MAINTENANCE
MANUAL
- Alexander Kosarev. M- 0275 -
-Order no. 40835 & 40933-
- PV-system 1200 -
Table of contents
Individual specification of PV-system .............................................................................................. 3
Customer Information ...................................................................................................................... 3
Individual specification of components ........................................................................................... 3
Parts list for the PV-tank................................................................................................................... 4
Description of the power unit arrangement .................................................................................... 5
Parts list for the power unit .............................................................................................................. 5
Spare parts- and maintenance manual ............................................................................................ 8
PV-tank, Maintenance and spare parts ............................................................................................. 8
Non-return flaps ........................................................................................................................... 8
Connection between tank and power unit .................................................................................... 8
Bolt assemblies ............................................................................................................................ 8
Tank sensors, Maintenance and spare parts ..................................................................................... 9
Fork sensors ................................................................................................................................. 9
Flowmeter with display.................................................................................................................. 10
4-way valve, maintenance and spare parts ..................................................................................... 11
4-way valve, 6" .......................................................................................................................... 11
Hydraulic parts for PV-system, maintenance and spare parts ....................................................... 12
Hydraulic diagram...................................................................................................................... 12
Hydraulic cylinder for 4-way valve, 6” ..................................................................................... 15
Hydraulic water supply, 3/4” ..................................................................................................... 16
Hydraulic bypass valve, 4" ........................................................................................................ 17
Hydraulic DN100 shutoff valve ................................................................................................. 18
Knife valve for in and outlet of the PV-tank .............................................................................. 19
Pneumatic solenoid valve for knife valve .................................................................................. 20
-2-
Individual specification of PV-system
Customer Information
Date ([Link])
Buyer
Order no. 40835
PV system model
Tank Serial number(s) 1125 / 1126
Control Box Number 8367-10 / 8496-10
Remote control, box number -
Electrical data 3x 400 V – 50 Hz + PE
When enquiring please inform order number and tank number.
Individual specification of components
Title: Type / Make: Prod. code
Engine / no. 30 kW
Pump / no. W9
Flaps, inlet 280x350x5, inlet unloading ALF0264
Flaps, outlet 280x290x5, in/outlet LF & outlet unloading ALF0265
Belt type/ coupling and size Original
Hydraulic Pump incl .valves Hydr. pump w/0.37 kW [Link] (AC) 5 ltr NHY0014
tank, incl. valves: 3 pcs. DS3-TA 10N/cm-
incl. 24 VAC coils
Hydraulic Pump excl .valves Hydraulic pump w/ 0.37 kW electric motor NHY0019
5 ltr. tank, excl. valves
Solenoid valve for supply water DS3-TA [Link] 24VAC VHY0108
Solenoid Valve for 4-way valve DS3-TA [Link] 24VAC VHY0108
Solenoid valve for Bypass valve DS3-TA [Link] 24VAC VHY0108
Coil for Solenoid valve Coil for DS3-TA VHY0109
Cylinder, 4-way valve INOX 25/12x150 YHY0020
Cylinder, 4" bypass valve Klinkby DVGFS 40/20-60 YHY0052
Water Valve Omal DN20 - 3/4” SA931 ALF0478
Hydraulic accumulator Accumulator hydraulic 1.5 l / 18 bar MHY0041
Flow metre Flowmetre with display for flow amount MKS0330
24 V DC
Top Sensor for PV-tank Fork Sensor FTL31 DC MKS0355
Bottom Sensor for PV-tank Fork Sensor FTL31 DC MKS0355
Included documents:
Electrical diagrams according to control cabinet number.
Manual for liquid ring pump
-3-
Parts list for the PV-tank
Item No Description
10 PV-Tanks
11 Tank foundation
12 Inlet for PV-tank
13 Outlet of PV-tank
14 Separate outlet valve LF
15 Tank Sensor, top
16 Tank sensor, bottom
17 Level hose
18 Connection to a Power unit with floating ball
20 Pipe connection between the tank and outlet valve
21 Outlet valve unit
22 Hydrophore
23 Relief valve
Arrangement of PV-tank for unloading of fish
-4-
Description of the power unit arrangement
The PV-tank is equipped with a power unit with control system. There are many different kinds of
power units depending on the pumping condition.
