VALSTEAM ADCA ADCAMAT POP User manual

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
INSTALLATION AND MAINTENANCE INSTRUCTIONS
ADCAMAT POP –PPO-14 –PPA-14 PRESSURE OPERATED PUMPS
GENERAL
•These instructions must be carefully read before any work involving products supplied by VALSTEAM ADCA
ENGINEERING S.A. is undertaken.
•The installation procedure is a critical stage in a life of the equipment and care should be taken to avoid
damage to the equipment.
•They give their maximum performance only when the equipment associated with them is correctly sized and
installed in accordance with our recommendations.
•The POP pumps are designed for condensate pumping, cold water and other group 2 fluids, without the use of
electricity. They are specially recommended to return high temperature condensate back to boiler houses to
save and conserve energy.
•The ADCAmat automatic pumps can lift hot condensate, oils and other liquids as high as 60m (200ft) or
discharge against an equivalent total back pressure. The pump starts when there is something to pump and
stops when there isn’t.
•Liquid flows by gravity into the pump through an inlet check valve lifting a float which at the upper limit of its
travel opens the supply valve which allows steam or compressed air to enter the pump body. Pressure in the
pump builds up until just sufficient to overcome back pressure. The pressurized liquid opens the outlet check
valve and discharge commences. When the float reaches the minimum lower level, it closes the steam or
compressed air supply valve and opens the vent allowing the liquid to fill the pump again, beginning other cycle.
Note:
•Current regional safety regulations should be taken in to account and followed, while doing the installation and
maintenance work.
•Handling, installation and maintenance work must be carried out by trained personnel. A supervisor must follow
and check all activities.
•For the problems that cannot be solve with the help of this instructions, please contact the supplier or the
manufacturer.
•The manufacturer reserves the right to change the design and material of this product without notice.
•If necessary to perform hydrostatic test on the equipment/installation be aware of the limits according to the
table below. The internal mechanism cannot be subject to the hydrostatic test of the body.
Press.
bar
Temp.
ºC
Press.
bar
Temp.
ºC
16 50 16 50
14 100 16 100
13 195 13 195
12 250 12 250
16 50 16 50
13 195 13 195
Minimumoperation temp. : -10ºC; Design code: ASMEVIII
* Rating according to EN1092:2007
LIMITING CONDITIONS*
ANSI
Cl.150
PN16
PN16
ANSI
Cl.150
POP-S/PPO-14S/PPA-14S
POP-SS/PPO-14SS/PPA-14SS
RATING POP-S/PPO-14S/PPA-14S POP-SS/PPO-14SS/PPA14SS
PN16 23 bar 26 bar
Note: The internal mechanism cannot be subject to the hydrostatic test of the body
PRESSURETEST [bar] 20ºC

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
CE Marking: This product has been designed for use on water, steam, air and other gases which are in Group 2 of
the European PED-Pressure Equipment Directive in use and it complies with those requirements.
All the sizes fall within category 2, DN100 pump falling in the category IV and PPA-14 falling in the category III. The
products carry the CE mark.
- If malfunction of any other equipment or system operation failure may result in a dangerous overpressure, over
temperature or even vacuum condition, a safety device must be included in the system to prevent such
situations.
- Do not touch the equipment without appropriate protection during working operation because it may conduct
heat if the used fluid is at high temperature.
- Before starting maintenance be sure that the equipment is not pressurized or hot. Even if upstream and
downstream isolating valves have been closed care should be taken since fluid under pressure may be trapped
between them.
- The equipments must be used within the working temperature and pressure limits laid down for them, otherwise
they may fail (refer to nameplate and/or IS- Information Sheet).
- Manual handling of products may present a risk of injury. You are advised to assess the risks taking into
account the task, the individual, the load and the working environment.
- Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine ADCA
replacement parts.
0,80 kg/dm3
5º Engler
10 bar
0,5 bar
11,2 l
Minimummotive pressure
Pump discharge per cycle DN25 to DN40
APPLICATION LIMITS POP LC
Minimumdensity
Maximumviscosity
Maximummotive pressure
0,80 kg/dm3
5º Engler
10 bar
0,5 bar
16 l
25 l
APLICATIONLIMITS POP-S AND PPO-14
Minimumdensity
Pump discharge per cycle DN80 x DN50
Maximumviscosity
Maximummotive pressure
Minimummotive pressure
Pump discharge per cycle DN25 to DN50
0,80 kg/dm3
5º Engler
10 bar
1 bar
325 l
Minimummotive pressure
Pump discharge per cycle DN100 x DN100
APLICATIONLIMITS POP-S DN100
Minimumdensity
Maximumviscosity
Maximummotive pressure
0,80 kg/dm3
5º Engler
10 bar
1 bar
21 l
APLICATIONLIMITS PPA-14
Minimumdensity
Maximumviscosity
Maximummotive pressure
Minimummotive pressure
Pump discharge per cycle DN80 x DN50

