Edition 01.2016 · 610.44440.40.

000 Original operating instructions · English

Operating instructions L-BV2, L-BV5

2BV2060
2BV2061
2BV2070
2BV2071
2BV5110
2BV5111
2BV5121
2BV5131
2BV5161
2BV5410
2BV5411
2BV5421
2BV5470
2BV5471

L-Serie
L-Series
Flüssig-
keitsring
Liquid Ring
Contents

Contents

Layout of the units .............................................................................................................................. 3 

1  Safety ..................................................................................................................................................4 
1.1  Definitions .................................................................................................................................4 
1.1.1  Warning symbol............................................................................................................4 
1.1.2  Key word ......................................................................................................................4 
1.2  General safety instructions .......................................................................................................4 
1.3  Other risks .................................................................................................................................6 
2  Correct use of the equipment ..............................................................................................................7 
3  Technical data .....................................................................................................................................8 
3.1  Mechanical data ........................................................................................................................8 
3.2  Electrical data ..........................................................................................................................10 
3.3  Operating conditions normal operation ...................................................................................10 
4  Transport ...........................................................................................................................................13 
5  Installation .........................................................................................................................................15 
5.1  Installing the unit .....................................................................................................................15 
5.2  Mechanical connection of the unit...........................................................................................16 
5.2.1  Connecting the suction and discharge connections...................................................16 
5.2.2  Making the operating-liquid connection......................................................................17 
5.2.3  Connecting up system components ...........................................................................17 
5.2.4  Ancillaries ...................................................................................................................18 
5.3  Connecting the electric motor .................................................................................................18 
5.3.1  Connection to the motor terminal box ........................................................................19 
5.3.2  Operation with a frequency converter ........................................................................19 
6  Commissioning ..................................................................................................................................20 
6.1  Preparation of the unit .............................................................................................................20 
6.2  Start-up of unit with operating-liquid supply ............................................................................20 
6.3  Start-up of unit with self-suction of operating-liquid ................................................................21 
6.4  Checking the direction of rotation ...........................................................................................21 
7  Operation ...........................................................................................................................................22 
7.1  Operation with supply of the operating-liquid, automatically controlled operation ..................22 
7.2  Operation with supply of the operating-liquid, non-automatic control of operation .................22 
7.3  Operation with self-suction of the operating-liquid ..................................................................23 
7.4  Checking and correcting the operating-liquid flow-rate...........................................................23 
8  Decommissioning the machine and shutting it down for a longer period of time ..............................24 
8.1  Draining down .........................................................................................................................24 
8.2  Preparations for long-term shutdown ......................................................................................25 
8.3  Storage conditions ..................................................................................................................25 
8.4  Commissioning after a long shutdown period .........................................................................25 
9  Maintenance ......................................................................................................................................26 
9.1  Maintenance ............................................................................................................................27 
9.2  Repairs / Troubleshooting .......................................................................................................28 
9.3  Service / Customer service .....................................................................................................30 
9.4  Decontamination and declaration of Clearance ......................................................................30 
10  Disposal .............................................................................................................................................30 
11  Explosion-protected design ...............................................................................................................30 
EU declaration of conformity ............................................................................................................ 31 

© 2016 Gardner Denver Deutschland GmbH · Industriestraße 26 · 97616 Bad Neustadt · Germany
Replication, distribution and / or editing of this document and the use and distribution of its content is
prohibited unless explicitly permitted. Violation obligates compensation for damages.
All rights reserved in case of the issue of a patent, utility patent or design patent.
 Layout of the units

Layout of the units

610.44440.99.B01…B03

Fig. 1: Layout of the units

Item Designation 2BV2… 2BV51.. 2BV54..-.F 2BV54..-1G

1 Terminal box
2 Mounting feet

Intermediate plates — 2BV5110-….2-.S

3 2BV5410-1G —
2BV5121-….2-.S
4 Drain tapping(s) G 1 /4 G 3 /8 G 3 /8 G 3 /8
Anti-cavitation
5 connection G 3 /8 G 3 /8 — —

Operating-liquid G 3/4 OR
3
6 connection G /8 Flange (stainless G 3 /8 G 3 /8
steel)
Discharge connec-
7 tion Threaded Flanged Flanged Threaded

8 Inlet connection Threaded Flanged Flanged Threaded

Direction of rota-
9 tion arrow

© Gardner Denver Deutschland GmbH 3 / 32 610.44440.40.000

Safety

1 Safety CAUTION
1.1 Definitions Danger of material damage.
The following key words and symbols are used to Indication of a possible danger which could lead
impart warnings, important information and notes to material damage if the appropriate precau-
tions are not observed.
in these operating instructions:

CAUTION
1.1.1 Warning symbol Indication of a possible disadvantage, i.e. unde-
sired circumstances may arise if the appropriate
The warning symbol  is depicted in the safety precautions are not observed.
instructions in the related title frame on the left
next to the key word (DANGER, WARNING, NOTE
CAUTION).
Safety instructions and warning symbols indicate Indicates a possible advantage, if the appropri-
danger of personal injury. ate precautions are observed; tip.
Please follow these safety instructions to protect
yourself against injury or death!
Safety instructions without warning symbols indi-
1.2 General safety instructions
cate danger of material damage.
 WARNING
1.1.2 Key word Improper handling of the unit
can result in serious or even fatal injuries!
DANGER The key words are in the title frame This operating manual
in the safety instructions.
WARNING  must be read and understood before com-
They follow a defined hierarchy and mencing any work on or with the unit, and
CAUTION they indicate (in connection with
 must be complied with and
ATTENTION the warning symbol, see chap-  must be available at the unit's location
ter 1.1.1) the importance of the
NOTE danger or the nature of the instruc-
tion.  WARNING
Refer to the following clarifications: Improper handling of the unit
can result in serious or even fatal injuries!
 DANGER Operate the unit
 for the purposes specified under "Correct use
Danger of personal injury. of the equipment", page 7!
Indication of an immediately threatened danger  using the media specified under "Correct use
which could lead to death or serious injury if the of the equipment", page 7!
appropriate precautions are not observed.
 using the values specified under "Technical
data", page 8!
 WARNING
Danger of personal injury.  WARNING
Indication of an immediately threatened danger Improper handling of the unit
which could lead to death or serious injury if the can result in serious or even fatal injuries!
appropriate precautions are not observed.
Only trained and responsible specialist
personnel may work on or with the unit
 CAUTION (transport, installation, commissioning,
Danger of personal injury. shutdown, maintenance, disposal)!
Indication of a possible danger which could lead
to medium or light injury if the appropriate pre-
cautions are not observed.

610.44440.40.000 4 / 32 © Gardner Denver Deutschland GmbH

 Safety

 WARNING  WARNING
Working on the unit involves a risk of injury, Hazard presented by rotation of the unit's
e.g. through cutting / shearing, squashing impeller!
and burning! Operate the unit only if the cover is fitted!
 First get personal protection gear (helmet, Removal of the cover is forbidden!
gloves, safety shoes)
 and only then work on the system!  WARNING
 WARNING Hazard in case of overpressure and negative
pressure!
Hair and clothing can be drawn into the unit Hazard presented by leaking media!
or caught or wound in by moving parts!
Hazard presented by rotation of the unit's
 Do not wear any large or loose items of cloth-
impeller!
ing!
Operate the unit only with the piping / hoses
 If you have long, loose hair, wear a hair net!
connected up to the suction and discharge con-
nections and to the operating-liquid connection!
 DANGER
Electrical hazard!  WARNING
Before starting work on the unit or system, the Hazard of cutting or severing of limbs by the
following precautions are to be taken: unit's impeller!
 De-energize it.  Do not reach inside the unit through open
 Protect it from being switched on again. connections!
 Make sure that it is de-energized.  Do not put objects into any of the openings in
 Earth it and bypass it. the unit!
 Cover or block off adjoining parts which are
still live.  WARNING
Hazard in case of overpressure and negative
 DANGER pressure!
Electrical hazard!  Pressure-test the piping and vessels installed
Work on electrical equipment must be per- in the system!
formed by specialist electricians!
 WARNING
 DANGER Hazard in case of overpressure and negative
Electrical hazard! pressure!
 First check that it is de-energized. Hazard presented by leaking media!
 Then open the motor terminal box!  Check the piping / hose connections for leak-
age!
 WARNING
 WARNING
Hazard in case of overpressure and negative
pressure! Danger of burns or scalding from hot sur-
faces on the unit and from hot media!
Hazard presented by leaking media!
 Do not touch when in operation!
Before starting work on the unit or on the sys-
 After shutdown, allow system to cool down!
tem:
 Shut off the operating-liquid supply.
 CAUTION
 Vent the piping and the unit (de-pressurize).
Danger of crushing if the unit should tip
 WARNING over!
 Secure the unit to it's foundation before start-
Hazard presented by rotation of the unit's up!
external fan!
Operate the unit only if the fan guard is fitted!

