M 109 0305

M/109/0305

Single Disc

Cast Iron Positive Displacement Mechanical Diaphragm Pumps Operating Manual

Operating ManualAlfa LavalBirch Road, Eastbourne,East Sussex BN23 6PQTel No : (01323) 412555 Fax (01323) 412515

EC DECLARATION OF CONFORMITY

We hereby declare that the following machinery conforms to the machinery directive 89/392/EEC as amended by 91/368/EEC, 93/44/EEC and 93/68/EEC and to the following otherrelevant directives. The machinery has been designed and manufactured in accordance withthe transposed harmonised European standards; European and national standards as listed:

Machine Description

Type/Size Serial Number

Other Applicable Directives

Applicable Standards/Specifications

A technical construction file for this machinery is retained at the above address.

Signed Date(Authorised Person)

Name Position

Single Disc Pump - Motorised

Electrical Equipment Low Voltage Directive 73/23/EEC

Electromagnetic Compatibility Directive 89/336/EEC

EN292 Parts 1 and 2 : 1991 Safety of Machinery - Basic concepts, general principles fordesign.

EN294 : 1992 Safety distances to prevent danger zones being reached by the upper limbs.

EN60204 Part 1 : 1993 Safety of Machinery - Electrical equipment of machines -specification for general requirements.

BS5304 : 1988 Code of Practice for Safety of Machinery.

ISO9001 : 2000 Quality Management System.

P.SWEET QUALITY MANAGER

Operating Manual

Contents1.0 General

1.1 Pump Limits Of Application Or Use1.2 Duty Conditions1.3 Noise Levels1.4 Utility Requirements1.5 Safety Precautions1.6 Health And Safety Information

2.0 Unpacking, Handling and Storage

2.1 Documents2.2 Unpacking2.3 Handling2.4 Pump Storage

3.0 Description of Pump or Pump Unit

3.1 General Pump Description3.2 Principle Of Operation3.3 Pump Dimensions And Weights3.4 Pump Displacement And Capacities

4.0 System Design and Installation

4.1 System Design Advice4.2 Pump And Base Foundations4.3 Installation4.4 Pipework4.5 Priming Pipework4.6 Priming4.7 Maintenance4.8 Self-cleansing Velocity4.9 Syphoning4.10 Re-priming4.11 Surge Arrestors

5.0 Start Up and Shut Down

5.1 Start Up Checklist5.2 Pump Shut Down Procedure5.3 Direction Of Rotation

Page No

111123

4445

6677

899

1011111111121212

131414

Operating Manual

Contents

7.0 Disassembly and Assembly

7.1 Before Dismantling the Pump7.2 Replacing the Diaphragm7.3 Replacing the Non-Return Valves7.4 Replacing the Connnecting Block Assembly

8.0 Faults, Causes and Remedies

9.0 Pump Drawing and Parts List

9.1 Torque Specification Chart

Page No

151515

16171718

19

20

20

6.0 Maintenance and Inspection

6.1 Maintenance Schedule6.2 Drive Unit Lubrication6.2 Recommended Spare Parts

Operating Manual

1.1 Pump Limits of Application or use

This range of pumps has been designed forpumping a variety of sludge applications andhas good tolerance of suspended solids andrag.

Pressures of up to 1.5 bar, speeds to 81rpmand temperatures to 70°C can be obtained onthis range of pumps depending on pump model/size. The model type/size will be shown on thenameplate positioned on the pump.

It is important that the pump user confirms thatthe materials of construction are compatiblewith the pumping application.

For specific guidelines contact your supplierquoting :- pump model/size, serial number andsystem details (e.g. product, pressure, flowrate).

Important :- The pump is not designed for usewith Agri foodstuffs or use underground.

1.2 Pump Duty Conditions

The pump should only be used for the duty forwhich it has been specified. The operatingpressure, speed and temperature limits havebeen selected at the time of order and MUSTNOT be exceeded for the pump. These detailsare stated on the original documentation and ifnot available may be obtained from your supplierquoting :- pump model and serial number.

1.3 Noise Levels

Depending upon the pumping system and dutycondition the pump noise levels may vary. Thesound pressure level measurement stated isgiven for typical pumps/pump units at maximumpressures/speeds. The results being taken onwater at ambient temperature:-

Recorded sound pressure level :- 85 dB(A):(Ref 20µPa).

