Checkpoint ATP Series Manual de usuario

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 1 of 12

Series ATP

Electric Chemical Injection Pump

Operating Manual

CheckPoint Headquarters

CheckPoint UK

CP Pumps & Systems FZE

21356 Marion Lane

C2 Lombard Centre

Shed 2, Warehouses 7 & 8

Mandeville, Louisiana 70471

Kirkhill Place, Kirkhill Industrial Estate

RAK Technology Park | P.O. Box 54796

United States of America

Dyce, Aberdeen AB21 0GU Scotland

Ras Al Khaimah | UAE

+1 (504) 340-0770

+44 (0)1224 775205

+971 (4) 8806278

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 2 of 12

TABLE OF CONTENTS

1. SYSTEM REQUIREMENTS 3

1.1 Inspection....................................................................................................................................................3

1.2 Storage.........................................................................................................................................................3

1.3 Unpacking....................................................................................................................................................3

1.4 Safety ...........................................................................................................................................................3

1.5 Location .......................................................................................................................................................3

1.6 Typical Installation Schematic ...................................................................................................................4

1.7 Connect chemical and process lines to checks.........................................................................................4

2. MOTOR INSTALLATION 5

2.1 Motor Requirements ..................................................................................................................................5

3. INJECTION HEAD ASSEMBLY 6

3.1 Adding an Injection Head. .........................................................................................................................7

4. STROKE LENGTH ADJUSTMENT 9

4.1 Adjusting the stroke length.......................................................................................................................9

5. OPERATION 10

5.1 Initial Startup ............................................................................................................................................11

6. TROUBLESHOOTING 11

6.1 Pump does not stroke ..............................................................................................................................11

6.2 Drive is excessively noisy .........................................................................................................................11

6.3 Miscellaneous............................................................................................................................................12

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 3 of 12

1. SYSTEM REQUIREMENTS

1.1 Inspection

1.1.1 Before installation, please inspect the pump carefully. If the pump appears to have sustained damage in

transit, call your CheckPoint Authorized Distributor or CheckPoint Customer Service directly at +1 (504) 340-0770

to report and confirm damage. If it is determined that damage occurred in transit, a carrier claim will be required.

1.2 Storage

The Series ATP pump has been thoroughly tested at the CheckPoint factory prior to shipment. This testing may

leave residual fluids in the pump head. Although our pumps can be placed in service without environmental

protection, we suggest that they are stored indoors until being commissioned.

1.3 Unpacking

The ATP pump can be shipped as a single-head or dual-head pump. Please ensure that unpackaged pumps are

securely placed in a safe area. Refer to the CheckPoint Quick Setup Guide for installation of the ATP pump.

1.4 Safety

The Series ATP can produce high rod loads. All CheckPoint pump heads used with the ATP are designed to

provide cover plates to minimize pinch points. Use of the ATP with another brand of pump head is not

recommended and may present safety hazards.

1.5 Location

1.5.1 For safe and continuous operation, locate the pump with supplied base on a stable surface with sufficient

access for the operator.

1.5.2 CheckPoint requires horizontal mounting for the Series ATP. Improper mounting could result in poor drive

performance and difficulty during priming. The Series ATP base is provided to ensure proper orientation.

1.5.3 The pump may be mounted to a skid or other surface in a number of ways; however, clamping around the

outside of the drive is not recommended. Proper mounting techniques increase accessibility during maintenance

and troubleshooting.

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 4 of 12

1.6 Typical Installation Schematic

FIGURE 1: TYPICAL INSTALLATION

CheckPoint offers Series ATP pump packages, which contain all necessary components indicated within the Package Limit Line in Figure 1.

CheckPoint can also supply pump packages that contain ALL components indicated in Figure 1, including the tank, mounted on a single skid,

with or without full leak containment.

1.Suction Line Block Valve 4. CheckPoint Calibration Gauge* 7. PRV –Discharge Lline 10. Discharge Check Valve*

2. CheckPoint Chemical Filter* 5. Tank Gauge 8. CheckPoint Series ATP Chemical Pump

3. Calibration Gauge Block Valve 6. Discharge Line Block Valve 9. Discharge Pressure Gauge

All items in Figure 1 can be purchased from CheckPoint. Call today for our latest prices on pumps, gauges, packages and other components.

*CheckPoint OEM products

1.7 Connect chemical and process lines to checks

Always clean suction lines and check chemical containers to ensure that they are free of all foreign matter, sand,

sludge, or chemical buildup.

NOTE: Even new chemical tanks can contain debris, which may cause system damage. Removing foreign

debris from suction lines and chemical containers will substantially extend the life of the packing

and other pump components.

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 5 of 12

NOTE: A presuction in-line chemical filter is strongly recommended to prevent early packing failure.