© Gardner Denver Deutschland GmbH 5 / 32 610.44440.40.000

Safety

1.3 Other risks

 WARNING
It is possible for long, loose hair to be drawn
into the external fan through the grille in the
fan guard!
 Wear a hair net!

 WARNING
Long, loose hair can be caught and wound in
by the rotation of the shaft between the mo-
tor end-shield and the pump casing.
 Wear a hair net!

 WARNING
Injury can be caused by friction (abrasion,
burning, etc.) against the rotating shaft be-
tween the motor end-shield and the pump
casing.
 Do not reach into the openings between the
motor end-shield and the pump casing!
 Do not insert any objects into the openings
between the motor end-shield and the pump
casing.

 WARNING
Hot surfaces can cause burning / scalding!
 Do not touch!
 Wear protective gloves!

610.44440.40.000 6 / 32 © Gardner Denver Deutschland GmbH

 Correct use of the equipment

2 Correct use of the equipment - in the case of pH-values or operating-liquids

deviating from the above, please contact
the manufacturer.
This operating instructions
 are suitable for a deep vacuum range.
 is applicable for Liquid ring vacuum pumps/  are fitted with one of the following types of
compressors (units) : drive motor:
series L-BV2, L-BV5
- standard design,
types 2BV2060 2BV2061 2BV2070
- explosion-protected design.
2BV2071 2BV5110 2BV5111
2BV5121 2BV5131 2BV5161 These operating instructions are only applica-
2BV5410 2BV5411 2BV5421 ble for units in the standard design.
2BV5470 2BV5471 For the explosion-protected design - see sup-
in standard design, plementary special operating instructions.
 contains instructions for the unit’s transporta-  are available in two constructions:
tion, installation, start-up, operation, shut- - cast iron construction for normal require-
down, storage, maintenance and disposal, ments,
 Must have been read and properly understood - stainless steel construction for higher corro-
by operating and maintenance staff before sion-resistance and hygiene requirements
beginning any work with or on the unit. (only 2BV2070, 2BV2071, 2BV51..).
 must be complied with and
 are designed for industrial plants.
 Must be at hand where the unit is installed.
 Are designed for continuous operation.
Operating and maintenance personnel For operation of the units, please refer to chap-
ter 3, "Technical data", page 8 hereunder for the
Operating and maintenance personnel L-BV2, L- specified tolerance limits which must be adhered
BV5 units must be trained and authorised for the to.
work to be carried out.

Work on electrical installations may only be car- Foreseeable misuse

ried out by a specialist electrician.
A specialist electrician is someone who can eval- The following are forbidden:
uate and identify potential risks for the assigned
task as a result of their technical training,  to use the unit in non-industrial systems,
knowledge and experience as well as knowledge to operate the system if it does not include the
about relevant regulations. necessary precautions and protective devices,
e.g. protection against touching by small fin-
gers,
The L-BV2, L-BV5 units  to operate the unit in spaces in which explo-
sive gases may be present, insofar as the unit
 create a vacuum or overpressure. is not specifically designed for such condi-
 are used to extract, deliver and compress the tions;
following gases / vapours:  extraction, conveyance and compression
- all dry and humid gases, of explosives, combustible, aggressive or poi-
which are not explosive, flammable, ag- sonous media,
gressive insofar as the unit is not specifically designed
or poisonous, for such conditions,
- Air or air-vapour mixtures.  operation of the unit at any values other than
- In the case of explosive, flammable, ag- those specified in chapter 3, "Technical data",
gressive or poisonous gases / vapours, page 8 hereunder.
please consult the manufacturer. Modifications to the units are forbidden for safety
- The gases / vapours must be free of solid reasons.
matter. The operator is allowed to carry out maintenance
Small quantities of light suspended matter and repair work only to the extent described in
or liquids can be conveyed along too. these operating instructions.
 are designed for operation with the following Maintenance and repair work which goes beyond
operating-liquids: this may only be carried out by companies which
have been authorised by the manufacturer (ask
- Water the service department for details).
of pH-value between 6 and 9,
that are free of solid matter (e.g. sand).

© Gardner Denver Deutschland GmbH 7 / 32 610.44440.40.000

Technical data

3 Technical data Minimum clearances for heat dissipation

Type Minimum clearance

3.1 Mechanical data
Fan guard - adjacent surfaces
Mass / Weight [mm] [in]
2BV206. 34 1.34
Type Material- Weight*
conveying 2BV207. 53 2.09
parts approx. approx.
[kg] [lbs] 2BV511. 53 2.09
2BV2060 Cast iron 25 55.5 2BV5121 53 2.09
2BV2061 Cast iron 26 57.5 2BV5131 53 2.09
2BV2070 Cast iron 35 77.5 2BV5161 80 3.15
Stainless steel 42 93.0 2BV54.. 53 2.09
2BV2071 Cast iron 61 135
Stainless steel 67 148
Noise level
2BV5110 Cast iron 95 201
Measured area sound pressure in accordance
Stainless steel 98 216 with EN ISO 3744, measured at 1 m [3.28 ft]
distance at medium throttle (100 mbar abs.
2BV5111 Cast iron 110 243
[1.45 psia]) and with piping connected, tolerance
Stainless steel 113 249 ±3 dB(A)
2BV5121 Cast iron 170 375 Type Sound pressure level measured at
Stainless steel 182 401 1 m distance, L [dB(A)]

2BV5131 Cast iron 50 Hz 60 Hz

181 399
2BV2060 70 70
Stainless steel 196 432
2BV2061 70 70
2BV5161 Cast iron 252 556
2BV2070 70 71
Stainless steel 264 582
2BV2071 72 76
2BV5470 Cast iron 68 150
2BV5110 70 70
2BV5471 Cast iron 77 170
2BV5111 70 74
2BV5410-.F Bronze 95 210
2BV5410- 2BV5121 70 75
Cast iron 87 192
1G 2BV5131 73 77
2BV5411 Cast iron 137 302 2BV5161 74 75
2BV5421 Cast iron 153 337 2BV547. 70 70
* Specified is the weight for the largest motor size. 2BV5410 70 70
2BV5411 70 71
2BV5421 71 71

Operating speed

See nameplate.
The operating speed is specified for a 50/60 Hz
power supply.
For other speeds please contact the manufactur-
er.

610.44440.40.000 8 / 32 © Gardner Denver Deutschland GmbH

 Technical data

ATTENTION Tightening torques for

non-electrical connections
If the permissible operating speed is exceeded
this has a detrimental effect on the unit's operat-
ing characteristics: Thread [Nm] [ft lbs]
 increased pump performance requirement M4 2.7 - 3.3 1.99 - 4.44
 higher noise levels M5 3.6 - 4.4 2.65 - 3.25
 heavy vibrations
M6 7.2 - 8.8 5.31 - 6.5
 reduced grease useful lifetime
 reduced time between changing bearings M8 21.6 - 26.4 15.9 - 19.5
The maximum speed should not be exceeded, M10 37.8 - 46.2 27.9 - 34.1
as damage can result from higher operating M12 63.0 - 77.0 46.5 - 56.8
speeds.
M16 90 - 110 66.42 – 81.18

Operating speeds standard operation at

50/60 Hz The following specifications for electrical connec-
tions apply to all terminal board connections with
Type n [min-1]* the exception of terminal strips.
50 Hz 60 Hz:
Tightening torques
2BV2… 3000 3600 for electrical connections
2BV5110 -
2BV5131 1500 1800
Thread [Nm] [ft lbs]
2BV5161 1000 1200
M4 0.8 - 1.2 0.59 - 0.89
2BV54.. 1500 1800
M5 1.8 - 2.5 1.33 - 1.84
* No account is taken of motor slip
M6 2.7 - 4 1.99 - 2.95

