UNIBLOC FLOTRONIC ONE-NUT User manual

Flotronic ‘One-Nut’ Pumps –
10” Slimline Stainless Steel
Installation, Operation and
Maintenance Manual

AMENDMENT RECORD
Issue
No.
Date Signature Issue
No.
Date Signature
1 06/02/2020 D.GILES
2 09/11/2020 D.GILES
3 10/03/2021 D.GILES
4 26/05/2021 D.GILES
5 27/05/2021 D.GILES

Contents
3
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Contents
0. General ........................................................................................................................................... 5
Introduction .................................................................................................................................... 5
Safety Notice ................................................................................................................................. 5
Declaration of conformity ............................................................................................................... 6
Training .......................................................................................................................................... 6
Limitations of use ........................................................................................................................... 6
0.5.1. Health Hazard Warning ......................................................................................................... 7
ATEX Safety Information ............................................................................................................... 8
0.6.1. General .................................................................................................................................. 8
0.6.2. ATEX Directive 2014/34/EU (Equipment for Explosive Atmospheres) ................................. 8
0.6.3. Personnel qualifications and training ..................................................................................... 8
0.6.4. Products used in potentially explosive atmospheres ............................................................. 8
0.6.5. Scope of compliance ............................................................................................................. 9
0.6.6. Marking .................................................................................................................................. 9
0.6.7. Avoiding excessive surface temperatures ............................................................................. 9
0.6.8. Pump media temperature ...................................................................................................... 9
0.6.9. Preventing the build-up of explosive mixtures ..................................................................... 10
0.6.10. Preventing sparks ................................................................................................................ 10
0.6.11. Preventing leakage .............................................................................................................. 10
0.6.12. Maintenance to the double diaphragm pump to avoid potential hazards ............................ 10
0.6.13. Additional safety instructions ............................................................................................... 11
1. Installation ...................................................................................................................................12
Packaging and Shipping Inspection ............................................................................................ 12
Storage ........................................................................................................................................ 12
Installing the Slimline Pump ........................................................................................................ 12
1.3.1. Foundation ........................................................................................................................... 12
1.3.2. Connection of suction and delivery pipes ............................................................................ 13
1.3.3. Connection of Air Pipes ....................................................................................................... 14
1.3.4. Air Pressure ......................................................................................................................... 14
1.3.5. Air condition ......................................................................................................................... 14
Example of Installation................................................................................................................. 14
2. Operation .....................................................................................................................................15
Before starting the pump ............................................................................................................. 15
Operation of pump ....................................................................................................................... 15
Noise levels ................................................................................................................................. 15
Recommendations for Best Pump Performance ......................................................................... 15
3. Maintenance.................................................................................................................................16
Routine inspection ....................................................................................................................... 16
Complete inspection .................................................................................................................... 16
Chapter Title Page no.

Contents
4
Disassembly of the pump ............................................................................................................ 16
Assembly of the pump ................................................................................................................. 22
Air valves ..................................................................................................................................... 29
3.5.1. Air valve unit inspection and replacement ........................................................................... 29
4. Spare parts...................................................................................................................................32
F Series Slimline metallic pump .................................................................................................. 32
Ordering spares ........................................................................................................................... 33
5. Data ...............................................................................................................................................34
Technical data ............................................................................................................................. 34
Tightening torques ....................................................................................................................... 34
Dimensions .................................................................................................................................. 35
6. Warranty .......................................................................................................................................36
Warranty ...................................................................................................................................... 36
Returning parts ............................................................................................................................ 37
6.2.1. Disclaimer ............................................................................................................................ 37
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General
5
0. General
Introduction
The Flotronic Pumps ‘One-Nut’ Slimline Stainless Steel Pump is used in a wide range of industries including
chemical, cosmetic, paints, pharmaceutical, adhesive and hygienic applications.
The pumps are designed to be safe, simple, easy to use and maintain due to the ‘One-Nut’ design.
With proper attention to maintenance, Flotronic Pumps ‘One-Nut’ Stainless Steel Pumps will give efficient
trouble free operation.
This manual will familiarise operators with detailed information on installing, operating and maintenance
procedures.
Safety Notice
The following safety notices are included throughout this manual but are listed here for clarity:
1. Operation of this equipment must be carried out in accordance with the instructions provided
within this manual.
2. Personnel involved in the installation, operation and/or maintenance of this equipment must
be competent to carry out the procedures detailed within this manual.