Note :- Readings taken in accordance withISO3746.

1.4 Utility Requirements

Electrical Supply :-

This pump will require an electrical supply foroperation.

General

1

Operating Manual

All warnings in this manual are summarised onthis page.

Pay special attention to the instructions belowso that severe personal injury or damage to thepump can be avoided.

Personnel performing installation, operationand maintenance of the pump must have therelevant experience required.

Installation

Operation

Maintenance

: Always observe the technical data.

: The pump must be electrically connected by authorised personnel. (See the motorinstructions supplied with the drive unit).

: Never put your hands or fingers inside the port connections

1.5 Safety Requirements Warnings Signs:

General safety instructions arepreceded by this symbol.

Electrical safety instructions arepreceded by this symbol.

Take great care when using causticagents.


: Never touch the pump or the pipelines when pumping hot liquids.

: Never stand on the pump or pipelines.

: Never run the pump with both the suction side and the pressure side blocked.

: Always handle toxic and acidic liquids with great care.

: Never put your hands or fingers inside the port connections.


: Always disconnect the pump from the power supply when servicing the pump.

: The pump must never be hot when servicing it.

: The pump and pipelines must never be pressurised when servicing the pump.

: Never put your hands or fingers inside the port connections.

Study this manual carefully2

Operating Manual

Material Use Major Hazard

Oil and Grease Oil - Drive lubrication Skin and eye irritant.Grease - crank assembly

Elastomeric compounds Diaphragm and valve Releases fumes when heated.

Paint External pump surfaces. Releases dust and fumes ifmachined. Treat as a hazard.

General First Aid

If potentially hazardous substances areaccidentally inhaled, or skin or eyescontaminated, then the following basicprecautions should be taken

Inhalation - Remove to fresh air

Skin - Wash with soap and water

Eyes - Flush with water, seek medicalattention

In all cases, if symptoms persist, seek medicalattention.

1.6 Health and Safety Information

Potential Safety Hazards

The following section gives information onhandling, storage and disposal of parts andmaterials used in the pumps which may beconsidered hazardous to health.

Please pass this information on to your SafetyOfficer, he may need it to comply with Healthand Safety, and COSHH regulations.

Electric motors - the pumps have an electricmotor fitted, so ensure that the relevant fireequipment is available.

The information contained here is brief.

3

Operating Manual

2.0 Unpacking, Handling and Storage

To avoid any problems, on receipt of your pumpalways use the following procedure:-

2.1 Documents

1. Check the delivery note against the goodsreceived.

2. If the pump has been delivered with anelectric motor check that the motorinstructions are available.

2.2 Unpacking

Care must be taken when unpacking the pump,and the following stages must be completed:-

1. Inspect the packing for any possible signsof damage in transit.

2. Carefully remove the packing away fromthe pump.

3. Inspect the pump for any visible signs ofdamage.

4. Clean away the packing from the pumpport connections.

2.3 Handling

Refer to the pump weights guide, prior to usingany lifting gear. Use the correct lifting slings forthe pump weight.

The pump should be lifted by wrapping theslings around the ports as shown below.

Note : To stop the slings slipping always crossthe slings on the lifting hooks.

4

Operating Manual

2.4 Pump Storage

After receipt and inspection if the pump is not tobe installed immediately the pump should berepacked and placed in suitable storage. Thefollowing points should be noted:-

1. Plastic or gasket type port covers shouldbe left in place.

2. Pumps received wrapped with corrosioninhibiting treatment material should berewrapped.

3. A clean, dry storage free from vibrationlocation should be selected. When amoist dusty atmosphere must be used forstorage, further protect the pump or unitwith a moisture repellent cover until it is tobe installed.

4. All associated ancillary equipment shouldbe treated similarly.

5. Rotate the drive unit by hand every 3months.

5

Operating Manual

Upward stroke

Downward stroke

Suction

Discharge

GearedMotor

CrankAssembly

Spring

Non Return Valves

SuctionPort

DischargePort

Diaphragm

3.1 General Pump Unit

The pump supplied is a positive displacementsingle diaphragm pump, supplied with a driveunit (see below). The drawing below indicatesvarious parts of the pump.

