ZM Bombas ZM 44 MAXXI User manual

Instruction Manual
ZM Pompe

Thank you for buying a ZM–MAXXI hydraulic pump.
ZM–MAXXI pumps are designed to give you long service life,
low maintenance and constant water delivery.
First, some basic technical facts concerning installation and use.
Installation
Pumpsshouldbeinstalledonalevel,firmplatformorotherconcreteorwoodsurface.Setthepumpframeleveland
squareontheplatform,securewithbolts.
Then,assemblethepump,fittingthesuctionandpropulsionpipesandthewaterwheel.Thenbringawaterstreamtothe
wheel (as shown) to commence operation.
Movement of the Wheel
Thewheelcanbedrivenbywaterfallingfromtheopenendofawooden,cement,plasticorP.V.C.pipe.
Table of water flow need to move the wheel
MODEL
WATER FLOW TO
TURNWHEEL
ESTIMATED
FLOW
FLOW (l/sec)
DISTANCE
TOTALHEAD
PRODUCTION
(l/day)
HEIGHT
FROM BASE
ZM 44 MAXXI
50mm –100mm
50mm
2
12km
190m
4–10,000
1,5m
ZM 38 MAXXI
100mm –150mm
50–75mm
2–4
12km
300m
5–11,000
1,75m
ZM 51 MAXXI
75mm –200mm
75–200mm
4–30
12km
200m
9–18,000
1,9m
ZM 63 MAXXI
150mm –200mm
200mm
15–30
12km
150m
16–32,000
2,0m
ZM 76 MAXXI
175mm–250mm
250mm
30–60
12km
200m
30–55,000
2,3m
ZM 95 MAXXI
200mm –300mm
300mm
50–70
12km
130m
40–90,000
2,5m
NB! For applications where water is to belifted to heights greater than 70 meters between the pump and and the retention tank, an
additional wheel should be employed. This pump should also be driven by a more powerful water stream.
** Rotation estimated between 20 and 40 r.p.m. (revolutions/min)
A Diameterofthewheel
B Distance between the tube
andthetopofthewheel:
approximately10cm
C Lengthofthetube:
D Slopeofthetube:3%to5%
ofthelength
E Betweenthewheelandthe
ground:notlessthan10cm
A

Water feed
Dependingontheavailabilityofwaterandpipework,thepump’swheelcanbedriveninoneofthreeways:
1 –Water supply at top
Thisisthebestwaytodrivethewheel.Thedeliverypipemustbecentralised
withthetopofthewheelnomorethan10cmabovethedrivevanes.Thedelivery
ofwaterwilldeterminetherotationofthewheel.
2 –Water supply at lower level
Insituationswhereitisnotpossibletoprovideawatersupplytothetopof the
wheel,itispossibleto directthejetatthespokesofthewheelanddriveitin
thatfashion.Wherethismethodologyisrequired,itisessentialtoutilisealarger
wheelinordertooptimisethewaterpressureavailable.
3 –Water supply at ground level
Whentopographicconditionsdonotpermitinstallationofthefeedwatertube
inthenormalway,asuitableculvertshouldbeconstructedeitherfrombrickor
wood.Thisshouldbeapproximatelythesamewidthasthepaddlesonthewheel,
inordertooptimisethewaterpressureavailable.Thismethodofpropulsion
isnotveryefficientandatypicalrotationspeedis8–12r.p.m.shouldbe
anticipated.Toincreaseefficiency,multiplestreamscanbefedintotheculvertto
increase feed water volume and thereby, pressure.
Wheelsshouldbespecifiedforspecificwaterfeedapplicationsandpreferably
onlyafterasurveyofthewateravailabilityhasbeenundertaken.
Suction System
Notes
• ThemaximumverticalliftinwaterheadpossiblewithZM–MAXXIpumpsis
approximately7m.Horizontally,thesuctiondistanceisapproximately60m.
Forinstallationsexceeding2mvertically,orahorizontaldistancemorethan
5m,anonreturnvalveshouldbeinstalledatthefootofthepump.
• Pumpsshouldalwaysbeprimedwithwaterbeforeuse,whenpointofsuction
ismorethan2mfrompump.
• Asarule,1mofverticalwaterliftisequivalentto10mhorizontalpumping
• Waterqualitywillaffectthepump’sleathersealsandmechanism.Wheresand
andothergrittysubstancesarecarriedinthewaterflow,thelifeofthepump
couldbeadverselyeffected.Thisadditionalwearandtearisnotcoveredby
theunit’sguarantee.
NB! Gap between paddles and base
must not be less than 50mm