3. Do not operate this equipment if it has a known fault.
4. Only original Flotronic Pumps spare parts should be used in the repair and maintenance of
this equipment.
5. Do not exceed 7.2 Barg (105PSI) air supply pressure and ensure the compressed air supply
is filtered, dry and oil free to the specifications detailed in section 1.3.5.
6. Do not modify this equipment from manufacturers original specifications.
7. Regular maintenance schedules must be followed to ensure safe and reliable pump operation.
See ‘Section 3. Maintenance’ for more details.
8. Before maintenance ensure the air supply, delivery and suction pipelines have been isolated
and that any residual pressure within the pump has been relieved.
9. Always wear safety glasses when operating this equipment. In the unlikely event of a
diaphragm failure product may be ejected through the air silencers
10. Never operate the pump without the suction and delivery pipe work connected.
11. Work area must be kept clear to avoid potential hazards.
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General
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Declaration of conformity
As defined by the Machinery Directive 2006/42/EC, and complies with the essential Health & Safety
requirements, Annex 1, and the technical construction file requirements of the Directive.
Where necessary, this pump can comply with ATEX Directive 2014/34/EU.
A declaration of conformity accompanies all pumps, and all pumps carry the UKCA Mark as required by UK
Law and the CE Mark as required by European Law.
Training
Personnel involved in the installation, operation and/or maintenance of equipment supplied by Flotronic
Pumps must be competent to carry out the procedures detailed within this manual. As a minimum we
recommend that personnel be trained in:
1. The safe use of compressed air.
2. Manual handling.
3. Use of lifting equipment, (should it be required).
Limitations of use
All performance figures are based on tests carried out by Flotronic Pumps using water at ambient
temperature.
Operating temperatures are governed by the materials of construction and it is the installer’s responsibility
to ensure that these maximum temperatures are not exceeded under any circumstances.
Performance figures provided by Flotronic Pumps against individual enquiries are estimates only, and are
subject to variations depending upon air pressure and volumes of air provided by the client, head losses
due to pipework, valves and any other installation factors which may be unknown to Flotronic Pumps.
All performance figures, temperatures, flow rates, dimensions and other details are subject to change
without notice.
Due to the wide variety of media handled by Flotronic pumps, it is impossible for Flotronic Pumps to give a
firm recommendation regarding materials of construction for pump components. It is the users or specifiers
responsibility to determine the effect of corrosion, abrasion and the general suitability of any pump supplied
for any individual application. Flotronic Pumps will, however, give advice regarding such material selection
as it may be able to do so in good faith.
WARNING - WHEN HANDLING FLOTRONIC PUMPS PRODUCTS, PLEASE OBSERVE WEIGHTS
GIVEN WITHIN FLOTRONIC PUMPS LITERATURE, LIFTING EQUIPMENT MAY BE REQUIRED IN
CERTAIN CASES.
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General
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All pumps despatched from our works are tested with water and during storage, packing and installation,
some water will have remained in the pump body. This water may cause spillage during handling. Water
could react with the media you wish to pump, and it is your responsibility to check this before putting the
pump into operation. Water may also freeze if the pump is exposed to sub-zero temperatures. Do not
operate the pump under these conditions as ice inside the pump may cause damage to working parts of
the pump.
At all times the installer must wear suitable clothing, footwear, goggles, etc. for personal protection. This
particularly applies when the pump is being operated or maintained.
In the case of diaphragm failure leakage of media can occur from the exhaust silencers unless a guardian
protection system is fitted.
If the media being processed is hazardous, then provision must be made by the user to deal with this
problem. This can be achieved by specifying a guardian protection system as part of the original pump
specification or as a retrofit from Flotronic Pumps, or the silencers must be removed and replaced by
pipework which can carry the leakage to a safe place. Please note that wherever the media is piped, pulses
of mixed air and media will occur at the end of the pipework when diaphragm failure has occurred. Provision
must be made to accept the volumes of air/media mixture that may be present.
WARNING - MEDIA MAY REMAIN INSIDE THE PUMP AFTER USE AND MAY BE UNDER PRESSURE.
HEALTH HAZARD WARNING
Flotronic Pumps products may contain PTFE depending upon specification.
At temperatures up to 250 °C polytetrafluoroethylene (PTFE) is completely inert.