3.2 Principle of Operation

The pump operates by rotation of the gearboxdrive shaft turning the crank assembly and thusproviding the reciprocating pumping action ofthe diaphragm, as shown below. On the upwardstroke the product is pulled through the suctionvalve into the pump body. The downwardstroke shuts the suction valve whilst at thesame time forcing the product out through thedischarge valve.

3.0 Description of Pump or Pump Unit

6

Operating Manual

3.4 Pump Displacement and Capacities

NOTE : Suction and discharge connections finished :-3" (80mm) BS4504 (DIN2533) or BS1560 ASA/ANSI 150

Weights - 2.2kw/46rpm = 200kg4.0kw/81rpm = 209kg

Maximumspeed(rpm)

81

Displacementlitres/rev

4.9

Maximum stroke(mm)

70

Maximum capacityat maximum speed

m³/hr

22

The following table details the maximum pumpcapacity and displacement for the pump. Thefigures given below are for 1.5 bar dischargepressure and will vary depending upon thepump speed, crank stroke, pressure, viscosityand suction lift.

3.3 Pump Dimensions and Weights

165

200240390

Suction Discharge

1096-46 RPM/2.2 KW1102-81 RPM/4.0 KW

1017

375

685

165245

291.5 4 holes 12 diameter

7

Operating Manual

4.1 System Design Advice

When designing the pumping system :-

Do - confirm that the pumping systemhas not altered since the pump wasordered.

Do - avoid high suction lifts and manifold/common suction lines for two pumpsrunning in parallel, as this may causevibration.

Do - protect the pump against blockagefrom hard solid objects e.g. nuts,bolts etc. Also protect the pumpfrom accidental operation against aclosed valve by using one of thefollowing methods :- relief valves,pressure switch, current monitoringdevice.

Suction linePlan view

Discharge line

4.0 System Design and Information

Do - fit suction and discharge pressuregauges to monitor pressures fordiagnostic purposes.

Do - install non-return valve to preventsyphoning when high pressures areapplied to the pump whilst it is not inuse. Valves are also recommendedif two pumps are to be used onmanifold/common discharge lines.

Note: It may be necessary to fit apulsation damper in this situation.

Do - provide a hose cleaning facility toassist maintenance, ensuring thedrive unit meets the specification forhose cleaning.

Do not- use the pump on high suction orhigh discharge static heads.

8

Operating Manual

securing the pump unit a foundation is required,this will also absorb vibration, strain or shock onthe pumping unit.

Foundation Size

The foundation should be approximately 150mmlonger and wider than the mounting base of theunit. The depth of the foundation should beapproximately 150mm.

Bolt Location Dimensions

The location and sizes of the relevant boltingdown holes can be provided on a certifieddrawing from your supplier.

Typical Foundation Bolts

The drawing below shows two methods forfoundation bolt retaining. The sleeve allows for'slight' lateral movement of the bolts after thefoundation is poured. Use rag or paper toprevent the concrete from entering the sleevewhile the foundation is poured. A minimum of14 days is required to allow the curing of theconcrete prior to operation.

D = Diameter of foundation bolts

4.2 Pump and Base Foundations

To provide a permanent, rigid support for

4.3 Installation

Before the pump is installed it is advisable toconsider the following:

Always - Ensure that the mountingsurface is flat and always allowat least one metre for pumpaccess/maintenance allaround the pump.

Weight - Consider the weight of thepump and drive for lifting gearrequirements.

- Ensure that there is anadequate electrical supplyclose to the pump drive unit.This should be compatible withthe electric motor selected.

½ D

1D

ElectricalSupply

9

Operating Manual

All pipework must be supported. The pumpmust not be allowed to support any of thepipework weight.

Remember - Pipework supports must alsosupport the weight of theproduct being pumped.

Always :-

Have - Short straight suction lines toreduce friction losses in thepipework thereby improvingthe NPSH available.

Avoid - Bends, tees and any restraintsclose to either suction ordischarge side of pump. Uselong radius bends whereverpossible.

Provide - Isolating valves on each sideof the pump to isolate the pumpwhen necessary.

Fit - where possible, a pipe of adiameter which maintains a selfcleaning velocity.

Keep - Pipework horizontal whereapplicable to reduce air locks.If required include eccentricreducers on suction lines.