The following values apply specially for metallic

Maximum speeds for operation with electron- and plastic cable and pipe unions:
ic frequency converter
Tightening torques for metal
Type nmin [min-1] nmax [min-1] threaded glands/unions
2BV2060 2636 4612
2BV2061 2636 4612 Thread [Nm] [ft lbs]

2BV2070 2123 3715 M12x1,5 4-6 2.95 - 4.43

2BV2071 2123 3715 M16x1,5 5 - 7.5 3.69 - 5.53

2BV5110 M25x1,5 6-9 4.43 - 6.64

1402 2454
M32x1,5
2BV5111 1402 2454 8 - 12 5.9 - 8.85
M40x1,5
2BV5121 1290 2258
2BV5131 1180 2066 Tightening torques for plastic
threaded glands/unions
2BV5161 913 1597
2BV54.. 1402 2454 Thread [Nm] [ft lbs]
M12x1,5 2 - 3.5 1.48 - 2.58
Tightening torques M16x1,5 3-4 2.21 - 2.95
M25x1,5 4-5 2.95 - 3.69
The following values shall apply insofar as no
other specifications are available. M32x1,5
5-7 3.69 - 5.16
The basis for non-electrical connections is tight- M40x1,5
ness classes 8.8 and 8 or higher in accordance
with EN ISO 898-1.

© Gardner Denver Deutschland GmbH 9 / 32 610.44440.40.000

Technical data

3.2 Electrical data Pressures

See motor rating plate. Max. discharge pressure p2 max for vacuum op-
eration*
Type [bar abs.] [psia]
3.3 Operating conditions normal operation 2BV2... 1.1 16.0
Temperatures 2BV5... 1.3 18.9
* when the design operating-liquid flow is main-
Temperatures of the gases/ vapours
tained.
Maximum +80°C +176°F
For higher media temperatures provisions have to Max. discharge pressure, p2 max for compressor
be made in the system to protect against burning, operation
e.g. fitting of guards. (at suction pressure, p1 = 1 bar abs. [14.5 psia])
In this case one of the following provisions can be Type [bar abs.] [psia]
made:
50 Hz 60 Hz 50 Hz 60 Hz
 increase of the operating-liquid flow-rate to 2.5
times (2BV2…) or to 2 times (2BV5…) the de- 2BV2060–....2–.. 2.5 2.2 36.3 31.9
sign operating-liquid flow-rate (cooling circula- 2BV2061–....3–.. 2.4 1.9 34.8 27.6
tion)
2BV2070–....3–.. 3.6 2.9 52.2 42.1
 installation of a pre-condenser
2BV2071–....5–.. 3.5 2.6 50.8 37.7
Temperature of the operating-liquid
Maximum +80°C +176°F 2BV5110–....1–.. 1.85 1.6 26.8 23.2

Minimum +5°C +41°F 2BV5111–....3–.. 1.9 1.5 27.6 21.8

Nominal value +15°C +59°F 2BV5121–....3–.. 1.85 1.4 26.8 20.3

2BV5131–....1–.. 1.7 1.4 24.7 20.3
Ambient temperature
2BV5161–....2–.. 1.8 1.5 26.1 21.8
Maximum +40°C +104°F
2BV5470 2,2 1,9 31.9 27.6
Minimum +5°C +41°F*
2BV5471 1,9 1,8 27.6 26.1
2BV5410-.F 2,0 2,0 29.0 29.0
2BV5410-1G 2,6 2,0 37.7 29.0
2BV5411 1,6 2,4 23.2 34.8
2BV5421 2,3 1,8 33.4 26.1

Max. permissible pressure within unit, pint max

Type [bar abs.] [psia]
2BV2… 8 116
2BV51.. 8 116
2BV5410-.F 6 87.0
2BV54..-1G 8 116
2BV547. 8 116
If higher pressures can occur elsewhere in the
system, then appropriate protection devices are to
be installed

610.44440.40.000 10 / 32 © Gardner Denver Deutschland GmbH

 p1 = Absolute suction pressure
[mbar abs.]

tBF = Temperature of the operating fluid

[°C]

60 Hz = Cavitation zone starts at 60 Hz

[mbar abs.]

50 Hz = Cavitation zone starts at 50 Hz

[mbar abs.]
2BV2

p1 min = Minimum achievable suction pressure depend-

© Gardner Denver Deutschland GmbH

[mbar abs.] ing on the operating fluid [mbar abs.]
A = Continuous operation at 60 Hz only with cavita-
[mbar abs.] tion protection measures
B = Continuous operation at 50 Hz only with cavita-
[mbar abs.] tion protection measures

The values of the diagrams apply to standard conditions:

11 / 32
 operating fluid: water
 gases/vapours: air with +20°C and 100% relative humidity
 rated operating fluid flow
As a general rule:
Minimum achievable suction pressure p1 min with vacuum operation

The higher the temperature of the operating fluid, the lower the
suction capacity, i.e. the higher the minimum achievable suction
pressure.
Cavitation:
2BV5

emergence and sudden collapse (implosion) of vapour bubbles in

the rotating operating fluid. During the implosion, noise and ex-
treme pressures occur on very small surfaces. These forces can
destroy the pump over a long period of time due to surface erosion.

610.44440.40.000
Fig. 2: Pressure characteristics and cavitation zone
Technical data
Technical data

Liquid quantities Design operating-liquid flow [ft³/h]

For extraction of dry air and using water at 15°C Type Flow rate Flow
[59 °F] as the operating-liquid, the following de- Vacuum operation rate,
sign operating-liquid flows apply: com-
in the pressure range [psi] pressor
Design operating-liquid flow [m³/h] 0.479- 2.90- >7.25 opera-
Type Flow rate, Flow 2.90 7.25 tion
Vacuum operation rate, 2BV2060 7.06 7.06 7.06 7.06
com-
in the pressure range 2BV2061
pressor 8.12 8.12 8.12 8.83
[mbar] opera-
tion 2BV2070 9.89/ 4.94/ 4.94/
33-200 200-500 >500 17.66
12.0* 6.0* 6.0*
2BV2060 0.20 0.20 0.20 0.20
2BV2071 8.12/ 8.12/
15.89 24.72
2BV2061 0.23 0.23 0.23 0.25 9.89* 9.89*
0.28/ 0.14/ 0.14/ 2BV5110 28.25 12.36 10.59 31.78
2BV2070 0.50
0.34* 0.17* 0.17*
2BV5111 42.38 14.13 12.36 42.38
2BV2071 0.23/ 0.23/
0.54 0.70 42.38/
0.28* 0.28* 2BV5121 14.13 12.36 52.97
52.97*
2BV5110 0.80 0.35 0.30 0.90 2BV5131 63.57 15.89 14.13 63.57
2BV5111 1.20 0.40 0.35 1.20 2BV5161 84.76 24.72 17.66 84.76
2BV5121 1.20/
0.40 0.35 1.50 2BV5470 12.7/9.89* 42.38
1.50*
2BV5131 1.80 0.45 0.40 1.80 2BV5471 52.97/
24.72/19.1*
42.38*
2BV5161 2.40 0.70 0.50 2.40 2BV5410-
.F 28.25 28.25 19.4 28.25
2BV5470 0,36/0,28* 1,2
2BV5471 2BV5410-
0,70/0,54* 1,5/1,2* 28.25 42.38
1G
2BV5410-
0,80 0,80 0,55 0,80 2BV5411 42.38 49.44
.F
2BV5410- 2BV5421 42.38/52.97* 52.97
1G 0,8 1,2
* Value for 50 Hz operation / value for 60 Hz op-
2BV5411 1,2 1,4 eration
All other values for 50 Hz and 60 Hz operation.
2BV5421 1,2/1,5* 1,5
* Value for 50 Hz operation / value for 60 Hz op- Quantity of operating-liquid for first fill
eration Type [l] [gal (US)] [gal (UK)]
All other values for 50 Hz and 60 Hz operation.
2BV206. 0.5 0.13 0.11
2BV207. 1.0 0.26 0.22
2BV511. 3.0 0.80 0.66
2BV5121 3.0 0.80 0.66
2BV5131 3.0 0.80 0.66
2BV5161 8.0 2.12 1.76
2BV547. 2,0 0.53 0.44
2BV541. 3.0 0.80 0.66
2BV5421 3.0 0.80 0.66

610.44440.40.000 12 / 32 © Gardner Denver Deutschland GmbH

 Transport

Maximum permissible quantity of water carried  CAUTION

along through the inlet connection
Tilting or falling over can result in crushing
1x or breaking of bones, etc.!
Sharp edges can cause cuts!
1x +D D Wear personal protective gear (helmet, gloves,
and safety shoes) during transportation!