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
- Do not remove the nameplate attached to the equipment. Serial number and other useful information is
stamped on it.
- During the assembly work, apply protective measures against dirt.
- When connecting flanges, the bolts should be mounted from the counter flange side with the hexagon nuts from
the valve side and it must exist a perfect match between the connection flanges.
- Tighten flange connection bolts uniformly in a diagonal sequence.
- Correct installation of the equipment is full responsibility of the contractor.
TRANSPORT AND STORAGE
- Handling and lifting of materials should be made with adequate equipments.
- Do not damage the paint job. It protects against corrosion during transportation and storage.
- The pumps and equipments should be protected from impacts and forces during transportation and storage.
- The manufacturer doesn’t assume the responsibility of damaged equipments due to inappropriate handling
during the transportation and storage. See figure below for correct position in transportation.
Incorrect position Correct position
INSTALLATION
- Account for over pressure conditions, according with the local laws or standards.
- Pumps must not be used with other purpose than the one they were built for (e.g. climbing aids or as
connecting points for lifting gear).
- For the problems that cannot be solve with the help of this instructions, please contact the supplier or the
manufacturer.
- The pump operation is only guarantee if ADCA non-return valves are used. When installing and uninstalling
these valves, care should be taken to prevent any position inversions during the installation (in those cases
where the DN is the same), because they have different settings.
- A strainer installation is highly recommended in the condensate feeding to the pump for non-return valves
protection. The strainer shall be cleaned after the commissioning and then with some regularity. If this
requirement is not accomplished, it can cause a feeding restriction into the pump, reducing significantly the
pumping capacity.

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
Installation area requirements:
•The installation area should have easy access and provide enough space for maintenance and removing
operations.
•The installation area should have the necessary firing system to prevent damage of the equipment due to over
temperature/pressure cause by fire.
Procedure:
•Prior to install check that the product is suitable for the intended application: materials and
pressure/temperature ratings.
•Before installing remove, plastic covers placed on flanges or connection ends. The equipment has an arrow or
Inlet/Outlet designations. Be sure that it will be installed on the appropriate direction.
•Take care with jointing material to ensure that none may be permitted to block or enter the equipment.
•The pump must be handled carefully in order to avoid any mechanism damage.
•The pump must be installed at the lower level of the equipment to be drained and the exhaust DN 1”
connection pointing upwards.
•For the correct installation and operation of the pump, Y strainer, isolating valves and steam trap must be
provided. Please refer to Information Sheet IS 9.101 E. Special application information can be obtained by
contacting the distributer or Valsteam SA directly.
•Ensure that the unit is leveled for proper operation.
•External stresses that may be induced by the system due to pipe expansion, etc, can affect this product. The
necessary precautions are recommended during the systems design and equipment assembly.
•The pipework should be properly supported and free from strain and it should not be subjected to undue surges
of pressure. The start-up condition should be considered.
START UP
- Current regional safety regulations should be take in to account and followed.
- Protective insulation and warning notice may be required.
- Until the start up of an existing or a new plant, the following must be checked:
- All works are completed.
- The equipment is correctly installed.
- All the necessary safety devices have been installed.
- At start up, the presence of small particles in the motive fluid (dirt, scale, weld splatters, joint particles,
remains of Teflon tape, etc) may cause anomalies. If this occurs, proceed to an accurate cleaning.
Periodical checking:
•24 hours after the start up, it is recommended to check pipe connections for leaks and retighten the connections
if necessary.
MAINTENANCE
•We recommend the pumps to be serviced as necessary. Pumps should be checked periodically (at least
yearly), to verify if they are operating correctly and to verify the wear of the internal parts specially the motive
fluid admission and exhausting valves.
•Strainers, steam trap and receiver should be cleaned.

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
•When reassembling make sure that all gasket faces are clean and always use a new gasket. Tighten cover
bolts uniformly in a diagonal sequence.
•Estimated lifetime under satisfactory working conditions: 5 years; after this period, we recommend the wall
thickness examination using appropriated inspection equipment. Pour quality water or corrosive fluids will
reduce this period.
•Always apply the mentioned torques, see recommended tightening torques table when maintenance operations
are carried out.
•Maintenance should proceed as follows:
1. Isolation valves should be closed, and the pressure and temperature must be atmospheric.
2. Remove the type of connections used.
3. Execute the maintenance work.
4. Replace and tighten the connections. (Don’t forget to substitute the gasket).
5. Consider the start up conditions.
TROUBLESHOOTING
- If the malfunctions cannot be solved with the help of the following chart, please consult the manufacture.
- Some of these faults may only occur in some models.
TROUBLE SHOOTING CHART
FAULT
POSSIBLE REASON
SOLUTION
Continuasly leak through the
exaust.
Motive fluid admission/exhaust valves
damaged.
Replace.
Premature erosion of admission
valve.
Pour quality steam.
Check the trapping of the motive
fluid (steam).
Pump stops to work.
Broken spring *
Float with water in the interior *
Replace.
Replace.
Blocked in the maximum/lowest
level.
Detuned.
Readjust (See Figure 1).
Pump discharge capacity is
decreasing
Clogged/obstructed strainer
Clean or replace the filter element
* Manufacture to be informed. The life time of this component is assured beyond the guarantee validity.

