TapFlo Sanitary T Series Manual de programación

Instructions for installation, operation and maintenance.

sanitary series air operated diaphragm pumps.

STOP

Read this instruction manual carefully,

before you install and operate the pump

Pump models:

T30

T225

T80

T425

T125

IOM MANUAL

InstructionmanualsanitarypumpsT30-T425 2

CONTENTS

CE CERTIFICATE 3

0 GENERAL 4

0.1 Introduction 4

0.2 The warning symbols 4

1 INSTALLATION 5

1.1 Receiving inspection 5

1.2 Storage 5

1.3 Foundation 5

1.4 Suction and discharge pipings 5

1.4.1 Connection of suction pipe 5

1.4.2 Connection of discharge pipe 5

1.5 Air connection 5

1.5.1 Air treatment system 6

1.6 Example of installation 6

1.7 Recommended installations 6

1.7.1 Flooded 6

1.7.2 Selfpriming 6

2 OPERATION 7

2.1 Health and safety 7

2.1.1 Protection 7

2.1.2 Environments in danger of explosion 7

2.1.3 Air pressure 7

2.1.4 Noise level 7

2.1.5 Temperature hazards 7

2.2 Before starting the pump 7

2.3 Starting and operating 8

2.3.1 Dry running 8

2.3.2 Optimizing the pump lifetime 8

2.4 Pump stopping 8

2.5 Cleaning of the pump 8

2.5.1 CIP - Clean in place 8

3 MAINTENANCE 9

3.1 Performance test 9

3.2 Routine inspection 9

3.3 Complete inspection 9

3.4 Location of faults 9

3.5 T30-Dismantlingthepump 10

3.5.1 Beforethedismantlingprocedure 10

3.5.2 Mainparts 10

3.5.3 Centerblock 10

3.6 T30 -Assembly of the pump 11

3.6.1 Centerblock 11

3.6.2 Assembling of the main units 11

3.6.3 Test run 11

3.7 T80-T425-Dismantlingthepump 12

3.7.1 Beforethedismantlingprocedure 12

3.7.2 Mainparts 12

3.7.3 Centerblock 12

3.8 T80-T425-Assemblyofthepump 13

3.8.1 Centerblock 13

3.8.2 Assembling of the main units 13

3.8.3 Test run 13

4 SPARE PARTS 14

4.1 T30-Drawingandspare part list 14

4.2 T80-T425-Drawingandsparepartlist 15

4.3 Stockingrecommendation 16

4.4 Howtoorderparts 16

4.5 Pumpcode 16

5DATA 17

5.1 Capacitycurves 17

5.2 Capacitychanges 17

5.3 Dimensionsandtechnicaldata 18

5.4 Tighteningtorques 18

6 WARRANTY & REPAIR 19

6.1 Warrantyform 19

6.2 Returningparts 20

6.3 Warranty 20

InstructionmanualsanitarypumpsT30-T425 3

Declaration of conformity

Machinery directive 89/392/EEC, Annex 2A

Tapflo AB declares that:

Product name: Air operated diaphragm pumps

Models: T…

Is in conformity with the essential health and safety requirements and technical

construction file requirements of the EC Machinery directive 89/393/EEC with

amendments 91/368/EEC, 93/44 EEC and 93/68 EEC.

Manufacturer: Tapflo AB

Address: Filaregatan 4

S-442 34 Kungälv

Sweden

Tapflo AB, september 1st 1999

Börje Johansson

Managing director

CE CERTIFICATE

InstructionmanualsanitarypumpsT30-T425 4

0.1 Introduction

The Tapflo Air Operated Diaphragm Pump range is a complete series of pumps for industrial

applications. The pumps are designed to be safe simple and easy to use and maintain. The

construction is sealless and without rotating parts. The pumps are suitable for a variety of duties in

hygienic installations.

With proper attention to maintenace, Tapflo Pumps will give efficient and trouble free operation.

This instruction manual will familiarise operators with detailed information about installing, opera-

ting and maintaining the pump.

0.2 The warning symbols

The following warning symbols are present in this instruction manual. This is what they say.

This symbol stands next to all safety instructions in this instruction manual where danger

to life and limb may occur. Observe these instructions and proceed with utmost caution

in these situations. Inform also other users of all safety instructions. In addition to the

instructions in this instruction manual, the general safety and accident prevention

regulations must be observed.

