IMPORTANT: Please read this manual carefully before installation or service work is carried out.

Transcription

1 OPERATING MANUAL INSTALLATION AND SERVICE INSTRUCTIONS IMPORTANT: Please read this manual carefully before installation or service work is carried out. AIR OPERATED PUMPS for mineral oil based fluids. Pressure ratio 5 : 1 Air inlet Model Dimension in Inch Pump tube Total Weight in lbs. 1730A 9 1/16" 19 7/8" 6.2 Max. air pressure: Min. air pressure: Max. fluid pressure: Burst pressure: Free delivery 1) US G Air inlet adapter Fluid outlet adapter Fluid inlet 1730A: Drum adapter with 2" Noice level at 100 psi 145 psi 28.5 psi 725 psi Min psi approx G/min G/hour 1/4" NPS (f) 3/4" NPS (f) 1" NPS (f) Adapter is included with the pump 84 db(a) Fluid outlet Fluid inlet 1) Motor oil SAE at 68 degrees F and max. air pressure. WARNING! Do not exceed the stated maximum working pressure of the air motor or the lowest rated component in your system. Do not alter or modify any part of this equipment. Do not operate this equipment with combustible gas. Do not attempt to repair or disassemble the equipment while the system is pressurized. Tighten all fluid connections securely before using this equipment. Always read and follow the fluid manufacturer recommendations regarding fluid compatibility and the use of protective clothing and equipment. Inspect all equipment frequently and repair or replace worn or damaged parts immediately. IMPORTANT! Failure to observe these warnings including misuse, over pressurizing, modifying part, using incompatible chemicals and fluids or using worn or damaged parts may result in equipment damage and or serious personal injury, fire explosion or property damage. National Spencer PO Box 57 Wichita, KS fax Revised

2 Instructions for 5:1 Air operated pumps Model Number 1730A Content Page Front Page / Presentation 1 Safety Precautions 2 General Installation Requirement 3 Installation / Operation 4 Maintenance / Service 4-5 Service Instructions 5-6 Spare Part Drawing 7 Spare Part List 8 Safety Precautions 1. The pump is to be used with non-corrosive fluids like oil, light grease and may not be used for other purposes. It must not be used for pumping petrol or other explosive liquids. WARNING! The pump contains zinc and aluminum materials, which can react with some solvents and create explosive gases. 2. Check that all accessories and components are suitable for the working pressure of the system. 3. Do not exceed the maximum air pressure of the pump 145 psi. 4. The system must be tested to 1,3 times the working pressure before being put into operation. All test results must be kept and filed together with this manual. 5. Close and disconnect the air supply and relieve the liquid pressure in the system before any work to the pump or the system is carried out. 6. Only use genuine manufactures spare parts. Never use any worn or damaged spare parts. 7. Do not direct outlet valves or any other dispensing valve against the body or any other person as the liquid can penetrate the skin or damage the eyes. In the event of accidental penetration of the liquid into the skin or eyes seek immediately medical advice. 8. Periodically inspect all system components for leakage or damage, especially the hoses which can be worn out due to wear and age. Rectify any defects immediately. 9. If there is a risk or the line pressure increasing due to direct heat on the pipe work from example, hot air blowers, heaters, radiants, etc. causing the fluid to expand in the pipe work which in turn may cause the equipment to fail or hoses burst, than a pressure relief valve must be fitted. This pressure relief valve should be fitted into the pump housing or between the pump outlet and the discharge hose. 10. Always turn off the air pressure to the pump when the premises are unattended. Page A

3 GENERAL The air operated pump has two main parts. One double acting air motor driving a double acting liquid pump. The liquid is sucked into the pump tube through the bottom valve when the piston is on the upward stroke. The liquid is discharged in both up and down strokes. The relationship between the area of the air piston and the area of the pump piston decides the pressure ratio. The pressure ratio is 5:1 and the theoretic pressure when the pump has stopped is 5 times higher than the air pressure. The exhausted air is blown out through a silencer, which is made of sintered brass. Page A

