SERIES -EMS -NS INSTALLATION
OPERATION MAINTAINANCE INSTRUCTION
BULLETIN NO : SERIES-EMS
(INTRODUCTION)..
GENERAL DESCRIPTION
SERIES EMS Metering pumps are positive
displacement reciprocating pumps . They combine the high efficiency of the
plunger pump with diaphragm sealing to prevent product leakage. Each pump
consists of a power end and a process end seperated by a mechanically
operated diaphragm. Individual pumps will vary in appearance due to
various liquid ends, and accessories, howecer, the basic principles of
operation remain the same.
(PRICIPLES OF
OPERATION)..
1. OVERALL OPERATION
A diaphragm reciprocates at a preset stroke length, displacing an exact
volume of process fluid. Diaphragm retraction causes the product to enter
through the suction check valve.
Diaphragm advance causes the discharge of
an equal amount of the product through thedischarge check valve.
II. COMPONENT OPERATION
A typical model with manual external adjustment is
shown:
A). Standard Head
Assembly
At The typical head assembly consists of head, diaphragm, and
suction and discharge check valves. This assembly is the only part of the
pump to contact the process liquid , consequently, maintainance is
critical to pump performance.
B). Control Assembly
SERIES EMS pumps incorporate a lost motion style of
stroke length adjustment to limit diaphragm travel during the suction
portion of each stroke. The stroke length setting is indicated by a
(0-100) scale located on the top of the
unit.
Stroke length is changed by depressing
and turning the hand knob. This turns a screw which locates a slider cam
to position the follower pin as to limit rearward travel of the
diaphragm.
C). Gear Ratio
Assembly
SERIES-EMS, pumps are driven by a standard C-face electric
motor mounted on the motor adapter input flange. The motor drives a set of
worm gears which convert rotational speed into torque. They, in turn,
power the eccentric shaft assembly that converts rotary motion into
reciprocating motion.
(EQUIPMENT
INSPECTION)..
Check all equipment for completeness against the order and for
any evidence of shipping damage. Shortages or damage should be
reported immediately to the carrier and your authorized representative or
distributor of SERIES-EMS, pumps.
STORAGE INSTRUCTIONS 1. SHORT TERM
Storage of SERIES_EMS, pumps for up to 12 months is considered
short-term. The recommended short-term shortage procedures are :
A).Store the pump indoors at room temprature in a dry
environment.
B).Within two months after date of shipment, fill the
eccentric box to its normal operating level with grease. If required by
the operating environment, take any steps required to prevent entry of
water or humid air into the eccentric enclosure.
C).Prior to start up, inspect housing, and gear box.
Replenish eccentric and gearbox grease as required to maintain Operating
levels. If water or condensation is present, change grease as decribed
under "Equipment StartUp".
D). Prior to startup, perform a complete inspection
and then start up in accordance with instructions in this manual.
2. LONG TERM
Every twelve months, in addition to the above short-term procedures,
power up the motor and operate a pump for a minimum of one hour. It is not
necessary to have liquid in the head during this Operation, but the
suction and discharge ports must be open to atmosphere.
After twelve months of storage, our warranty cannot cover such Items
which are subject to deterioration with age such as seals and gaskets. If
the pump has been in storage longer than twelve months, it is recommended
that such items be inspected and replaced as necessary prior to startup.
Materials and labor to replace this class of item under this circumstance
are the purchaser's responsibility. For a continuance of the initial
warranty after extended storage, equipment inspection and any required
refurbishing must be done by our representative.
(INSPECTION)..
1.
LOCATION
While selecting an installation site
or designing a skid package, consideration should be given to
access for routine maintainance.
SERIES-EMS, pumps are designed to operate indoors and outdoors, but it
is desirable to provide a hood or covering for outdoor service. External
heating is required if ambient tempratures below 0*C(32 * F) are
anticipated. Check with the factory if concerned with the suitability of
the operating environment.
The pump must be rigidly bolted to a solid and flat foundation or a
flat surface if mounted on tank to minimize vibration, which can loosen
connections. When the pump is bolted down, care must be taken to avoid
distorting the base and affecting alignments. The pumps must be level
within 5*. This will assure that the eccentric and gear grease is
maintained at the proper levels and that the check valves can operate
properly .
