Acromet ACRO-SMART AS.1 User manual

ACRO-SMART
DIAPHRAGM
ANEW STANDARD IN CHEMICAL METERING
UNCOMPLICATED
ECONOMICAL
ACCURATE
ELECTRONIC METERING
R

Acro-Smart Electronic Series January 2017
Acro-Smart Electronic Series
LABORATORY ACCURACY
INDUSTRIAL DURABILITY
Acromet offers competitively priced chemical metering to suit all applications
Motor driven electronic series with continuous proportional metering
0.37 kW 415/3/50 motor with option for 240/1/50
IP.66 Motor and Electronic enclosure
Performance accuracy better than API.675
Linearity better than ±1%
Repeatability better than ±1%
Manual digital capacity adjustment:
Displayed in Litres /Hour
Adjusted in 0.1 increments
Auto capacity adjustment via external 4-20mA input and 4-20mA
feedback signal
Precise and positive volumetric displacement
Self-cleaning ball valve operation
5 Year diaphragm warranty
Pump wetted parts available in PVC, PP, 316SS
Heavy duty mechanical actuation
SELECTION GUIDE: Simplex Diaphragm Metering Pump
Pump Speed - (Strokes / Min)
Pressure
Pump
Rating
Model
46
72
92
112
136
(kPag)
CAPACITY –Litres per Hour
PVC
316SS
AS.1
----
2.0
3.0
----
4.0
1000
1500
AS.2
7
11
15
18
22
1000
1500
AS.3
14
22
28
34
41
1000
1500
AS.4
42
66
85
103
125
1000
1250
AS.5
75
118
151
185
224
850
850
AS.6
150
234
300
365
----
700
700
Local & Remote
Manual Digital Adjustment
in Litres/Hour
Remote adjustment is
limited to a maximum cable
distance from the pump of
15 metres

Acro-Smart Electronic Series January 2017
Acro-Smart Electronic Series

Acro-Smart Electronic Series January 2017
Acro-Smart Electronic Series
Contents
1. SAFETY .................................................................................................... 2
1.1 General ................................................................................................ 2
1.2 Mechanical Precautions........................................................................... 2
1.3 Electrical Precautions ............................................................................. 2
2. INTRODUCTION....................................................................................... 3
3. INSTALLATION ........................................................................................ 3
4. PIPING ...................................................................................................... 3
4.1 General ................................................................................................ 3
4.2 Suction................................................................................................. 4
4.3 Discharge ............................................................................................. 5
4.4 Piping Arrangement ............................................................................... 6
5. OPERATION ............................................................................................. 7
5.1 Before Starting...................................................................................... 7
5.2 After Starting ........................................................................................ 7
6. CAPACITY ADJUSTMENT....................................................................... 8
7. MAINTENANCE...................................................................................... 11
7.1 Pre Maintenance Cleaning ......................................................................11
7.2 Lubrication...........................................................................................11
7.3 Suction & Discharge Valves ....................................................................11
7.4 Diaphragm...........................................................................................12
8. TROUBLESHOOTING............................................................................ 13
9. ACRO-SMART ELECTRONIC SERIES METERING PUMP................... 16
9.1 Drive End (Simplex) –Side Elevation ......................................................16
9.2 Drive End (Simplex) –Side Elevation - Parts List ......................................17
9.3 Drive End (Simplex) –End Elevation .......................................................18
9.4 Drive End (Simplex) –End Elevation - Parts List .......................................19
9.5 Liquid Head Section Drawings ................................................................20
10. CALIBRATION OF A METERING PUMP ............................................... 32
Calibration Cylinder –Installation Guide ..................................................33
11. SERIES 500 VALVE INSTRUCTIONS.................................................... 34
12. ACRO-SMART WIRING CONNECTION DETAILS................................. 38
APPENDIX........................................................................................................... 39
1EQUIPMENT DECONTAMINATION ADVICE DOC. No. SD-19.0-1..............40-41

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Important –For Manual Capacity Pumps
Please refer to Clause 6 “Capacity Adjustment” on page 8, 9 &
10 and familiarise yourself with the contents prior to starting
the pump.
The Manual Capacity Adjustment Default setting for this pump
has been set to;
...................... L/Hr.
For details on how to reset this default to suit your particular
requirements please refer to clause 6.10 to 6.10.6 on page.10.
Pump Serial Number:................................................

