e 2 20 00 06 6 4 42 2 E EC C 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 ab...

Page 5: ...fications 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...

Page 6: ...nsions 2 TECHNICAL DATA DOC1619221A 524 86 901 249 472 320 295 455 Ø80 45 k6 598 195 Ø162 5 Ø13 5 A B C E F D DOC1619221A Pos Description Size A Water inlet hose stud Ø20 G 3 4 B F Drain plug G 3 4 C E Housing plug G 1 2 D Shell plug G 3 8 ...

Page 7: ...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 the...

Page 8: ...00 22 50 25 00 27 50 30 00 100 200 300 400 500 600 700 800 900 1000 1100 800 RPM 8 0 0 R P M 1200 RPM 1500 RPM 1650 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 POW kW 1100 1000 900 800 700 600 500 400 300 200 100 PERFORMANCE m3 h m3 h 5 10 DOC11582 2 3 Power consumption and output 2 3 1 Performance ...

Page 9: ...5 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 0 8 0 0 R P M 1 2 0 0 R P M 1 5 0 0 R P M 1 6 5 0 R P M 1 8 0 0 R P M 9 00 8 00 7 00 6 00 5 00 4 00 3 00 2 00 1 00 0 m POWER kW 0 100 kW kW 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 2 3 2 Consumption ...

Page 10: ... 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 ver...

Page 11: ...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 temper...

Page 12: ... DOC9063L Ocean Master 1000 3 DESIGN OF A SYSTEM DOC1627418_1 Pos Description 1 Liquid ring pump 2 4 way valve 3 Pressure gauge 4 Regulating valve 5 Water pump 6 Pipe connection Critical pipe 7 Stop valve ...

Page 13: ...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 illustra...

Page 14: ... 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 performa...

Page 15: ...e 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 t...

Page 16: ...ump 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 A B C DOC1627543_2A ...

Page 17: ... 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 pip...

Page 18: ...salignemt 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 Angul...

Page 19: ...esult 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 cartri...

Page 20: ...brication 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 ...

Page 21: ... the service liquid inlet The start up power is too high Too much service liquid in the pump prior to start up Noise at start up and possible overload of the power supply Check the stop valves in the liquid supply for leakage Noise during operation Cavitation Too much water in the pipe system when switching from pressure to vacuum Severe damage to the pump and potential risk of breakdown Adjust th...

Page 22: ... below PRODUCT CODE OM 1000 R 0 S E E 2 1 S SD CE CONFORMITY MARK MANUFACTURING DATE SERIAL NO ORDER CONFIRMATION NO A NO Configuration example Type Model Rotation Rotor type Pump housing Shell Flow plates Generation of pump Drive Colour Documentation Location of ID plate DOC107944C 7 1 Marking and identification ...

Page 23: ...ed AISI 316 0 Pump housing Cast iron EN GJL 250 EN1561 S Shell Cast iron EN GJL 250 EN1561 S Stainless steel AISI 316 E Flow plates Stainless steel AISI 316 E Generation of pump 0 or 2 2 Drive Belt drive 0 Direct drive 1 Colour Grey primer P Ocean Master Blue S On request X Documentation Samson standard SD ATEX Zone 1 X1 7 2 How to order ...

Page 24: ...24 DOC9063L Ocean Master 1000 48 17 34 43 30 22 25 8 18 14 47 11 15 42 2 5 20 23 26 28 29 31 32 35 45 50 57 52 55 56 7 3 Spare parts GENERATION 0 ...

Page 25: ...25 DOC9063L Ocean Master 1000 DOC1627408_3 27 13 39 38 37 36 51 3 6 12 46 10 7 9 4 15 1 41 44 49 19 40 52 33 24 21 54 16 Included in gasket set DOC1627408_3 ...

Page 26: ... Shell 1 Cast iron 1618076 Shell 1 Stainless steel 13 1619046 Bearing cover NDE 1 Cast iron 14 1619048 Bearing cover DE 1 Cast iron 15 1619199 Bearing housing 2 Cast iron 16 15054 P Gasket set Ocean Master 1000 1 17 1619076 Branch pipe 2 Cast iron 18 1619150 Ball guide DE 1 Plastic 19 1619151 Ball guide NDE 1 Plastic 20 152 336 Rotor R 1 Stainless steel 152 354 Rotor L 1 Stainless steel 21 9100001...

Page 27: ... 70 2 Rubber 44 15054 P Gasket set Ocean Master 1000 1 45 15054 P Gasket set Ocean Master 1000 1 46 15054 P Gasket set Ocean Master 1000 1 47 15054 P Gasket set Ocean Master 1000 1 48 925000136 Plug 4 Steel 49 925000240 Hose nipple 1 Brass 50 930000002 Roler bearing spherical 1 Steel 51 930000087 Ball bearing 1 Steel 52 962000062 Valve ball 16 Plastic 54 1619168 Insert for bearing housing 1 Stainl...

Page 28: ...28 DOC9063L Ocean Master 1000 35 50 1 25 28 19 54 2 5 53 52 51 55 23 4 36 13 14 47 48 41 34 35 33 8 49 30 29 45 18 17 27 42 59 57 3 7 4 Spare parts GENERATION 2 ...