1x +K K
Transportation by hand:

 WARNING
Danger when lifting heavy loads!
Lifting by hand is permitted only within the fol-
lowing weight limits:
610.44440.99.B05
 max. 30 kg [max. 66 lbs] for men
Type Continuous oper- max. 2 sec  max. 10 kg [max. 22 lbs] for women
ation [D]* [K]*  max. 5 kg [max. 11 lbs] for pregnant women
2BV2… 2.5x 7x Weight of the unit, see table "Mass / Weight",
page 8.
2BV5 1.. 2.5x 5x Above these limits suitable lifting gear or
2BV5410-.F 7x 7x transport must be used!
2BV541.-1G 6 m /h [212 ft³/h]
3
6 m /h [212 ft³/h]
3

2BV542. 5 m3/h [177 ft³/h] 5 m3/h [177 ft³/h] Transport with lifting gear:
2BV547. 5 m /h [177 ft³/h]
3
5 m /h [177 ft³/h]
3
 WARNING
* 1x = design operating-liquid flow
Hazard presented by tilting or falling loads!
The following basic rules should be observed
when transporting with the aid of lifting gear:
4 Transport  The load-bearing capacity of the lifting gear
and load-handling devices must correspond
 WARNING to the weight of the unit.
Weight of the unit, see table ""Mass /
Improper handling of the equipment can re- Weight", page 8.
sult in serious or even fatal injuries!
 Secure the system so that it cannot tilt over
Have you read the safety notes in chapter 1, or fall off.
"Safety", page 4 above?
 Do not stand under suspended loads!
If not then you are not allowed to carry out any
work on or with the equipment! Transportation is expected to be carried out by
crane using lifting straps/chains.
 WARNING
Hazard presented by tilting or falling loads!
Before transport, make sure that all the compo-
nents are securely assembled and that all the
components for which the fixings have been
loosened are either properly secured or re-
moved!

© Gardner Denver Deutschland GmbH 13 / 32 610.44440.40.000

Transport

Transport of type 2BV2…:

Transport using crane and lifting straps.

 Run the lifting straps under the pump casing
and under the fan guard (Fig. 3, page 14).
 The lifting straps should locate securely in the
undercuts so that the unit cannot slip out from
them.
 The lifting straps must be long enough
(spreading angle less than 90°).
 Take care that the fittings are not damaged.

Fig. 4: Lifting points 2BV51..

Fig. 5: Lifting points 2BV541./2BV5421

Fig. 3: Lifting points 2BV2…

Transport of type 2BV5…:

Transport using crane and chains.
 the lifting points are the lifting eyes on the
motor and one drilling in the discharge con-
nection or the suction connection (Fig. 4 - Fig.
6, page 14).
 secure the chains to these lifting points.
 take care that the fittings are not damaged.

Fig. 6: Lifting points 2BV547.

610.44440.40.000 14 / 32 © Gardner Denver Deutschland GmbH

 Installation

5 Installation Conditions for setting up the system:

The unit should be set up:
 WARNING  on a level surface with a load-bearing capabil-
Improper handling of the equipment can re- ity suitable for the weight of the unit,
sult in serious or even fatal injuries!  with the shaft in a horizontal position,
Have you read the safety notes in chapter 1,  on stationary (fixed) surfaces or structures,
"Safety", page 4 above?  with a clearance from adjacent surfaces in
If not then you are not allowed to carry out any accordance with the table, "Minimum clear-
work on or with the equipment! ances for heat dissipation", page 8
 at a maximum height of 1000 m [3280 ft]
above sea level.
If the conditions for setting up the unit deviate
5.1 Installing the unit from the above please contact the service de-
partment.
 CAUTION
Danger of crushing if the unit tilts over when When setting up, take due account of vibration
installation is not yet completed! characteristics at the location. The unit's overall
vibration will depend on:
 Wear gloves and safety shoes!
 Handle the unit cautiously! - the unit's own vibration,
- the alignment and positioning,
 CAUTION - the condition (vibration characteristics) of
the supporting surface,
Danger of tripping and falling over the unit! - The effects resulting from oscillations in
 avoid the places where tripping may occur! other components and parts of the plant
(external oscillations).
 WARNING The maximum permissible value for oscilla-
tions is veff = 4.5 mm/s [0.177"/s].
Electrical hazard! The measuring points for determining the os-
The system is to be installed in such a way that cillating speed are shown in Fig. 7, page 15.
external effects cannot lead to damage of the
electrical equipment. 2BV2… 2BV5…
 Lay out the connecting cables safely, e.g. in
cable ducts or in the ground.

 CAUTION
Danger of injury due to parts flying off of a
broken external fan!
610.44440.99.B08
 Set the unit up such that if parts of a broken
Fig. 7: Measuring points for oscillating speed
external fan should fly through the grille, no
personnel can be hit!
Securing the unit:
CAUTION  the unit's mounting feet (item 2, page 3) are to
Risk of damaging the unit by overheating be bolted to the base using suitable fixings.
due to blocking the path of dissipated heat Fit bolts in all fixing holes!
and cooling air supply! The types 2BV5110-….2-.S, 2BV5121-….2-.S
 Observe the requirements stated in and 2BV5410-1G are supplied with intermediate
"Minimum clearances for heat dissipation", plates for height adjustment.
page 8.
 The intermediate plates (item 3, page 3) are
 Make sure that the exhaust air from other
to be inserted under the mounting feet on the
equipment is not drawn in!
pump casing before securing.
 The unit's mounting feet (item 2,, page 3) are
to be bolted to the base using suitable fixings.
Fit bolts in all fixing holes!

© Gardner Denver Deutschland GmbH 15 / 32 610.44440.40.000

Installation

5.2 Mechanical connection of the unit

CAUTION
The unit is supplied with all connection openings
When attaching pipelines / hoses, make sure
sealed off to prevent the ingress of foreign mat-
that these are free from mechanical stresses.
ter.
 Only remove the seals immediately before CAUTION
connecting up the piping / hoses.
In the case of gases/vapours containing
impurities:
The gases /vapours are drawn in through the  if necessary a filter, strainer or separator
inlet connection (item 8, page 3) and expelled should be installed in the suction line.
through the discharge connection (item 7,
page 3).
The unit has to be continuously supplied with
CAUTION
operating-liquid during operation. In order to prevent residues left over from instal-
This supply is introduced via the operating-liquid lation work (e.g. welding beads) entering the
connection (item 6, page 3) and is expelled to- unit, an intake strainer should be fitted in the
gether with the gases / vapours via the discharge suction line for the first 100 operating hours.
connection.
Connection sizes, suction / discharge
Type Connection
Filling up with operating-liquid: 2BV206. Threaded end G1
The initial charge of operating-liquid is dependent 2BV207. Threaded end G11/2
on the type of operating-liquid supply: 2BV511. Flange 50 ND10-DIN 2501 or
 When operating with self-suction of the oper- ANSI-B16,5-2-150
ating-liquid: Gasket DN50 PN40 DIN EN 1514-1
before installation, see description below. form FF
 When operating with supply of the operating- 2BV512. Flange 65 ND10-DIN 2501 or
liquid: 2BV513. ANSI-B16,5-2 1/2-150
after completion of installation, see "Filling up Gasket DN65 PN6 DIN EN 1514-1
with operating-liquid", page 20. form FF
2BV516. Flange 80 ND10-DIN 2501 or
For operation with self-suction of the operating- ANSI-B16,5-3-150
liquid, fill the unit's operating chamber with oper- Gasket DN80 PN6 DIN EN 1514-1
form FF
ating-liquid before the piping / hoses are installed
on the unit. 2BV547. Threaded end G2

 Fill up with operating-liquid through the open 2BV5410-.F Flange 50 ND10-DIN 2501 or
inlet connection or discharge connection in ANSI-B16,5-2-150
Gasket DN50 PN40 DIN EN 1514-1
accordance with the table, "Quantity of operat-
form FF
ing-liquid for first fill, page 12.
2BV541.-1G Threaded end G2
2BV5421 Threaded end G21/2

5.2.1 Connecting the suction and discharge

connections The inlet connection (item 8, page 3) is marked
with an arrow pointing downward. The gases /
CAUTION vapours are drawn inward in this direction.