Retain - Liquid in the pump at all times.See below for pipeworkarrangement.

4.4 Pipework

10

Operating Manual

4.5

4.6

Suction Lift Application

Note: Always use long radius bends.

Self cleansing velocity

In situations where the pump is to bepumping down long discharge lines and isdesigned with rest periods of sufficienttime to allow solids to settle, we wouldrecommend that the lines be flushedthrough with clean water. This water shouldbe pumped through the system at a selfcleansing velocity to ensure that no solidmatter is left in the lines.

Priming Pipework

If this pump type is to be installed on anapplication where it is to perform a suctionlift, we would recommend that primingpipework be fitted to the pump in-order tocreate a fluid trap around it, as shown inthe diagram below.

Priming

On initial installation or after pumpmaintenance, the pumps will requirepriming.

Maintenance

Consideration should be given whendesigning the installation that sufficientspace is available for maintenance.

4.7

4.8

11

Operating Manual

Syphon Break Application

Note: Always use long radius bends

Syphoning

On installations where the top water levelin the suction tank is above the dischargeinvert level there is a theoretical chanceof the pumps syphoning this is particularlyso on thin watery sludge’s. Provisionshould be made on these types ofinstallations to counter this effect by wayof a siphon break or a motorised valvewhich comes in to operation when thepump stops.

Re-priming

On installations were the pump is seeinga positive discharge head and has to bestriped/removed for maintenance,difficulty may be experienced in re-primingthe pump. For this type of installation wewould recommend that either thedischarge line be emptied or a backpressure relief system be employed. Thiscould be done by teeing into the dischargeline local to the pump and returning itback to the suction tank.

Surge arrestorsSurge arrestors should be fitted to anypump working with either a high dischargehead and long delivery pipework or longsuction lifts. This is due to surge hammerwhich is the main cause of mechanicalfailure within the pump. There is also asignificant improvement in sound powerreadings if surge arrestors are fitted.

4.9

4.10

4.11

Float switch

When considering the installation of asingle disc pump caution should beexpressed over a suction condition whichis flooded. This is due to a potential leakpassage to atmosphere if the pumpdiaphragm fails. In such an installation it isimportant that a protection devise such asour diaphragm float switch be employedto either send an alarm or isolate thepump automatically if this situation shouldarise.

12

Operating Manual

If there are any pumping problems refer to the fault finding chart.

All answers should be 'yes' before proceeding.

YES NO5.0 Start Up and Shut Down5.1 Pump Start-Up Check List

1. Is the location of the 'stop' button clear?

2. Has the pipework system been flushedthrough to purge welding slag and anyother hard solids?

3. Have all obstructions been removedfrom the pipework or pump?

4. Are the pump connections and pipeworkjoints tight and leak-free?

5. Is there lubrication in the drive unit?

6. To assist priming has the pump beenfilled with water via the plug on the suctionside of the pump?

7. Are the pipework valves open?

8. Are all safety guards in place?

9. Are the pump speed/pressure settingsbelow the pump maximum limitations?

13

Operating Manual

Discharge Port

Suction Port

Flow direction arrowcast on this side ofpump body

5.2 Pump Shut Down Procedure

1. Turn the pump off.

2. Isolate the pump/drive unit from all powerand control supplies.

3. Close the pipework valves to isolate thepump.

4. If the pump is to be dismantled refer to thedismantling section.

5.3 Direction of Rotation

The direction of flow is dictated by the directionof the arrow cast into the pump body. Thepump only has one direction of flow (seebelow).

14

Operating Manual

6.0 Maintenance and Inspection

6.1 Maintenance Schedule

It is advisable to install pressure gauges oneither side of the pump so that any problemswithin the pump/pipework will be highlighted.

Your monthly schedule should include:

Checking the oil level in the drive unit.

Greasing the crank bearing via thegrease nipple. (Use Mobilplex 48 greaseor equivalent).

6.2 Drive Unit Lubrication

The drive unit lubrication capacity is 2.0 litres.The following is a list of recommended oilgrades for the drive unit :-

6.3 Recommended Spare Parts

The following table details the recommendedspare parts which should be retained withinyour maintenance stock.