4 INSTALLATION / OPERATION Mobil Units 1. Page A Remove the protective packing from the pump including plugs from the air inlet and the fluid outlet. 2. Remove the drum adapter from the pump tube. Mount the adapter into the 2 hole in the drum or pump bracket. 3. Put the pump vertically into the drum and lock the pump so that the outlet comes into the desired position. Set the pump ½ clear of the bottom of the drum and lock the pump with the adapter. 4. Connect the liquid outlet hose into the outlet adapter at the pump (NPS ¾ f). Mount the air coupler into the air inlet adapter. (NPS ¼ f). WARNING! If the air pressure in the system is higher than the working pressure of the pump it will be necessary to install an air regulator and gauge into the air line prior to the pump A shut-off valve should always be installed into the air line before fixing the air hose, filter, regulator and gauge. 5. The pump is pre-lubricated with silicon grease. It is not necessary to use a lubricator under normal operating conditions. WARNING! If a lubricator has been used with the pump it will be necessary to continue to use it. This is because the oil from the lubricator will have washed the silicon grease away. If the lubricator is not continuously used this could result in the pump being damaged. Fixed Installations Besides points 1-5 above, please also note the following. 6. The pipework system must be installed according to local regulations for this type of equipment. 7. Do not mount a pump directly onto a sheet metal wall or similar construction, which can create noise resonance and augment the normal noise level of the pump. 8. A hose must be mounted between the outlet of the pump and the fixed pipework. This hose should have sufficient length to make it possible to lift the pump in and out of the drum or tank without any problems. 9. A shut-off valve must always be installed at the beginning of the pipework to make service easier and to make it possible to cut off the flow of liquid when necessary. 10. At each branch and before each hose reel outlet a shut-off valve should be installed. It is also advisable to fit an oil filter. The shut off valve and oil filter should have the same pressure rating as the corresponding working pressure of the system. 11. When starting up the system for the first time, all valves and meters should be opened to bleed air from the system. If air gets compressed in the pipework, this could damage the meters. Sometimes it may be necessary to bleed the system at a high point to release any air pockets. These air pockets can be difficult to remove, but they have to be removed so that the meters and solenoid valves work correctly. In a monitoring system it is essential to bleed away all air from the system. 12. If there are filters mounted in the system to take care of dirt, it will be necessary to clean out these filters from time to time. It is especially necessary to clean out the filters after a new system has been commissioned. 13. Do not let the pump run fast when starting up a new system or changing barrels in an existing system. Start the pump by lowering the air pressure on initial priming and increase the air pressure gradually as the system is primed. Always check in a new system that there are no oil leaks. MAINTENANCE Page A 1. For your personal safety disconnect the air motor form the air line and relieve the system pressure before any service is undertaken. 2. Check the following regularly: 2.1. Air filter. Empty and clean out If a lubricator is installed it should always be filled with air tool oil or similar. Mineral based motor oil, SAE 10, can also be used. Synthetic oil or other oils must not be used Possible leakage in the connections or couplers All connected hoses for wear or possible damage. 3. Keep the lubricant and the equipment clean and free from dirt. Page A

5 4. When changing drums it is especially important that the pump tube and bottom valve is kept off the floor and free from dirt. The dirt will otherwise enter the pump and contaminate the oil and possibly damage the pump. Put the pump into a clean drum directly or rest the pump on a bracket while changing the drum. 5. Have spillage container available when unloading or uncoupling the pipework. 6. Re-check all the connections in the system for leakage after the first 6-8 hours of operation. TROUBLE SHOOTING Symptom Possible Fault Remedy Pump stationary No or low air pressure Check the airline valve, regulator and quick coupler. or run very slowly Faulty air motor Check air motor mechanism. Check seals as required and replace any faulty parts. Try to restart by pushing the lower servo piston with a screwdriver or similar tool through the hole in the bottom cover. See Service "Air Motor". Lack of lubricant in air mechanism Blocked air inlet filter Ice blocking air exhaust Foreign object jamming movement of central bar If there is a lot of water in the compressed air you have to install an air lubricator in the air feed line. Lubricate the yellow piston and all rubber o-rings inside mechanism. Change or clean the air inlet filter. Inspect for possible condensation in air filter, or if the pump has "raced" that there is no leakage in the pipe work. As above. Check for free movement and for foreign objects in piston valve etc. Pump reciprocating No oil Check oil level in drum/tank in relation to riser tube/outlet but not delivering point. Float valve jammed (if fitted) Foot valve inoperative Piston valve or seals worn Check floats valve frees to move as required. Check spring and ball for correct operation and seating. Check for foreign objects jammed in foot valve. Check for foreign objects in piston valve seat. Check seals for wear and damage. Oil coming out from Packing between air Change packing. See Service "Exchange of packing the "leakage" hole in motor and pump is worn between air motor and pump tube". the outlet body out or damaged Pump is running despite Packing on the lower Change worn or damaged parts. See Service "Pump the outlet being closed piston assembly is worn mechanism". out or damaged Dirt in the bottom valve or in the lower piston Assembly See Service "Pump mechanism". SERVICE General 0.1. For your personal safety disconnect the air motor from the airline before any service is undertaken All screws and threads are right handed unless otherwise indicated Avoid damage to packing and all moving surfaces. When servicing the pump, all parts should be protected from dirt, especially the cylinder and the central bar. Keep the working area and tools clean Be very careful when dismantling and assembling the O-Rings and seals. At the least suspicion that parts are damaged or worn out, these suspect parts must be replaced Clean and grease all surfaces with silicon grease or similar. Especially all O-Rings and moving surfaces before reassembling Use kerosene or similar liquids for cleaning the parts. If a water-based fluid is used, all parts must be dried immediately and carefully directly after cleaning in order to avoid any corrosion. Page A