If the unit is connected to a vacuum tunnel  Connect the system suction line.
the operating-liquid can be drawn out of the
unit into the system risking damage to the
system. The discharge connection (item 7, page 3) is
 Fit a check valve in the suction line. marked with an arrow pointing upward. The gas-
es / vapours as well as the operating-liquid are
CAUTION expelled in this direction.

The tightening torque for piping connections to  Connect the system discharge line.
the suction and discharge connections may not
exceed 100 Nm [73.8 ft lbs]!

610.44440.40.000 16 / 32 © Gardner Denver Deutschland GmbH

 Installation

5.2.2 Making the operating-liquid connec- 5.2.3 Connecting up system components

tion
 Connect up the components in accordance
CAUTION with the flow diagram shown below:

In the case of operating-liquid with impurities: Operation with supply of the operating-liquid,
 if necessary a filter, strainer or separator automatically controlled operation
should be installed in the supply line.
1 2 3 4 5 6 7

ATTENTION
If the operating-liquid is highly calciferous:
 soften the operating-liquid
OR
 decalcify the unit regularly (chapter 9.1,
"Decalcifying the unit", page 27). 610.44440.99.B09

1 Unit
2 Flow meter/ Flow limiter
Connection sizes, operating-liquid inlet 3 Throttle valve
Type Connection 4 Solenoid valve coupled to the motor
2BV20 Threaded tapping G3/8, 12 mm [] 5 Bypass line with shut-off valve (for initial filling)
deep 6 Strainer
2BV51 Threaded tapping G3/4, 24 mm [] 7 Operating-liquid supply line
Cast iron deep Fig. 8: Operation with supply of the operating-
3 liquid: automatically controlled operation
2BV51 Threaded tapping G /4, 24 mm []
Stainless deep
steel OR Operation with supply of the operating-liquid,
flange in accordance with non-automatic control of operation
EN 1092-PN40-DN15 and
ANSI-B16.5-1/2-150 1 2 3 4 6 7

3
2BV54..-1G Threaded tapping G /8, 20 mm []
deep
2BV54..-.F Threaded tapping G3/4, 24 mm []
deep

 Connect the operating-liquid supply line to the

operating-liquid inlet (item 6, page 3). 610.44440.99.B10

1 Unit
2 Flow meter/ Flow limiter
3 Throttle valve
4 Shut-off valve
6 Strainer
7 Operating-liquid supply line
Fig. 9: Operation with supply of the operating-
liquid: non-automatic control of operation

© Gardner Denver Deutschland GmbH 17 / 32 610.44440.40.000

Installation

Operation with self-suction of the operating- 5.3 Connecting the electric motor
liquid
7 4 8
 DANGER
9 1 Electrical hazard!
p1 ≤ pat – 150 mbar
a [2.17 psi]
Incorrect actions can lead to severe harm to
persons and material damage!

 DANGER
≤1m Electrical hazard!
≤ 3.28 ft Electrical connection may only be carried out by
b specialist electricians!

610.44440.99.B11  DANGER
1 Unit
4 Shut-off valve Electrical hazard!
7 Operating-liquid supply line Before starting work on the unit or system, the
8 Suction line following precautions are to be taken:
9 Operating-liquid storage vessel  de-energize it.
a Liquid level necessary on start-up  protect it from being switched on again.
b Min. liquid level during operation  make sure that it is de-energized.
Fig. 10: Operation with self-suction of the operat-  earth it and bypass it.
ing-liquid
 cover or block off adjoining parts which are
still live.

5.2.4 Ancillaries CAUTION

The following ancillaries can be supplied from our Incorrect connection of the motor can result in
catalogue: severe damage to the unit!
 liquid separator including return line and cavi-
tation-protection line
 cavitation-protection valve Regulations:
 check valve
 connection and contra-flanges The electrical connection is to be set up as fol-
 gas ejector lows:
 flow limiter.  in accordance with the currently valid national,
local and system-specific regulations and re-
quirements,
 in accordance with the current regulations of
the power supply company which apply to the
place of erection.

Supply of electrical power:

The conditions at the place of use must agree

with the details on the data plate.

Permissible deviations which do not lead to loss

of performance:
 ±5% variation in voltage
 ±2% deviation in frequency

610.44440.40.000 18 / 32 © Gardner Denver Deutschland GmbH

 Installation

5.3.1 Connection to the motor terminal box

A B
 WARNING
Electrical hazard!
The air-gaps between non-insulated, energized
components in relation to each other and to C
earth must be at least 5.5 mm [0.217"] (at a de-
sign voltage of UN ≤ 690V).
No exposed wires are permissible. 610.44440.99.B13

The electrical connections must be permanently A Standard entry union

secured. B Entry union with reducer
C Installation position of backing nut
 WARNING Fig. 12: Entry unions with backing nut

Electrical hazard! To protect the motor against overloading:

Terminal boxes must be free of
 Use a power limiting switch.
 foreign objects, These have to be adjusted to the design cur-
 dirt and rent specified on the rating plate.
 moisture.
Close and seal the cover to the terminal box and
also seal the cable entry openings against the
5.3.2 Operation with a frequency converter
entry of dust and water.
Check regularly to make sure they are sealed  High-frequency current and voltage harmonics
tight. in the motor supply line can create electro-
magnetic interference. This is dependent on
 Any scale / blind plugs are to be properly re- the converter design (type, manufacturer, in-
moved (Fig. 11, page 19). terference suppression measures).
 Fit the entry union (item A , Fig. 12, page 19)  Observe the EMC instructions provided by the
 Screw in the reducer for the PTC resistor manufacturer of the converter.
connection (item B, Fig. 12, page 19).  Use screened supply cables.
 Connect the protective conductor to the termi- For optimum screening a large area of the
nal . screen should be connected to the motor's
 connect up the connection frame in accord- metallic terminal box using a metallic, conduc-
ance with the wiring diagram inside the tive union.
terminal box (item 1, page 3).  Depending on the type of converter used,
- For tightening torques for terminal boards when using motors having integral sensors
see the table "Tightening torques", page 9. (e.g. PTC resistors) interference can be cre-
- For cable terminals with retaining clips, set ated in the sensor cables.
up the cable so that both sides of the bridge  For the maximum speed of rotation see the
are at about the same clamping height. table, "Maximum speeds", page 9.
- Bend the individual conductors into a U-
form or connect up using a suitable terminal
end.  In the USA, units having UL approbation may
- The protective conductor and the outermost not be operated on frequency converters
earth conductor must be bent into a U-form. without testing by an appropriate inspection
authority.

610.44440.99.B12

Fig. 11: Knocking out the openings in the terminal

box

© Gardner Denver Deutschland GmbH 19 / 32 610.44440.40.000

Commissioning

6 Commissioning  Measure the motor insulation resistance.

At values ≤ 1kΩ / Volt of measurement poten-
tial, dry the windings.
 WARNING  Check the piping / hose connections for leaks.
Improper handling of the equipment can re-
sult in serious or even fatal injuries!
Have you read the safety notes in chapter 1, 6.2 Start-up of unit with operating-liquid
"Safety", page 4 above? supply
If not then you are not allowed to carry out any
work on or with the equipment! Filling up with operating-liquid

 WARNING For operation with supply of the operating-liquid,

Hazard in case of overpressure and negative now fill the unit's operating chamber with operat-
pressure! ing-liquid.

