Emerson YARWAY CONDENSAVER Series Manual

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YARWAY CONDENSAVER™ SERIES STEAM CONDENSATE RETURN PUMPS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Before installation, these instructions must be carefully read and understood.
© 2024 Emerson. All Rights Reserved. FCIM-20083-EN 24/02
INSTALLATION
The unit should be installed in a level position.
Follow the piping arrangement of Figure 1 for
a vented receiver application or Figure 2 for a
pressurized receiver application.
Upstream piping must always be equal to or
larger than the check valve connection size
and block valves must be full ported to achieve
rated capacities. The pump should not be used
to support the weight of the piping.
To prevent water hammer and damage to
the pump’s outlet check valve when lifting
condensate large heights, install a check valve
at the highest point of the return line.
Vented Receiver and Pressurized Receiver
To prevent upstream equipment flooding
while the pump is discharging, a condensate
receiving vessel should be installed directly
above the CondenSaver™ Series with the
necessary filling head distance between the
bottom of the receiver and the top of the pump.
FIGURE 1
Vented Receiver Application
Condensate
Atmospheric Vent
Pump Exhaust
Motive Pressure
Filling Head (In.) Lift Pressure
(Ft. X 0.4333)
Return Line
Return Line
Pressure
Pressure Driven
Pump
To Drain or Vent
Drip Trap Use
with Steam Only
Inlet Lift
Check Valve
Outlet Lift
Check Valve
Vented Receiver
FIGURE 2
Pressurized Receiver Application
Condensate from
Steam Traps Pump Exhaust
Motive Pressure
Filling Head (In.)
Lift Pressure
(Ft. X 0.4333)
Return Line
Return Line
Pressure
Pressure Driven
Pump
Drip Trap Use
with Steam Only
Inlet Lift
Check Valve Outlet Lift
Check Valve Process Steam Trap
Pressurized System

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YARWAY CONDENSAVER™ SERIES STEAM CONDENSATE RETURN PUMPS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
COMMISSIONING
1. Open the motive pressure line block valve.
If steam, ensure that the steam trap
is functional.
2. Open the block valves on the inlet and outlet
condensate lines to commission the system.
NOTE
Proper operation can be verified by observing the level
in the sight glass. During the fill cycle the level should
rise and during the discharge cycle, it should fall.
WARNING
Hot discharge from this product may cause severe
burns. Discharge must be piped away or directed
so that persons in the vicinity are not endangered.
This product must be isolated, vented and cool to
the touch before repairing or inspecting.
MAINTENANCE
The Yarway CondenSaver™ Series does not
require frequent service. It is recommended,
however that routine maintenance be
performed at least on a yearly basis, depending
on the quality of the liquid being pumped.
During this service, the system including
strainers, tanks, valves and piping should be
flushed or cleaned to prevent the accumulation
of rust and other contaminants from fouling
the check valves or the working mechanism of
the pump.
NOTE
Any malfunction of this product must be reported to
the service department. Repare made to the product
by unauthorized personnel will void the warranty.
DISASSEMBLY
1. Remove the entire internal operating
mechanism from the pump by removing the
eight hex bolts (19)
2. Remove the operating mechanism from
the top flange (15) by removing the two
hex bolts (19). The valve internals will come
out with the valve actuator plate (9). Discard
the valve internals.
3. Remove and discard the valve bodies from
the top flange (15).
4. Clean any debris from the operating
mechanism and the top flange (15). Inspect
the moving parts. Replace any worn or
damaged components.
REASSEMBLY
1. Install the new valve bodies. The body with
the captivated ball is the inlet valve body and
must be installed in the hole ported to the
½ in. NPT connection. Torque the bodies to
30 to 40 ft-lbs (41 to 54 N•m).
2. Place the new valve internals in the slots
on the valve actuator plate (9). The valve
internal for the inlet plate has the narrow tip.
Reinstall the operating mechanism to the
top flange (15) with the two hex bolts (19).
Torque to 40 to 50 ft-lbs (54 to 68 N•m)
3. Check the operating mechanism for proper
tripping operation by carefully raising and
lowering the float (1). All parts should move
freely and the valves should change position
with a snap action.
4. Reassemble the pump using a new gasket.
A thread lubricant should be applied to the
threads of the eight hex bolts. Torque to
70 to 75 ft-lbs (95 to 101 N•m)
TROUBLESHOOTING
In the event of operational difficulties, refer to
Table 1 to identify and correct the problem.
TABLE 1. TROUBLESHOOTING GUIDE
Symptom Possible Cause Corrective Action
Pump does not deliver rated capacity Insufficient filling head Raise filling head
Clogged strainer Clean the strainer
Insufficient motive pressure Increase motive pressure
Back pressure too high Reduce back pressure
Inlet check valve is leaking Clean or replace valve
Pump fills but does not cycle Damage float Replace float
Broken Spring Replace spring
Mechanism jammed with debris Clean the pump and free up the mechanism
Constant discharge of steam or air Valves have a seat leakage Replace the inlet and exhaust valves
Liquid is being discharged from the exhaust port Damage float Replace float
Broken Spring Replace spring
Mechanism jammed with debris Clean the pump and free up the mechanism

3
YARWAY CONDENSAVER™ SERIES STEAM CONDENSATE RETURN PUMPS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
FIGURE 3
PARTS ORDERING
Pump Mechanism Quick Change Kits include
Items 1 to 19
Item Description
1Float
2Float Arm
3Rear Link
4Spring End Cap
5* Compression Spring
6Spring Arm
7* Inlet Valve Assembly
8* Exhaust Valve Assembly
9Valve Actuator Plate
10 Stand Off
11 Frame
12 Shaft
13 Washer
14 Cotter Pin
15 Top Flange
16 Pipe Plug
17* Gasket
19 Hex Bolt
* Recommended spare parts
PARTS LIST

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YARWAY CONDENSAVER™ SERIES STEAM CONDENSATE RETURN PUMPS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
FCIM-20083-EN © 2024 Emerson Electric Co. All rights reserved 02/24. Yarway is a mark owned by one of the companies in the Emerson
Automation Solutions business unit of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other
marks are the property of their prospective owners.
The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy,
they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or
applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the
designs or specifications of such products at any time without notice.
Emerson Electric Co. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use
and maintenance of any Emerson Electric Co. product remains solely with the purchaser.
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WARNING
Materials used in manufacture of Yarway products are considered in a stable condition when shipped.
However, under certain conditions purchasers could create potential hazardous conditions by their
future operations.
CAUTION
Welding, cutting, burning, machining or grinding of this product can generate toxic dust and fumes of
potentially hazardous ingredients. The dust or fumes can cause irritation of the respiratory tract, nose,
throat, skin and eyes. It may cause temporary or permanent respiratory disease in a small percentage
of exposed individuals. Use moderate ventilation when grinding or welding. Avoid breathing dust, fumes
or mist. Avoid prolongued skin contact with dust or mist. Maintain dust levels below OSHA and ACGIH
levels. Use protective devices. Wash hands thoroughly after contact with dust before eating or smoking.
Right to know laws and OSHA standard 29CFR (1910.1200)
Material Safety Data Sheets on the following Yarway products:
Valves, Steam Traps and Strainers
The OSHA Hazard Communication Standard 29CFR 1910.1200, states that the standard does not
apply to “articles.” The standard defines an article as:
“A manufactured item formed to a specific shape or design for a particular use which does not
release or otherwise expose an employee to a hazardous chemical under normal conditions
of use.”
The above named products fall within the definition of an “article”, no Material Safety Data Sheets
are available or are required. Our product is manufactured as an “end product.”
If the product is a weld end the following applies.