Aqua Msa series User manual

USE AND MAINTENANCE MANUAL FOR

DIAPHRAGM ACTUATED MOTOR DRIVEN DOSING PUMPS

SERIES

MSA –MSB –MSC

Operating manual

AQUA S.p.A. ENGLISH Page 2

SUMMARY

INTRODUCTION......................................................................................................................................................................................3

RESPONSABILITY LIMITATIONS.......................................................................................................................................................3

VALIDITY.............................................................................................................................................................................................3

ENVIRONMENT AND SAFETY REQUESTS...........................................................................................................................................5

ICONS AND SUGGESTIONS IN THE FOLLOWING INSTRUCTIONS ................................................................................................5

POTENTALLY EXPLOSIVE AREA USE..............................................................................................................................................5

SAFETY VALVE ..................................................................................................................................................................................5

SUITABILITY AND CHEMICAL COMPATIBILITY CHECK...................................................................................................................5

ELECTROMAGNETIC COMPATIBILITY NOTE:..................................................................................................................................5

NOISE LEVELS...................................................................................................................................................................................6

VIBRATIONS.......................................................................................................................................................................................6

HOT SURFACE...................................................................................................................................................................................6

TRANSPORT, MOVEMENT AND STORAGE..........................................................................................................................................6

RECEIVEMENT CHECK......................................................................................................................................................................6

STORAGE...........................................................................................................................................................................................6

TRANSPORTATION AND RAISING ....................................................................................................................................................7

STANDARD PACKAGE.......................................................................................................................................................................7

DESCRIPTION.........................................................................................................................................................................................7

DATA STICKER...................................................................................................................................................................................7

LIQUID END MATERIALS ...................................................................................................................................................................8

FUNCTION PRINCIPLES ....................................................................................................................................................................8

USE RESTRICTIONS..........................................................................................................................................................................9

PREDICTED USE................................................................................................................................................................................9

RATIONALLY PREDICTED WRONG USE ..........................................................................................................................................9

FORBIDDEN USE..............................................................................................................................................................................10

FLOWRATE ADJUSTMENT SYSTEM...............................................................................................................................................10

MANUAL ADJUSTMENT WITH KNOB AND LINEAR VERNIER........................................................................................................10

TECHNICAL DATA............................................................................................................................................................................10

INSTALLATION.....................................................................................................................................................................................11

GENERAL INDICATIONS:.................................................................................................................................................................12

CONNECTION TO PLANT PIPES .....................................................................................................................................................12

ELECTRIC MOTOR CONNECTION ..................................................................................................................................................12

HYDRAULIC PART INSTALLATION..................................................................................................................................................13

SUCTION PIPE..................................................................................................................................................................................14

PROTECTION BY IMPURITIES:........................................................................................................................................................16

LIQUIDS WHIT GAS EMISSIONS:.....................................................................................................................................................16

CALIBRATION POT...........................................................................................................................................................................16

DISCHARGE PIPE.............................................................................................................................................................................16

SAFETY VALVE ................................................................................................................................................................................17

PULSATION DAMPENER..................................................................................................................................................................18

MANOMETER....................................................................................................................................................................................18

START 18

PRELIMINARY CHECKS...................................................................................................................................................................18

STARTING SEQUENCE....................................................................................................................................................................18

MAINTENANCE PROGRAM..............................................................................................................................................................18

PERIODICAL VISUAL CHECK ..........................................................................................................................................................19

PRECAUTIONS BEFORE MAINTENANCE.......................................................................................................................................19

VALVE GROUP REPLACEMENT......................................................................................................................................................19

DIAPHRAGM REPLACEMENT..........................................................................................................................................................20

PUSHING ROD SEAL REPLACEMENT ............................................................................................................................................20

GEARBOX OIL CHECK AND REPLACEMENT. ................................................................................................................................21

MALFUNCTIONS AND possible SOLUTIONS .....................................................................................................................................21

DECOMMITIONING, Disposal and demolition.....................................................................................................................................22

DECOMMITIONING...........................................................................................................................................................................22

DISPOSAL AND DEMOLITION..........................................................................................................................................................22

WARRANTY ..........................................................................................................................................................................................24

REPAIRS TO AQUA ASSISTANCE CENTER....................................................................................................................................24

Operating manual

AQUA S.p.A. ENGLISH Page 3

INTRODUCTION

Thanks for choosing an AQUA product. A careful reading of this manual and its compliance is recommended to preserve product and its safety

requests for a long period.