II. PIPING SYSTEM
All piping systems should include :
1. A seperate
system relief valve is recommended to protect piping and
process equipment, including the pump from excess process pressures. This
is to be provided by purchaser and is out of pump supply scope.
2. Shuttoff valves and unions (or flanges) on
suction and discharge piping. This permits check valve inspection without
draining long runs of piping shutoff valves should be of the same size as
connecting pipe. Ball valves are preferred since they offer minimum
flow restriction.
3. An inlet strainer, if the product is not a
slurry. Pump check valves are susceptible to dirt and other
solid containments unless designed for that service, and any accumulation
can cause malfunction. The strainer should be located between the
suction shutoff valve and the pump suction valve. It must be sized to
accomodate the flow rate and the anticipated level of contamination. A 100
mesh screen size is recommended. (For various chemical compatibility you
can discuss with our authorized sellers).
4. Vaccum/pressure gauges in the suction and
discharge lines in order to check system operation. Gauges should be
fitted with protected shutoff valves for isolation while not in use. (To
be supplied by purchaser if felt necessary or site permits).
In piping assembly, use a sealing compound chemically
compatible with the process material. Users of sealing taps are cautioned
to ensure that the entering pipe thread ends are not taped, and that
tape is removed from previously used threads to the maximum practical
extent prior to re-use. Both new and existing piping should be
cleane, preferably by flushing with a clean liquid(compatible with process
material) and blown out with air, prior to connection to the pump.
III. SUCTION PRESSURE
REQUIREMENTS
Although SERIES-EMS , metering pumps have suction lift
capability, a flooded suction (i;e, suction pressure higher than
atmospheric pressure) is preferable whenever possible. The pump should be
located as close as possible to the suction side reservoir or other
source.
For fluid with a vapor pressure of 5 psia or less ( at
operating temprature) the wet suction lift capability is ten(10) feet. If
this requirement is not met, the pump will not provide reliable, accurate
flow. The Net Positive Suction Head Required (NPSHR) is 0.35 bar(5
psi).
The maximum inlet pressure is limited to 0.35 bar(5
psi) below the operating discharge pressure.
Refer to Appendix 1 for procedures for the calculation
of suction pressure.
IV. DISCHARGE PRESSURE
REQUIREMENTS
All SERIES-EMS, Metering Pumps are designed for continous
service at the rated discharge pressure. If system suction pressure wre to
exceed system discharge pressure ( a condition sometimes described as
"pumping downhill"), flow would be generated (siphoning) in addition to
that caused by the pump, resulting in a reduction in accuracy and loss of
control over the metering process. To prevent this condition, commonly
referred to as "flow through", the discharge pressure must exceed
suction pressure by at least 0.35 Bar (or 5 psi). This can be achieved
where necessary by the installation of a back pressur valve in the
discharge line.
Refer to Appendix 1 for procedures for the calculation
of discharge pressure.
(EQUIPMENT STARTUP)..
1. LUBRICATION
SERIES-EMS, Pumps use Grease for the eccentric box and
Gearbox.
It is recommended that adequate supplies of Grease be on
hand for peridic changes and emergency requirements.
The approximate amounts of Grease required to fill
SERIES-EMS, pumps to specified levels are:
-------->350 Gm - Lithium M.P.Grease NLGI-3 (RL-3
of Indian Oil or equivalent may be used)
A). The recommended Grease change intervals are
dependent upon the operating environment and level of pump usage,
classified as follows:
1. Normal Service: clean/dry
atmosphere, an ambient operating temprature of 0*C to 40* C
(32* F to 104* F) and upto 2000 annual operating hours.
2. Severe Service: humid
atmosphere, an ambient operating temprature below 0*C(32 * F) or above
40*C(104* F), and over 2000 annual operating hours.
II. STARTUP
A). Output
Adjustment
All SERIES-EMS, pumps have a handwheel for manual stroke
length adjustment. Mounted atop the eccentric box, the handwheel can
be adjusted at any point from (0 to
100%) stroke setting by pressing down and then rotating as required.
Stroke length is locked during operation to prevent drift:pressing the
handwheel down temporarily disengages the lock for adjustment; release
after adjustment automatically resets the lock at the new setting. An
indicator adjacent to the handwheel displays the output setting.
