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

EC Declaration of Conformity

Guardian Mk3.1

Introduction

Warning symbols

Receiving inspection

Storage

Mounting

Electrical connections

Air connections

Air preparation

Air pressure

Health & safety

Protection

Explosive environments

Function plate

Set point adjustment

Remote reset

Alarm output

Barrier & Stop (BARR)

Principle of operation

Recommended installation

Set point adjustment

Operation

Trouble shooting

Dry-run & Stop (DR&S)

Principle of operation

Recommended installation

Set point adjustment

Operation

Trouble shooting

Dead-head & Stop (DH&S)

Principle of operation

Recommended installation

Set point adjustment

Operation

Trouble shooting

Dead-head & Restart (DH&R)

Principle of operation!

Recommended installation

Set point adjustment

Operation

Trouble shooting

Specifications

Dimensions

Connections

Characteristics

Guardian coding

Maintenance

Routine inspection

Complete inspection

Tightening torques

Guardian parts

Returning parts

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

Gas group

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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0.2 The warning symbols

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0.3 Qualification and training of personnel

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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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0.3 Qualification and training of personnel

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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

Function plate

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

Guardian Mk.3.1

Set point adjustment screw

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

Guardian Mk3.1

3/2 NC valve

Shown as push button/spring, could also be solenoid/spring

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

Guardian Mk3.1

Alarm O/P

Valve O/P

Pneumatic visual indicator

Audible alarm (Such as TPUK-PA or TPUK-PAM)

Volt free contacts (Such as TPUK-VFC)

Plugged (standard)

Air in 5-8 bar

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