????
UNDERGROUND
TUBE
DIAMETER
Output pipe
Wheninstalling,prepareatrenchfromthepumptotheholdingtank.Specifyapipewithsufficientinternaldiameterto
optimisewaterflowandlaythispipeinthetrench.Runthepumptoensuretherearenopunctures,orholesinthepipe
and then cover.
ZM–MAXXI pumpscanpumpwaterhorizontallyupto12,0000m(12km)ortoanelevationofupto300m(definedas
WaterColumnMeters),accordingtothemodelandthetableno.3below.Acombinationofdistanceandheightispossible
andadviceinthisregardisavailablefromZMPompe’sengineers.
Wheretheheightfromthepumpandholdingtankisgreaterthan70m,anextrawheelisrecommendedonthepump.
Also,asdistancebetweenpumpandtankincreases,itisrecommendedthatthewaterpipediameterbeincreasedto
minimisepressureloss(seetableNo.2).
Useful Recommendation
Theuseofaunionattheexitofthepumpandanonreturnvalvenearofthepump(within2m)isstronglyadvised.In
situationswhereextendeddistanceandheightsareencountered,anonreturnvalveisnecessaryforevery20mofwater
head created.
= Non–return
valve every 20m
100
80
60
40
20
0 1 2
km
3 4 5
Percentage Losses
DISTANCE
0,5km
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0km
0,75”
2.00
7,50
16,00
27,00
35,00
58,00
80,00
100,00
•
•
1,0”
0,70
2,70
5,00
10,00
16,00
21,50
26,00
37,00
45,00
55,00
1,25”
0,20
0,75
1,60
2,70
4,50
6,00
8,00
10,00
12,00
15,50
1,5”
•
0,22
0,50
0,80
1,40
1,80
2,40
3,00
3,70
4,70
2,0”
•
0,08
0,17
0,28
0,40
0,60
0,80
1,05
1,30
1,60
2,5”
•
•
•
0,07
0,12
0,16
0,22
0,27
0,32
0,42
3,0”
•
•
•
•
•
0,05
0,08
0,10
0,12
0,15
m
of
w
at
er
head

Maintenance
Lubrication
• SAE90oilisrecommendedinthebodyofthepump
• Theoillevelcanbeseenintheportprovidedinthepump’scasing
• Theoilmustbechangedbetween6and12monthsdependingonusage
• Checktheoillevelevery30to60days,topping–upasnecessary.Thecapacity
ofthebodycastingis: ZM44 –MAXXI =1,2litres,
ZM 38/51/63 –MAXXI = 2 litres, ZM 76/95 –MAXXI = 3 litres
Fixing
• Checkthetightnessofthepumpanditsfixingsevery60days
Explanation of the tables
• Pumpsaremanufacturedinthenormalversionsshowninthegreenrowsofthetables
• TheelevationcolumnindicatesthemaximumwaterheadpossibleinMetersofWaterColumn
• Thewaterflowspecifiedinthetablesreferstoa24hoursproductioncycle
• Allthemodelshaveaextrastrokeofthepiston,thatisusedinsituationswherethecustomerhaslandwithasmall
elevationandalargequantitiesofwaterandwhereitispossibletouseefficientlytheequipmentreferringtotheextra
columnoftheannextables
Maximum elevation: 300m Maximum elevation: 190m
Maximum elevation: 200m Maximum elevation: 200m
ZM 38 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
6,230
9,340
12,460
15,570
200m
Normal
5,250
7,800
10,500
13,000
220m
A
4,500
6,880
8,000
11,400
240m
B
3,900
5,800
7,500
9,600
260m
C
3,200
4,900
6,500
8,200
280m
D
2,200
3,400
4,500
5,700
300m
ZM 44 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
5,200
7,800
10,400
13,000
130m
Normal
4,300
6,400
8,600
10,800
150m
A
3,400
6,100
6,900
8,600
170m
B
2,600
3,900
5,200
6,400
190m
ZM 51 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
10,600
16,000
21,000
26,600
140m
Normal
9,000
13,300
18,000
22,200
160m
A
8,000
11,700
15,600
20,000
170m
B
6,800
10,000
13,700
17,000
180m
C
5,700
8,300
11,200
14,000
190m
D
3,600
5,800
7,800
10,000
200m
ZM 76 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
31,500
47,250
63,000
78,700
130m
Normal
27,500
41,300
55,000
68,700
150m
A
23,600
35,400
47,200
59,000
160m
B
19,600
29,500
39,300
49,100
170m
C
15,750
23,600
31,500
39,300
200m