This signal stands at points in this instruction manual of particular importance for

compliance with regulations and directives, for correct work flow and for the prevention

of damage to and destruction of the complete pump or its subassemblies.

0. GENERAL

STOP

InstructionmanualsanitarypumpsT30-T425 5

1. INSTALLATION

1.1 Receiving inspection

Although precaution is taken by us when packing and shipping, we urge you to carefully check the

shipmentonreceipt.Make sure that all parts andaccesorieslistedon the packing list are accounted

for. Immediately report any damage or shortage to the transport company and to us.

1.2 Storage

If the equipment is to be stored prior to installation, place it in a clean location. Do not remove the

protective covers from the suction, discharge and air connections which have been fastened to

keep pump internals free of debris. Clean the pump thoroughly before installation.

1.3 Foundation

The support of the pump is furnished with mounting holes. Fix the pump on a stable foundation,

which is able to absorb vibrations. It is essential for the operation of the pump to mount the pump

with the feet in a downward direction (see sketch in chapter 1.6).

1.4 Suction and discharge pipings

Suction and discharge piping should be fully supported and anchored near to but independent of

the pump. The piping to the pump should be a hose, to prevent undue stress and strain on the

pump connections and the pipings.

1.4.1 Connection of suction pipe

Remember that the suction pipe/connection is the most critical point, especially if the pump is

priming. Just a small leakage will dramatically reduce the suction capability of the pump. When

connecting the suction pipe, following is recommended.

1) For satisfactory operation, use reinforced hose (the suction power may otherwise shrink the

hose) or other flexibel piping. The internal diameter of the hose should be the same as on the

suction connection (at the bottom of the pump) to have best suction capability.

2) Make sure that the connection hose - pump is completely tight, otherwise the suction capability

will be reduced.

3) Always use as short suction pipe as possible. Avoid air pockets which can arise with long

pipings.

1.4.2 Connection of discharge pipe

For this connection it is only recommended a simple and positive flow connection. Use a hose or

flexible piping (minimum one meter) between the discharge connection and any rigid fixed piping.

Coil the hose at least one turn. All components (hose, pipe, valves etc) on the discharge piping

must be designed for minimum PN 10.

1.5 Air connection

Screw the air hose into the air intake on the center block of the pump with for example a bayonet

coupling.Forbestefficiency,usethe same hose diameter as the internaldiameteroftheconnection

on the air intake.

STOP

InstructionmanualsanitarypumpsT30-T425 6

1. INSTALLATION

1.5.1 Air treatment system

The air valve is constructed for oilfree air. Lubrication of the air is not allowed. However, if the air

is very dry (laboratory air), the air may be lubricated with water. Maximum air pressure is 8 bar. As

preventionpurpose, a filtration of the air by means of a5 micron filteror finer is recommended.Dirt

in the air can under unfortunate circumstances be the cause of breakdown.

Tofacilitate the operation of the pump we recommend an airtreatment system connectedto the air

supply. These components should be included:

1) Regulator to adjust the air pressure

2) Manometer to read the actual pressure

3) Needle valve to adjust the air flow

4) Filter

These components are included in Tapflos Air treatment system which can be ordered from us.

1.6 Example of installation

1) Gate valve compressed air

2) Filter and pressure regulator

3) Flexible hose

4) Needle valve

5) Flexible piping

6) Gate valve suction

7) Gate valve discharge

8) Coiled flexible piping

9) Flow gauge

1.7 Recommended installations

The Tapflo pump is flexible in the way you are able to install it.

1.7.1 Flooded

Thepiping system is designedwith a positive suction head. This isthe best way ofinstalltion where

itisnecessarytocompletelyevacuate all liquid from the container, or whereviscous(thick)products

are transfered.

1.7.2 Selfpriming

The Tapflo pump is designed to pull a high vacuum. It is able to evacuate an empty suction pipe

without any damage to the pump. The suction lift is up to 5 meter (16.4 ’) from an empty suction

pipeand up to8 meter (26.2’) from a wetted pipe. The suction capability depends on thepump size

(see chapter 5)

InstructionmanualsanitarypumpsT30-T425 7

2. OPERATION

2.1 Health and safety

The pump must be installed according to local and national safety rules.

