Dover PSG BLACKMERMLX4B Manual

BLACKMER POWER PUMPS 966909
INSTRUCTIONS NO. 106-A00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: MLX4B, MLXW4B, MRLX4B, MRLXW4B
MLN4B, MRLN4B
Section
Effective
Replaces
106
Jan 2014
Aug 2010
TABLE OF CONTENTS Page
PUMP DATA
Technical Data ........................................................2
Initial Pump Start Up Information.............................2
INSTALLATION
Pre-Installation Cleaning .........................................3
Location and Piping.................................................3
Pump Mounting.......................................................3
Coupling Alignment.................................................4
Pump Rotation.........................................................4
To Reverse Pump Rotation.....................................4
Check Valves ..........................................................4
Optional Jacketed Heads ........................................4
Manual Bypass Valve..............................................4
OPERATION
Pre-Start Up Check List...........................................5
Start Up Procedures................................................5
Running the Pump in Reverse Rotation ..................5
Flushing the Pump ..................................................6
Pump Relief Valve...................................................6
Relief Valve Setting and Adjustment.......................6
MAINTENANCE ..............M(R)LX(W)4B........M(R)LN4B
Lubrication ....................7 .........................12
Vane Replacement .......8 .........................12
Pump Disassembly .......8 .........................13
Pump Assembly ............9 .........................14
TROUBLE SHOOTING ...................................................16
NOTE: Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts List No.
106-A01 for MLX4B, MLXW4B, MRLX4B, MRLXW4B and
106-A02 for MLN4B, MRLN4B.
Blackmer pump manuals and parts lists may be obtained
from Blackmer's website (www.blackmer.com) or by
contacting Blackmer Customer Service.
SAFETY DATA
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the product, or in the manual,
look for one of the following signal words and be alert to the
potential for personal injury, death or major property
damage
Warns of hazards that WILL cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
NOTICE:
Indicates special instructions which are very
important and must be followed.
NOTICE:
Blackmer Pumps MUST only be installed in systems, which
have been designed by qualified engineering personnel.
The system MUST conform to all applicable local and
national regulations and safety standards.
This manual is intended to assist in the installation and
operation of the Blackmer ML4B Series pumps, and MUST
be kept with the pump.
Pump service shall be performed by qualified technicians
ONLY. Service shall conform to all applicable local and
national regulations and safety standards.
Thoroughly review this manual, all instructions and hazard
warnings, BEFORE performing any work on the pump.
Maintain ALL system and pump operation and hazard
warning decals.

106-A00 page 2/20
SAFETY DATA
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Hazardous
machinery can
cause serious
personal injury. Hazardous voltage.
Can shock, burn or
cause death.
Failure to stop the pump before
adjusting the shaft packing can cause
severe personal injury.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous
machinery can
cause serious
p
ersonal in
j
ur
y
. Hazardous pressure
can cause personal
injury or property
damage
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
Hazardous or toxic
fluids can cause
serious injury. Hazardous pressure
can cause personal
injury or property
damage
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
PUMP DATA
PUMP IDENTIFICATION: A pump identification tag, containing the pump serial number, I.D. number, and model designation,
is attached to each pump. Record and file the data from this tag for future reference. If replacement parts are needed, or if
information pertaining to the pump is required, this data must be furnished to a Blackmer representative.
MLX4B – Full size liner, External Ball Bearings MLXW4B – MLX4B w/ Wear resistant liner and discs
MRLX4B – MXL4B w/ Reduced Capacity Liner MRLXW4B – MRLX4B w/ Wear resistant liner and discs
MLN4B – Full size liner, Sleeve Bearings (Bushings) MRLN4B – MLN4B w/ Reduced Capacity Liner
TECHNICAL DATA
MLX4B, MLXW4B
MRLX4B, MRLXW4B MLN4B, MRLN4B
Maximum Pump
Speed 600 RPM 600 RPM
Max. Operating
Temperature * 240 – 400°F (115 – 204°C) 240 – 400°F (115 – 204°C)
Maximum
Viscosity * 30,000 – 100,000 SSU (6,300 – 21,000 cSt) 30,000 – 500,000 SSU (6,300 – 108,000 cSt)
Max. Differential
Pressure 200 psi (13.8 Bar) 150 psi (10.3 Bar)
Max. Working
Pressure 250 psi (17.2 Bar) 200 psi (13.8 Bar)
* Maximum operating limits are dependent on the materials of
construction. See Blackmer Material Specs 106-091, 106-093.
INITIAL PUMP START UP INFORMATION
Model No.: ____________________________________
Serial No.: ____________________________________
ID No.: _______________________________________
Date of Installation: _____________________________
Inlet Gauge Reading: ____________________________
Discharge Gauge Reading: _______________________
Flow Rate: _____________________________________