Hazard presented by leaking media!  For automatically controlled operation:

Hazard presented by moving parts! the shut-off valve in the bypass line (item 5,
Fig. 8, page 17) is to be opened for approx.
The unit may only be started up if: 20 s.
 the fan guard and cover are fitted.  For non-automatic control of operation:
 the piping is connected to the suction and the shut-off valve (item 5, Fig. 9, page 17) is
discharge connections and the operating- to be opened for approx. 20 s.
liquid inlet.
Setting the initial pressure of the operating-
 the piping and connections have been pres-
liquid
sure and leak tested.
 Vacuum operation:
CAUTION adjust the initial pressure pB in the operating
fluid supply line (item B, fig. 13, page 20) by
If the unit runs dry the rotary seals will be de-
approx. 1 bar [14.5 psi] via the suction pres-
stroyed within a matter of seconds.
sure pA in the suction line (item A, fig. 13,
 DO NOT switch on until the system has been page 20).
filled with operating-liquid!  Compressor operation:
adjust the initial pressure pB in the operating
fluid supply line (item B, fig. 13, page 20) by
6.1 Preparation of the unit approx. 1 bar [14.5 psi] via the compressor
pressure pC in the pressure line (item C, fig.
13, page 20).
CAUTION
If the gases / vapours expelled on the discharge pB ≥ pC + 1 bar B pB ≥ pA + 1 bar
side are to be transferred onward, then care [14.5 psi] [14.5 psi]
must be taken that the maximum outlet pressure
is not exceeded! C A
See the section, "Pressures", page 10 above.

ATTENTION
Maximal permissible quantity of water carried
along through the inlet connection:
see the table, Maximum permissible quantity of
water carried along", page 13.

610.44440.99.B14

If a shut-off device is installed in the discharge A Suction line

line: B Operating-liquid supply line
C Discharge line
 Take measures to ensure that the unit
CANNOT be operated with the shut-off device Fig. 13: Adjusting the operating-liquid flow-rate:
closed. setting the initial pressure
Further steps at start-up are identical to the pro-
cedures during operation.

610.44440.40.000 20 / 32 © Gardner Denver Deutschland GmbH

 Commissioning

6.3 Start-up of unit with self-suction of op-

erating-liquid

Fill up with operating-liquid

Units with self-suction of operating-liquid are filled
with operating-liquid before completion of the
installation (Filling up with operating-liquid,
page 16.

Further steps at start-up are identical to the pro-

cedures during operation.

6.4 Checking the direction of rotation

 Check the piping / hose connections on the
suction and discharge connections.
 The unit may not run dry!
See the section, "Filling up with operating-
liquid", page 16 and page 20.
 Briefly switch the unit on then off again.
 The intended direction of shaft rotation is
marked by an arrow (item 9 page 3) on the
pump casing.
 Before shutting the unit down compare the
actual direction of rotation of the external fan
with the intended direction of rotation of the
shaft.
 If necessary, reverse the direction of rotation
of the motor.

© Gardner Denver Deutschland GmbH 21 / 32 610.44440.40.000

Operation

7 Operation 7.1 Operation with supply of the operating-

liquid, automatically controlled opera-
tion
 WARNING
Improper handling of the equipment can re- Starting the unit up
sult in serious or even fatal injuries!  Switch on the power supply.
Have you read the safety notes in chapter 1,  The unit will start to draw in the gases / va-
"Safety", page 4 above? pours to be handled.
If not then you are not allowed to carry out any  The solenoid valve (item 4, Fig. 8, page 17)
work on or with the equipment! opens and the operating-liquid is supplied.

 WARNING
Hazard in case of overpressure and negative Switching the unit off:
pressure!  Switch off the power supply.
Hazard presented by leaking media!  The unit interrupts suction of the gases / va-
Hazard presented by moving parts! pours.
The unit may only be started up if:  The solenoid valve (item 4, Fig. 8, page 17)
closes and supply of the operating-liquid
 the fan guard and cover are fitted. ceases.
 the piping is connected to the suction and  The throttle valve (item 3, Fig. 8, page 17) is
discharge connections. used for setting the operating-liquid flow rate:
 the piping and connections have been pres- during operational shutdown the valve-setting
sure and leak tested. (i.e. the position of the valve or the cross-
sectional area of the valve that is open) is not
CAUTION to be changed.
If the unit runs dry the rotary seals will be de-
stroyed within a matter of seconds.
 DO NOT switch on until the system has been 7.2 Operation with supply of the operating-
filled with operating-liquid! liquid, non-automatic control of opera-
tion
 WARNING
Starting the unit up
Danger of burns or scalding from hot sur-
faces on the unit and from hot media!  The shut-off valve (item 4, Fig. 9, page 17) is
 Do not touch when in operation! to be opened manually.
the operating-liquid is supplied.
 After shutdown, allow system to cool down!  switch on the power supply.
 The unit will start to draw in the gases / va-
ATTENTION pours to be handled.
Maximum permissible quantity of water carried
along through the inlet connection:
see the table, "Maximum permissible quantity of Switching the unit off:
water carried along", page 13.
 Switch off the power supply.
 The unit interrupts suction of the gases / va-
pours.
 The shut-off valve (item 4, Fig. 9, page 17) is
to be closed manually.
supply of operating-liquid ceases.
 The throttle valve (item 3, Fig. 9, page 17) is
used for setting the operating-liquid flow rate:
during operational shutdown the valve-setting
(i.e. the position of the valve or the cross-
sectional area of the valve that is open) is not
to be changed.

610.44440.40.000 22 / 32 © Gardner Denver Deutschland GmbH

 Operation

7.3 Operation with self-suction of the oper- 7.4 Checking and correcting the operating-
ating-liquid liquid flow-rate
 When switching the unit on there should be a  using the flow meter (item 2Fig. 8, page 17, or
vacuum in the suction line (item 8, Fig. 10, item 2, Fig. 9, page 17)
page 18) of min. 900 mbar abs. [13.1 psia].
 When switching on the liquid level in the sup- OR
ply line (item 7, Fig. 10, page 18) or in the
storage vessel (item 9, Fig. 10, page 18) must  by measuring the quantity of operating-liquid
be at the same level as the operating-liquid per unit of time flowing from the discharge
connection on the unit (item a, Fig. 10, connection using a measuring cup (Fig. 14,
page 18). page 23)
 During operation the liquid level in the storage
vessel (item 9, Fig. 10, page 18) may not sink C B
below approx. 1 m [3.28 ft] under the level of
the operating-liquid connection (item b, Fig.
10, page 18).

Starting the unit up

 Switch on the power supply.
 The unit begins to draw in the operating-liquid
and the gases / vapours to be handled.
610.44440.99.B15

B Operating-liquid supply line

Switching the unit off: C Discharge line
Fig. 14: Adjusting the operating-liquid flow-rate:
 Switch off the power supply.
Measuring the flow-rate using a measuring
 The unit ceases drawing in the operating- cup
liquid and the gases / vapours.
Correcting the operating-liquid flow-rate for
unit with operating-liquid supplied
 Correct the operating-liquid flow-rate by
means of the throttle valve (item 3, Fig. 8,
page 17, or item 3, Fig. 9, page 17).
see the table, "Design operating-liquid flow",
page 12.

For self-suction of operating-liquid the oper-

ating-liquid flow-rate varies as follows:
The higher the suction pressure, the lower the
operating-liquid flow-rate.
The lower the suction pressure, the lower the
operating-liquid flow-rate.

© Gardner Denver Deutschland GmbH 23 / 32 610.44440.40.000

Decommissioning the machine and shutting it down for a longer period of time

8 Decommissioning the machine  Switch off the power supply.

and shutting it down for a longer  Take the abovementioned precautionary
measures for safety when working on the unit
period of time
or system.
 Place suitable drain-off containers underneath
 WARNING the cover.
 Open the screwed plugs in all drain tappings
Improper handling of the equipment can re-
(item 4, page 3).
sult in serious or even fatal injuries!
 Allow the liquid to drain off.
Have you read the safety notes chapter 1,  Whilst doing so turn the shaft in its normal
"Safety", page 4 above? direction from time to time (Fig. 15, page 24).
If not then you are not allowed to carry out any For 2BV2…:
work on or with the equipment!
- screw in an M8 bolt of sufficient length into
the shaft end on the external fan side.
- use a wrench to turn the shaft manually.
8.1 Draining down For 2BV5…:
 DANGER - remove the fan guard.
- turn the external fan by hand.
Electrical hazard!
 if necessary remove the fixings from the
Before starting work on the unit or system, the
mounting feet and tip the unit over by 45° to-
following precautions are to be taken:
ward the cover side.
 de-energize it.  continue these measures until no further liquid
 protect it from being switched on again. comes out.
 make sure that it is de-energized.  close the screwed plugs in all drain tappings
 earth it and bypass it. (item 4, page 3).
Tightening torques: 2 3 Nm
 cover or block off adjoining parts which are [1.48 ... 2.21 ft lbs].
still live.
 for 2BV2… remove the bolt from the shaft
end on the fan side.
 WARNING  For 2BV5… refit the fan guard.
Hazard in case of overpressure and negative  reinstall the fixings in the mounting feet.
pressure! 2BV2 ... 2BV5 ...

