DATE OF
INSTALLATION...........................................................
VERY
IMPORTANT
WHEN
PUMPING CHEMICALS
Please ensure all tubings/pipings are securely attached to fitting. Tubing and pipings are properly shielded.
Protective face and body coverings are used. Observe all safety rules.
I. UNPACKING
Parts Supplied loose:
a). Foot Valve with Strainer.
b). PVC/PP Tubing.
c). Injection/Antisyphon Valve.
II. LOCATION
Pumps should be located whwre injection and electrical points are convenient. Though pumps have corrosion resistance housings, continous exposure to high temprature should be avoided.(Over 50*C).
III. MOUNTING
A back pressure of 10-15 psig is required for all electronically driven pumps to avoid over pumping. If this is not available at the injection point, a back pressure valve/antisyphon valve should be provided.
IV. TYPICAL INSTALLATION
V. ELECTRICAL
Pumps should be connected to a 3 prong, grounded, electrical outlet, Neutral and Earth connections should be provided. DO NOT USE EARTH FOR NEUTRAL.
VI. TUBING CONNECTIONS
A). SUCTION i). Cut tubing to required length, considering the foot valve size.Maximum lift is 1.5 mt.
ii). Foot valve should always remain vertical.
iii). Remove coupling nut from top of foot valve and threadle tubing through small
opening of coupling nut. Push tubing into tapered end of foot valve till the
tube end meets the face. Bring coupling nut to threaded portion of foot valve
and tighten by hand. DO NOT USE PIPE WRENCH.
iv). Follow above (iii) procedure for connecting the other end of tubing to pump
suction.
B). DISCHARGE i). Cut tubing to required
length upto injection point.
ii). Follow same procedure for pump discharges
connection as VI-A (iii).
iii). At injection point a 1/2" socket, with sufficient depth, should be fitted. This
fitting should be so installed so that when the injection check valve is fitted
it will remain vertical. Now fit the injection check valve and connect the
tubing. DO NOT USE EXCESSIVE FORCE OR PIPE WRENCH FOR TIGHTENING
FITTINGS.
VII. PRIMING
A). WITHOUT FOUR FUNCTION VALVE i). Remove tubing from injection valve and hold it above the pump level.
ii). Start pump on 100% stroke length and 100% speed, and as soon as liquid is
visible in the discharge tube, stop pump, it is now primed, reconnect tubing to
injection valve and run pump. Set your required dosage rate.
B). WITH FOUR FUNCTION VALVE i). Start pump on 100% settings and pull Air Relief knob (Red or Black) till liquid
is visible in the discharge tube. The pump is primed.
ii). Ensure the pressure relief tube is fitted to bypass relief port and routed back
to suction tank.
iii). Air bubbles in discharge tubing can be ignored, as this will disappear in a
short while, for air bubbles in suction tubing refer trouble shooting chart at
the end of this manual.
iv). Pump is usually self priming, if pump does not prime still, remove discharge
tubing from discharge end of pump head, remove discharge valve/FFV, remove ball
and pour water/ chemical slowly into the exposed port, until head is filled,
replace ball, discharge valve/FFV, tubing and follow priming
instructions.
VIII. CALIBRATION
i). Pump speed control is the smaller knob and pump stroke length control is the
larger knob. Pump is normally tested in water and the capacity of the pump
varies in direct proportion to the knob settings and pressure.
ii). To calculate the approximate output, using the knobs, multiply decimal point of
speed setting by decimal point of stroke length setting by capacity of
pump.
For example: if speed setting is 80% and stroke setting is 40%
and pump model is for 6 LPH:
0.8 0.4 x 6 = 1.92 lph.
iii). Since pump is calibrated with water as test medium, site conditions may differ
due to injection pressure, liquid, viscosity, etc. it may be required to
recalibrate the pump under actual site requirements. To do this, place the
suction tube with foot valve and strainer in a graduated container and connect
the discharge tube with the back pressure valve/ anti syphon valve into the
injection point.
Fill graduated container with liquid to be
pumped and measure the discharge quantity in the time unit chosen.
TROUBLE SHOOTING
PROBLEM
CAUSES
REMEDIES
1. Air bubbles in Suction
1. Liquid container empty
1. Fill liquid container.
2. Strainer Chocked.
2. Remove suction tube and clean
strainer.
3. Suction Tube Damaged.
3. Check for pin holes and replace,if
required.
4. Suction side coupling nut
loose.
4. Check and retighten coupling
nut.
5. Head loose.
5. Check for damage or retighten head.
6. Suction lift too high.
6. Max. suction lift 1.5 mts.Check
and reduce.
2. High pump Output
1. Knobs set to higher output.
1. Reset knobs,
recalibrate pump, if required.
2. Syphoning taking place.
2. Check back pressure valve/
antisyphon
valve.
3. Incorrect Knob settings.
3. Remove stroke control
Knob, turn shaft anticlockwise till pump stops pumping, refit Knob on zero and
tighten.
3. Low Pump Output.
1. Trapped air.
1. Follow Problem 1
remedies.
2. Damaged Ring Seals.
2. Remove suction and
discharge valve and replace ring
seals.
3. Incorrect knob
settings.
3. Follow Problem 2, Cause
3
Remedies.