This machine must be installed and used by qualified personnel, aware of national and plant safety regulations in the installation country.

Noncompliance of the following instruction will void any applicable guarantee. Warranty terms must be moreover completed by local legislative

and technical rules, in force in the country where the product will be installed. Following instructions does not replace any plant regulation or

further additive limitations, even not legislative released as safety instruction.

For a correct manage and maintenance please follow scrupulously the recommendations in this manual.

It is mandatory that technician and maintenance personnel read and understand the instructions in this manual.

The instruction Manual should be stored in a safe and dry place, easy to find and available for further questions consultation in case of needs.

In order to allow easy recognition of important indications, it is recommended to maintain this manual in good conditions (eventually

replacing it) , as like the following alerts present directly on the machine:

•Machine data sticker

•Arrow indicating motor rotation direction

•Maintenance and service stickers

RESPONSABILITY LIMITATIONS

Missed observance of rules present in this manual will release AQUA from any responsibility. For any further question, not explicitly included in this

manual, please contact AQUA technical support.

Dismantling, alterations or general tampering attempts will invalidate the guarantee and will release AQUA by any further responsability

for persons or object damage.

Furthermore, AQUA will not responsible in the following cases:

-Wrong installation;

-Improper machine use;

-Missing observance of installation country rules;

-Missing or incorrect maintenance;

-Non original spare parts or spare parts not specified for the requested machine

-Due to force majeure damages.

VALIDITY

This manual is valid for the following AQUA machines.

Series: MSA –MSB –MSC

Type: 4,9,14,5 ,19,22,7,18,26,34,39,11,27,41,49,54,14,30,40,65,35,75,105,150,50,110,170,250,140,300,430,670,200,450,700,1000.

Operating manual

AQUA S.p.A. ENGLISH Page 4

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ENVIRONMENT AND SAFETY REQUESTS

ICONS AND SUGGESTIONS IN THE FOLLOWING INSTRUCTIONS

Metering pumps are machines composed by dangerous parts, so:

•Improper use or tampering,

•Safety devices removal or disconnection,

•Missing or infrequent maintenance

Can provide critical damage to object and personnel

In particular, the staff must be informed about danger deriving from:

Malfunction and/or damages to device or personnel.

Explosions.

Parts in tension

Rotating or moving parts

Corrosive or pressurized pumped

Hot surface

POTENTALLY EXPLOSIVE AREA USE

PDM metering pumps in STANDARD version ARE NOT adequate for potentially explosive areas!

ATTENTION: classified area version must be ordered for this kind of use! In ATEX area require ONLY machines in ATEX execution

with flameproof motor . Such machines are suitable for Group II category 3, in 2/22 Zone purpose (no risks during normal use)

ATTENTION: In any case PDM metering pumps ARE NOT suitable for use in zone 0/20 or 1/21 !

SAFETY VALVE

ATTENTION: Diaphragm metering pumps are volumetric pumps that MUST HAVE an external safety valve installed on the

discharge pipe to protect against overpressures. Working pressure can’t in any case be above the max admittable pressure indicated on

the pump sticker, even during safety valve discharge.

SUITABILITY AND CHEMICAL COMPATIBILITY CHECK

PDM pumps are suitable to LIQUID chemical dosing ONLY. All pumps are supplied in agreement to order request.

PLEASE NOTE: any different use that agreeded with AQUA during the order is not appliable and will cause warranty dissolution.

ELECTROMAGNETIC COMPATIBILITY NOTE:

If correctly installed and directly connected to the power supply, PDM metering pumps respect the limit indicated by electromagnetic rules (EMC

–generic rules for industrial facilities).

Pumps with inverter connection or other electrical components have to be ordered for this use. Customer have to take care about

checks and expedients to comply to those limits.

Operating manual

AQUA S.p.A. ENGLISH Page 6

NOISE LEVELS

Noise levels tested in agreement to European rule 2006/42/CE are reported here below. Used test procedure is the same as described by UNI EN

ISO 3744:2010 rule.

Table value is referred to pumps used within the limits of use and installed accordingly with the instructions contained inthe present operating manual.