At higher temperatures however, small quantities of toxic fumes can be produced and the direct inhalation
of these can cause an influenza type of illness, which may not appear for some hours, but which subsides
without after effects in 24 to 48 hours. Such fumes can arise from PTFE particles picked up on the end of a
cigarette, or in the presence of any open flame or similar i.e. electric fire, therefore smoking should be
prohibited when pumps are being serviced or PTFE components are being handled.
The disposal of PTFE components such as diaphragms etc. must be carefully controlled and under no
circumstances should be burned.
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General
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ATEX Safety Information
0.6.1. General
These instructions must be kept close to the product’s operating location or directly with the product.
These instructions are to be followed to comply with ATEX safety requirements. Any further local regulations
must also be adhered to. Always coordinate repair activity with operations personnel, follow all plant safety
requirements and applicable safety and health/law regulations.
These instructions should be read prior to installing, operating, using and maintaining the equipment in
conjunction with the main user instructions provided. The equipment must not be put into service until all
the conditions relating to safety instructions have been satisfied.
0.6.2. ATEX Directive 2014/34/EU (Equipment for Explosive Atmospheres)
Where applicable the equipment is in conformance with the Directive. To establish if the equipment is CE
marked for ATEX, observe the equipment nameplate and the certification provided.
It is the responsibility of the user to ensure that the equipment is correctly rated for the environment in which
it is to be used.
A technical file is lodged with Intertek Italia S.P.A, notified body 2575 under document number 3010075.
0.6.3. Personnel qualifications and training
All personnel involved in the operation, installation, inspection and maintenance of ATEX compliant products
must be qualified to carry out the work involved.
0.6.4. Products used in potentially explosive atmospheres
Measures are required to:
4. Avoid excess temperature.
5. Prevent build-up of explosive mixtures.
6. Prevent the generation of sparks.
7. Prevent leakages.
8. Maintain the equipment to avoid potential hazard.
The following instructions for pumps and ancillary equipment, when installed in potentially explosive
atmospheres, must be followed to help ensure explosion protection. All equipment must meet the
requirements of European Directive 2014/34/EU.
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General
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0.6.5. Scope of compliance
Use equipment only in the zone for which it is appropriate and suitably rated.
0.6.6. Marking
An example of ATEX equipment marking is shown below. The classification of the pump will be engraved
on the nameplate (Fig 1).
Fig 1 Example ATEX Nameplate
Special attention must be paid to the marking on the ATEX nameplate.
It is essential to comply with the instruction prohibiting dismantling of the equipment in a flammable
atmosphere where applicable.
0.6.7. Avoiding excessive surface temperatures
WARNING - ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE
HAZARD ZONE
0.6.8. Pump media temperature
Pumps have a temperature class as stated on the nameplate. These are based on a maximum ambient of
40 ºC (104 ºF). Refer to Flotronic Pumps if higher ambient temperatures are to be considered.
Where there is any risk of the pump being run for prolonged periods against a closed or partially closed
valve generating high media and casing external surface temperatures, it recommended that users fit an
external surface temperature protection device.
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General
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0.6.9. Preventing the build-up of explosive mixtures
WARNING - ENSURE PUMP IS PROPERLY FILLED WHENEVER POSSIBLE AND DOES NOT RUN
DRY FOR LONGER THAN 5 MINUTES CONTINUOUSLY.
Ensure the pump and relevant suction and delivery pipeline system is totally filled with media during the
pumping operation, so that an explosive atmosphere is prevented.
If the operation of the system cannot avoid this condition, ensure that the pump does not run dry for more
than 5 minutes continuously.
0.6.10. Preventing sparks
To avoid the potential hazard from an electrostatic charge generating a spark, the earth stud on the pump
casing or foot must be connected to ground.
Do not rub non-metallic surfaces with a dry cloth for cleaning.
0.6.11. Preventing leakage
The pump must only be used to handle media for which it has been approved to have the correct corrosion
resistance.
Avoid entrapment of media in the pump and associated piping due to closing of suction and delivery valves,
which could cause dangerous excessive pressures to occur if there is heat input to the media.
0.6.12. Maintenance to the double diaphragm pump to avoid potential hazards
WARNING - CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH
GIVE A RISK OF EXPLOSION.
The responsibility for compliance with maintenance instructions is with the plant operator.