Page 29: ...29 DOC9063L Ocean Master 1000 DOC1619221_3 26 44 22 10 15 20 16 37 21 4 6 58 25 38 40 39 46 24 11 7 9 12 17 32 31 43 56 Included in gasket set DOC1619221_3 ...

Page 30: ...cean Master 1000 G2 1 15 1619248 Pipe for water supply 1 Stainless steel 16 1619249 Shell 1 Stainless steel 1619272 Shell 1 Cast iron 17 1619263 Retainer 2 Stainless steel 18 1619270 Flow limiter Ø8mm 2 Stainless steel 19 15058 P Gasket set Ocean Master 1000 G2 1 20 1624096 Label Ocean Master 1000 2 Plastic foil 21 1624074 Label 2 Plastic foil 22 1624087 Label arrow right 1 Plastic foil 23 1634825...

Page 31: ...ainless steel 46 930000002 Roller bearing 1 Steel 930000086 Ball bearing 1 Steel 47 930000086 Ball bearing 1 Steel 48 930200057 LOCK NUT 1 Steel 49 962000062 Valve ball 14 Plastic 50 1619076 Branch pipe 2 Cast iron 51 922100085 O ring 2 Rubber 52 910200010 Nut 16 Stainless steel 53 910100013 Washer 16 Stainless steel 54 1634822 Plug 4 Stainless steel 55 1634827 Plug 4 Stainless steel 56 910300137 ...

Page 32: ... 39 920000028 Shim 90x110x0 1 4 Steel 920000029 Shim 90x110x0 2 4 Steel 920000030 Shim 90x110x0 3 4 Steel 40 920000016 Shim 40x50x0 1 2 Steel 920000193 Shim 40x50x0 3 2 Steel 920000009 Shim 40x50x0 5 2 Steel 44 922100095 O ring Ø88 49x3 53 2 Rubber 45 922200069 Radial shaft seal 55x80x8 1 Rubber Steel 46 922200258 Radial shaft seal 50x80x8 1 Rubber Steel 47 922200093 Radial shaft seal 50x65x10 1 R...

Page 33: ...r shell flow plate 1 0 mm 2 Paper 11 1619243 Gasket pump housing flow plate 0 5 mm Gasket 2 Paper 14 1619247 Gasket for Water Flange 2 Paper 19 1619271 Gasket for Retainer 2 Paper 40 922100391 O ring 4 Rubber 41 922100376 O ring 1 Rubber 42 922100378 O ring 4 Rubber 43 922200069 Lip seals 2 Rubber Steel 44 922200269 Sealing ring 1 Rubber Steel See spare parts drawing DOC1619221_3 for positions DOC...

Page 34: ...00080 M12x55 Allen screw DIN 912 8 8 FZB 4 Steel 7 910300186 Plug 3 4 black conical hexagon 3 Steel 9 922200269 Sealing ring 48x72x8 DIN 3760A NBR Type OA 1 Rubber Steel 10 932300059 Taper Bush 2012 40 1 Cast iron 11 932300058 Taper Bush 2012 45 1 Cast iron 12 932400127 Coupling hub Klonex 55 70 cast iron 2 Cast iron 13 932400126 PU Polyuretan Red 98 Shore A 1 Rubber 15 944000085 Hydraulic motor 0...

Page 35: ...eel 3 1629108 Bearing mounting tool set DE 1 Steel 4 1629178 Mandrel radial shaft seal Ø50 Ø55 1 Plastic 5 1629179 Mandrel radial shaft seal Ø40 Ø50 1 Plastic 6 1629180 Guide pin M12 2 Steel 7 1629181 Guide pin M10 2 Steel 8 1629182 Machined bearing cap 2 Steel 9 1634151 Mounting sleeve for Ø50 mechanical shaft seal 1 Plastic 10 1634152 Mounting sleeve for Ø55 mechanical shaft seal 1 Plastic 11 91...

Page 36: ...1 1629374 Mandrel radial shaft seal Ø48 Ø55 1 Plastic 2 1629375 Machined bearing cap 1 Steel 3 1629107 Bearing mounting tool set NDE 1 Steel 4 1629108 Bearing mounting tool set DE 1 Steel 5 1629354 Bearing tool set 1 Steel 6 1629370 Mounting sleeve for Ø60 mechanical shaft seal 1 Plastic 7 1629369 Mounting mandrel for water supply pipe 1 Plastic ...

Page 37: ...37 DOC9063L Ocean Master 1000 Notes ...

Page 38: ...38 DOC9063L Ocean Master 1000 Notes ...

Page 39: ...39 DOC9063L Ocean Master 1000 Notes ...

Page 40: ...where the pumps are usually installed onboard fishing vessels Gamma Series is designed to handle the harshest industrial vacuum jobs At the core of Samson Pumps activity is the strong belief that our liquid ring vacuum pumps must be of superlative quality for our customers to focus on what they do best We always improve the quality and design of our pumps to better suit the vacuum units built by O...