Part Description

DiaphragmNon Return ValveSealing Washers

Quantity

123

Make Grade

Castrol Alpha SP220Shell Omala 220Esso Spartan EP220

Texaco Meropa 220Mobil Mobilgear 630/Mobilube GX90

Duckham Fleetoid 90/Hypoid 90BP BP energol/GRXP220

Gulf EP HD220

15

Operating Manual

Before starting to dismantle the pumpAlways:-

Purge -

the pump and system if any noxious/potentially explosive products have beenpumped, and ensure the area is well ventilated.

Isolate -

pump/drive unit from all power and control supplies.

Close -

pipework valves to isolate the pump

Read this section firstbefore continuing to dismantle the pump.

7.0 Disassembly And Assembly

7.1 Before Dismantling the Pump

16

Operating Manual

Diaphragm to be fitted with theoutside rim downwards

1. Remove the guard.

2. Remove the drive unit and support bracketbolts from the drive supports.

3. Release the socket set screw from thedrive shaft crank assembly, and withdrawthe crank/drive unit from the conrod.

4. Use lifting gear to remove the drive unit.

5. Carefully loosen the top housing retainingbolts and remove the top housing,ensuring the spacers are not misplaced.

6. Release the plunger retainer screws andplunger retainer.

7. Inspect and replace the diaphragm ifnecessary. Always replace the threesealing washers prior to reassembly.

8. Reassemble the pump in reverse order.

OutletAdaptor

Notch

Notch on Non-ReturnValve

PumpBody

7.2 Replacing The Diaphragm 7.3 Replacing The Non Return Valves

Both Non-Return Valves Are Identical.

Suction (inlet) Side

The suction side is denoted by the large arrowcast into the pump body. Access to the valveis achieved by releasing and removing the nutsand bolts which retain the inlet adaptor.

Discharge (outlet) Side

The larger oval shape of the outlet adaptorhouses the valve which is removed by releasingthe nuts and bolts which retain the adaptor andbracket.

Refitting the Non Return Valves

Before refitting always inspect the valves forsigns of wear. A notch is provided on both thepump body and the outlet adaptor which mustbe used to line up with the mating notch on thenon-return valve.

17

Operating Manual

1. Remove the guard.

2. Remove the drive unit and supportbracket bolts from the drive supports.

3. Release the socket set screw from thedrive shaft crank assembly and withdrawthe crank/drive unit from the con rod.

4. Use lifting gear to remove the drive unit.

5. Carefully loosen the top housing retain-ing bolts and remove the top housing,ensuring the spacers are not misplaced.

6. Release the plunger retaining screwsand plunger retainer (always replacethree sealing washers prior to re-assem-bly).

7. Release diaphragm.

8. Remove con rod cap head.

9. Spring, plunger will now be loose. Re-place if required.

10. Re - assemble in reverse order ensuringcrank con rod nut is torqued to 150Nmand setting length for con rod spring iscorrect. NOTE : Setting length dimen-sion is irrespective of crank size.See Fig 1.

7.4 Replacing Connnecting Block Assembly

Figure 1.

Torque to150 Nm

Note: Use Permabond A130 or equivalent onall screws shown.

mm

18

Operating Manual

8.0 Faults, Causes and Remedies1.

Cur

e al

l air

leak

s2.

Cle

an s

eatin

g an

d ch

eck

3. C

lean

stra

iner

4. L

ower

pum

p or

rais

e liq

uid

leve

l5.

Che

ck a

nd re

plac

e di

aphr

agm

6. C

lean

out

suc

tion

hous

ing

7. E

nsur

e pu

mp

has

liqui

d in

dis

char

ge p

ipew

ork

8. C

lean

out

suc

tion

pipe

9. D

eslu

dge

man

ually

or r

ecirc

ulat

e un

til th

inne

r

1. R

educ

e pr

essu

re o

r inc

reas

e sp

eed

to c

ompe

nsat

e2.

Low

er p

ump

or ra

ise

liqui

d le

vel

3. C

lean

out

pum

p an

d su

ctio

n pi

pe4.

Ren

ovat

e as

nec

essa

ry5.

Incr

ease

pum

p sp

eed

1. F

it la

rger

mot

or o

r red

uce

dist

ance

pum

ped

2. R

educ

e to

tal h

ead

3. O

pen

valv

e4.