6 AIR MOTOR 1.1 Fasten the outlet housing of the pump into a vice in vertical position. Loosen the 4 screws in the lid. Remove the lid. Air supply nipple (Pos 2) is sealed by two O-Rings in the valve mechanism. 1.2 To inspect the air filter you thread carefully a screw, (UNC ¼ ), a ½ up to 1 turn inside the filter. Pull up and clean or change it. 1.3 Loosen the silencer s (Pos 22) 4 screws (Pos 27) and pull of the protective cover (Pos 30). Unscrew the 6 screws (Pos 29) which keep the mechanism (Pos1) in position. N.B! Do not loosen any of the O-Rings between air motor and valve mechanism. It is possible to keep them in position with a little silicon grease. 1.4 Now it is possible to inspect and investigate the valve mechanism. Exchange it or replace the valve spool kit (Pos 31). 1.5 To inspect the air motor cylinder, loosen the 4 lower screws (Pos 38). Pull of the air motor from the air piston. Change all damaged or worn parts and reassemble in reverse order. WARNING! It is important to lubricate all parts and seals with silicon grease before reassembling. No other grease should be used. EXCHANGE OF PACKINGS BETWEEN AIR MOTOR AND PUMP TUBE 2.0 Fasten the outlet housing of the pump into a vice with the pump tube in horizontal position. Loosen the 4 lower screws (Pos 28) and pull off the air motor with the complete valve mechanism. 2.1 Unscrew the pump tube with a strap wrench. Do not use a pipe wrench, as the pump tube will be damaged. Do not pull off the pump tube (Pos 18 or 23) completely. Only enough to get access to knock out the clamping pin (Pos 16). Unscrew the piston rod (Pos 17 or 24). 2.2 Pull out the central bar (Pos 15) through the outlet body. Inspect all working surfaces and replace it if necessary. 2.3 Release the lock rings (Pos 11) to change the u packing (Pos 7). Push the u-packing and there respectively sleeves (Pos 8) upwards and (Pos 9) downwards out of the pump body. Inspect and replace if necessary. PUMP MECHANISM 3.1 See item 2.0 and 2.1. Page A 3.2 Pull off the pump tube (Pos 18 or 23) change the cup seal (Pos 20). If the adapter (Pos 14) gets loose, exchange the O-Ring (Pos 12) which is situated between the pump body and the adapter (Pos 14). 3.3 Be careful to avoid any dirt getting in and around the piston assembly. Replace all parts, which are worn or damaged. 3.4 If you suspect dirt in the bottom valve (Pos 21 or 25) unscrew for inspection. If the bottom valve is removed, the O- Ring (Pos 13) between the bottom valve and the pump tube must be replaced. 3.5 When reassembling, seal the pump tube against the adapter with Loctite Pipe Sealant or similar. Do not use flax or teflon tape. The O-Ring (Pos 13) will seal against leakage between foot valve and pump tube. Do not over tighten the bottom valve or pump tube when reassembling. Page A

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