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METERING PUMPS
ACRO-SMART SERIES
1. SAFETY
1.1 General
Please read and familiarise yourself with all sections of this and other equipment
manuals before proceeding with installation.
Observe all standard precautions which apply to moving machinery.
Observe all standard precautions which apply to electrical equipment,
drives and controls.
Pay particular attention to special safety 'cautions' and 'notes' in this
manual.
1.2 Mechanical Precautions
Prior to undertaking any mechanical maintenance repair, installation,
etc. SWITH OFF, and disconnect power before proceeding.
Personnel must wear the appropriate protective safety attire and remove
loose clothing, jewellery etc.
1.3 Electrical Precautions
Before undertaking work on the electrical controls or drives, disconnect
power and place a notice to advise others of the type of work in process.
Ensure all necessary grounds are in place and solid.
Do not disconnect or disable ground connections
CAUTION Follow all electrical regulations where required by electrical
engineering trades.

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2. INTRODUCTION
Acromet metering pumps are designed and manufactured for long, low maintenance
service life and when properly applied, will give many years of consistent accurate
metering and trouble free operation.
The following instructions should be read and followed to correctly install and operate
the pump and ensure optimum pump life and performance.
Sectional arrangement drawings and Part Lists are enclosed at the end of this manual.
3. INSTALLATION
3.1 It is desirable to locate the pump as close as possible to the supply source
(eg tank) in order to minimise friction losses in the suction line.
3.2 The pump should be located with sufficient free space provided around the
pump to allow access for:
Adjustment of the manual capacity adjustment device;
To facilitate ease of routine and breakdown maintenance.
3.3 The mounting surface should be even and level. The pump base (mounting
plate) is provided with four (4) holes for mounting bolts.
4. PIPING
4.1 General
4.1.1 The pump suction valve is located at the bottom of the pump head
and the discharge valve on top. The pump cannot operate without
these valves and for correct operation, valves must be vertical.
4.1.2 Discharge pressure should be more than 20 kPa greater than suction
pressure to prevent over feeding or syphoning and to maintain
metering accuracy.
NOTE: When the difference is less than 20 kPa, a back pressure valve
and pulsation dampener should be installed in the discharge
line. The pulsation dampener should be located between
pump and valve, as close to the pump as possible.
4.1.3 A characteristic of reciprocating pump performance is pulsating flow.
Piping should be sized for flow rates at least 3.5 times greater than
maximum capacity of pumps.
NOTE: Small diameter piping will produce unpredictable flow rates
and system pressures.

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4.1.4 Piping should be as short and straight as possible and arranged to
avoid loops or pockets where gas may accumulate.
4.1.5 All piping should be separately supported close to the pump to avoid
imposing pipe loads on the pump. When handling high or low
temperature liquids, measures should be taken to prevent distortion
of piping imposing loads on the pump.
4.1.6 All pipe work should be flushed clean of any solids which may be
present in the pipe work (i.e. weld slag, dirt following construction or
repair) before final connection to the pump and start-up.
4.1.7 Make provision in discharge piping where necessary to facilitate initial
priming of pumps against reduced pressure.
4.1.8 Capacity adjustment range for accuracy of metering, avoid over
sizing of metering pumps. Flow rates of less than 10% of pump
maximum capacity may produce unacceptable accuracy.
4.1.9 Where lengthy suction and discharge pipelines are involved or there
is limitation on size, install pulsation dampeners close to the pump
to:
Avoid cavitation –maintain metering accuracy.
Reduce amplitude of pulsations
4.1.10 Ensure that the drain line from any pressure relief valve in the
system is:
Suitably sized to ensure correct operation of the relief valve.
Returns to the suction tank.
Is fitted with a sight glass for visual indication.
4.2 Suction
4.2.1 Piping must be air tight.
4.2.2 For ease of maintenance an isolating valve should be located near the
pump inlet.
4.2.3 Solids should be prevented from entering low volume pumps or
pumps used for high accuracy metering. A strainer of 150-200 mesh
is recommended and should be adequately sized to prevent
restriction of flow.
4.2.4 Suction pipe entrance should be at least 75 mm above the bottom of
solution tank to allow settlement of larger solids in the tank.
4.2.5 Make provision in suction piping where necessary to facilitate
automatic venting of any gases likely to accumulate.