Parts list for the power unit
Pos. No Description
50 Liquid ring pump
51 Motor
52 Transmission
53 Water System
54 Control Box
55 Hydraulic pump for valve control
56 Manifold for liquid ring pump
57 By-pass valve, hydraulic
58 Relief valve
59 4-way valve
60 Hydraulic cylinder for 4-way valve
61 Inlet and outlet pipe for liquid ring pump
62 Inlet and outlet pipe for bypass
63 Connection pipe to the PV-tank
64 Manual bypass valve, pressure side
65 Manual bypass valve, vacuum
66 Hydraulic accumulator
67 Fuel Tank
Arrangement of power unit with electric motor up to 15 kW -belt drive
IRAS PV-SYSTEM
-5-
Arrangement of power unit with electric motor starting from 22 kW -belt drive
IRAS PV-SYSTEM
Arrangement of power unit w/ electric motor up to 15 kW -direct drive
IRAS PV-SYSTEM
-6-
Arrangement of power unit w/ electric motor starting from 22 kW -direct drive
IR AS P V-SY STEM
-7-
Spare parts- and maintenance manual
PV-tank, Maintenance and spare parts
Non-return flaps
Inlet and outlet of the PV-tank is equipped with counter-flaps, these have to fit very tightly to the
pipe
By prolonged use the flap may begin to shut less tightly to the pipe, it is possible to buy new flaps
for the PV-tank.
Determination of size and type, see section "Individual Specification"
When transporting live fish it’s very important, that the water level when filling don’t reach the
non-return valve, otherwise the fish can be damaged.
Connection between tank and power unit
It is recommended to mount a flexible joint to absorb the shock impacts between the power unit and
the tank.
For this purpose a strong hose or a proper compensator might be used.
The tank connection is equipped with a floating ball to prevent the fish to work its way into the
pump by overfilling.
Determination of size:
Ø140 float ball is used with the following models of liquid ring pumps:
Samson W9, W11, W16, TRVX1007 and TRVX1257
Pos. Prod. code Text: Comment:
no /Vare nr.:
1
2 KPK0025 Floating ball, 140 mm rubber
Bolt assemblies
Please note, that all bolt assemblies shall be tightened periodically.
Bolt joints are exposed to vibrations from the PV system during operation and might loosen.
It is recommended to check the bolt assemblies once a month during normal operation.
-8-
Tank sensors, Maintenance and spare parts
Fork sensors
The fork sensor operates by the same principle as a tuning fork.
The symmetrical fork sensor vibrates at its resonant frequency which changes when the liquid
covers the forks. The change in frequency is detected by the electronics and the output signal
changes.
The fork sensor is equipped with two diodes located at the top of the sensor at the four-pole
connector. The green diode indicates that the sensor is applied voltage, and the yellow diode
indicates the output signal.
The fork sensor requires no real maintenance. However, the fork sensors must be cleaned on a
regular basis to remove scraps of fish, fish scales and the like.
It is possible to check the fork sensors. This can be achieved by gripping forks and thereby change
the oscillation, by which a signal can be read at the sensor and at the flow diagram of the control
cabinet. Furthermore, a strong magnet might affect the sensor to provide signal, the magnet is
placed on the body of the sensor.
Pos. Prod. code Text: Comment:
no /Vare nr.:
Fork sensor
1 MKS0355 FTL31 DC
Hirshmann Plugs
2 MKS0193 - for solenoid valve
Coupling set for fork sensor
complete, consisting of:
3 MKS0159
1 pcs. 1" part of coupling
1 pcs. 1.5" part of coupling
-9-
Flowmeter with display
The placement of the Flowmeter is shown in the section ”Hydraulic water supply”
After some time of operating the Flowmeter may become inaccurate. This is due to a coating
building up inside the tube.
This coating is removed with a bottle brush and a mild detergent. How often this cleaning must be
done depends of the media that is pumped through.
For easier access to dismount and clean the Flowmeter this is mounted with unions.
Warning!
To avoid twisting the sensor during dismounting and mounting it is important only to tighten on the
two unions (Half-part of union and its counterpart)
It is important that the supply plug is tightened to be waterproof, but it is very important that the
supply plug does not rotate in the socket.
Pos. Prod. code Text /Tekst: Remark:
no. /Vare nr.:
Flowmeter with display
1 MKS0330
6-60 ltr/min, 24 V DC
Half-part of Union
Flowmeter
Half-part of Union
- 10 -
4-way valve, maintenance and spare parts
Maintenance
The 4-way valve must be greased at every 10 hours of operation. The 4-way valve should be
lubricated with grease through the 2 grease nipples on the top side and underside while the valve is
in motion to distribute the fat in the valve.
