TapFlo Guardian system Mk3.1 Manual

!
Issue : 020913-B TPUK-GU31X!
English
MODEL
TPUK-GU31X-_T
Operation &
Maintenance
Manual
Guardian system Mk3.1
Instructions for the installation, start-up, operation,
maintenance and repair
Spare parts
STOP
Read this instruction manual carefully before you
install and operate this system!

CONTENTS
Issue : 020913-B TPUK-GU31X
Page
Section
Sub-section
1
EC Declaration of Conformity
2
Guardian Mk3.1
Introduction
Warning symbols
Receiving inspection
Storage
Mounting
Electrical connections
Air connections
Air preparation
Air pressure
Health & safety
Protection
Explosive environments
5
Function plate
6
Set point adjustment
7
Remote reset
8
Alarm output
9
Barrier & Stop (BARR)
Principle of operation
Recommended installation
Set point adjustment
Operation
Trouble shooting
17
Dry-run & Stop (DR&S)
Principle of operation
Recommended installation
Set point adjustment
Operation
Trouble shooting
23
Dead-head & Stop (DH&S)
Principle of operation
Recommended installation
Set point adjustment
Operation
Trouble shooting
29
Dead-head & Restart (DH&R)
Principle of operation!
Recommended installation
Set point adjustment
Operation
Trouble shooting
35
Specifications
Dimensions
Connections
Characteristics
Guardian coding
37
Maintenance
Routine inspection
Complete inspection
Tightening torques
Guardian parts
Returning parts
39
Warranty
Warranty / return form
Sketch of installation

EC DECLARATION OF CONFORMITY
Issue : 020913-B TPUK-GU31X 1
EC Declaration
of Conformity
Tapflo (UK) Ltd
Victory Close
Chandlers Ford
Hampshire
SO53 4BU
England
Description
Guardian Mk.3.1
Air operated pump protection & energy management system.
Product
codes
TPUK-GU31X-AT
TPUK-GU31X-ST
TPUK-GU31X-TT
Conformity
This document certifies that the above equipment complies with
the requirements of the Directive 94/9/EC (the “ATEX’ directive).
Ratings
Equipment group
IIG (Gas) / IID (Dust)
Category
2
Gas group
II
Protection method
Constructional safety
Maximum surface temperature
135OC
Marking
Standards /
Directives
EN13463-1
EN13463-5
The Machinery Directive (2006/42/EC) / Non Annex IV
Machinery, Self-declaration / Technical file.
Manufacturer
Tapflo (UK) Ltd, SO53 4BU, England.
Notified body
Full details of the conformity assessment procedure can be found
in the technical reference file “Guardian Mk3.1-ATEX”. In
accordance with the requirements of the directive 94/9/EC a copy
of this file has been archived with the following notified body.
Intertek, KT22 7SB, England.
Type examination certificate number : ITS10ATEX17029X/1
Date
August 2013
Signature
Mick Barnes, Managing Director, Tapflo (UK) Ltd

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 2
Introduction
Tapflo (UK) pump control systems are designed to offer simple solutions for
industrial pumping applications. The systems work in harmony with each
pump application utilising similar means of power and methods of construction
to give safe, simple and reliable use.
With proper installation, set-up and maintenance Tapflo (UK) systems give
efficient and trouble free operation. This manual will familiarize operators with
detailed information about installing, operating and maintenance of the
system.
Warning symbols
The following warning symbols are present in this instruction manual. The
warning information should be observed when either of these symbols is
present.
This symbol highlights all safety instructions in this manual where
danger to persons may occur. Observe these instructions carefully
and proceed with the utmost caution in these situations. Inform all
users of all safety instructions. In addition to the instructions in this
manual, the general safety and accident prevention regulations
must be observed.
This symbol highlights points in the instruction manual of particular
importance for compliance with regulations and directives, for
correct work flow and the prevention of damage to, or destruction
of the system or its associate equipment.
This symbol signals possible danger caused by the presence of
electric fields or live wires.
Receiving inspection
Although every precaution is taken when packing and shipping, please
carefully check goods on receipt, ensuring all parts listed on the packing note
are accounted for. Report any damage or shortages to the delivery company
and Tapflo (UK) within 24 hours of receipt.
Storage
If the equipment is to be stored prior to installation, place in a
clean dry location ensuring it is not exposed to extreme
temperature or humidity, ideally in original packaging to prevent
contaminates entering the system.
!"#$%&'$()"*+,"&,-*./*'0"$%(1&2,-*3&+3# !
0. GENERAL
0.1 Introduction
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0.3 Qualification and training of personnel
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STOP
!
STOP