4. Ruptured Diaphragm*.
4. Check and
replace.
5. Clogged injection
point.
5. Remove injection check
valve and check.
6. Low Voltage.
6. Voltage Correct to 240
V.
*To change Diaphragm:-
Remove suction tube from container and dip into neutralizing agent, remove
discharge tube and put into the same container, the discharge tube should be
remove from injection point, now run the pump for the proper length of time to
ensure than the original chemical has been neutralized. Wear proper protective
clothing and face mask, follow all safety rules.
Remove. suction tube from neutralizing agent, leaving the
discharge tube, and pump till the neutralizing agent is removed. stop pump.
Remove head by unscrewing the four screws, the diaphragm is exposed. Unscrew
the LHmaged diaphragm, by turning anti-clockwise, and screw in the new
diaphragm, while the pump is running, till the diaphragm starts to buckle at the
centre. Stop the pump, and with a straight edge check the centre of the
diaphragm and the edges of the spacer are flush. Adjust as required, replace
head, tighten screws and reconnect the tubings.
4. Pilot lamp blinks but pump does not give output.
1. Solenoid coil jammed.
1. Remove spacer and
dismantle solenoid coil, using emery paper clean shaft and bush of coil,
apply a thin film
of oil/grease and reassemble.
2. Overheated coil.
2. Due to excessive heat in
coil the thermostat will disconnect electricity to coil.Switch off pump,
let coil cool,meanwhile check reasons for heating, follow Problem 3 cause
5 remedy and also Problem 4 cause 1
remedy.
3. Connections loose/broken.
3. Cehck coil writing &
repair/replace.
5. Pilot lamp stays off.
1. Blown Fuse.
1. Check and replace
fuse,if fuse blows again,coil defective, change coil. If after replacing fuse pilot light
still stays off check switch and potentio meter, if switch is okay,then
potentio meter is at
zero. Correct the settings.
2. After following 1 above
the pilot lamp is still off.
2. Check line voltage, if okay
and coil is working, pilot lamp is defective,
change.
6. Pilot lamp stays on.
1. Coil defective.
1. Disconnect power
supply and remove coil connections, check resistance across coil it should read
240-300 ohms, if not,
coil is defective, replace.
2. Pulsar defective.
2.
If coil resistance is okay, pulsar is defective,
replace.
7. Pump Pulsates faster/slower than 95-100 spm.
I. Fast Pulsation:- 1. Defective Pulsar.
1. Replace.
II. Slow Pulsation:- 2. Wiring/Potentio
meter/Switch defective.
2. Check all connections, if found okay, check
potentio meter and switch. Pot. meter should read 0 & 1 mega-ohm at
zero and 100% settings.Switch also should read zero and infinity in OFF
and ON positions. Replace if necessary. If found okay then pulsar is
defective, replace.
DRIVE ASSEMBLY
EA-11/12/13
SPARE PARTS LIST(DRIVE ASSEMBLY) - EA - 11/12/13
KEY NO.
PART NO.
DESCRIPTION
QTY./PUMP
1
EA-01-DA
Oil Seal(Diaphragm
Shaft)
1
2
EA-02-DA
Alien Head
Screws(Head)
4
3
EA-03-DA
Spacer
1
4
EA-04-DA
Alien Head
Screws(Spacer)
8
5
EA-05-DA
Spring (Large)
1
6
EA-06-DA
Spring (Small)
1
7
EA-07-DA
Spring Retention
1
8
EA-08-DA
Washer (Diaphragm
Shaft)
1
9
EA-09-DA
Diaphragm Shaft
1
10
EA-10-DA
Hex Bolt for coil
plate
2
11
EA-11-DA
Spring Washer for Hex
Bolt
2
12
EA-12-DA
Solonoid Coil plate
1
13
EA-13-DA
Circlip Washer for
Solonoid Coil
1
14
EA-14-DA
Solonoid Coil Body
1
15
EA-15-DA
Pump Body
1
16
EA-16-DA
Anti-Vibration pads
(Rubber)
2
17
EA-17-DA
Solonoid Coil
(Complete)
1
18
EA-18-DA
Pump Mounting Feet
2
CONTROL ASSEMBLY
EA-11/12/13
SPARE PARTS LIST(CONTROL ASSEMBLY) - EA - 11/12/13
KEY NO.
PART NO.
DESCRIPTION
QTY./PUMP
1
EA-01-CA
Shaft (Stroke Length
Control)
1
2
EA-02-CA
Electronic Pulser
Unit
1
3
EA-03-CA
Control Switch
1
4
EA-04-CA
Potentio
Meter
1
5
EA-05-CA
Neon Lamp
1
6
EA-06-CA
Speed Control Knob
1
7
EA-07-CA
Stroke length Control Knob
1
8
EA-08-CA
Control Panel
Board
1
9
EA-09-CA
Grommet
1
10
EA-10-CA
Fuse
Holder
1
11
EA-11-CA
O Ring (Stroke Length
Shaft)
1
12
EA-12-CA
Fuse
1
LIQUID HANDLING
SPARE PARTS LIST(LIQUID HANDLING SIDE) - EA - 11/12/13
VERSATILE CHEMICAL DOSING
SYSTEM