Maximum elevation: 150m Maximum elevation: 150m Maximum elevation: 130m
Possible defects, causes and solutions
Problems
Causes
Solutions
The wheel turns and stops
Water flow insufficient to drive the
wheel.
Increase the water volume to move the wheel or change the stroke
of the pistons. *
The pump functions but doesnot
propel water
1) Grit/obstructions in the valve
2) Air intake
3) The propulsion tube is cracked
1) Clean the suction tube and place a nylon screen (mosquito
net type), in front of tube
2) Clean the valve, remove obstructions
3) Check the connections at the top and base of the suction
tube, eliminating any possibility of air intake
4) Adjust the leather seals by moving the lateral part of the
leather assembly, or replacement
5) To test the pressure of the pump, close the exit. If you have
an reduction (stop) of the rotation of the wheel, the different
closing of the pump are corrects, in this case the tube is
fissured. In this case that the wheel does not stop stop,
check the valves and the leathers of the pump
The pump doesn’t suck water
1) The level difference between the
pump and the water to be lifted is
higher than 7 meters.
2) Problem in the valves
3) Degraded leathers
4) If water to be lifted is higher than
the level of the pump, the water
enters the pump with an abnormal
pressure, closing the suction valve
1) Instal a vertical non return valve and prime the tube with
waterbefore use
2) Verify that the valves are not blocked
3) Change theleatherseals
4) Bring water in a tank near of the pump and make the suction
in this tank.
The pump pumps in a jet
1) Valves blocked
2) Degraded leather seals
1) Verify that the valves are not blocked
2) Adjust leather seals
Production (flow) insufficient of the
pump
1) Degraded leather seals
2) Water flow to the wheel is
insufficient
3) Valves out of alignment
4) Water availability limited
1) Change theleatherseals
2) Verify if the water production is suitable for the wheel
rotation
3) Change the valves
4) Find another water source
* See the instruction on the pistons stroke modification –pg ?
ZM 63 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
17,300
25,900
34,600
43,300
100m
Normal
14,500
21,800
29,100
36,400
110m
A
12,700
19,100
25,500
31,900
120m
B
10,900
16,400
21,800
27,300
130m
C
9,000
13,600
18,200
22,700
140m
D
6,300
9,500
12,700
15,900
150m
ZM 95 MAX 1
Production by revolutions and pump stroke
Stroke
20 r.p.m.
30 r.p.m.
40 r.p.m.
50 r.p.m.
Elevation
Extra
48,900
73,400
97,800
–
90m
Normal
42,800
64,200
85,600
107,000
100m
A
36,600
55,400
73,900
92,300
110m
B
30,500
45,700
61,000
76,200
120m
C
24,200
36,700
48,900
61,100
130m

Terms of Guarantee
ZMPumpeguaranteestheequipmentinthismanualandwillrepair,orreplaceanycomponentswhichmightfailinnormal
service,orwheremanufacturingdefectmaybeidentified.
Period of guarantee
24(twentyandfour)months,fromthedateofthesale.
Application of the guarantee
TheguaranteewillhonouredbyZMPompe,afterexaminationofthefaultyunitandwherefailureisasaresultofa
mechanical, or manufacturing defect.
Pumpswillonlybereplacedinsituationswhererepairscannotbesuccessfullycarriedoutbyreplacementoffailed
components.
Loss of the guarantee rights
Anyoneofthefollowingthatwillautomaticallyrevoketheprovisionsoftheguarantee:
Useofequipmentincontraventionoftherecommendationsofthismanual,abuse,overwork,oraccidents
• Incorrect handling, preventive/corrective maintenance of incorrect usage
• UseofcomponentsnotprovidedbyZMPompe
• Alterationstothepump,orcomponentsnotsanctionedbyZMPompe
• Change,destructionorlossoftheoriginalsaledocumentation
Items exluded from the guarantee:
Theitemsbelowarenotcoveredbytheguarantee:
Wearandtearduetonormalusage:thefilterelements,theleathercarriers,Orings,valves,cylinders,movements,aswell
asthecarryingoutofroutinemaintenance
• Componentsdestroyed,ordisabledbynaturalcauses,otherthancausedbymanufacturing,installation(ifbyZM
Pompe)orrawmaterialdefect
• Failure due to accident
• Incorrectlyspecified,oremployedhydraulicoils,lubricants,greasesandsimilarmaterials
• Damagebytheuser,orathirdparty
• Damage caused during transit
Note:
Theguaranteedoesnotcovertheexpenseoftransportation.Thischargewillforthecustomer’saccount.
Precautions
• Donotattempttostopthepumpwithpiecesofwood,ironorotherobjects
• Donotlubricatetheleatherswiththegrease,oilorotherlubricants,onlyuseVaseline
• Donotexceedtheoillimitstipulatedinthemanual
• Donotforgettochangethepumpoilafterit’susefullife
• Ensurethatwatertobeliftedisnotinthesamestreamasthewaterusedtodrivethepump
• Donotpermitthepumprotationalspeedtoexceedthemaximumr.p.m.indicatedinthespecification
• Donotattempttoliftwatercontaining sandand/orgrit
• Donotreusetheleatherseals
• Ensurethathepumpisproperlyinstalledandclearofanyrocks,treesorotherelementswhichmightcausedamage
under extreme weather and environmental conditions
• Utiliseadecantingtankandafilterforsandinthesuctionsection
Followthesesimpleinstructionsformaximumpumplifeandminimalmaintenance.