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 3
Mounting
Tapflo (UK) systems will operate properly without being mounted
unless otherwise stated. If the system is to be mounted please
ensure the surface is suitable for the load detailed in the
specifications and appropriate to the system and application.
Electrical connections
The system must be installed by suitably trained personnel in
accordance with the prevailing code of practice.
Efficient installation, inspection and maintenance of the system is
essential.
Air connections
Ensure all connections observe the specifications of the system,
failure to observe this could result in damage to the system and
danger to personnel.
Air preparation
All Tapflo (UK) systems are designed to run on clean, dry air,
lubrication is not recommended. Maximum pressure is 7 bar (G)
unless otherwise stated. An inline filter of 5 micron or finer is
recommended to preserve the life of the system.
Air pressure
The maximum pressure specified in the data section of this
manual must not be exceeded. Higher pressures can cause
damage and may cause injury to personnel.
Health and Safety
Systems must be installed according to local and national safety
rules. The system must be suitable for the application. Failure to
do so could result in poor performance and a risk to plant and
personnel. Consult Tapflo (UK) if in doubt.
Protection
In the interest of health and safety it is essential to wear
appropriate PPE when operating and/or working in the vicinity of
the application.
Explosive environments
Not all Tapflo (UK) Ltd systems are certified for use in explosive
environments. Consult Tapflo (UK) for further information.
Incorrect installation or use may cause injury or death to
personnel in the vicinity of the installation!
!"#$%&'$()"*+,"&,-*./*'0"$%(1&2,-*3&+3# !
0. GENERAL
0.1 Introduction
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0.2 The warning symbols
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0.3 Qualification and training of personnel
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STOP
!
STOP

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 4
Principle of operation
The Guardian is an energy conservation device designed to protect an air
operated double diaphragm (AODD) pump from operating in an inefficient
manner that uses unnecessary energy and reduces the life of its parts.
The Guardian is a fully pneumatic, chemically inert pressure trip with integral
latching output control valve with the following features
•Fully pneumatic
•Floating PTFE diaphragm
•316L stainless steel, PTFE (conductive) or Aluminum wetted parts
•Pilot output to control the associate pump
•Integral reset button
•Integral visual indicator
•Pneumatic alarm output
•External reset from solenoid valve
•Mounting bracket
The Guardian monitors pressure, changing it’s output if the monitored
pressure rises above or falls below the set point of the Guardian (dependant
on configuration), controlling the associate pump accordingly for the following
applications
•Dry-Run & Stop (DR&S)
•Dead-Head & Stop (DH&S)
•Dead-Head & Restart (DH&R)
•Barrier pump monitoring and control (BARR)

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 5
Function plate
The Guardian Mk.3.1 is user configurable and must be configured to the
desired mode prior to use. Check the configuration of the function plate as
shown if Fig.GEN-01 in conjunction with the associate table below.
To reconfigure undo the 4x retaining screws and rotate the plate to the correct
orientation and refit, being careful to ensure the retained seals remain in place
Fig.GEN-01
1
Function plate
2
Retaining screws (x4)
Position
Function
Mode
POS. 1
Falling pressure trip
DR&S, DH&R
POS. 2
Rising pressure trip
BARR, DH&S

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 6
Set point adjustment
The Guardian must be adjusted to the correct set point to ensure proper
operation. Follow the instructions detailed in the application specific sections
of this manual.
Fig.GEN-02
1
Guardian Mk.3.1
2
Set point adjustment screw
3
Set point output connection (supplied plugged M5)

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 7
Remote Reset
The Guardian Mk.3.1 has a remote reset connection that enables the
Guardian to be reset by an external pneumatic signal. This input is applicable
to Barrier, Dry-run & Stop, and Dead-head & Stop modes only.
To use the remote reset facility, see Fig.GEN-03
•Install a 4mm to M5 push fit connection into the Reset I/P connection.
•Connect a 3/2 NC valve to the reset I/P connection
•Valve could be manual or solenoid operated and only need be a small
orifice M5 size valve.
•The reset signal will need to mimic that of the reset button, see operation
sections of application specific sections later in this manual.
For full piping arrangements see application specific sections of this manual.
Fig.GEN-03
1
Guardian Mk3.1
2
3/2 NC valve
Shown as push button/spring, could also be solenoid/spring
P2
Air in 5-8 bar