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4.3 Discharge
4.3.1 Should it be necessary to install an isolating valve in the discharge
line, a relief valve must be installed between the pump and isolating
valve.
4.3.2 The 2500 Metering Pump, being a positive displacement pump, will
be damaged if operated against a closed valve.
NOTE: The relief valve should be set to operate at the maximum rated pump
discharge pressure or maximum system operating pressure,
whichever is lower.
CAUTION: When pumping hazardous liquids the relief valve discharge
should be piped back to the supply source.
NOTE: Where relief valve is likely to operate frequently, to ensure correct
operation and maximise valve life, a pulsation dampener should be
installed between valve and pump
4.3.3 A pressure gauge with gauge protector should be installed to check if
the pump is not operating at too great a discharge pressure. The
gauge should be provided with a petcock valve for isolation from the
system when not required.
4.3.4 When pumping into a high pressure system, a non return valve
should be installed as a safety precaution at the injection point.
4.3.5 Make provision in pipe work to facilitate priming against reduced
pressure.

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4.4 Piping Arrangement
Should it be necessary to
install an isolating valve in
the discharge line, a relief
valve must be installed in
the line between the pump
and isolating valve.
WRONG
CORRECT
Metering pumps are positive displacement pumps and produce pulsating flow. Consequently there
is considerable line pressure loss and suction piping should be sized to ensure adequate NPSHA. If
piping extends for a considerable distance a suitable break tank or pulsation dampener should be installed near
pump.
the pump.
Avoid pockets or loops in piping where gas may accumulate.
WRONG
CORRECT
Where the pump discharge line connects
with a high pressure line, install a
non return valve as a safety precaution.
The presence of solids in the pumped liquid can cause incorrect
pump valve operation and affect metering accuracy.
If solids are present install a strainer with 150 to 200 mesh
and large mesh surface in order to keep pressure drop as small
as possible and ensure that strainer does not become
quickly clogged.
CORRECT

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5. OPERATION
5.1 Before Starting
5.1.1 Ensure the pump will be operated within its specification.
5.1.2 Check gearbox oil level. Prior to leaving factory, each pump is filled
to the correct level with the recommended grade of oil (see
maintenance section).
5.1.3 Check direction of rotation. Correct direction is anti-clockwise when
viewing pump from top of motor.
5.1.4 Ensure system control of isolating valves in discharge line are open.
5.2 After Starting
5.2.1 Pump will normally prime automatically. However, it may be
necessary to run the pump at maximum capacity to clear air. If this
is unsuccessful install a return line from discharge pipe to supply tank
with valve to facilitate priming at reduced pressure and/or air release.
CAUTION: If pumped liquid is hazardous do not disconnect
discharge pipe work.
5.2.2 Check that pump is operating correctly against discharge pressure.
5.2.3 Ensure that any problems are noted and appropriate corrective or
preventative action is taken.

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6. CAPACITY ADJUSTMENT
4-20 mA Automatic Adjustment
6.1 This pump is capable of accepting a 4-20 mA input signal to operate the
capacity adjustment automatically.
6.2 Ensure when connecting your 4-20 mA two (2) wire input signal are
connected to Plug “D” and terminals T.1(+) and T.2(-) as shown in section 12
page 32 of this manual.
6.3 The capacity (Speed) adjustment will always default to the 4-20 mA input
signal.
If the 4-20 mA input signal fails for any reason then the pump will
AUTOMATICALLY switch over to the Manual Capacity Adjustment Panel.
6.4 For operating instructions of the Manual Capacity Adjustment Panel please
refer to clause 6.6
6.5 When the 4-20 mA input signal has been re-established the pump will
AUTOMATICALLY switch from the manual capacity mode back to the 4-20 mA
input signal.