To avoid potential explosive hazards during maintenance the tools used must not give rise to sparking or
adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and schedule is adopted, in line with the user instructions
provided, to include the following:
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1. Check for any leaks from gaskets and seals. The condition of the divider seal must be checked regularly
to ensure correct functioning.
2. Check that the duty condition is in the safe operating range for the pump.
3. Check that dirt and dust is removed from operational areas of the pump and any surfaces liable to
experience high temperatures.
4. Check the operation of the air valve.
5. Check the condition of the thrust tube bearings and renew the complete thrust tube if any sign of excess
wear or damage is apparent.
6. Inspect the diaphragms and renew if any sign of damage is apparent.
0.6.13. Additional safety instructions
When installing a pump either for the first time or after maintenance, a check must be made to ensure that
the earth connection terminal on the pump and any external metalwork is at ground potential.
Ensure that all metallic pump shrouds and casings are correctly fitted after maintenance, and that earth
continuity between them is at ground potential.
Only genuine Flotronic Pumps spare parts should be used to ensure ATEX compliance.
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Installation
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1. Installation
Packaging and Shipping Inspection
Although precaution is taken when packaging and shipping, we urge you to carefully check the shipment on
receipt. Make sure that all parts and accessories listed on the packaging list are accounted for. Immediately
report any damage or shortage to the Transport Company and Flotronic Pumps.
Storage
If the equipment is to be stored prior to installation, place in a clean location. The pump should be stored in
an ambient temperature of 15◦C (59◦F) to 25◦C (77◦F) and relative humidity below 65%. Do not remove the
protective covers from the suction, delivery and air connections which have been fastened to keep pump
internals free of debris.
Installing the Slimline Pump
1.3.1. Foundation
The pump will operate properly without being fixed to a foundation, however if the pump is required to be
fixed in position, all Flotronic Pumps are provided with mounting plates and suitable holes for bolting.
1. Mount the pump to a suitable base plate or foundation.
2. Make sure the foundation is able to absorb vibrations.
3. Ensure fixings used are suitable for the duty.
4. Fixing hole size can be found in section 5.3
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Installation
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1.3.2. Connection of suction and delivery pipes
WARNING - ANY ASSOCIATED PIPEWORK (FLEXIBLE OR RIGID) SHOULD BE FITTED TO
CORRECT STANDARDS TO MINIMISE STRESS CAUSED BY PIPE VIBRATION/MOVEMENT.
PIPE STRESS CAN CREATE A HAZARD TO PERSONNEL.
Flotronic Pump connections are designed of adequate thickness to absorb normal pipe
loads/connections. Do not over tighten or force pipes into threads (particularly female plastic
threads).
Connecting the suction and delivery pipework properly is critical to performance sustainability.
When connecting the suction pipework, observe the following:
1. Flexible piping should be used between the suction connections and any rigid pipework.
2. The internal diameter of the pipe should be the same or larger than that of the suction connection
to maintain efficient suction capability.
3. Ensure connections to the pump are flanged, screwed or clamped to appropriate standards.
4. Ensure connections are completely tight and that bends and/or restrictions to the pipework are kept
to a minimum.
5. Any leakage in the suction pipework will dramatically reduce the suction capability of the pump.
When connecting the delivery pipework, observe the following:
1. Flexible piping should be used between the delivery connections and any rigid pipework.
2. The internal diameter of the pipe should be the same or larger than that of the delivery connection
to maintain efficient delivery capability.
3. Ensure connections to the pump are flanged, screwed or clamped to appropriate standards.
4. Ensure connections are completely tight, that bends and/or restrictions to the pipework are kept to
a minimum.
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Installation
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1.3.3. Connection of Air Pipes
Air pipework and connections must be suitable for the purpose.
Air supply pipework and fittings must correspond to the air connections on the pump.
It is recommended that air connections must include a short length of flexible pipework to avoid side or end
loads being applied to the tie rod assembly.
Any remote isolation valve in the air supply line should be installed within 1 metre of the pump.
Do not over tighten or force pipes into threads.
1.3.4. Air Pressure
WARNING - OPERATING THE PUMP AT A HIGHER PRESSURE THAN INSTRUCTED BELOW
CAN DAMAGE THE PUMP AND MAY CAUSE INJURY TO PERSONNEL.
Maximum air pressure must not exceed 7.2 bar (105 psi) and the pump should be operated at the lowest
pressure to achieve adequate performance from the pump.