106-A00 page 3/20
INSTALLATION
NOTICE:
Blackmer pumps must only be installed in systems
designed by qualified engineering personnel. System
design must conform with all applicable regulations and
codes and provide warning of all system hazards.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Disconnect and lockout electrical power
before installation or service
Electrical supply MUST match motor
nameplate specifications.
Hazardous voltage.
Can shock, burn or
cause death.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
PRE-INSTALLATION CLEANING
NOTICE:
New pumps contain residual test fluid and rust inhibitor.
If necessary, flush pump prior to use.
Foreign matter entering the pump WILL cause extensive
damage. The supply tank and intake piping MUST be
cleaned and flushed prior to pump installation and operation.
LOCATION AND PIPING
Pump life and performance can be significantly reduced when
installed in an improperly designed system. Before starting
the layout and installation of the piping system, review the
following suggestions:
1. Locate the pump as near as possible to the source of supply
to avoid excessive inlet pipe friction.
2. The inlet line must be at least as large as the intake port on
the pump. It should slope downward to the pump and must
not contain any upward loops. Eliminate restrictions such as
sharp bends; globe valves, unnecessary elbows, and
undersized strainers.
3. Install a strainer in the inlet line to protect the pump from
foreign matter. Locate the strainer at least 24" (0.6m) from
the pump, and have a net open area of at least four times
the area of the intake piping. Strainers must be cleaned
regularly to avoid pump starvation.
4. The intake system must be free of air leaks.
5. Expansion joints, placed at least 36" (0.9m) from the pump,
will compensate for expansion and contraction of the pipes.
Contact the flexible connector/hose manufacturer for
required maintenance/care and design assistance in their
use.
6. Install pressure gauges in the NPT ports provided in the
pump casing to check pump at start up.
7. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
8. Check alignment of pipes to pump to avoid strains which
might later cause misalignment. See Figure 1. Unbolt
flanges or break union joints. Pipes must not spring
away or drop down. After pump has been in operation
for a week or two, completely recheck alignment.
Figure 1
9. When pumping liquids at elevated temperature, make
provisions to compensate for expansion and contraction
of the pipes, especially when long pipe lines are
necessary. Steel pipe expands approximately 3/4” (1.9
cm) per 100 feet (30.49 m) per 100°F (37.8°C) rise in
temperature.
PUMP MOUNTING
A solid foundation reduces noise and vibration, and will
improve pump performance. On permanent installations it is
recommended the pumping unit be secured by anchor bolts
as shown in Figure 2. This arrangement allows for slight
shifting of position to accommodate alignment with the
mounting holes in the base plate.
Figure 2 - Pipe Type Anchor Bolt Box
For new foundations, it is suggested that the anchor bolts be
set in concrete. On existing concrete floors, drill holes into
the concrete to hold the anchor bolts.
When installing units built on channel or structural steel type
bases, use care to avoid twisting the base out of shape when
anchor bolts are tightened. Use shims under the edges of the
base prior to tightening of the anchor bolts to level the base
and prevent distortion.