Hazard presented by leaking media!

Before starting work on the unit or system:
 shut off the operating-liquid supply.
 vent the piping and the unit (de-pressurize).

 WARNING
Danger of burns or scalding from hot sur-
faces on the unit and from hot media! 610.44440.99.B16

 Do not touch when in operation! Fig. 15: Turning the shaft

 After shutdown, allow system to cool down!

 WARNING
Hazard presented by combustible, caustic or
poisonous substances!
In order to protect persons and the environment:
Units that have come into contact with hazard-
ous substances must be flushed out whilst run-
ning, before opening the unit up.

610.44440.40.000 24 / 32 © Gardner Denver Deutschland GmbH

 Decommissioning the machine and shutting it down for a longer period of time

8.2 Preparations for long-term shutdown 8.3 Storage conditions

For longer shutdown periods (from approx. This chapter applies to:
4 weeks) or in the event of frost hazard proceed
as follows:  new units,
 units that have been prepared for long-term
Cast iron construction: shutdown as described in chapter 8.2,
"Preparations for long-term shutdown",
 Drain down the unit as described in chap- page 25.
ter 8.1, "Draining down", page 24.
 Remove the piping / hoses from the suction In order to avoid damage during shutdown and
and discharge connections. storage periods, the ambient conditions should
 Pour a preserving agent (anti-rust oil, e.g. be as follows:
Mobilarma 247 supplied by the Mobil Oil Co.)
 dry,
into the open suction and discharge connec-
 free of dust,
tions.
 low vibration (effective value for the speed of
Charge required:
oscillation veff ≤ 2.8 mm/s [0.11"/sec]).
for 2BV2…:  ambient temperature:
½ l [0.132 gal (US); 0.110 gal (UK)] max. +40°C [+104°F].
For 2BV5…:
1 l [0.264 gal (US); 0.220 gal (UK)]
 Seal off the suction and discharge connec-
tions as well as the operating-liquid connec- 8.4 Commissioning after a long shutdown
tion or alternatively reinstall the piping / hoses. period
 Start and stop the unit briefly to distribute the
preserving agent. CAUTION
 There are two alternatives for storage:
Risk of material damage due to insufficient
- the unit remains connected up to the sys- lubrication of roller bearings after long term
tem, storage!
- or the unit is removed and stored separate-  If the unit is stored for a period of more than
ly. 2 years then the roller bearings will require
new greasing (see Re-grease or renew roller
bearings, page 28).
Stainless steel and bronze constructions:
 Drain off the preserving agent (chapter 8.1,
 Drain down the unit as described in chap- "Draining down", page 24).
ter 8.1, "Draining down", page 24. No further cleaning of the unit is necessary.
 There are two alternatives for storage:  Dispose of the preserving agent in accord-
- the unit remains connected up to the sys- ance with the manufacturer's recommenda-
tem, tions.
OR  In the event that the impeller does not rotate
- or the unit is removed and stored separate- freely:
ly. Decalcifying the unit or To free it, rotate the
shaft (chapter 9.1, "Maintenance", page 27).
 For new units proceed as described in chap-
ter 5, "Installation", page 15.
 For units having been shut down for long pe-
riods proceed as described in chapter 6
"Commissioning", page 15.

© Gardner Denver Deutschland GmbH 25 / 32 610.44440.40.000

Maintenance

9 Maintenance  WARNING
Danger of burns or scalding from hot sur-
 WARNING faces on the unit and from hot media!
Improper handling of the equipment can re- After shutdown, allow system to cool down!
sult in serious or even fatal injuries!
Have you read the safety notes in chapter 1,  WARNING
"Safety", page 4 above?
If not then you are not allowed to carry out any Hazard presented by rotation of the unit's
work on or with the equipment! impeller!
Removal of the cover is forbidden!
 WARNING
 WARNING
Improper handling of the unit
can result in serious or even fatal injuries! Danger of injury if components tip over or
All maintenance and service work on the system fall off!
must be carried out by the service department! If fixings have come loose then some compo-
The operator may only carry out maintenance nents may only be held by their centring, their
work on the unit if they are in possession of the seating or even not at all and so they could fall
relevant maintenance instructions! off.
 take appropriate precautions when disman-
Please consult our service department!
tling and reinstalling components.
 DANGER
 WARNING
Electrical hazard!
Hazard presented by combustible, caustic or
Before starting work on the unit or system, the poisonous substances!
following precautions are to be taken:
 Units that have come into contact with haz-
 de-energize it. ardous substances must be flushed out whilst
 protect it from being switched on again. running, before opening the unit up.
 make sure that it is de-energized.
 earth it and bypass it.
 cover or block off adjoining parts which are
still live.

 WARNING
Hazard in case of overpressure and negative
pressure!
Hazard presented by leaking media!
Before starting work on the unit or system:
 shut off the operating-liquid supply.
 vent the piping and the unit (de-pressurize).

610.44440.40.000 26 / 32 © Gardner Denver Deutschland GmbH

 Maintenance

9.1 Maintenance

Interval Maintenance procedure

monthly  check the piping and screwed joints for leakage and secure fixing then reseal and
retighten them as necessary.
monthly  check the terminal box cover and cable entry openings for proper sealing and reseal
if necessary.
dependent on the Check the fan guard, the external fan and the cooling vanes on the motor for con-
concentration of tamination and clean if necessary
contaminant par-
ticles in the am-  Take protective measures appropriate for the use of compressed air:
bient air get personal protection gear (gloves and protective safety glasses).
secure the surrounding area. Remove any objects lying around in the area.
 Clean the fan guard, external fan and motor cooling vanes using compressed air.
dependent on the  separator, filter or strainer to be installed in the supply line.
concentration of
Flushing the pump casing
contaminant par-
ticles in the oper-  Shut down the unit.
ating-liquid  Dismantle the piping / hoses.
 Place suitable drain-off containers underneath the cover.
 Open the screwed plugs in all drain tappings (item 4, page 3).
 Connect a hose to the discharge connection and run it to the drain-off container.
 Connect a flushing liquid hose to the operating-liquid connection.
use a clean, non-hazardous medium (e.g. water) for flushing.
 Start the unit up and keep the flushing liquid supply flowing continuously.
- contaminants will be flushed out of the pump casing along with the flushing liquid.
- continue the procedure until the flushing liquid emerges free of contamination.
 Shut down the unit.
 Remove the hoses from the discharge connection and from the operating-liquid con-
nection and reconnect the system piping to the unit.
 Close the screwed plugs in all drain tappings (item 4, page 3). Tightening torques:
2 ... 3 Nm [1.48 ... 2.21 ft lbs].
depending on the  Operating-liquid to be softened.
hardness of the
Decalcifying the unit (3-monthly intervals)
operating-liquid
(hardness  Get personal protection gear (gloves and protective safety glasses).
> 15°dH)  Shut down the unit.
 Drain the unit down (see chapter 8.1, "Draining down", page 24).
 Dismantle the piping / hoses.
 Fill the unit with decalcifying agent through one of the connection openings. use a
10% acetic acid concentrate or another commercially available decalcifying agent.
 Leave the decalcifying liquid in the unit for at least 30 min.
 Whilst doing so turn the shaft in its normal direction from time to time (Fig. 15,
page 24).
2BV2…: 2BV5…:
 Screw in an M8 bolt of sufficient length into  Remove the fan guard.
the shaft end on the external fan side.
 Turn the external fan by hand.
 Use a wrench to turn the shaft manually.
 Refit the fan guard.
 Remove the bolt.
 Drain off the decalcifying liquid from the unit (see chapter 8.1, "Draining down",
page 24).
 Flushing the pump casing(see page 27).
 Reconnect the piping / hoses.
 Start up the unit again (see chapter 6, "Commissioning", page 20).
 Dispose of the decalcifying agent in accordance with the applicable directives.