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Manual Adjustment
6.6 Standard manual capacity adjustment is by means of a key pad on the digital
set point box mounted on the side of the electric motor.
6.7 The manual capacity parameters for your pump have been pre-set and do not
need any adjustment.
6.8 The operating functions of the key pad are detailed as follows.
Stop Button.
Start Button.
DO NOT TOUCH.
Function Button Only.
Increase / Decrease Manual Capacity Button.
When power is first applied the blue L.E.D’s will flash on and off. Press the
start button to engauge the pump.

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CAUTION
6.9 When power is turned off, or a power failure has occurred, the Blue LED lights
on the key pad, will flash ON and OFF, when the power is restored.
To restart the pump press the green start button to restore the preset
default (L/Hr) setting and then adjust the manual capacity button to your
specific requirements.
6.10 To reset the default (L/Hr) setting.
6.10.1 Stop the motor and the Blue LED lights will flash ON and OFF.
6.10.2 With the LED lights flashing press the up arrow until the LED’s reads
“P051”.
6.10.3 Press ok .
6.10.4 Press the up or down arrows to the desired default flow rate.
6.10.5 Press ok to enter the new setting.
6.10.6 Press the start button .
Note:
1/ Do not set the “Default” P051 to zero (0).
2/ The blue LED readout is only associated with the manual adjustment and it
does not change when the pump is operated from a 4-20mA input signal.
The Manual Capacity Adjustment Panel is normally located on the
side of the motor.
This unit can also be mounted remotely. For remote mounting the cable length must
not exceed 15 metres.
Note:
1/ The programming parameters for your pump have been pre-set and do not need
any adjustment.
2/ Wiring of the pump is as per the wiring drawings section 12 of this manual.

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7. MAINTENANCE
7.1 Pre Maintenance Cleaning
Pump maintenance should only be carried out by authorised qualified
personnel with appropriate metering pump and system maintenance
experience.
The suction and discharge lines must be isolated and pipework de-
pressurised and drained of chemicals.
Flush the pump liquid head internals to remove all chemical residue.
Clean the pumps exterior to ensure chemical free surface.
Check that appropriate chemical handling and cleaning standards have
been met.
CAUTION: ACROMET (AUST)PTY LTD IS UNABLE TO ACCEPT ANY METERING PUMP
RETURNED FOR MAINTENANCE THAT HAS NOT BEEN SUITABLY CLEANED.
It is an Acromet Quality Assurance policy that all equipment returned for repair or
service be supplied with a completed copy of the 'Equipment Decontamination Advice'
form, as shown on page 37 of this manual.
7.2 Lubrication
7.2.1 Change oil after 750 hours of operation and at 4,500 hours intervals
thereafter.
The following are recommended grades:
SHELL : OMALA 320
BP : GR-XP-320 ISO
MOBIL : MOBIL GEAR 632
CASTROL : ALPHA SP 320
7.2.2 Fill oil until oil starts to overflow from the filler port.
Oil volume : 450 ml
7.3 Suction & Discharge Valves
7.3.1 During routine maintenance, valves should be dismantled and
checked. Replace worn ball checks and valve seats. When pumping
clean liquids of moderate viscosity, valves will give many years of
trouble free service. However, valve life can be reduced in
applications where discharge pressure is high, liquid viscosity low or
solids are present.
NOTE: Should it be necessary to service the valves, cleanliness is essential
and care should be taken to avoid damaging components.
Refer to valve drawing at end of manual prior to dismantling.
7.3.2 When reassembling, ensure that all O-Rings, ball checks and ball
stops are in the correct position. Failure to fit ball stops can result in
closed head situation and severe pump damage.

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7.4 Diaphragm
7.4.1 When fitting a new diaphragm, the diaphragm bolt should be
tightened firmly with the correct spanner available from Acromet.
7.4.2 Before tightening the diaphragm bolt, capacity adjustment should be
set at 0% eg stroke length should be in the extreme forward position.
7.4.3 Place diaphragm in position ensuring holes line up and screw in two
(2) solution head bolts (opposing each other) through diaphragm bolt
holes into solution head adaptor. This is to ensure that the
diaphragm does not rotate when tightening the diaphragm bolt.
7.4.4 Having tightened diaphragm bolt, remove solution head bolts and fit
solution head.
NOTE: Excessive tightening of solution head bolts should be avoided
as this will result in early diaphragm failure.
7.4.5 After the new diaphragm has been fitted, calibration should be
checked and monitored until diaphragm has stabilised.
All major mechanical repairs should be undertaken by Acromet's specialist servicing
workshop in Melbourne. In most cases a pump can be repaired and despatched in one
day.