METALLIC / PLASTIC LIQUID END MATERIAL

Pump model

Noise pressure level

PDM 250

< 70 dB(A)

PDM 1000

< 75 dB(A)

Employer will have to take care about technical and safety measures needed to reduce risks derived by daily exposition to noises into work

environment and whatever required to guarantee and preserve personnel’s health.

VIBRATIONS

PDM metering pump series are not “human direct contact machines”. Vibrations created are not substantial if installed respecting this manual. They

result anyway under 2,5 m/s2and are not able to create dangerous situations. In case of significant vibration, stop the machine immediately and

contact maintenance service.

HOT SURFACE

Some surfaces may become hot during normal use, especially near the motor and its connection flange to the pump.

Please check that the motor can be enough ventilated and that nearby objects or sunrays will not irradiate it with additional heat.

TRANSPORT, MOVEMENT AND STORAGE

RECEIVEMENT CHECK

AQUA metering pumps are supplied packaged with materials, which protect them against accidental damages during transportation.

In any case, during the reception of the package, Customer should have to verify package integrity.

Eventual damages must be notified to the transporter, and added to the Transport Document Notes.

In case of damages, before starting the machine, please contact AQUA technical assistance.

STORAGE

AQUA recommends to store the machines in their original package.

In any case if not immediately used, pumps have to be stored with adequate protections in warm and dry environment, clean, without vibrations into

and protected against bad weather. Furthermore, be sure to protect from ground humidity by using a raised plan (e.g.: shelf/pallet). Avoid ambient

temperature below - 20°C. If the machine will not be used for a long period, AQUA recommends to load the oil to preserve internal components by

oxidation. Do not stack packages (except when explicitly allowed) in order to avoid damages to the below machine or package tilting and fall, which

may cause injuries. Be sure that the shelf is able to support package weight. Before starting the machine, keep it in warm environment for few hours,

in order to stabilize its temperature to the working conditions.

If required, please notify in advance about special storage conditions, in order to prepare an adequate package.

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TRANSPORTATION AND RAISING

During transportation, pumps have to be adequately secured and packaged to protect the contents against accidental hits, falls, or exposition

to humidity. A particular attention is recommended to the pump connection.

Before than transport, oil must be drainer. Every AQUA pump is supplied with a 250 cc plastic bottle. However, after the first opening, the cap must

be sealed with adhesive tape for a perfect lightening.

Standard version (manual adjustment) of PDM metering pumps does not weight above 15kg, therefore can be moved by hand. In case of special

executions, please use an adequate device (trans pallets, forklift, tackle etcetera) according of packages dimension and weight.

ATTENTION: NEVER grab the pumps from their connections! This can damage the pump irreparably and cause leaks and

malfunctions!

STANDARD PACKAGE

Each AQUA pump is packed into a carton box with an appropriate protection guaranteed by a foam system, which completely envelop the

machine during its transport and movement.

DESCRIPTION

PDM metering pumps are composed of:

•A single-phase or tree-phase alternative current electric motor;

•A reduction gearbox which determinate pump stroke/min;

•A liquid end chemically compatible with the pumped fluid;

•A stroke adjustment knob, from 0 to 100% to requested flow rate.

DATA STICKER

Each pump comes with a sticker fixed on the pump body, like the one shown in the below picture:

1 = Pump code

2 = Max guaranteed flow rate (l/h)

3 = Max working pressure (Bar)

4 = Pump serial number.

5= Made in –CE marking

ATTENTION: Keep the data sticker in good reading condition, protecting carefully.

•Mentioned data are mandatory in case of spare parts request, maintenance informations or technical assistance.

•Never remove the sticker by its original position .

•Never edit or falsify the data mentioned in the sticker.

Liquid end materials are indicated as per the below chart, in case of special executions.