© Gardner Denver Deutschland GmbH 27 / 32 610.44440.40.000

Maintenance

Interval Maintenance procedure

2.5 years or Re-grease or renew roller bearings
20,000 operating
hours  Open roller bearings and adjacent grease cups are to be cleaned of old grease and
contamination.
 Fill approx. 50% of the free space in the roller bearings and approx. 65% of the vol-
ume in the adjacent areas with grease.
Grease type: UNIREX N3 (ESSO Co.)
Alternative grease acc. DIN 51825-K3N
 Sealed roller bearings are to be renewed and the adjacent areas do not require
greasing.
 It is recommended that the rotary seal, the V-ring and the valve head are checked for
wear and replaced if necessary.
The specified intervals apply only when using UNIREX N3 grease. Avoid mixing different
types of grease.

9.2 Repairs / Troubleshooting

Fault Cause Correction Remedy

Motor does Electrical power sup-  Check fuses, terminals and cables for continuity. Re- Electrician
not start ply failure pair any break in continuity.
Impeller does not ro- To free it, rotate the shaft: Operator
tate freely
2BV2…: 2BV5…:
 Screw in an M8 bolt of suf-  Remove the fan guard.
ficient length into the shaft
end on the external fan  Turn the external fan
side. by hand.
 Use a wrench to turn the  Refit the fan guard.
shaft manually.
 Remove the bolt.
See "Decalcifying the unit", page 27. Operator

See "Flushing the pump casing", page 27. Operator

 Check the clearance adjustment on the impeller and Service
readjust if necessary.
Foreign matter in the  Remove the foreign matter. Service
unit
 Check that the unit functions correctly.
Defective impeller  Replace the impeller. Service
Defective motor bear-  Replace the motor bearing. Service
ing
Circuit Short-circuit in the  Check the winding. Electrician
breaker trips winding
out again Motor When operating with supply of the operating-liquid: Operator
after it has overloaded
been  Check the operating-liquid flow-rate and if necessary
switched on reduce it (see chapter 7.4, "Checking and correcting
the operating-liquid flow-rate", page 23).
Excessive backpres-  Reduce the backpressure. Operator
sure in the discharge
connection
Proportion of liquid  Reduce the proportion of liquid. Operator
entrained in the main
flow is too high

610.44440.40.000 28 / 32 © Gardner Denver Deutschland GmbH

 Maintenance

Fault Cause Correction Remedy

Impeller does not ro- See "Impeller does not rotate freely", page 28 Operator
tate freely
Power con- Build up of lime-scale See "Decalcifying the unit", page 27. Operator
sumption or
too high contamination See "Flushing the pump casing", page 27. Operator
Unit does No operating-liquid When operating with supply of the operating-liquid: Operator
not generate supply
 Check and correct the operating-liquid flow-rate. (see
a vacuum
chapter 7.4, "Checking and correcting the operating-
liquid flow-rate, page 23).
When operating with self-suction of the operating-liquid:
 See 7.3, "Operation with self-suction of the operating-
liquid", page 23.
 Clean out the operating-liquid supply hose.
 Increase the diameter of the operating-liquid supply
hose.
Large-scale leak in the  Seal off leaks in the system. Operator
system.
Incorrect direction of  Change the direction of rotation by switching polarity Electrician
rotation between two of the electrical power supply phases.
System Insufficient operating- See "No operating-liquid supply", page 29. Operator
generates liquid
too little Operating-liquid too  cool the operating-liquid or increase the flow-rate (see Operator
vacuum warm chapter 7.4, "Checking and correcting the operating-
liquid flow-rate", page 23).
(nominal temperature: 15°C [59 °F]).
Erosion / Corrosion  Inspection of the casing, the impeller and the control Service
disk.
 Renew the affected components.
Leakage in the system  Repair leakage in the system. Operator
Rotary seal leaking  Replace rotary seal. Service
Motor connection in-  Check and repair motor connection. Electrician
correct
Electrical power sup-  Check and repair electrical power supply. Electrician
ply incorrect
Unit is too small  Install a larger unit. Operator
Squealing Cavitation in the unit 2BV2… and 2BV51.. 2BV54.. Operator
noises
 Connect separator  Check that the pressure set-
cavitation-protection ting is in accordance with the
hose (ancillary) or permitted operating pressure.
clean out cavitation-
protection system.
Operating-liquid flow-  Check the operating-liquid flow-rate and if necessary Operator
rate too high reduce it (see chapter 7.4, "Checking and correcting
the operating-liquid flow-rate", page 23).
Leakage in Defective seals  Check the seals. Service
the unit

© Gardner Denver Deutschland GmbH 29 / 32 610.44440.40.000

Disposal

9.3 Service / Customer service The declaration of Clearance,

Our service department (ref. cover sheet of these  must be completed and signed by authorized
operating instructions) is always available for technical personnel,
work that is not described in these operating  must be completed separately for each unit
instructions (fitting of replacement parts and dispatched (i.e. one declaration for each unit),
maintenance and repair work).  must be affixed to the outside of the unit's
packaging
When returning units to us:  and a copy should be sent (e.g. by fax) to the
workshop which is to carry out the work, be-
 before dispatch: fore the unit is dispatched.
- Drain down the unit completely as de-
scribed in chapter 8.1, "Draining down", This ensures that:
page 24.  the unit has not come into contact with haz-
- Clean the unit internally and externally, ardous substances,
as described under "Flushing the pump cas-  a unit which has come into contact with haz-
ing", page 27. ardous substances has been sufficiently de-
 The unit must be delivered complete, i.e. not contaminated,
disassembled.  the inspection, maintenance or repair staff
 A suitable individual packaging is necessary can, where necessary, take any necessary
on dispatch to prevent transport damage. safety precautions.
 A “Decontamination and declaration of Clear-
ance” must accompany the delivery. CAUTION
 The unit's original data plate must be correctly
The inspection / maintenance / repair of the unit
in place, intact and readable.
at the workshop will only be commenced
All claims against guarantee lapse where they
when the declaration of conformity is in our pos-
apply to systems which are delivered for an
session!
estimate of damage to be made, and where
the system is without the original data plate or If the declaration of conformity is not delivered
where the original data plate has been de- with the unit then this could result in delays!
stroyed.
 In the event of any guarantee claim the manu-
facturer must be notified of the operating con-
ditions and duration of operation as well as 10 Disposal
any other details on request.
The entire unit should be disposed of complete
for scrapping by a suitable disposal specialist. No
special measures need be taken in this respect.
9.4 Decontamination and declaration of
Clearance Please contact our service department for further
information regarding disposal of the unit.
 WARNING
Hazard presented by combustible, caustic or
poisonous substances! 11 Explosion-protected design
 Units which have come into contact with haz-
ardous substances must be decontaminated Units in explosion-protected construction are
before being sent to a workshop! supplied with supplementary operating instruc-
tions containing additional relevant information.
Every unit that is sent to a workshop for inspec-
tion, maintenance or repair must be accompanied
by what is known as a declaration of Clearance.

610.44440.40.000 30 / 32 © Gardner Denver Deutschland GmbH

 EU declaration of conformity

EU declaration of conformity

EU declaration of conformity
Manufacturer: Gardner Denver Deutschland GmbH
Industriestraße 26, 97616 Bad Neustadt, Germany
Representative for the compila- Holger Krause
tion of technical documents: Industriestraße 26, 97616 Bad Neustadt, Germany
Designation of the machine: Compressor/Vacuum Pump
Series L-BV2 / L-BV5
Types 2BV2060 2BV2061
2BV2070 2BV2071
2BV5110 2BV5111
2BV5121
2BV5131
2BV5161
2BV5410 2BV5411
2BV5421
2BV5470 2BV5471
The manufacturer bears sole responsibility for issuing this declaration of compliance.
The machine described above complies with all applicable harmonisation legislation of the Community:
2006/42/EG Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machin-
ery, and amending Directive 95/16/EC

harmonised standards and other technical specifications on which the declaration of compliance is based:
EN 1012-1:2010 Compressors and vacuum pumps - Safety requirements
 - Part 1: Compressors
EN 1012-2:1996 Compressors and vacuum pumps - Safety requirements
 - Part 2: Vacuum pumps
+A1:2009
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO
12100:2010)

Signed for and on behalf of: Gardner Denver Deutschland GmbH

Bad Neustadt, 19.01.2016
(Place and date of issue)

Andreas Bernklau, Product management/Authorised signatory Joachim Stößer, Operations/Authorised signatory

(Name and function) (Name and function)
664.44440.40.000

© Gardner Denver Deutschland GmbH 31 / 32 610.44440.40.000