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8. TROUBLESHOOTING
Trouble
Cause
Corrections
(A) Pump does not start.
Blown electrical. Fuse.
Check cause and change to
suitable capacity fuse
Electrical overload relay
trips.
Change relay capacity to
correct value.
Electrical wiring breakdown
or defective contact.
Change or reconnect.
Low voltage.
Difference in supply
voltage and rated voltage
of motor.
Find cause and correct.
Defective motor.
Check and replace.
Excessive pressure in
discharge line.
Reduce pressure.
Valve in discharge line
closed.
Open valve
Pump discharge valve
incorrectly reassembled
during maintenance.
Ball stop cushion missing
Reassemble correctly.
Air in liquid end.
Relieve pressure in
discharge line.
(B) No Flow
Valve in discharge line
closed.
Open valve.
Pump discharge valve
incorrectly reassembled
during maintenance.
Ball stop cushion missing.
Reassemble correctly.
Overload relay
Reset the switch after
checking the cause and
correcting.
(C) Pump does not work
after operating
normally
Overload relay
Reset the switch after
checking the cause and
correcting.
Discharge pipe clogged.
Clear the pipe.
Valve in discharge line
closed.
Open valve.
Pump discharge valve
incorrectly reassembled
during maintenance.
Ball stop cushion missing.
Reassemble correctly

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Trouble
Cause
Corrections
(D) Reduced pump flow
rate or unstable rate.
Valve clogged.
Clean.
Worn valve seat.
Replace seat or valve.
Flow meter incorrect.
Inspect meter, repair or
change.
Leakage from relief valve.
Inspect, repair or change.
Air leaking into suction
piping
Check for leak source and
repair.
Air lock in suction line.
Review suction pipework
layout to eradicate air
pockets.
Change in pump rpm
Correct electric power
sources, speed control etc.
(E) Reduced pump flow
rate.
Unstable flow rate.
Flow rate does not
increase as stroke
length is increased.
Cavitation noise may
be apparent.
Insufficient NPSH
available:
(a) Suction pipe diameter
too small.
(b) Suction lift too great.
Enlarge suction pipe, or
install accumulator in the
line close to pump or raise
level of tank.
Raise liquid level.
Viscosity of liquid too high.
1. Heat or lower viscosity
by other means.
2. Increase suction pipe
diameter.
3. Increase suction
pressure.
Vapour pressure high.
1. Lower liquid
temperature at inlet
port.
2. Raise liquid level.
Suction piping and/or valve
clogged
Clean
Suction strainer clogged or
too small
Clean or replace with
larger unit.

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Trouble
Cause
Correction
(F) Excessive pump flow
rate.
Flow continues after
pump has stopped.
Pressure difference across
pump less than 20 KPa
Increase pressure
difference (ie install back
pressure valve).
Discharge line too long or
diameter too small
Reduce length and/or
increase diameter.
Install accumulator in
discharge line.
(G) Liquid leakage from
pump adaptor drain
Ruptured diaphragm.
Check/replace diaphragm.
(H) Knocking sound in
gearbox
Excessive discharge
pressure
Check discharge pressure.
(I) Liquid end noise
Rhythmic noise of pump
valves
Normal
Clogged discharge or
suction valve
Clean
(J) Overheating of motor
Improper voltage
Adjust voltage to motor
specification.
Overload
(Refer to Section K).
Inadequate ventilation
Change motor or relocate
(K) Overload
Improper Oil
Change
Discharge pressure too
high
Lower to permissible
pressure
Erratic noise of pump
valves
1. Clean valves.
2. Increase pressure
difference (ie install
back pressure valve).

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9. ACRO-SMART ELECTRONIC SERIES METERING PUMP
9.1 Drive End (Simplex) –Side Elevation