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AQUA S.p.A. ENGLISH Page 8

LIQUID END MATERIALS

Wetted parts, such as Pump-head, Ball valve, Valve seats, Valves OR and Valve cage, may be made of different materials (as pert the below

chart), according to the chemical compatibility toward the dosed chemical:

PUMP-HEAD

BALL VALVE

VALVE SEAT

VALVES OR

VALVE CAGE

PYREX

PVC

FPM

PYREX

PVC

EPDM

CERAMIC

PVC

FPM

PTFE

PVC

FPM

SS316L

FPM

CERAMIC

PVC

EPDM

PTFE

PVC

EPDM

SS316L

EPDM

SS316L

SILICON

HASTELLOY

INCOLOY

EPDM

PVDF

PTFE

PVDF

PTFE

PVDF

CERAMIC

PVDF

PTFE

PVDF

HASTELLOY

PVDF

PTFE

PVDF

SS316L

FPM

SS316L

EPDM

SS316L

PTFE

SS316L

FPM

SS316L

EPDM

SS316L

FPM

SS316L + MOLLA

SS316L

EPDM

SS316L + MOLLA

SS316L

SILICON

Non standard execution codification may differ from the above mentioned ones.

FUNCTION PRINCIPLES

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AQUA S.p.A. ENGLISH Page 9

PDM series mechanical Diaphragm metering pumps have a spring return mechanism. Their movement is generated by an electric motor through a

gearbox which allow the rotation of an eccentric shaft that axially push a pushing rod connected to the diaphragm, thus generating the Discharge

phase and compressing the spring at the same time. While the rotation of the eccentric continues, the spring extends, letting the rod to go back to its

original position, thus generating the Suction phase. Alternative motion produced by this mechanism allows suction and discharge of the chemical

trough the liquid end with a movement so similar to a syringe piston, while the resulting action of the check valves defines the flow direction. The drive

distance of the pushing rod, and consequently the quantity of dosedchemical, can be modified through the adjustment located behind the pump body.

Theorical flow rate match with pumping part inducted volume. Actual flow rate is lower cause of the volumetric efficiency of the pump, and depends

by pump type and dimensions, liquid nature and viscosity and working pressure.

USE RESTRICTIONS

Admittable project temperature Ta for all pump types is comprehended between -10 °C and +40°C. Maximum temperature of pumped fluid depends

by the liquid end material (as well as the fluid own characteristics)

NOTE: Periodically check the respect of temperatures limits!

Motor power mentioned in the motor plate refers to operation at altitude below 1000m a.s.l. and ambient temperatures between +5°C and

+40°C. In case of installation above 1000m a.s.l., motor power will decrease proportionally, as shown in the below picture:

PREDICTED USE

PDM metering pumps are designated to liquid dosing ( ambient temperature or heated).

Any other use must be considered “IMPROPER USE” and it is not admitted.

AQUA decline any responsibility for any eventual damage.

PDM metering pumps are suitable for a non-continuous duty 12/24 h/day and can be used for the following applications:

-Water and waste water treatment;

-Pharmaceutical manufacturer;

-Food industrial and agro industrial;

-Paper mills;

-Cleaning products manufacturing and dosing;

-CIP plants;

-Potabilization plants.

RATIONALLY PREDICTED WRONG USE

Following uses of PDM pumps have to be considered incorrect:

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AQUA S.p.A. ENGLISH Page 10

-Without a safety valve immediately installed after the discharge valve and in any case before than any other accessory;

-Dosing different product than specifically indicated;

-In corrosive and stagnate atmosphere enclosed in not enough ventilated area;

-Pressure dosing without manometer installed (see Discharge pipe- Manometer)

-Powered by inverter or other electric devices (if not specifically requested for this use)

-With motor faster than original (different poles)

-In potentially explosive areas (if not specifically requested for this use)

FORBIDDEN USE

It has to consider forbidden use PDM pumps in mining plants or under water.

Furthermore it is forbidden:

To use the pumps without Safety devices or with the same tampered or out of order

To Use STANDARD version pumps in ATEX areas!

To use PDM pumps in ATEX version in 0/20–1/21 explosive zones!

FLOWRATE ADJUSTMENT SYSTEM

PDM pumps flow rate adjustment is continuous and regular and can be modified with pump working or steady. However it’s easier to adjust when the

pump is working, especially for pumps with large plunger diameter.

MANUAL ADJUSTMENT WITH KNOB AND LINEAR VERNIER

Standard version of PDM metering pumps are supplied with manual micrometric adjustment. Thanks to this adjustment is possible to manage the

flow rate in a very precise way with a fixed stroke progress of 1 mm each turn. This means that if the pump stroke is 4mm, you will be able to complete