Adjustments can be made while the pump is at rest or operating, although
adjustments are easier to make while the pump is in operation. Manual
adjustment serves as backup for pumps provided with an MLCA stroke length
controller.
B).Printing the Head
1. Open the suction and discharge line shutoff
valves.
2. If the piping system design and the storage tank
are such that the product flow due to gravity through the pump,
reduce the discharge pressure and the system will self prime when the pump
is started. In the event the discharge line contains a significant amount
of pressurized air or other gas, it may be necessary to lower the
discharge pressure to enable the pump to self-prime.
3. If the installation involves a suction lift,
it may be necessary to prime the reagent head and suction line. Try
priming the reagent head first. See Maintainance Section On Check
Valves.Remove the discharge valve assembly. Fill the head through the
discharge valve port with process (or compatible) liquid, then reinstall
the valve.
4. Start the pump at the zero stroke length
setting and slowly increase the setting to 100 to prime the pump. If this
does not work, it will be necessary to fill the suction line.
5. Filling of the suction line will necessitate the
use of a foot valve or similar device at the end of the suction line so
that liquid can be maintained aove the reservoir level. Remove the suction
valve assembly, fill the line, replaces the valve, then remove the
discharge valve assembly and fill the reagent head as described in Step(3
above).The pump will now self prime when started up her step(4)
above
(MAINTENANCE)..
CAUTION Before performing any maintainance requiring head or valve
(wet end) disassembly, be sure to relieve pressure from the piping system
and, where hazardous process materials are involved, render the pump
safe to personnel and the environment by cleaning and chemically
neutralizing as appropriate. Wear protective clothing and equipment as
appropriate.
Accurate records from the early stages of pump operation
will indicate the type and levels of required maintainance. A preventive
maintainance program based on such records will minimize operational
problems. It is not possible to forecast the lives of wetted parts such as
diaphragms and check valves. Since corrosion rates and operational
conditions affect functional material life, each matering pump must be
considered according to its particular service conditions.
1. WET END REMOVAL, INSPECTION, AND REINSTALLATION
CAUTION
If the diaphragm has failed, process fluid may
have contaminated the pump Lubrication (although normally, any process
fluid behind a failed diapragm would pass through the bottom drain hole).
Handle with appropriate care, clean and replace Grease
if
required.
A). Standard
Diaphragm
SERIES-EMS, diaphragm do not have a specific cycle life;
however, the accumulation of foreign material or debris sufficient to
deform the diaphragm can eventually cause failure. Failure can also occur
as a result of system over pressure or chemical attack. Periodic diaphragm
inspection and replacement are recommended.
1. Adjust the stroke setting to "50" percent and disconnect
the power source to the drive motor.
2. Relieve all pressure from the piping system.
3. Take all precautions described under "Caution" to prevent
environmental and personnel exposure to hazardous materials.
4. Close the inlet and outlet shutoff valves.
5. Disconnect piping to the reagent head and drain any
proces liquid, following material safety precautions described.
6. Place a pan underneath the pump head adapter to catch any
liquid leakage.
7. Remove all but one top reagent head blot. Product will
leak out between the pump head adapter and reagent head as the bolts
are loosened.
8. Tilt the head and pour out any liquids retained by the check
valves into a suitable container, continuing to follow safety precautions
as appropriate.
9 Remove the final bolt and rinse or clean the reagent head
with an appropraite material.
10. Remove the diaphragm by turning counter=clockwise and inspect the
diaphragm. the diaphragm must be replaced if it cracked,seperated, or
obviously damaged.
11. To install a diaphragm, first ensure that the critical sealing
areas of diaphragm,reeagent head, and pump head are clean and free of
debris. Then lubricate the elastomer side of the diaphragm liberally,
where it is in contact against the pump head and deflection plate with a
lubricant compatible to the fluid being pumped(sili-Olube).
Thread the diaphragm(clockwise)fully onto the shaft. When reinstalling
a used diaphragm it is not necessary to maintain the previous orientation
relative to the reagent head or pump head hole
pattern.
12. Install the reagent head bolts and tighten in an alternating
pattern to ensure an even seating force. Torque to the values
recommended in Appendix III.
13. Reprime the pump as per the procedure outlined under "Priming the
Reagent Head".