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
SPARE PARTS
POP-S (Till DN80), PPO-14 and PPA-14
POP LC
POP-S
A.95.5800.025
INLET/OUTLET VALVES ALL 4, 5 1 Set
A.95.5800.125 FLOAT AND GASKET ALL 3, 7 1 Set
A.95.5800.225 SPRING SET ALL 8 1 Set
A.95.5800.325 COVER GASKET ALL 3 1 Set
A.95.5500.025 PPA-14 INLET/OUTLET VALVES 80 4, 5 1 Set
A.95.5500.125 PPA-14 FLOAT AND GASKET 80 3, 7 1 Set
A.95.5500.225 PPA-14 SPRING SET 80 8 1 Set
A.95.5500.325 PPA-14 COVER GASKET 80 3 1 Set
A.61.1140.025A INLET ADCAMAT NON RETURN VALVE 25 9.2 1
A.61.1140.040A INLET ADCAMAT NON RETURN VALVE 40 9.2 1
A.61.1140.050A INLET ADCAMAT NON RETURN VALVE 50 9.2 1
A.61.1140.080A INLET ADCAMAT NON RETURN VALVE 80 9.2 1
A.61.1140.025B OUTLET ADCAMAT NON RETURN VALVE 25 9.1 1
A.61.1140.040B OUTLET ADCAMAT NON RETURN VALVE 40 9.1 1
A.61.1140.050B OUTLET ADCAMAT NON RETURN VALVE 50 9.1 1
CODE
DESIGNATION
QTY.
POS.NR.
SIZE
DN

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
PPA-14
PPO-14

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
POP-S DN100
How to replace Inlet/Outlet valves on POP LC (till DN40), POP-S and PPO-14 (till DN80):
1. With the float at the lowest position remove the bolts Nr.21 and disassemble the support Nr.15.
2. The valve set is supplied duly calibrated from the factory. Do not unscrew the nuts Nr.17A and 19A.
3. After replacing the valves and support, make sure that the mechanism is working correctly by manually
operating the float.
POP-S DN100
-FLOAT AND GASKET 3, 5 1 set
-COVER GASKET 3 1 set
-INLET/OUTLET VALVES - 1 set
SPRING SET - 1 set
-INLET ADCAMAT NON RETURN VALVE 7 1
-OUTLET ADCAMAT NON RETURN VALVE 6 1
CODE
DESIGNATION
QTY.
POS.NR.
17B
16
15
21
17
17A
54
19A
TUNE WITH THE
EXHAUSTING VALVE
CLOSED.

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
Adjustment of upper level switch on POP-S and PPO-14 till DN80:
1. Tighten up screw nr.18A - decrease maximum level.
2. Untighten the screw nr.18A - increase maximum level.
Adjustment of lower level switch on POP-S and PPO-14 till DN80:
1. Tighten up screw nr.18C - increase lower level
2. Untighten the screw nr.18C - decrease lower level
How to replace Inlet/Outlet valves on PPA-14:
1. With the float at the lowest position remove the bolts Nr.21 and disassemble the support Nr.15.
2. The valve set is supplied duly calibrated from the factory. Do not unscrew the nuts Nr.17 and 19.
3. After replacing the valves and support, make sure that the mechanism is working correctly by manually
operating the float.

 ADCA
VALSTEAM ADCA
IMI 9.101 E 02.17
-The screws must not be adjusted without specific factory information.
STROKE COUNTER
- In order to ensure that the stroke counter works reliably, it is recommended a minimum backpressure of at least
500mbar on the pump´s outlet RD40 check valve. If this value cannot be achieved, we recommend a RD40 with a
strongest spring in the pump outlet connection.
PRODUCTS RETURNING
- Information regarding any hazards and precautions to be considered because of contaminating fluids and
residues or mechanical damage that may represent a health, safety or environmental risk, must be provided in
writing by the distributors and costumers when returning products to Valsteam ADCA engineering.
- Health and safety data sheets regarding substances identified as hazardous or potentially hazardous must be
provided with the information mention above.
- LOSS OF WARRANTY: Total or partial disregard of above instructions involves loss of any right to warranty.