The pumps are constructed for particular applications. Do not use the pump on applications

different from that for which it was sold without consulting us to ascertain its suitability.

2.1.1 Protection

In the interest of health and safety it is essential to wear protective clothing and safety goggles

when operating, and/or working in the vicinity of Tapflo pumps.

2.1.2 Environments in danger of explosion

The standard stainless steel series pumps are not allowed to operate in environments in danger of

explosion. Static electricity may occur in the pump under operation, which may cause explosion

andinjury. SpecialATEX approvedpumpsareavailable for such applications.ConsultTapfloABfor

furtherinformation. Follow the explosion safety rules applicableat the locationfor the pump.

2.1.3 Air pressure

The maximum air pressure for Tapflo pumps is 8 bar. Higher air pressure than 8 bar can damage

thepump and may causeinjury to personel invicinity of thepump. If you intendto apply a higherair

pressure than 8 bar, please consult us.

2.1.4 Noise level

Attests,thenoiselevelfromaTapflopumphasnotexceeded80dB(A).Undersomecircumstances,

for example if the pump is operating under high air pressure at low discharge head, the noise can

be inconvenient or hazardous for personel staying for long periods in vicinity of the pump. This

hazard can be prevented by:

- using suitable ear protection

- lower the air pressure and/or raise the discharge head

- lead the outcomming air from the placeby connecting a hose fromthe muffler connection of the

pump.

- use elastomer valve balls (EPDM, NBR or polyurethane) instead of PTFE, ceramic or stainless

steel, provided that the elastomer is compatible with the pumped liquid.

2.1.5 Temperature hazards

Raised temperature can cause damage on the pump and/or pipings and may also be hazardous

forpersonelinthevicinityof the pump/pipings. Avoid quick temperature changesanddonotexceed

the maximum temperature specified when the pump was ordered. See also general max tempe-

ratures based on water in chapter 5 "Data".

2.2 Before starting the pump

- Make sure the pump is installed accordning to the installation instruction (section 1).

- Filling of the pump with liquid before start is not necessary.

- Wheninstallation is new orreinstalled, a testrun of the pumpwith water shouldbe conducted to

make sure the pump operates normally and does not leak.

STOP

InstructionmanualsanitarypumpsT30-T425 8

2. OPERATION

2.3 Starting and operating

- Open the discharge valve.

-Note! Considering the suction capacity when air is still in the suction pipe, it is

recommended to start with low air pressure/flow in the beginning. This is not necessary

if the pump is filled with liquid before start.

- When the pump has been filled with liquid, the air pressure/flow may be raised to increase the

suction capacity of the pump.

- The performance of the pump can be adjusted through the air supply by using a needle valve

and a pressure regulator. The performance can also be adjusted by normal flow control on the

discharge side of the system.

2.3.1 Dry running

The pump may run dry without any problem.

2.3.2 Optimizing the pump lifetime

Running at full frequenzy (maximum air pressure/flow) continiously will cause premature wear of

the components. As a general rule, we recommend to run at half of the maximum capacity of the

pump. For instance, a T80 pump should run continious maximum at 40 l/min.

2.4 Pump stopping

The pump can be stopped in two ways:

1) Closethe discharge valve. The pressure from the system will stopthe pump automatically.This

will not do any damage to the pump. The pump restarts easy when the valve is opened again.

2) Stop the air supply.

2.5 Cleaning of the pump

2.5.1 CIP - Clean in place

The importance of easy cleaning is especially great in hygienic applications. Tapflo stainless steel

pumps are designed for CIP (clean in place). This allows the pump to be internally cleaned without

strip down. The pump can be cleaned by flushing through with a CIP fluid (usually a mild solution

of sodium hydroxide and a sanitizing additive) or by injection of hot steam. The CIP fluid tempera-

ture varies, but in the sanitary field, the temperature is usually about 90°C. Make sure that the CIP

fluid is compatible with the materials in the pump/piping (consult us for further information).

The solution is passed through the system by either from the operation of the pump itself, or by a

centralized cleaning system. The CIP fluid must pass through the pump at a minimum velocity of

1.5 m/s in the normal flow direction (from inlet to outlet).