Cle

an o

ut p

ump

and

suct

ion

pipe

1. R

educ

e to

tal h

ead

2. C

lean

line

s3.

Red

uce

visc

osity

or u

se a

ltern

ativ

e pu

mp

4. C

lean

out

suc

tion

line

5. R

enov

ate

as n

eces

sary

6. S

uppo

rt pi

pew

ork

at c

lose

r int

erva

ls7.

Fit

dam

pers

8. R

educ

e pu

mp

spee

d

1. C

heck

and

rect

ify a

lignm

ent

2. F

lush

pip

elin

es

1. R

educ

e to

tal d

eliv

ery

head

2. U

se o

ptio

nal d

isc

mat

eria

l3.

Red

uce

prod

uct t

empe

ratu

re

SYM

PTO

MPO

SSIB

LE C

AU

SER

EMED

IES

NO

PR

IME

OR

SLO

W P

RIM

E

EXC

ESSI

VE V

IBR

ATI

ON

PUM

P TA

KES

EXC

ESSI

VEPR

ESSU

RE

NO

T EN

OU

GH

LIQ

UID

DEL

IVER

ED

POO

R D

RIV

E LI

FE

POO

R D

ISC

LIF

E

SYPH

ON

ING

1. S

uctio

n lin

e no

t air

tight

2. V

alve

(if f

itted

) not

sea

ting

3. S

train

er c

logg

ed4.

Suc

tion

lift t

oo h

igh

5. D

iaph

ragm

wor

n or

dam

aged

6. D

iaph

ragm

not

sea

ting

prop

erly

due

to s

olid

s ac

cum

ulat

ion

7. O

n su

ctio

n lif

ts n

eeds

liqu

id h

ead

reta

ined

in d

isch

arge

pip

ewor

k8.

Blo

cked

suc

tion

pipe

9. S

ludg

e de

nsity

too

high

1. D

iffer

entia

l pre

ssur

e to

o hi

gh2.

Exc

essi

ve s

uctio

n lis

t3.

Pum

p bl

ocke

d/or

pip

e bl

ocke

d4.

Pum

p w

ear

5. P

ump

spee

d/cr

ank

stro

ke to

o lo

w

1. L

iqui

d to

o th

ick

or s

peci

fic g

ravi

ty g

reat

er th

an in

pla

nned

dut

y2.

Tot

al h

ead

too

high

3. C

lose

d di

scha

rge

valv

e4.

Cho

cked

pum

p or

pip

elin

e

1. H

ead

too

high

2. P

ump

or p

ipel

ine

bloc

ked

3. L

iqui

d to

o th

ick

4. C

avita

tion

due

to b

lock

ed s

uctio

n5.

Pum

p da

mag

ed6.

Inad

equa

tely

sup

porte

d rig

id p

ipew

ork

7. P

ulsa

tion

dam

pers

requ

ired

8. F

low

rate

ove

r spe

cific

atio

n

1. M

isal

ignm

ent b

etw

een

driv

e an

d cr

ank

asse

mbl

y2.

Blo

cked

pip

ewor

k

1. H

ead

pers

iste

ntly

too

high

2. M

ediu

m a

ttack

ing

disc

mat

eria

l3.

Liq

uid

tem

pera

ture

too

high

1. N

o fo

rwar

d ba

rrier

to fl

ow1.

Ens

ure

disc

harg

e pi

pew

ork

high

er th

en s

uctio

n ta

nk,

s

ypho

n br

eak

may

be

requ

ired

19

Operating Manual

2

3

4

5

6

7

98

10

11

12

1314

15

1

ITEM

1234567

DESCRIPTION

Inlet AdaptorDiaphragmSpringTop HousingConnnecting Block ScrewGuardConnecting Block

ITEM

89

101112131415

DESCRIPTION

Crank AssemblyDrive UnitOutlet AdaptorNon Return ValvePump BodyPlungerRetainer SpacersRetainer

TORQUENm lbft

15 10

56 41

15 10

56 41

98 72

DESCRIPTION

Inlet Adaptor Nuts

Outlet Adaptor Nuts

Plunger Retainer Screw

Top Housing Nuts

Drive Unit/Support Nuts

SPANNER/KEYSIZE

17

17

10

19

19

9.1 Torque Specification Chart

9.0 Pump Drawing And Parts List

20