II. CHECK VALVES
A). General
Description
Most fluid metering problems are related to check
valves. Problems usually stem from solids accumulation between valve and
seat, corrosion of seating surfaces, erosion or physical due to wear or
the presence of foreign objects.
The valve incorporates a ball, guide and seat. Flow in the unchecked
direction lifts the ball off the seat, allowing liquid to pass through the
guide. Reverse flow forces the ball down, sealing it against the sharp
edge of the seat. The guide permits the ball to rotate but
restrictsvertical and lateral movement in order to minimize "slip" or
reverse flow. Ball rotation prolongs life by distributing wear over the
entire surface of the ball. Since ball return is by gravity, hte valve
must be in the vertical position in order to function properly. Parts are
sealed by "O"-rings.
B). Plastic
Constuction Removal, Inspection and Reinstallation
Note : Plastic construction valving is of the cartridge design and
is intended to be replaced as an assembly.
1. Disconnect the power source to the drive
motor.
2. Relieve all pressure from the piping system.
3. Take all precautions described under "Caution" to
prevent environmental and personnel exposure to hazardous materials.
4 Close the inlet and outlet shutoff
valves.
5. Disconnect the suction line at the installed union
and the suction port.
6. Loosen and remove the suction valve
cartridge slowly to drain any liquid from the reragent head
cavity.
7. Disconnect the discharge line at the installed
union and the discharge port.
8. Loosen and remove the discharge valve cartridge
slowly to drain any trapped liquid.
9. Reinstall both new valve
assemblies, taking care to ensure that thet are in the correct ports. It
is not necessary to coat the threads of the cartridge valve with a pipe.
Refer to Figure 15.
10. Reinstall both suction and discharge piping.
C). Metal
Construction Removal, Inspection and Reinstallation.
1. Disconnect the power source to the drive motor.
2. Relieve all pressure from the piping system.
3. Take all precautions described under "Caution" to
prevent environment and personnel exposure to hazardous materials.
4. Close the inlet and outlet chutoff valves.
5 Loosen the suction valves tiebar bolts and spring the
suction piping slightly to drain any liquid from the reagent head cavity.
If the piping is closely connected it may be necessary to disconnect &
union or flange.
6. Remove the suction check valve assembly (ball contained
within guide and seat), holding it together as a unit.
7. Loosen the tiebar bolts on the discharge valve and
spring the piping slightly to drain any liquid.
8. Remove the discharge check valve assembly, holding it
together as a unit as before.
9. Disaasemble both valves and examine components for
wear. Seats should have sharp edges or a small chamter, free from
dents and nicks. Hold the ball firmly against its mating seat in front of
a bright light to inspect for fit; observation of light between ball and
seat is cause for replacement of either or both componets.
10. Reassemble both valves using new
parts as required. Sealin "O"- rings should always be replaced.
11. Reinstall both valve assemblies, taking care to ensure that
they are correctly oriented with balls above seats and the seat with the
right angle knife edge up (chamferred edge down). Refer to Figure 16.
12. Tighten the tiebar bolts
evenly, making sure the valve assemblies are assembled squarely.
Refer to Appendix III for torque values.
Note:
For best results,always loosen the unions or flanges on either side of
the system piping prior to retightening of the check valve assemblies.
Retighten the Unions or flanges after the check valves are securely
tightened into position.
13. Check for leaks and retighten tiebar boltds as
necessary.
A). Removal and Replacement
1.
To replace the pump shaft seal, first remove the reagent head
assembly.Then remove the
diaphragm.Remove the pumpshaft by
unscrewing counter-clockwise.Take
care not to allow any shims to drop into the eccentric box when removing the
shaft.The shaft is located to the
crosshead assembly.Remove three
(3) socket head screws and seal retainer plate.Seal can now be removed. DO NOT reuse
damaged pump shaft or polish old one too smooth.A shaft too smooth will weep oil over
time when running.
2.
To replace the motor adapter seal, first remove the motor per “Motor
Removal and Reinstallation”.Loosen
the coupling set screw through the access plug hold in the motor adapter and
remove the worm coupling half.
Remove the four motor adapter bolts and withdraw the motor adapter from
the gearbox.Take care not to loose
the shims from between motor adapter and gearbox.Remove the oil seal from the motor
adapter.Lubricate the replacement
seal with gear oil and install by pressing into position.Reassemble by reversing the above
disassembly procedure.Refer to
Figure 19.
