ARRANGEMENT AND USE OF THE OPERATING INSTRUCTIONS :
Please first make sure that the number given below of this cover of
this instruction manual is the same as that given on the identification plate
of the Metering Pump.
You must be able to depend on your Metering Pump.For this reason, all personnel being
responsible for the Installation, Operation, Ordering of new parts and repair,
should be familiar and have access to these instructions.
If reconstructing or upgrading the Pump, you automatically receive from
us the documentation for the new assemblies.
By inserting the new documentations, your operating instructions are
brought upto date.
KEY INSTRUCTIONS :These pumps are designed, based on enquiry data furnished by the
clients.In case of changes, if any, of
the datas, please do not operate the pump without consulting us.
CROSS SECTIONAL DRAWINGS :This helps you to know the different parts and its
code number while ordering for spares.This shows the clear assembly of the internal parts and its fitments.
INSTALLATION OF THE PUMP : Needless to mention that the accuracy and
reliability of single acting reciprocating type controlled volume metering pump
depends upon proper installation.A
typical schematic diagram of metering pump is shown in figure TPA-PA-02.
MOST IMPORTANT NOTE REGARDING SPARES :Since this is the Taylor
Made M/C, it is very difficult to keep stock of Spares like PLUNGER, GLAND PACKINGS AND NON RETURN
VALVES.The delivery time of such
spares are at least 4 weeks.Therefore,
we request you to order important such spares along with the pump itself.`
CAUTION !ALWAYS CHECK THE DIRECTION
OF ROTATION BEFORE COUPLING/STARTING THE MOTOR.
OPERATING PRINCIPLE AND MECHANISM :-
OPERATING PRINCIPLE
The rotation of the motor is reduced by worm and worm wheel and then
changed to a reciprocation by an eccentric unit (worm shaft, eccentric and
spring etc.)
This reciprocation is transmitted to a diaphragm by the eccentric which
is connected to the diaphragm directly, hereby operating the pump owing to the
change the volume of diaphragm chamber with the movement of check ball in pump
head.
STROKE CONTROL UNIT
The stroke length is adjusted by the control of eccentric amount of
eccentric with the adjusting dial.
PLACE OF INSTALLATION
The
pump should be installed as near to a suction tank as possible and should be
easily accessible for inspection and maintenance.
It is recommended that the pump be placed lower
than the suction liquid level.
Take
sufficient space around the pump so as to facilitate maintenance and
check.In order to ensure safety during
disasters such as floods, an emergency plan should be established for the motor
and power distribution unit.
For
foundation of pump, the surface should not be tiled.
Prepare
a concrete foundation or a rigid base plate suitable to support the weight of
the pump.
PIPING:-
The
piping should be done under the best condition of the suction and discharge.
The
best piping arrangement for minimum loss is based on straight runs with as few
bends and fitting as possible.And do
not make such a room in the pipe to collect air.All piping should be supported independently so that unnecessary weight
and vibration are not transmitted directly to the pump.Flexible piping is recommended to avoid
damaging the plastic pump head especially.
When
feeding a high or low temperature liquid, be care to prevent the pump from
suffering thermal stress.
When
feeding a viscous liquid, poisonous liquid or coagulative liquid, provide a
washing pipe line for maintenance and inspection.
When
selecting a piping material, check thoroughly its corrosion resistance to the
liquid to be treated and the pressure to be applied to the pipe.
When
using the adhesive for PVC piping, please do not allow to soak the adhesive
into the pump.
Before
the pipe distribution, wash thoroughly the inside of the pipe and remove the
protective cover fitted to the discharge port and suction port of pump.
The
reciprocating pump should be provided with a safety valve.Be sure to fit a safety valve to the
discharge pipe near the pump.
When
a diluted liquid is used, the liquid is frozen in the pump head and the pipe in
winter, sometimes breaking the pump.So, please provide a drain valve at the suction/discharge pipe.And wash inside of pump with water for the
interval operation.
SUCTION PIPING WORK:-
Be
sure to fit the suction pipe according to the forced feed method.The diameter of the suction pipe should be
larger than or same with that of the pump suction diameter.
Carefully
fit the joint of the suction pipe in such a manner that no air is sucked in
it.If air flows into the suction pipe,
the pumping capacity will not be stabilized.
SUCTION PIPING WORK:-
Provide
a safety valve near the discharge pipe of the pump.And do not install any other valves between the pump and the
safety valve.
Use
a discharge pipe whose withstanding pressure is higher than the pressure
setting of the safety valve.Also,
carefully fit the joint of the discharge pipe.
PLACE OF INSTALLATION:-
Make
sure of voltage, number of poles, and power supply of the motor before wiring,
and make correct wiring.Always do not
failing grounding.
The
arrow mark indicates the rotating direction on the upper portion of the
coupling (motor) cover.Make the wiring
of the motor so as to rotate in the direction indicated by the arrow mark.The motor should be rotated clockwise when
viewed from the motor fan cover side.
For
wiring, use a wiring tool of good quality and take sufficient care of safety in
accordance with the technical standards and the indoor wiring regulation of the
electric installation.
Firmly
install the electromagnetic switch and thermo relay meeting the specifications
of pump motor (voltage, capacity, etc.)