GUARDIAN MK3.1
Issue : 020913-B TPUK-GU31X 8
Alarm O/P
The Guardian Mk.3.1 has a pneumatic alarm output that can be used to signal
a variety of indicators such as visual, audible or electrical (VFC) that in turn
can be fed back into a control system such as a PLC.
This output is applicable to Barrier, Dry-run & Stop, and Dead-head & Stop
modes only.
To use the Alarm O/P facility, see Fig.GEN-04
•Remove the M5 plug and install a 4mm to M5 push fit connection into the
Alarm O/P connection Fig-GEN-04 (2).
•Connect any of the output options as shown in Fig.GEN-04 (4,5,6 or 7).
•The Alarm O/P is active if the guardian is set and the visual indicator is
raised.
For full piping arrangements see application specific sections of this manual.
Fig.GEN-04
1
Guardian Mk3.1
2
Alarm O/P
3
Valve O/P
4
Pneumatic visual indicator
5
Audible alarm (Such as TPUK-PA or TPUK-PAM)
6
Volt free contacts (Such as TPUK-VFC)
7
Plugged (standard)
P2
Air in 5-8 bar

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 9
BARRIER & STOP
(BARR)

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 10
Principle of operation
Barrier or containment AODD pumps typically contain an additional set of
diaphragms used to back-up the primary diaphragms.
In the event of a breach in the primary diaphragms the back up diaphragms
prevent the pumped media from being spilled from the exhaust of the AODD
pump (typical failure), which could pose significant risk to plant and personnel
near by.
Typically no additional system is used to determine if a breach has occurred
and the fault goes unnoticed, contaminating the media with incompatible
materials, and eventually the back up diaphragms breach and a spill occurs,
defeating the principle of the pump.
The Guardian monitors the pressure in the voids between the primary and
back up diaphragms of the AODD pump, stopping the AODD pump if the
pressure in the voids increases above the set point, preventing the spill and
containing the leak in it’s media compatible chamber.
Fig. BARR-01 shows a graph of time against pressure showing barrier breach
and stop principal
Fig. BARR-01

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 11
Recommended installation
The Guardian should be installed as per Fig. BARR-02. The media connection
can be directly connected with rigid pipe work using double ferrule
compression fittings, or placed independently with a flexible hose between the
pump and Guardian. Ensure the pipe work is appropriately selected for the
media and is suitable for the maximum pressure under breach conditions.
Ensure the Guardian does not cause any tensions or strain on the pump or
mounting. The Guardian must have an air supply of at least 1 bar greater than
the required set point.
•Function plate must be in Pos.2 (see page 6).
•Media connection is connected to the barrier void ports.
•The void ports should be linked as shown in Fig. BARR-02 (4)
•P2 Air supply is connected to a filtered and regulated compressed air
source of 5-8 bar.
•‘Valve O/P’ output pilots an external pilot valve, sized appropriately for
the pumps air inlet, such as a Tapflo TPUK-BV. Fig.BARR-2 (3)
•‘Alarm O/P’ can be connected to a variety of indicators or plugged if not
used (see Alarm O/P section of this manual).
•For ATEX applications the Guardian must be bonded using the earth tag.
Fig. BARR-02. Barrier and stop installation circuit diagram
P1
Pump air supply
P2
Guardian air supply 5-8 bar
1
Guardian
2
Barrier pump (representation)
3
Pilot valve
4
Barrier connection
5
Pump suction
6
Pump discharge
7
Reset button/visual indicator
8
Alarm O/P connection
9
Reset I/P connection (see page 7 for more details)

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 12
Set point adjustment
The Guardian’s set point must be set to the desired trip pressure.
There are three ways to set the Guardian’s set point;
Representative, Direct or Calculated.
To adjust the set point you will require a small flat bladed screwdriver.
Representative
This method of set up adjusts the Guardian to the application by creating the
condition in-situ.
1. Using a flat bladed screwdriver adjust the set point regulator adjustment
screw (Fig.GEN-01, 2) of the Guardian anti-clockwise until it turns freely.
2. Turn the air supply on.
3. Press and hold the reset button of the Guardian.
4. The pump should start and the reset button should try to extend,
continue to hold it in.
5. Slowly increase the set point regulator adjustment screw (Fig.GEN-01,
2) (clockwise) until the reset button stops trying to pop out.
6. Increase the set point regulator clockwise by a further half turn.
7. The Reset button should remain in the in position and the pump can be
started and stopped normally by turning the supply to the Guardian
on/off, however if not (or it stops the pump erratically) increase the set
point regulator clockwise in half turn increments until the pump runs
consistently.
8. The set up is now complete and the system is ready for use.
Direct
This method of set up is used when the set point pressure is known. The
Guardian’s set point is adjusted using an external source to generate the set
point pressure, such as a calibrated air pressure regulator and gauge or a
pressure calibrator. This method requires the Guardian to be removed from its
installed position and the calibration pressure applied directly to the media
connection.
A spare fluid side can be purchased as a test rig, see maintenance section of
this manual.
1. Using a flat bladed screwdriver adjust the set point regulator adjustment
screw (Fig.GEN-01, 2) of the Guardian anti-clockwise until it turns freely
2. Connect the calibration pressure source to media connection.
3. Plug all other open ports, except reset.
4. Connect an air supply to air in connection.
5. Turn the air supply on.
6. Apply the required set point pressure.
7. Press and hold the reset button of the Guardian.