1.3.5. Air condition
A clean supply of compressed air is required (maximum particle size after filtration of 25 microns). The pump
will run most efficiently on dry non-lubricated air.
Example of Installation
Fig 2 Example of Installed Pump
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Operation
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2. Operation
WARNING - DO NOT OPERATE THIS EQUIPMENT IF IT HAS A KNOWN FAULT.
Before starting the pump
1. Make sure the pump is correctly installed in accordance with the installation instruction detailed in
chapter 1.
2. When a pump is newly installed, check all fastenings are tightened to the correct torque value.
Torque figures are detailed in chapter 5.2 Table 3.
Operation of pump
1. Ensure any valves located in the suction and delivery pipework are open.
2. Open the air inlet valve and apply air pressure.
3. If a valve is fitted adjacent to the pump on the delivery side of the fluid pipework, this can be used
to control flow. Alternatively the pump may be controlled by adjusting the air supply.
Noise levels
Noise levels from the Flotronic Pumps pump will generally not exceed 85 decibels at one metre distance.
Hearing protection may be required.
Recommendations for Best Pump Performance
The following points should be observed to achieve the best results from all Flotronic pumps:
1. Operate the pump at the minimum speed and pressure to achieve the required duty point.
2. Ensure suction pipework is free from restrictions and as short as possible.
3. Suction pipework diameter should be at least the same as the pump inlet
4. Dry running should be kept to a minimum.
5. Air connection to have a minimum ID of 10mm.
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Maintenance
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3. Maintenance
The unique ‘One-Nut’ construction enables the user to carry out all maintenance quickly and efficiently.
WARNING - AIR SUPPLY TO THE PUMP MUST BE ISOLATED BEFORE ANY MAINTENANCE IS
CARRIED OUT.
WARNING - MEDIA COULD REMAIN INSIDE THE PUMP AND MAY BE UNDER PRESSURE.
PERSONNEL MUST WEAR APPROPRIATE PPE AT ALL TIMES.
WARNING - ONLY ORIGINAL FLOTRONIC PUMPS SPARE PARTS SHOULD BE USED IN THE
REPAIR AND MAINTENANCE OF THIS EQUIPMENT.
Routine inspection
Frequent observation of the pump operation is recommended to optimise performance.
Complete inspection
The intervals for a complete inspection depend upon the operating conditions of the pump, the
characteristics of the media, temperature and running time.
It’s recommended that a complete inspection is carried out at least once per year.
If a problem has occurred or if the pump is in need of a complete inspection, refer to procedures below.
Disassembly of the pump
Disassembly of the Flotronic Pumps Slimline pump can be easily achieved by competent personnel.
Spares required: Service kit.
To disassemble the Flotronic pump perform the following procedure:
Fig 3
1. Loosen and remove main nut
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Maintenance
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Fig 4
2. Remove the dome washer assembly.
Fig 5
3. Remove the secondary air dome.
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Maintenance
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Fig 6
4. Slide out the air system complete with the air valve
and the primary air dome.
Fig 7
5. Gripping both diaphragms, unscrew and remove
either diaphragm from the thrust tube.
Fig 8
6. Withdraw the other diaphragm with the thrust tube
attached.
7. Unscrew the second diaphragm from the thrust
tube.
It is recommended that the thrust tube is held in a vice
using soft jaws to aid diaphragm removal and prevent
damage to the thrust tube surface.
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Maintenance
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Fig 9
Fig 10
8. Standard Divider Seal
Using a suitable tool, push the divider seal up into
the groove until the bottom can be pulled or pushed
out and removed.
The groove in the body is machined so that it
is deeper towards the top of the pump.
Fig 11
9. Snap Fit Divider Seal
The divider seal may be pushed out with a suitable
blunt tool whilst taking care not to damage the face
of the body.
Fig 12
10. Unscrew the two bolts and remove the delivery
manifold.
11. Remove the two delivery balls.
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Maintenance
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Fig 13
Fig 14
12. Use a suitable tool to remove the two delivery
manifold ‘O' rings.
Fig 15
13. Pumps fitted with optional replaceable seats will
have 2 ‘O’ rings per seat.
Fig 16
14. Unscrew and remove the two bolts securing the
suction manifold to the main body.
Example shown in Fig 16 is 1½” to 2” versions.
½” to 1” versions have two manifold securing bolts
through the centre of the footplate and manifold to
retain the body.
15. Lift the main body off the suction manifold and
remove the two suction balls.
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