Suggested quantity: 3-4 shots in each nipple with grease type: SHELL Calithia EP2, Shell Alvania
EP2 or similar grease.
If the system has not been used for a longer period, the valve must be lubricated before starting.
By lack of lubrication and prolonged use, the valve might start to leak around the plug It is possible
to buy new seals for the plug.
Determination of size:
The 6 "4-way valve used with the following models of liquid ring pumps:
W9, W11, W16, TRVX1007 and TRVX1257.
4-way valve, 6"
Pos. Prod. code Text: Comment:
No /Vare nr.:
ALF0271 Complete 6 "4-way valve
01 House
02 End cover, 1 sets of 2 parts
03 Plug
Gasket, 6 "4-way valve
04 ALF0278
complete
O-ring gasket f. 6" 4-way valve
05 ALF0581
1 set of 4 pcs. O-ring ø150x4mm
06 ALF0524 Cross Pin for 6 "4-way valve
Additional parts
- Grease nipple
- 11 -
Hydraulic parts for PV-system, maintenance and spare parts
Hydraulic diagram
- 12 -
Hydraulic pump station
The PV-system is equipped with a hydraulic pumping station, which will operate the hydraulic
water valve, the 4-way valve and the hydraulic bypass valve.
When the control distributes voltage to the coil of the solenoid valve and this pulls, the cylinder will
change position until its outer position is reached. The pressure might in some cases drop, but then
immediately increase to the pre-set working pressure. To minimize pressure drop during operation,
the system is equipped with a hydraulic accumulator.
Standard operating pressure is 30 Bar. The hydraulic pressure can be read on the manometer.
A. Oil Check: To be done once a month
B. Oil level: See diagram below.
C. Oil type: Shell Tellus T46,
Texaco Rando HD 2 46
MOBIL DTE 15 M.
D. Oil Pressure: Standard operating pressure is 30 Bar
Requirements for use / maintenance of hydraulic system:
1. Oil Supplier warnings and references must be followed.
2. By replacement of hydraulic oil, where the facility must be vented, there may be oil
spills and spraying oil.
3. If leaking at the site is found; stop this immediately and rectify the error.
4. By separating the plant there might, even if this is stopped, occur static pressure from
the accumulator, compressed oil and so on. This may lead to sudden spraying of
hydraulic oil.
5. Note that the oil after running the system may be at least 70 degrees Celsius. This
may cause danger of scalding by separation or bleed.
6. Always wear eye protection and oil-protecting gloves.
7. Iras recommend that before start up the plant, to tighten all hydraulic hoses on the
small hydraulic power station, just in case they have been shaken loose during
transport.
- 13 -
Pos. Prod. code Text: Comment:
No /Vare nr.:
- Complete hydraulic power station See "Individual Specification"
1 0.37 kW electric motor
2 Hydraulic Tank
3 Filling / draining pipe stub
4 Hydraulic Pump See "Individual Specification"
5 Solenoid Valve See "Individual Specification"
6 Coil for solenoid valve See "Individual Specification"
7 MKS0193 Connector for solenoid valve
Rubber hood for solenoid valve
8 VHY0107
/ manual actuation of the valve
- 14 -
Hydraulic cylinder for 4-way valve, 6”
Used in conjunction with the following liquid ring pumps:
Samson W9, W11, W16, TRVX1007 and TRVX1257.
Pos. Prod. code Text: Comment:
No /Vare nr.:
01 ALF0538 1:2 Console for cylinder
02 Guard for cylinder
Cylinder Ø25 for 4-way valve
03 YHY0020
SS Ø25/Ø12-150 mm
04 ALF0538 2:2 Lever for Cylinder
Cylinder Bracket, 6 "
05 ALF0580
1 set of 2 brass fittings
Additional Parts
Gasket 25/12, SS-cylinder
- YHY0017
all-purpose for YHY0020
- 15 -
Hydraulic water supply, 3/4”
Description of the water system of the section "General description and start of the PV system"
Pos. Prod. code Text Comment:
No /Vare nr.:
1 Connecting the water supply
Ball valve for supply water for the
2
liquid ring (normally closed)
Hydraulic OMAL water valve
3 ALF0478
DN20 - 3/4"
Flowmetre with display
4 See "Individual Specification"
for flow amount - 24 V DC
Ball valve for adjusting the water to
5
the liquid ring
Connecting the water supply to the
6
liquid ring pump
7 Union
- 16 -
Hydraulic bypass valve, 4"
4" Hydraulic bypass valve is used with the following liquid ring pumps:
Samson W9, W11, W16, TSC10 and LP32.