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 13
9. Slowly increase the set point regulator adjustment screw (Fig.GEN-01,
2) (clockwise) until the reset button stops trying to pop out.
10. Remove the set point pressure.
11. Press the Reset button and it should remain in the in position
12. Reapply the set point pressure and the reset button should automatically
extend.
13. If not repeat steps 6-12.
14. The calibration is now complete and the system is ready for use.
Calculated
This method of set up is used when the set point pressure is known. The
Guardian’s set point is simply adjusted to a specific pressure using an
external pressure gauge connected to the ‘set point o/p’ connection.
1. Remove the M5 plug and connect an external pressure gauge to the ‘set
point O/P’ connection.
2. Plug all other open ports, except reset.
3. Using a flat bladed screwdriver adjust the set point regulator adjustment
screw (Fig.GEN-01, 2) of the Guardian anti-clockwise until it turns freely
4. Turn the air supply on.
5. Slowly increase the set point regulator adjustment screw (Fig.GEN-01,
2) (clockwise) until the pressure gauge indicates 0.5 Bar below the
required set point (i.e. 3.0 bar switching = 2.5 bar set).
6. Turn off the air supply.
7. Remove the pressure gauge, and re-install M5 plug.
8. The set up is now complete and the system is ready for use.

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 14
Operation
•To start the pump, apply compressed air to the pump and Guardian.
•The pump should continue to run until either
1. Air to the pump and/or Guardian is interrupted.
2. The Guardian experiences an increased pressure, above the set point,
which is represented by the rest button of the Guardian being extended
(see post trip actions detailed below)
•To stop the pump, interrupt the air to the pump and/or Guardian.
Post trip actions
If the Guardian trips the system must be regarded as in
breach!
Thereafter the pump, Guardian and associate pipe-work should be
stripped, thoroughly cleaned and neutralized, checked and
maintained before being returned to service. Refer to the
‘Maintenance’ section of this manual for procedures to safely
maintain the Guardian. Please refer to the pump manual for
details on how to safely maintain the pump.
The reset button can be used momentarily as an over-ride to
purge the pump prior to maintenance, utilizing the back-up
diaphragms. Press and hold the reset button for the duration of
the purge, the button should oppose being pressed when the
pressure exceeds the set point. The over-ride function should only
be used under controlled conditions.
Abuse of the reset/over-ride could result in failure of the
back-up diaphragms, allowing media to escape through the
pumps exhaust, causing risk to plant and personnel!
Once the system has been rebuilt the set up procedure must be
completed. Refer to set point adjustment section of this manual.
(Page 13).

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 15
Trouble shooting
Check the system is configured as shown in the recommended configuration then
see possible solutions below. If the problem persists consult Tapflo (UK).
Symptom
Cause
Remedy
Pump failure.
See pump operating manual.
System is
inoperative
Unstable air supply.
Check all connections and air
supply.
Set point is not correct.
Perform set up procedure.
Air supply is not stable.
Fit air pressure regulator.
Pump stops
erratically
Media has changed.
Perform recalibration.
Leaking
interconnections.
Remake or replace interconnections.
Guardian set for
alternative application.
Check function plate position.
Consult Tapflo (UK) Ltd.
Incorrect configuration.
Check all connections against
recommended installation.
Air pressure too low.
Air pressure must be > 1bar higher
than set point.
Guardian
does not
work
Guardian tie rods loose.
Check torque is within specification.
Primary diaphragm
breach!
Immediately stop pump, isolate
and perform maintenance.
Poor installation.
Remake interconnections.
MEDIA
EGRESS
Guardian tie rods loose.
Check torque is within specification.
!

BARRIER & STOP (BARR)
Issue : 020913-B TPUK-GU31X 16
!

DRY-RUN & STOP (DR&S)
Issue : 020913-B TPUK-GU31X 17
!
DRY-RUN & STOP
(DR&S)

DRY-RUN & STOP (DR&S)
Issue : 020913-B TPUK-GU31X 18
Principle of operation
The Guardian monitors the fluid discharge pressure of the pump, changing it’s
output if the monitored pressure falls below the set point of the Guardian,
representing a loss of media in the pump suction line, stopping the associate
pump accordingly.
Fig. DR&S-01
Graph of time against pressure showing Dry-run and stop principle