2.5.1.1 Drainage of the pump (T80-T425)

After the CIP procedure, the pump usually has to be drained from the

CIPfluid.TheTapflo stainless steel series issuppliedwith a hygienic

stand, enabling 360° rotation of the pump unit.

1) Disconnect the pump from the pipings.

2) Simply loosen the two socket head cap screws (pos 4) and

rotate the pump 180° and let the remaining fluid drain off. The

airline may be left connected during this rotation.

3) Rotate back to normal position, connect the pump with the pipings

and fix the socket head cap screws (pos 4).

InstructionmanualsanitarypumpsT30-T425 9

3.1 Performance test

When installation is new, a test run of the pump should be conducted. Gauge the capacity at

specificair pressure/flow. Thisinformation is foruse in checking performance as wear takes place.

You will be able to set schedules for maintenance of the pump and to select spare parts to be kept

on stock.

3.2 Routine inspection

Frequent observation of the pump operation is recommended to detect problems. A change in

sound of the running pump can be an indication of weared parts (see below "location of faults").

Leakingliquidfromthe pumpandchangesofperformancemayalso bedetected.Routineinspections

should be conducted frequently.

3.3 Complete inspection

The intervals for a complete inspection depend upon the operation conditions for the pump. The

characteristics of the liquid, temperature, materials used in the pump and running time decide how

often a complete inspection is necessary.

If a problem has occured, or if the pump is in need of a complete inspection, see later this chapter

"location of faults" and "dismantling of the pump". You are of course warmly welcome to consult us

for further help.

Worn parts should be carried in stock, see our recommendation in chapter 4.

3.4 Location of faults

Problem Possible fault

The pump does not run The air pressure is to low

The air connection is blocked

Muffler is blocked

Air valve is defect

Dirt in the pump chamber

Diaphragm breakdown

The suction is bad Suction connection is not tight

Suction connection is blocked

Muffler is blocked

Valve balls are blocked

Valve balls are damaged

The pump runs irregularly Valve balls are blocked

Sealings are defect in air valve or center block

Diaphragm breakdown

Bad flow/pressure Pressurefall in incomming air

Suction or air connection blocked

Muffler is blocked

Air valve is defect

Valve balls worn out/broken

Air in liquid

Diaphragm breakdown

Liquid leaks from the pump Screws on the housing not properly fastened

Liquid comes out of the muffler Diaphragm breakdown

3. MAINTENANCE

InstructionmanualsanitarypumpsT30-T425 10

3.5 T30 - Dismantling the pump

3.5.1 Before the dismantling procedure

Be sure to drain all liquid from the pump. Cleanse or neutralize the pump thoroughly. Disconnect

the air connection and then the suction and discharge connections.

The numbers put in brackets refer to the positions on the asembly drawing.

3.5.2 Mainparts

1) Unscrew and remove the two upper clamps (138) from the pump. Remove the outlet manifold

(132),valveballs(23)andsealings(18).

2) Hold the pump when you unscrewandremovethetwolowerclamps(138)andcarefullyliftoffthe

pumphousing assembly.Take out the valve balls(23) and seals(18) from theinlet manifold.

3) Unscrew and release the domed nuts (37) from one side of the pump. Place the pump with the

housing (11) that still has the nuts on downwards. Then lift off the loose housing from the

centerblockunit and thencarefully pull the centerblock unit from the remaining housing with pin

screws (14).

3.5.3 Center block

1) Press the diaphragms (15) to their neutral position (both have the same distance to the center

block).

2) Holdone of the diaphragmsand unscrew theother. Then pull outthe remaining diaphragm with

the diaphragm shaft (16).

3) Place the center block on a clean place. Observe that this is a faying surface, so be careful not

to damage it. Pull out the circlip (27) carefully with pliers so it will not hurt you or disappear.

4) Turn the center block. Pull out the other circlip (27).

5) Press carefully out the air valvefromthehousing.Usea pressing device for this operation forthe

bestresult.Themain piston and air valve housingwillslowlycome out. Observe that the brassis

soft material and changes figure easy. If those details are deformed they must be changed, so

handlethoosewith care.

The pump is now completely dismantled. Check all components for wear or damage and replace if

necessary.

3. MAINTENANCE

STOP

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