Pos. Prod. code Text: Comment:
No /Vare nr.:
1 House of bypass valve
2 Cover for bypass valve
3 YHY0052 Cylinder 40/20x60
Valve plate for 4" bypass valve,
4 KPK0022
Ø115-plastic disk
5 Ø115x5 disc stainless steel
6 Ø60x3 disc stainless steel
7 Gasket for cover
8 Gasket for connection
9 4" suction and exhaust
10 Connecting flange
Additional Parts
Gasket 40/20-cylinder
- YHY0053
all-purpose for YHY0052
- 17 -
Hydraulic DN100 shutoff valve
(Used only at systems where several power units work together)
The Shut-off valve functions fully automatically and opens automatically when the power unit
starts. The Shut-off valve ensures that no false air is supplied by the pump not operating.
The Shut-off valve is located on the tank connection at the power unit.
Pos. Prod. code Text: Comment:
No /Vare nr.:
1 Console for cylinder
2 Guard for cylinder
Cylinder Ø25 for 4-way valve
3 YHY0020
SS Ø25/Ø12-150 mm
4 Lever for butterfly valve
Cylinder Bracket, 6"
5 ALF0580
1 sets of 2 brass fittings
6 DN100 butterfly valve
Additional Parts
Gasket 25/12, SS-cylinder
- YHY0017
all-purpose for YHY0020
- Hydraulic throttle check valve
- 18 -
Knife valve for in and outlet of the PV-tank
In- and outlet of the PV-tank can be equipped with a knife valve, which can be used as non-return
valve. (See section: Inlet Knife Valve and outlet Knife Valve)
For longer time of use the knife valve can be leaky and there is possible to adjust or change the
sealing.
Determination of size and type se chapter: Individual specification of PV-system.
Guidance about the pneumatic operated valve:
1. Pneumatic valve must not be repaired or removed during plant operation or when
there is pressure on the system.
2. For all repair / maintenance of the plant, the pneumatic pressure must be disconnected
and locked.
Pos. Code no. Text: Comment:
no. /Vare nr.:
1 VVA0066 Packing set f. DN50 Knife valve
1 VVA0067 Packing set f. DN80 Knife valve
1 VVA0059 Packing set f. DN100 Knife valve
1 Packing set f. DN150 Knife valve
1 VVA0068 Packing set f. DN200 Knife valve
1 VVA0069 Packing set f. DN250 Knife valve
1 VVA0060 Packing set f. DN300 Knife valve
1 VVA0085 Packing set f. DN350 Knife valve
Pack. cylind. DN50-65 knife valve
2 VVA0065 Packing set f. pneum. cyl. Ø80
Pack. cylind. DN80-100 knife valve
2 VVA0057 Packing set f. pneum. cyl. Ø100
Pack. cylin DN200/250/300 knife valve
2 VVA0058 Packing set f. pneum. cyl. Ø190
Pack. cylind. DN350-400 knife valve
2 VVA0065 Packing set for pneum. cyl. ø250
3 Body for knife valve
4 Cylinder for knife valve
5 Frame for knife valve
6 Knife
- 19 -
Pneumatic solenoid valve for knife valve
Solenoid valve is used for opening and closing knife valve.
Pos. Prod. code Text Comment:
No /Vare nr.:
Solenoid valve 5413,
24VAC, 50 - 60 Hz
Incl. fittings, consisting of:
1 YLU0012 3 pcs. 1/4" Nipple, straight
for 10mm hose 1 pcs. 1/4"
Silencer
Solenoid valve 6519
24 V AC, 50 – 60 Hz
Incl. fittings, consisting of:
2 YLU0015 3 pcs. ¼” Nipple, straight
for 10mm hose 1 pcs. ¼”
Silencer
Solenoid valve 6519
24 V AC, 50 – 60 Hz
Connection: Namur
3 YLU0016 2 pcs. ¼” Nipple, straight
for 10mm hose
Coil for Solenoid valve
5413
24 V AC, 50-60 Hz
4 YLU0013
- 20 -