SUCTION PIPING WORK..
PREPARATION:-
Check
every parts of the pump for defects, loosened bolts, oil leakage, etc....
Check the each parts for operating and transferring
liquid and power condition. etc...
HOW TO ADJUST THE STROKE LENGTH:
The stroke length is adjusted by the control of eccentric amount of slider with the adjusting dial. Please adjust the dial while the pump is running.
Check
every parts of the pump for defects, loosened bolts, oil leakage, etc....
Check the each parts for operating and transferring
liquid and power condition. etc...
OPERATION:-
When running the pump for the first item after installation, follow the
procedures below.
Open
the valve of the suction and discharge pipe.Do not operated the pump with the valves closed.
Turn on the power switch of the motor and the motor should be
rotated clockwise when viewed from the motor fan cover side.
Set the stroke length at 0%.
Purge
the internal air of the pump be supplying a liquid into the pump,opening
the air vent valve of the discharge pipe or by gradually increasing the stroke
length in such a manner that no pressure is applied to the discharge side.
Set
the stroke length at 100% and run the pump for a warm-up period of 30 to 60
minutes.
CHECKING THE DISCHARGE VOLUME:
If no abnormality is found in the pump, check the discharge volume
under the actual running conditions, using a gauge such as measuring cylinder
etc...
When
no remarkable variation in the discharge volume is found as the result of
repeated measurements and the discharge volume keeps diagrammatical linearity
as against the stroke length, the pump is judged to be normally running.
Make
a diagram of relationship between the discharge volume and stroke length under
the actual running conditions an determine an optimum discharge volume in
accordance with this diagram.
When
the discharge volume is increased or decreased by changing the stroke length,
measure the discharge volume after about a minute.
When
the pump test data is requested by the order, we submit our in-plant test
data.The pump test data are the test
results obtained by using clear water of normal temperature. so, note that
these are not obtained from an actual piping and actual liquid.
When staring to run the pump after it is stopped for a
short period of time (within a week), it can be started at a desired stroke
length and a prescribed discharge pressure.
However,
when starting to run again the pump after stropped for a long period of time
(over a week), be sure to set the stroke length at 0% and continue no-load
running for a few minutes until the pump drive unit is thoroughly lubricated.
PRECAUTIONS :
Be
sure to open both valves of discharge side pipe and suction side pipe before
starting to run the pump.
Be
sure to provide the pipe on the discharge side with a safety valve.
MAINTAINANCE AND INSPECTION DAILY INSPECTION
Check
that the pump runs smoothly.
Check
that the discharge volume and discharge pressure are not changed.
Check
for no leakage in the liquid end.
Check
the reduction gear and inside of gear box for oil shortage, leakage and dirt.
Check
that the amperage of the motor is normal.
If
spare pump is provided, run it from time to time.Also, keep up it well condition for running at any time.
REGULAR INSPECTION
Inspection
of discharge valve and suction valve inspect them every 6 months.ad if an abnormal flow or wear is found at
the time of inspection, replace the value with a new one.
Inspection of Diaphragm
The diaphragm is
an wearing part.It’s service life
varies according to the running condition of the pump.Inspect it every 1-2 months and if any
deterioration is found at this time, replace it with a new one.
Changing oil in the drive unit
Oil change intervals.Change oil of the drive unit, every 12
months. However, when emulsification or deterioration of the oil is found,
immediately change the oil.
How to change oil in the drive unit.
First,
remove the oil cap and drain plug, and drain the used oil.Next, clean the inside with flushing
oil.Then, supply new oil up to the
specified level of the oil gauge.
DISASSEMBLY OF VALVE UNIT.
First,
remove the pipes on the suction and discharge connecting parts.(flange or etc...)
After
remove the suction and discharge joint, and take out the valve parts (check
ball, ball guide, ball seat etc..)At
this time, if an abnormal flow or weared parts are found on the suction or
discharge valve parts, replace it with a new one.Use care to prevent accidents, as the internal liquid remaining
in the pump chamber and valve parts flow to the outside when the pump is
disassembled.
REASSEMBLY OF VALVE UNIT.
For
the reassembling of valve unit, please reverse the procedure.
Assemble
the valve unit by reversing the procedure, taking special care with the
direction and position of the ball guide.
Fit
the pipes on the suction side and discharge side.
DISASSEMBLY OF DIAPHRAGM.
Remove
the suction and discharge pipes.
Loosen
the pump head setting bolt.Set
stroke length 0% and turn off when the diaphragm comes to the top dead
point.And turn the diaphragm
counterclockwise, then the diaphragm can be simply removed.Replace to a new diaphragm, if any worn or
deformed part is founded.
REASSEMBLY OF DIAPHRAGM.
Fix
the new diaphragm firmly to the slider shaft by turning it clockwise.
Set stroke length to 100% of bottom dead point,
before reassembly the diaphragm.In this case, connect power supply and run
the motor temporarily by on-off until the diaphragm will be located to the
bottom dead point.
Fit
the pump head to the gear box flange with the bolts, if any.
Fit the pipe on the suction side and discharge side by reversing the procedure.
WHEN A FLEXIBLE HOSE IS USED.
Insert the hose into the hose adapter and firmly tighten the union nuts.