106-A00 Page 4/20
INSTALLATION
COUPLING ALIGNMENT
The pump must be directly coupled to a gear and/or driver
with a flexible coupling. Verify coupling alignment after
installation of new or rebuilt pumps. Both angular and
parallel coupling alignment MUST be maintained between the
pump, gear, motor, etc. in accordance with manufacturer’s
instructions. See Figure 3.
1. Parallel alignment: The use of a laser alignment tool or
dial indicator is preferred. If a laser alignment tool or dial
indicator is not available, use a straightedge. Turn both
shafts by hand, checking the reading through one
complete revolution. Maximum offset must be less than
.005" (125 microns).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90° increments
around the coupling (four checkpoints). Maximum
variation must not exceed .005" (125 microns). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
Figure 3 – Alignment Check
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
PUMP ROTATION
A right-hand pump rotates clockwise with the intake on the
right side, when viewed from the driven end.
A left-hand pump rotates counterclockwise with the intake on the
left side, when viewed from the driven end.
TO REVERSE PUMP ROTATION
ML4B Series pumps have double-ended shafts, allowing the
pump to be driven from either end. Rotation is changed by
reversing the position of the pump assembly. To do so, rotate
the pump 180 degrees so that the opposite shaft becomes
the driven shaft.
CHECK VALVES
The use of check valves or foot valves in the supply tank is
not recommended with self-priming, positive displacement
pumps.
If the possibility of liquid backflow exists when the pump is
off, a check valve in the pump discharge piping is
recommended because the pump can motor in the reverse
rotation and create undue stress on all attached components.
Never start a pump when it is rotating in the reverse rotation
as the added starting torque can damage the pump and
related equipment.
OPTIONAL JACKETED HEADS
Hot oil or steam can be circulated through jacketed heads by
connections at the ½” NPT pipe plugs directly above and
below the shaft for heating highly viscous liquids, or to "thaw
out" liquids which have congealed in the pumping chamber
and packing area. Maximum recommended steam pressure
is 150 psi (10.3 bar).
Make sure heat is applied early enough to sufficiently thin the
liquid before starting the pump. Liquids that congeal in the
relief valve chamber will make the valve inoperative.
Insulation of the pump with sufficient heat to the jackets will
usually thin the liquid in the relief valve chamber. Take
precautions to ensure the valve has free movement. It is
advisable to start the pump with an open discharge.
MANUAL BYPASS VALVE
WARNING
Excessive discharge pressure can result in damage to
the pump or personal injury. In order to control system
pressure, a bypass valve or other pressure limiting
device must be installed in the discharge pumping
system.
A bypass line from the pump discharge to the pump suction,
with a manual shut-off valve, is recommended when handling
volatile liquids, viscous liquids at a high lift, or when delivering
to piping too small to take the full flow from the pump. For
example:
1. When handling very viscous liquids, excessive pressure
may develop when starting the pump. To avoid possible
damage to the pump, open the bypass valve before
starting. After the pressure stabilizes and the pump is
running smoothly, close the valve slowly.
2. When liquids are pumped under a high suction lift,
cavitation may result, causing the pump to become very
noisy and begin vibrating. By cracking the manual
bypass valve open, and permitting some of the liquid to
recirculate, the noise and vibration can be reduced to an
acceptable level. See other causes of noise and
vibration in the "General Pump Troubleshooting"
Section.
NOTE: With a 4" size pump, a 2" manual bypass valve and
recirculation line is recommended.

106-A00 Page 5/20
OPERATION
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous pressure
can cause personal
injury or property
damage
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
Hazardous pressure
can cause personal
injury or property
damage
Pumps operating against a closed valve
can cause system failure, personal
injury and property damage
Hazardous pressure
can cause personal
injury or property
damage
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Support
pipes so that they do not spring away or drop down when
pump flanges or union joints are disconnected.
2. Verify proper coupling alignment.
3. Blackmer helical gear reducers (if supplied) are shipped
from the factory without oil in the gearcase. Fill with the
grade of oil indicated on the reducer tag. For more
specific instructions on Blackmer gear reducers, refer to
the appropriate Gear reducer Installation, Operation and
Instruction Manual.
4. Check the entire pumping system to verify that the proper
inlet and discharge valves are fully open, and that the
drain valves and other auxiliary valves are closed.
5. Install vacuum and pressure gauges on the pump in the
1/4” NPT connections provided. These can be used to
check actual suction and discharge conditions after pump
start-up.
6. Check the wiring of the motor, and briefly turn on the
power to make sure that the pump rotates in the direction
of the rotation arrow.
START UP PROCEDURES
NOTICE:
Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are experienced.
1. Start the motor. Priming should occur within one minute.
2. Check the vacuum and pressure gauges to see if the
pump is operating within the expected conditions.
3. Check for leakage from the piping and equipment.
4. Check for excessive noise, vibration or overheating of the
pump, reducer, and motor.
5. If possible, check the flow rate.
6. Check the pressure setting of the relief valve by briefly
closing a valve in the discharge line and reading the
pressure gauge. This pressure must be at least 15 - 20
psi (1.0 - 1.4 bar) higher than the maximum operating
pressure.
CAUTION: Do not run the pump for more than 10-15
seconds with the discharge valve completely closed.
If adjustments need to be made, refer to "Relief Valve
Setting & Adjustment."
Incorrect settings of the pressure relief
valve can cause pump component
failure, personal injury, and property
damage.
Hazardous pressure
can cause personal
injury or property
damage
RUNNING THE PUMP IN REVERSE
ROTATION NOTICE:
Do not operate the pump in reverse rotation for no more
than 10 minutes and only when a separate pressure relief
valve is installed to protect the pump from excessive
pressure.
It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation for a LIMITED time, at a reduced
performance level.