Abrasive particles carried into the pump through suction plumbing is a common cause of packing

failure. CheckPoint offers a range of chemical filters suitable for use with the Series ATP pump.

1.7.1 Suction Check

The attach point is a ¼” MNPT thread. Apply thread sealant, taking care to keep the sealant away from the suction

inlet port. Sealant entering the check could cause the pump to operate incorrectly.

1.7.2 Discharge Check

The attach point is a ¼” FNPT thread. Apply thread sealant, taking care to keep the sealant away from the process

line port. Sealant entering the process line could cause issues downstream.

2. MOTOR INSTALLATION

The base model Series ATP comes with the motor already installed. Should you need to remove the motor for any

reason, install per the motor install drawing located on the CP website.

Installation is made easier (though not required) using CheckPoint’s installation tool, available for purchase (insert

part # here).

2.1 Motor Requirements

2.1.1 The Series ATP drive input accepts a male a 5/8” shaft.

•CheckPoint recommends a motor/gear reducer combination not exceeding 120 rpm at the ATP drive input

shaft. The maximum-rated rotational speed of the ATP input shaft is 120 rpm. NEVER EXCEED 120 RPM.

2.1.2 Connect Power

•Special attention should be paid to motor type and location hazards prior to hookup. The electric motor

must be connected in accordance with all local regulations and area classifications and should include

overload protection.

•It is recommended that the Series ATP installation is equipped with an easily accessible “emergency off”

switch.

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 6 of 12

3. INJECTION HEAD ASSEMBLY

The base-level Series ATP pump assembly comes with a single head attached to the drive assembly (shown in

Figure 2).

FIGURE 2: INJECTION HEAD ASSEMBLY

*Motor and Base Removed for Clarity

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 7 of 12

3.1 Adding an Injection Head.

The base model Series ATP comes with a single head but can be easily converted to a double-headed

configuration. You will need the following assemblies:

Figure 3: Head Assembly - Typical Figure 4: Retainer Assembly –All Models

3.1.1 Install the retainer assembly (clamp screw towards the front cover) to the carriage assembly using (2) attach

screws.

FIGURE 5: RETAINER ASSEMBLY AND CARRIAGE ASSEMBLY INSTALLATION

*Motor and Base Removed for Clarity

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 8 of 12

3.1.2 Install plunger, snap ring, and screw assembly.

•Loosen the clamp screw approximately ½-turn.

•Screw the adjusting nut into the retainer assembly.

NOTE: The adjusting nut screwed in until it bottoms out on the end plate is full-stroke.

FIGURE 6: PLUNGER, SNAP RING, AND SCREW ASSEMBLY INSTALLATION

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 9 of 12

3.1.3 Attach head assembly

•Remove the two head bolts and install the thru drive housing wall.

•Add the approved grease on the tip of the plunger.

•Slide the head assembly over the plunger and tighten the head bolts to 20 in-lbs.

FIGURE 7: HEAD ASSEMBLY ATTACHMENT

4. STROKE LENGTH ADJUSTMENT

Both injection heads operate independently and have adjustable stroke lengths between 0” - 0.75”.

4.1 Adjusting the stroke length

Pump Delivery Volume is controlled by adjusting the stroke length. To change the stroke length, the adjusting nut

in the retainer assembly is screwed in or out depending upon the volume required. The retainer assembly block

has indicators for approximate percentage of stroke.

Max. stroke length ( ¾”)- Adjusting nut should be screwed in until it bottoms out on the end plate of the

carriage. Do not over-tighten nut.

Min. stroke length (0”) - Adjusting nut should be unscrewed until the bottom of adjusting nut is at the 0% mark.

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19Page 10 of 12

Adjust the stroke as directed below in Figures 8 and 9.

1. Turn off the drive system

2. Remove the front cover

3. Loosen the clamp screw ½-turn (or as required)

4. Insert the tool into the 3/16” adjusting nut hole

5. Rotate the adjusting nut to the desired stroke length (clockwise to increase stroke)

6. Restart the drive system

7. Check the flow rate

8. Once the desired flow is achieved, tighten the clamp screw.

NOTE: Very little clamping force is required to lock adjusting nut. Do not overtighten.

FIGURE 8: SHOWN AT 100% STROKE FIGURE 9: SHOWN AT 50% STROKE

5. OPERATION

The CheckPoint Series ATP drive requires no additional lubrication. The cam bearing is sealed, and the guide rods

have sufficient grease in the carriage assembly prior to shipment.

Pump Flow Rate –DC Motor

•The flow rate can be adjusted by changing the motor rpm and by changing the stroke length.

NOTE: Adjusting the motor’s rpm during operation will not damage the Series ATP pump. Refer to your

motor manufacturer’s manual to determine the effects of adjusting RPM during operation.

Pump Flow Rate –AC Motor

•The flow rate can be only adjusted by changing the stroke length.

End Plate

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