3.
To replace the gearbox oil seal, first drain the gearbox per
“Lubrication”.Remove the four
gearbox bolts and withdraw the gearbox from the eccentric box, sliding it off
the eccentric shaft.Remove the
seal.Lubricate the replacement
with Grease and install by pressing into position. Reinstall by reversing the
disassembly procedure.Refill the
grearbox with Grease per “Lubrication”.
4.
To replace the eccentric box seal, first remove the gearbox per step 3
above.Remove the four bolts which
retain the eccentric side cap to the eccentric box.Remove the eccentric side cap and
withdraw the eccentric shaft.Remove the seal.Lubricate
the replacement with Pulsalube 8G gear oil and install by pressing into
position.Reinstall by reversing
the disassembly procedure.Refill
the gearbox with Grease “Lubrication”.
IV. COVER ASSEMBLY
A). Removal and Reinstallation
Note:
The hand knob linkage employs a slip type coupling which can be reassembled in either of two
rotational orientations 180o apart from one another: therefore, the original
orientation must be retained for re-assembly so that pump calibration is
retained.
Removal
1. Adjust the stroke length until the dial indicator is set at the
zero stroke setting.Adjustment is easier with the drive motor running.Allow the locking mechanism to
engage to the nearest detent.
2. Disconnect the power source to the drive motor.
3. Remove the cover screws.
4. Using care not to rotate the adjustment shaft, remove the cover
vertically from the eccentric box.
Reinstallation
1. Rotate the stroke cam screw clockwise until the slider cam is in a
full upward position.
2.
Verify that the cover dial indicates the zero stroke setting.
3.
Using care not to disturb the adjustment shaft, install the cover
assembly, engaging the drive coupling.
4.
Replace the cover screws.
5.
Press the adjustment knob down and rotate it clockwise until it
stops.(Adjustment is easier with the drive
motor running.)Verify
that the cover dial indicates the zero stroke settings before: if so,
reinstallation is complete and if not, refer to step (6) below for
realignment.
6.
Loosen the screw in the center of the dial cover.
7.
Adjust the dial cover to align the pointer with the ‘zero’
mark.
8.
Retighten the screw in the center of the dial cover.
MOTOR
A). Removal and Reinstallation
1. Disconnect the power source to the drive motor.
2.
Disconnect the motor wiring from the motor.
3.
Remove the four bolts retaining the motor to the motor adapter and
remove the motor.
4.
The coupling is an interlocking jaw design and uses an elastomer
spider between the two coupling halves.One half of the coupling remains
on the worm shaft and the other coupling half on the motor shaft.Loosen the setscrew which retains
the coupling half to the motor shaft and remove the coupling half, taking
care to not loose the shaft key.
5.
Install the coupling half on the shaft of the replacement motor,
ensuring that the shaft key is in place.Align the end of the shaft flush
with the inner surface of the coupling and tighten the setscrew.
6.
Reinstall the motor by reversing steps (3) through (1) above.
Note: Motor rotation may be wired
for CW or CCW rotation.
VI. REPLACEMET
PARTS
(TROUBLESHOOTING CHART)
Difficulty
Probable Cause
Remedy
Pump does not start
1. Coupling disconnected
Connect coupling
2. Faulty power source
Check power source
3. Blown fuse, circuit breaker
Replace – eliminate overload
4. Broken wire
Locate and repair
5. Wired improperly
Check diagram
6. Pipe line blockage
Open valves
No Delivery
1. Motor not running
Check power source.Check wiring diagram
2. Supply tank empty
Fill tank
3. Lines clogged
Clean and flush
4. Closed line valves
Open valves
5. Ball check valves held open with solids
Clean – inspect
6. Vapor lock, cavitation
Increase suction pressure
7. Prime lost
Reprime, check for leak
8. Strainer clogged
Remove and clean.Replace screen if necessary
Low Delivery
1. Motor speed too low
Check voltages, frequency,wiring, and Terminal Check nameplate vs. specifications
2. Check valves worn or dirty
Clean, replace if damaged
3. Calibration system error
Evaluate and correct
4. Product viscosity too high
Lower viscosity by increasing product temperature.Increase pump and/or piping size
5. Product cavitating
increase suction pressure.Cool product as necessary.
Note: