LIQUI-MOVER PUMP HANDBOOK

Transcription

1 LIQUI-MOVER PUMP HANDBOOK Kadant Johnson Inc., 805 Wood Street, Three Rivers, MI USA fax: LMP Handbook-4002

2 What is a Liqui-Mover Pump? A Liqui-Mover pump is a positive displacement pressure powered pump with a minimum of moving parts. The pumping action is accomplished using a positive pressure to push the liquid from the pump tank into the return line. The Liqui-Mover pump can handle high temperature and high pressure condensate without difficulty. Liqui-Mover pumps are available in nine sizes. They are available in many configurations, from individual components that are field assembled to complete packaged systems ready for connection to field piping. A basic Liqui-Mover pump consists of a receiver/reservoir, pump tank, 3-way motive valve, inlet and outlet check valves, level control, and various other fittings. How a Liqui-Mover Pump Works In describing How a Liqui-Mover Pump Works, it is advantageous to look at the overall operation, and then break it down into smaller operations for a better understanding. Condensate from the equipment being drained enters the receiver/reservoir tank and flows down the fill line into the pump tank. When the predetermined high level is reached in the pump tank, the level control system sends out a signal, which causes the 3-way motive valve to cycle. When the 3-way valve cycles, the equalizing line between the receiver/reservoir and the pump tank is closed off and a regulated motive pressure is admitted into the pump tank. This motive pressure is confined above the condensate in the pump tank and its effect is to move the condensate out of the pump tank and into the return line. When the condensate reaches a predetermined low level, the level control sends another signal, causing the 3-way valve to revert to its original position. The residual motive pressure remaining in the pump tank will flow through the equalizing line, into the receiver/reservoir, enabling the pressures in the two tanks to equalize with each other. When this is complete, the flow of condensate from the receiver/reservoir to the pump tank will start again. The cycle will now repeat. See below for more details of each stage of the cycle: STAGE ONE: During the fill cycle, fluid flows from the receiving chamber (A) through the inlet check valve (B) into the pumping chamber (C). The 3-way valve (D) is open between the pumping chamber and the receiving chamber, equalizing the pressure between them through the equalizing line (E). STAGE TWO: When the level control (F) senses that the pumping chamber is full, the 3-way valve energizes to admit the motive pressure into the pumping chamber (C). The inlet check valve (B) prevents backflow into the fill line. The discharge cycle begins when pressure inside the pumping chamber is greater than in the discharge line. The discharge check valve (G) opens and fluid flows into the discharge line. During this cycle, incoming condensate is stored in the receiver. STAGE THREE: Once the level control (F) senses the pumping chamber has emptied, the 3- way valve (D) de-energizes, shutting off the motive pressure, and opening the vent port in the valve. This equalization cycle allows the pumping chamber (C) and the receiving chamber (A) to equalize in pressure, and the fill cycle begins again.

3 Installation Preparation For ease of future maintenance, the Liqui-Mover pump should be installed with the check valve side of the pump tank most accessible. Normally the motive inlet and the condensate discharge connections are on the left when facing the check valves. If a Johnson receiver is supplied, the replaceable sacrificial anode is also installed and removed from this end. On ERC and FAC (pneumatic operated 3-way valve) units, the control air is located on the right when facing the check valves. Refer to the enclosed assembly drawing for additional information. Setting the Unit On LOOO models, the pump tank has (4) holes for mounting to the floor. On LROO models, you will also need to install a Johnson supplied receiver. The receiver is held in saddles with U bolts supported by (4) pipes on floor flanges. The floor flanges have mounting holes for attachment to the floor. On LRFP models, the entire base of the frame should be supported. Mounting holes can be drilled through the frame base for attachment to the floor. All tanks should be installed level. Piping On LROO and LRFP models, the Johnson supplied receiver will normally have (3) top connections for: condensate inlet, atmospheric vent, and pressure gauge. For closed systems (no atmospheric vent), an air eliminator and safety relief valve will need to be installed. On LOOO models, the condensate is piped directly to the inlet check valve from an existing receiver or pipe accumulator. The motive pressure (normally steam or compressed air) is piped to the 3-way valve through a strainer and a pressure reducing valve. The strainer is supplied on LRFP models. Compressed air of at least 55 psig should be piped to the pilot valve through a filter/regulator/lubricator on ERC and FAC models. The pilot valve and the filter/regulator/lubricator are supplied with the unit. For LROO and LOOO models, friction loss through the piping should be kept to a minimum. Therefore, pipe reducers should not be used and pipe runs kept to a minimum. All hand valves should be full port if at all possible. Electrical Connect the electrical service to the on/off switch located on the door of the electrical enclosure per the instruction label located near the switch. The electrical voltage must be the same as the rating of the level control relay and the valve, unless a step-down transformer has been supplied. NOTE: An on/off switch is not standard on NEMA 7 units.

4 Pressure Reducing Valve Installation A pressure reducing valve (PRV) should be installed in the motive pressure line to regulate how fast the Liqui-Mover pump discharges the condensate out of the pump tank. When properly adjusted, the discharge time should not be less than 20 seconds. A longer discharge time is acceptable, so long as the Liqui-Mover pump can keep up with the incoming condensate load. Normally the motive pressure setting will be approximately 20 psig higher than the back pressure to achieve a 20 second discharge time. Here are some guidelines to be followed when installing a PRV in conjunction with a Liqui-Mover pump: 1. Never install a PRV immediately adjacent to the 3-way motive valve. The shock caused by the sudden opening and closing of the motive 3-way valve will ultimately damage the PRV. We recommend a distance of feet between the PRV and the 3-way valve, where the pipe size is the same as the 3-way valve connection. A larger diameter pipe of a shorter length that has an equivalent volume is also acceptable. The PRV should be sized by a pressure reducing valve manufacturer or representative. 2. A safety relief valve should be installed downstream of the PRV to prevent over-pressurization at the 3-way valve. The safety relief valve should be sized by a safety relief valve manufacturer or representative. 3. When steam is the motive pressure, a drip trap, dirt leg, and strainer should be installed ahead of the PRV. The drip trap should not be piped to the Liqui-Mover pump, unless the receiver is vented. When compressed air is the motive pressure, a liquid drainer, dirt leg, and strainer should be installed ahead of the PRV. The liquid drainer should not be piped to the Liqui-Mover pump. 4. The piping from the PRV outlet to the 3-way valve inlet should be sized to minimize the pressure drop under flow conditions. 5. A throttling valve should be installed immediately ahead of the 3-way motive valve so it can be used in conjunction with the PRV to adjust the Liqui-Mover pump discharge time. Typically the throttling valve is a globe valve. Motive Supply Header - Steam or Compressed Air Y Strainer Safety Relief Valve (Piped to safe location) Equalization Line To Receiver / Condensate Header 3-Way Valve Dirt Leg PRV Throttle Valve (Globe) To Liqui-Mover Pump Drip Trap(Steam) or Liquid Drainer(Air Motive) The above sketch is for reference only. Always consult with the PRV and safety relief valve manufacturer or representative for proper sizing and application of their products.

5 Printed on 12/15/2008 at 11:41:12 AM Property of Kadant Johnson - Confidential

6 Installation Diagram for Liqui-Mover Pump with Compressed Motive Motive - Compressed Air Supply Filter w/ Auto Drain Safety Relief Valve (When Needed) To Motive Inlet of Liqui-Mover Pump Regulator w/ Gage Throttle Valve (Globe) To 1/4" NPT Air Inlet Connection of Liqui-Mover Pump This Connection Required For Liqui-Mover Pumps Having a Pneumatic Operated 3-Way Valve (ERC and FAC units) Liqui-Mover Pump 1. This is the recommended piping for a Liqui-Mover pump with compressed motive. 2. The air should be clean, dry and regulated so that the Liqui-Mover pump discharges in the recommended time. 3. The above parts furnished by customer.

7 Start-Up Instructions 1. On Liqui-Mover pumps that are not pre-piped, inspect the inlet and outlet check valves for proper flow direction. Refer to the Liqui-Mover pump assembly drawing and parts list. 2. If the receiver and/or pump tank contains sub-cooled condensate, this needs to be drained prior to start-up. 3. On ERC and FAC units, open the compressed air line to the filter/regulator/lubricator and set the air pressure to 55 psig, minimum. 4. On ERC and ERS units, turn on the electrical power. 5. Open the motive steam or compressed air supply to the PRV and set the pressure to approximately 20 psig higher than the back pressure. The throttling (globe) valve should be closed. 6. Open all remaining isolation (hand) valves, except the isolation valve ahead of the inlet check valve (fill line). 7. Once condensate in seen in the receiver, slowly open the isolation valve in the fill line and watch for condensate to fill the pump tank. 8. When the 3-way motive valve energizes, slowly open the throttling (globe) valve ahead of the 3-way motive valve. This will allow the pump tank to discharge. 9. After a few discharge cycles, you will be able to fully open the throttling valve and set the motive pressure to achieve a second discharge time using the PRV. 10. The unit is now in service. Incoming Condensate Vent Line Motive Supply Equalize Line Check Valve Globe Valve PRV Strainer Control Panel Receiver May Be JoCo ASME Labeled Receiver, Existing Receiver, Oversized Pipe Header, or Etc. 3-Way Motive Valve Pumping Tank Drip Trap - Steam Liquid Drainer - Air TYPICAL INSTALLATION SKETCH Discharged Condensate Outlet Check Valve Inlet Check Valve NOTE: 1. The above sketch is for reference only. 2. Additional isolation hand valves may be added as required for maintenance purposes. 3. Globe valves should be used where flow restriction is required. 4. Gate valves should be used where minimal flow restriction is required. 5. For proper PRV installation, see manufacturers installation instructions.

8 CV3S-1000 Series with 4-Way Pilot Valve Pilot De-Energized Pilot Energized Solenoid Pilot Valve 4-Way Filter/Regulator/Lubricator Solenoid Pilot Valve 4-Way B Filter/Regulator/Lubricator B B EX B EX A IN A IN A A Port 1 (Common) Port 1 (Common) Port 3 (Motive In) Port 2 (Equalize) Port 3 (Motive In) Port 2 (Equalize) CV3S-100 Series with 3-Way Pilot Valve Pilot De-Energized Pilot Energized Solenoid Pilot Valve 3-Way Filter/Regulator/Lubricator Solenoid Pilot Valve 3-Way Filter/Regulator/Lubricator Equalize Equalize Common Common Motive In Motive In

9 Johnson Solenoid Coil and Fuse Specification Sheet Coil Voltage Freq. Coil No. Approx. Current Fuse Service JOCO Fuse No. Size (Amps) (Amps) Inrush Sealed B Cont. CSE B Cont. CSE B Cont. CSE C Cont. CSE C Cont. CSE C Cont. CSE D Cont. CSE D Cont. CSE D Cont. CSE D Cont. CSE D Cont. CSE D Cont. CSE D Int. * CSE D Int. * CSE D Int. * CSE Int. * : Intermittent service - solenoid energized not over 45% of the time and not longer than 1/2 hour at one time Fuses manufactured by: Gould Shawmut TR XX R Bussman FRN-R-XX (Replace X's with Fuse Amps) Reference Johnson Drawing A37786

10 Troubleshooting Contents General Troubleshooting General ERC and ERS Troubleshooting ERC Troubleshooting ERS Troubleshooting FAC Troubleshooting Preventative Maintenance Check List Preventative Maintenance Check List Additional For FAC Ceramic Electrode Plugs Electrode Lengths 8300 Series Relay Installation and Maintenance Intrinsically Safe Relay Installation and Maintenance

11 Page 1 - General Troubleshooting LMTSO GENERAL TROUBLESHOOTING OF LIQUI-MOVER PUMPS OBSERVATION PROBABLE CAUSE REMEDY 1. Liqui-Mover pump fails to fill. 1. Increase in liquid level in receiver, possible flood in receiver. Obstruction in fill line, valve closed, inlet check valve backwards. Inspect fill line for closed valve, inlet check valve in reverse, or obstruction in fill line. Refer to Assembly & Parts List Drawing. 2. Increase in liquid level in receiver, possible flood in receiver, increase in receiver pressure. 3. Receiver empty. Liqui-Mover pump level fluctuating Way Motive Valve will not deenergize. 3-Way Valve Assembly out of adjustment. Receiver pressure greater than pressure in discharge line. See observation under specific ERS or ERC Troubleshooting Section. Inspect 3-Way Valve Assembly. Refer to Valve Section. If unit has been in operation for a period of time without problems, check for traps blowing through. If new installation receiver pressure may be greater than anticipated. Back pressure may be less than anticipated. A 2-Way Controlled Valve may be required in discharge line. See specific remedy. 2. Liqui-Mover pump fills too slow. 1. No liquid level in receiver. Load to unit not as great as anticipated. No action required. 2. Receiver flooding. Obstruction or restriction in fill line. Inspect fill line for partially closed valve or defective check valve. Inspect fill line for proper size fittings and pipe. Refer to Assembly and Parts List Drawing for specific unit.

12 Page 2 - General Troubleshooting LMTSO OBSERVATION PROBABLE CAUSE REMEDY 3. Receiver flooding. Restriction in vent line, 3-Way Valve assembly out of adjustment. Inspect vent line for partially closed valve, proper size fittings and pipe. Refer to Assembly and Parts List Drawing. Inspect 3-Way Valve Assembly. Refer to Valve Section. 3. Liqui-Mover pump fills very rapidly. 1. Unit cycling almost normally, receiver flooding. Defective check valve in discharge line and/or fill line. Possible back flow to Liqui-Mover pump. Inspect discharge line check valve and fill line check valve. Refer to Assembly and Parts List Drawing. 4. Noise in or at fill line check valve. 1. Vibration and water hammer at fill line check valve. Cold condensate. Inspect for cold condensate. Throttle flow control valve, ahead of 3-Way Motive Valve Assembly. Refer to Assembly and Parts List Drawing, and start-up procedure. 5. Liqui-Mover pump discharges very rapidly. 1. Water hammer in discharge line. Motive pressure too high. Throttle flow control valve or install pressure reducing valve. See start-up procedure. 2. Receiver flooding, rise in receiver pressure during discharge. Defective check valve in fill line, discharging condensate back into receiver. Inspect fill line check valve. Refer to Assembly and Parts List Drawing. 6. Liqui-Mover pump discharge cycle too long. 1. Possible receiver flooding, discharge time greater than 30 seconds. Flow control valve throttled too much. No action required, if receiver not flooding. If receiver flooding, adjust flow control valve for discharge of seconds (approx.).

13 Page 3 - General Troubleshooting LMTSO OBSERVATION PROBABLE CAUSE REMEDY 2. Receiver flooding. Discharge time greater than 30 seconds. 3. No motive pressure flow. Receiver flooding. Restriction or increase of back pressure in discharge line. Motive supply failure, obstruction in motive supply line. Inspect discharge line for partially closed valve(s), obstructions or change in pressure. A pressure increase may require adjustment of flow control valve to reduce discharge time. Inspect discharge check valve. Inspect for motive supply pressure, closed valve, or obstruction in motive supply line. Inspect strainer Way Motive Valve noisy. Condensate in motive supply line. Inspect motive supply line for condensate. Check drip trap. Refer to Assembly and Parts List Drawing. 5. Receiver pressure increase during discharge Way Motive Valve will not deenergize. 3-Way Valve out of adjustment, leakage into receiver. See observation under specific Relay Section. Refer to Valve Section. See specific remedy.

14 Page 4 - ERC or ERS Troubleshooting GENERAL ERC & ERS TROUBLESHOOTING LMTSO OBSERVATION PROBABLE CAUSE REMEDY 1. 3-Way Valve erratic. Operates from one level only. 1. Condensate level in Liqui-Mover pump at one level. Electrode wires reversed. Poor ground connection. Refer to Relay Troubleshooting Section Way Valve erratic. Operates from low level only. 1. Condensate level in Liqui- Mover pump at low level. Electrode plugs shorted. Electrode plug grounded. Holding contact bad. Refer to Relay Troubleshooting Section Way Valve erratic. 1. Condensate level can be high or low. Moisture in electrode holder. Dirty electrodes. Cracked or broken electrode plug. Refer to Relay Troubleshooting Section.

15 Page 5 - ERC Troubleshooting TROUBLESHOOTING ERC UNITS (w/electrodes-relay-cylinder Operated Valves) LMTSO OBSERVATION PROBABLE CAUSE REMEDY 1. 3-Way Cylinder Operated Valve will not cycle on (closed motive side open vent side). 1. Relay pulls in. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to Valve Section. 2. Relay pulls in. Air pilot shifts. Obstruction in air line to cylinder. Check air lines for obstructions or breaks. 3. Relay pulls in. Air pilot not shifting. Air pilot valve. Check wiring, check for voltage to pilot coil. Check air pressure (55 psig minimum). 4. Relay will not pull in. Power failure. Refer to Relay Troubleshooting Section. 5. Relay will not pull in. Electrode circuit or relay malfunction. Refer to Relay Troubleshooting Section Way Cylinder Operated Valve will not cycle off (open motive side closed vent side). 1. Relay drops out. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to Valve Section. 2. Relay drops out. Air pilot not shifting. Air supply or air pilot valve. Check for proper air pressure. Inspect relay contacts for being welded together. If okay, repair or replace pilot valve. 3. Relay drops out. Air pilot shifts. Receiver flooding. 3-Way Cylinder Valve Assembly jammed. Inspect 3-Way Cylinder Valve Assembly for obstruction, dirt or foreign debris. Refer to Valve Section. 4. Relay will not drop out. Receiver flooding. Electrode holder wet or dirty, probe or wire grounded. Refer to Relay Troubleshooting Section Way Cylinder Operated Valve cycles On Off erratically. 1. Relay does not follow erratic valve operation. Air supply fluctuating. Inspect air supply for fluctuations. Air pilot requires 55 psig minimum.

16 Page 6 - ERS Troubleshooting TROUBLESHOOTING ERS UNITS (w/electrodes-relay-solenoid Steam Valve) LMTSO OBSERVATION PROBABLE CAUSE REMEDY 1. 3-Way Valve will not energize (closed motive side open vent side). 1. Relay pulls in. Liqui-Mover pump flooded. Overload tripped or fuse bad. Replace fuse. Refer to Valve Section. 2. Relay pulls in. Solenoid valve noisy. Packing nut too tight. Dirty armature. Back-off packing nut. Refer to Valve Section. Check valve adjustment. 3. Relay pulls in. Fuse not blown. Solenoid valve coil open. Inspect Solenoid Valve for burnt or broken lead wires or bad coil. Inspect Solenoid Valve for mechanical jam. Refer to Valve Section. 4. Relay will not pull in. Power failure. Inspect for supply voltage. Refer to Relay Troubleshooting Section. 5. Relay will not pull in. Electrode circuit or relay malfunction. Refer to Relay Troubleshooting Section Way Valve will not deenergize (open motive side close vent side). 1. Relay drops out. Receiver flooding. Packing nut too tight. Back off packing nut. Refer to Valve Section. 2. Relay will not drop out. Receiver flooding. Electrode holder wet or dirty, probe or wire grounded. Refer to Relay Troubleshooting Section. 3. Relay will not drop out. Receiver flooding. Electrodes shorted. Inspect Liqui-Mover pump chamber for debris. Refer to Relay Troubleshooting Section 4. Relay drops out. Receiver flooding. 3-Way Steam Valve Assembly jammed. Inspect 3-Way Solenoid Valve Assembly for obstruction, dirt, or foreign debris. Refer to Valve Section.

17 Page 7 - FAC Troubleshooting TROUBLESHOOTING FAC UNITS (Refer to General Troubleshooting Section, Pages 1 through 3, then the following.) LMTSO OBSERVATION PROBABLE CAUSE REMEDY 1. 3-Way Cylinder Operated Valve will not cycle on (closed motive side open vent side). 1. Air pilot shifts. Air pressure too low. Raise air pressure. 2. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to Valve Section. 3. Air pilot shifts. Obstruction in air line to cylinder. Check air lines for obstructions or breaks. 4. Air pilot not shifting. Wisker valve not operating or bad. Break air line between pilot valve and wisker valve. 1. If pilot valve still does not shift, break air line between air filter and choke. Clean.010 hole in choke or replace choke. Reassemble and retest. If pilot valve still does not shift, replace pilot valve. 2. If pilot valve shifts, shut off all steam, condensate, and motive lines to and from the unit. Reconnect the air line between the pilot valve and the wisker valve. Remove the cover (LMH or 6) and manually raise the float tube.

18 Page 8 - FAC Troubleshooting LMTSO OBSERVATION PROBABLE CAUSE REMEDY a. If the pilot valve shifts, disassemble flanges that mount the control head and remove, inspect, and repair float assembly as required. Refer to Dwg. A , Pg. 5. b. If the pilot valve does not shift, remove the air switch and inspect for missing or broken spring pins, magnet, or snap rings. Note: The magnet must be able to rotate freely only 30 degrees. If all appears proper, replace the wisker valve, Refer to Dwg. A , Pg Way Cylinder Operated Valve will not cycle off (open motive side closed vent side). 1. Air pilot shifts. Low air pressure. Raise air pressure. 2. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to Valve Section. 3. Air pilot shifts. Obstruction in air line to cylinder. Check air lines for obstructions or breaks. 4. Air pilot not shifting. Wisker valve not operating or bad. Break the air line between the pilot valve and the wisker valve. Block off air flow from the fitting on top of the pilot valve.

19 Page 9 - FAC Troubleshooting LMTSO OBSERVATION PROBABLE CAUSE REMEDY 1. If pilot valve does not shift, replace the pilot valve. 2. If the pilot valve shifts, shut off all steam, condensate, and motive lines to and from the unit. Reconnect the air line between the pilot valve and the wisker valve. Remove the cover (LMH or 6) and manually lower the float tube. a. If the pilot valve shifts, disassemble flanges that mount the control head and remove, inspect, and repair float assembly as required. Refer to Dwg. A , Pg. 5. b. If the pilot valve does not shift, remove the air switch and inspect for missing or broken spring pins, magnet, or snap rings. Note: The magnet must be able to rotate freely only 30 degrees. If all appears proper, replace the wisker valve. Refer to Dwg. A , Pg. 3.

20 LIQUI-MOVER PUMP PREVENTATIVE MAINTENANCE CHECK LIST HOW OFTEN CHECK REFERENCE 6 Months 1. Check electrodes for build up of foreign matter. With build up, poor conductivity may occur creating erratic pumping behavior. 2. Check 3-Way valve adjustment and make necessary adjustments. Also check valve packing and replace if required. Remove cap on electrode holder. Remove electrode plugs, this will also remove electrodes. Clean electrodes with steel wool or emery cloth. Replace. Refer to specific valve repair and maintenance guide. 1 Year 1. Check electrical wiring. Inspect wires at electrode plugs and valve for a deterioration of insulation and frayed wires. 2. Check anode in receiver tank. Drain tank remove anode by unscrewing anode plug on the receiver tank end. If over 60% eaten away, replace. 3. Clean gauge glasses when required. Disassemble and pull clean cloth through glass with cleaning wire. 4. Drain tanks to remove residue. Remove drain plugs in bottom of both tanks. Replace. 5. Check relay contacts (points). If dirty, clean. if burnt, replace, (ERS units only). 6. Check Solenoid Valve current. With Solenoid Valve energized, measure current. Too high a current could indicate a dirty armature or worn armature clean or replace as necessary. Refer to A in Valve Section. CAUTION: Before performing any of the above maintenance checks, shut off electrical power, steam, and condensate ahead of the unit.

21 Page 2 Preventative Maintenance FAC LIQUI-MOVER PUMP PREVENTATIVE MAINTENANCE CHECK LIST HOW OFTEN CHECK REFERENCE 1 Month 1. Oiler Level. Should deliver (1) drop per week. Adjustment screw. 2. Air Filter Main. Blow down or clean as required. 3. Air Filter Secondary. (Located on Control Head) Blow down or clean as required. 6 Months 1. Flush External Float Housing. Remove 1-1/2 drain plug and flush. CAUTION: These items in addition to standard Liqui-Mover pump maintenance check items. Before performing any of the above maintenance checks, shut off all steam, condensate and air lines.

22 8300 Series Relay Installation and Maintenance Black A.C. Line White BLACK A.C. Line WHITE 1 LCR 3 to SHORT ELECT. 4 to LONG ELECT. 5 GND. & ELECT. 2 LCR 1 LCR 3 to SHORT ELECT. 4 to LONG ELECT. 5 GND. & ELECT. 2 LCR LCR 9 10 OPT. COUNTER SOV1 OPT. CYCLE COUNTER LCR APR FU 9 APR 10 AUX PWR RELAY SOV1 OPT. COUNTER OPT. CYCLE COUNTER ERC ERS CAUTION: Since Line Voltage is often present during electrical tests, only qualified electricians should perform electrical tests. A. OPERATION This description applies to a pump down or direct type of level control. The sequence is as follows: 1. The relay is deenergized as shown in the diagram and the valve is deenergized and closed while the liquid in the tank is rising. 2. When the liquid reaches the high level electrode, it completes the circuit from terminal 5 to 3, energizing the relay. This can be heard as a click as the load contact is reversed. 3. The load contact closes and the valve opens admitting pressurized steam or air into the tank which causes the liquid level to lower. 4. When the relay energized, an internal holding circuit closed from terminal 4 to 3. When the liquid leaves the high level electrode this holding circuit through the ground, the liquid, and the low level electrode keeps the relay energized. 5. When the liquid drops below the low level electrode this holding circuit is broken and the relay is deenergized, opening the load contact. 6. The valve closes, shutting off the pressurized gas line and allowing the liquid to rise again. B. RELAY DOES NOT PULL IN 1. POWER FAILURE Check for voltage at the two (2) terminals located on the lower left hand corner of the level control relay. This voltage should be either 120 or 240 volts A.C. as determined by the voltage of the relay(s) and solenoid operated valve(s). 2. DEFECTIVE LEVEL CONTROL Disconnect the electrodes and jumper the terminal marked C to the terminal marked H. The 3-way steam valve should turn on when the jumper is connected and shut off when the jumper is removed. To check the holding circuit proceed as above but do not remove the jumper wire; instead add another jumper wire from the terminal marked C to the terminal marked L. Remove the first jumper wire connected to H and the relay should remain energized. If the relay does not remain energized, it is bad and will have to be replaced.

23 3. POOR GROUND CONNECTION The control will not function unless a good dependable ground connection is made to the terminal marked C. When installed in non-conductive tanks a third electrode (the longest) is required for a ground connection. 4. BROKEN WIRES Check for broken wires by grounding the spark plug holding the short electrode. If the relay fails to energize, one or both of the electrode leads are open, or there is a bad ground connection. Run temporary wires from the control panel to the electrode holder and retest. 5. BUZZ OR CHATTER If the resistance or conductivity of the liquid is too low, the relay may buzz, chatter, or fail to operate at all. Consult area representative for selecting a relay with proper sensitivity. 6. FOULED ELECTRODES Accumulated dirt, oil, and other deposits may insulate the electrodes and prevent operation. Electrodes should be inspected and cleaned at regular intervals. C. VALVE DOES NOT ENERGIZE WHEN THE RELAY DOES 1. FUSE ERS ERS units are equipped with a fuse for solenoid valve coil protection. Check the fuse for continuity and replace if bad. One spare is included with each Liqui-Mover pump. Refer to Drawing A-27541, Symbol No. A for solenoid coil protection. 2. SOLENOID COIL Remove the wires going to the solenoid coil from the terminal strip and check for continuity. If an open circuit is found, there is a broken wire, a bad connection, or the coil itself is bad. Repair or replace as necessary. 3. AUXILIARY RELAY ERS ERS units are equipped with an auxiliary relay because the level control relay contacts are not heavy enough to handle the inrush current of a direct operated solenoid valve. Inspect this relay for burnt contacts. Clean or replace contacts/relay as required. D. VALVE ENERGIZED WHEN RELAY IS NOT ENERGIZED 1. RELAY CONTACTS The relay contacts may have failed to open. On ERS units inspect the auxiliary relay visually for stuck contacts. On ERC and ERS units check the contacts on the level control relay with a V.O.M. E. RELAY WILL NOT DEENERGIZE 1. GROUND WIRE A wire from the relay to an electrode may be grounded to the conduit or enclosure. 2. WET PLUG Dirt or moisture on an electrode plug can ground the electrode to the holder. Cleaning the electrode plugs periodically and using a proper holder will help keep the plugs clean. 3. CRACKED PLUG The electrode plug may be cracked, allowing moisture to ground the electrode to the enclosure. F. RELAY FLUCTUATES AT HIGH LEVEL 1. ELECTRODE WIRING Wire to low level electrode may be broken. 2. ELECTRODE Low level electrode may have broken off or become insulated due to grease or dirt.

24 3. RELAY HOLDING CIRCUIT If the internal holding circuit of the relay fails to close, the relay would fluctuate at the high level. To test relay see Section B-2. G. RELAY FLUCTUATES AT LOW LEVEL 1. WIRES REVERSED Wires to electrodes may be reversed. 2. RELAY HOLDING CIRCUIT If the internal holding circuit of the relay is shorted, it would cause the relay to fluctuate at the low level. To test the relay see Section B-2. H. RELAY CHATTERS AFTER DISCHARGING 1. WET PLUG The underside of the electrode plug may be coated with dirt or moisture causing continuity across the insulator. If steam is used as the motive substance to lower the liquid level, when the tank is vented at the start of the fill period the steam expands. This may leave a film of moisture on the underside of the plug which can cause relay fluctuation a few times before the moisture evaporates and lets the relay drop out. This can be avoided by using a relay with lower sensitivity if the liquid is sufficiently conductive, or by insulating the electrodes, leaving 1/4 bare at the lower end.

25 INTRINSICALLY SAFE RELAY FOR LEVEL CONTROL 120 V AC V AC Sol. Valve 3 7 Sol. Valve Fuse B Fuse B Electrode Holder High Level Electrode Low Level Electrode A * Note: For ERC type units no overload is used. The air pilot valve is connected to relay terminals 11 and 7 or as shown on wiring assembly. B Older models use a thermal element in place of the fuse shown. INSTALLATION The electrode circuit of this relay is intrinsically safe and can be located in a hazardous area with an electrode holder and tank which are not explosion-proof. However, the rest of the circuits must be protected by explosion-proof enclosures and rigid conduit with conduit seals. OPERATION This description applies to a pump down type of level control and the sequence is as follows: 1. The relay is deenergized as shown in the diagram and the valve is deenergized and closed while the liquid in the tank is rising. 2. When the liquid reaches the high level electrode, it completes the circuit from terminal 14 to 15, energizing the relay. This can be heard as a click and all the load contacts are reversed. 3. Load contact 10 7 closes and the valve opens admitting pressurized steam or air which causes the liquid level to lower. 4. When the relay was energized, an internal holding circuit closed from terminal 16 to 15. Hence when the liquid leaves the high level electrode this holding circuit through the ground, the liquid, and the low level electrode keeps the relay energized. 5. When the liquid drops below the low level electrode this holding circuit is broken and the relay is deenergized, opening the internal holding connection from 14 to 16 and opening load contact The valve closes, shutting the pressurized gas line and allowing the liquid to rise again. When the liquid reaches the low level electrode the relay remains deenergized since the internal connection from 16 to 15 is now open, so the cycle will be repeated.

26 SERVICE INSTRUCTIONS For 120V Control. (For 240V see diagram) A. RELAY DOES NOT PULL IN 1. POWER FAILURE Check for voltage at terminals 11 and 12. Should be within 10% of rated value. 2. RELAY FAILURE Remove leads from terminals 14, 15, and 16. With power on, touch a jumper from 14 to 15 and you should hear the relay click on. If not, the relay should be replaced. To test see Section POOR GROUND CONNECTION There must be a low resistance ground connection from terminal 14 to the liquid either through the tank or through a ground electrode which contacts the liquid. 4. BROKEN WIRES An open connection in the line from 15 to the short electrode will prevent the relay from energizing. To check, run a temporary wire from terminal 15 to the short electrode. 5. FOULED ELECTRODES Deposits of dirt or grease on the upper electrode can insulate it and prevent relay from pulling in. If this occurs, electrodes should be cleaned regularly as required. If large quantities of oil, grease, or sludge are encountered, the electrodes can be mounted inside a pipe with the bottom below the lowest water level and a vent hole above high water level. A small flow of water into the top of the pipe will keep the electrodes operating in clean water. 6. ELECTRODES TOO SHORT If the liquid can not reach the high level electrode, the relay will not pull in. 7. LOW CONDUCTIVITY If the conductivity of the liquid is below 17 micromhos it may not allow conduction of enough current to operate the relay. Specify conductivity data to the factory and a more sensitive relay can be supplied. B. VALVE DOES NOT ENERGIZE WHEN RELAY DOES 1. OVERLOAD TRIPPED If the overload has tripped, reset it. If it continues to trip, see Drawing A RELAY CONTACT With relay energized (water at high level or a jumper on terminals 14-15) check for voltage on terminals If not voltage, and connection from is okay, relay contact 10-7 may be defective. Transfer its connections to spare contact SOLENOID COIL OR AIR PILOT VALVE COIL Check wires to coil. If coil is mechanically free, apply voltage to coil. If coil does not pull and wiring is proper, replace coil. C. VALVE ENERGIZED WHEN RELAY IS NOT 1. RELAY CONTACT Relay contact 10-7 may fail to open. Transfer its connections to spare contact 6-3. D. RELAY FLUCTUATES AT HIGH LEVEL 1. ELECTRODE WIRING Wire from 16 to low level electrode may be broken. 2. ELECTRODE Low level electrode may have broken off or become insulated due to grease or dirt. 3. RELAY HOLDING CIRCUIT If the internal holding circuit of the relay fails to close, the relay would fluctuate at the high level. To test relay see Section 1.

27 E. RELAY FLUCTUATES AT LOW LEVEL AFTER ONE CYCLE 1. ELECTRODE GROUND Turbulance may cause long electrode to contact stilling well or tank. 2. WET PLUG The underside of the electrode plug may be coated with dirt or moisture causing a short across the insulator. If steam is used as the motive substance to lower the liquid level, when the tank is vented at the start of the fill period the steam expands. This may leave a film of moisture on the underside of the plug which can cause relay fluctuation a few times before it evaporates and lets the relay drop out. This can be avoided by using a relay with lower sensitivity if the liquid is sufficiently conductive, or by insulating the electrodes, leaving 1/4 bare at the lower end. F. RELAY FLUCTUATES AT LOW LEVEL 1. WIRES REVERSED Wires to electrodes may be reversed. Terminal 15 should connect to high level (short) electrode and terminal 16 to low level (long) electrode. 2. RELAY HOLDING CIRCUIT If the internal holding circuit of the relay is shorted, it would cause the relay to fluctuate at the low level. To test the relay see Section 1. G. RELAY CONTINUOUSLY ENERGIZED AFTER ONE CYCLE 1. GROUNDED WIRE Wire from terminal 16 to the low level electrode may be shorted to the conduit or enclosure. 2. CRACKED PLUG The insulating plug on the low level (long) electrode may be cracked, allowing moisture to short the electrode to the enclosure. 3. SHORTED ELECTRODE The low level (long) electrode may be touching the stilling well or tank. H. RELAY CONTINUOUSLY ENERGIZED 1. GROUNDED WIRE Wire from terminal 15 to the high level (short) electrode may be shorted to the conduit or enclosure. 2. WET PLUG Dirt or moisture on the electrode plug for the high level electrode can short the electrode to the holder. Cleaning periodically or using a stilling well may help keep the plugs clean. If the problem persists it may be solved by using a relay with lower sensitivity if the liquid is sufficiently conductive, or by insulating the electrodes, leaving 1/4 bare at the lower end. 3. CRACKED PLUG The insulating plug on the high level relay may be cracked, allowing moisture to short the electrode to the enclosure. I. RELAY TEST To test the relay, disconnect leads from terminals 14, 15, 16, 7 and the solenoid wire to terminal 11. Connect a 120V lamp to 11 and 7. Connect one end of a 47,000 ohm resistor to 14. With 120V supplied to 11 and 12, placing jumpers as shown should give the indicated response: Jumper Resistor to 16 Leave Resistor to 16, Add Leave Resistor to 16, Remove Remove Resistor to 16 Response Lamp Off Lamp On Lamp On Lamp Off

28 THE JOHNSON LIQUI-MOVER PUMP CERAMIC ELECTRODE PLUGS PREVENTIVE MAINTENANCE TO: SUBJECT: All Sales Personnel ELECTRODE PLUGS The Ceramic Electrode Plugs supplied with Johnson Liqui-Mover pumps, are by the nature of their material, fragile. While it is true that they can operate at high temperatures and pressures with no adverse affect, any rough handling will be a source of future problems. To avoid operating difficulties always follow these tips to prevent damage to the Electrode Plugs. 1. Do not tap Upper Ceramic Insulator with any tool. 2. Do not use excessive force when tightening The Knurled Nut at the top of the Electrode Plug. 3. When tightening the Probe Rod to the Electrode Plug, do not apply torque to the Middle Collar on the plug, instead hold by coupling on bottom of Electrode Plug. 4. Do not bend Probe Rod after it is installed in Electrode Plug.

29 Assembly Instructions for Valve Packing Instructions Packing Gland Bull Ring Packing Stagger Ends Bull Ring Bushing 1. Remove worn packing. 2. Disconnect stem. Check surface for scratches and wear. 3. Install one bull ring, two piece packing (stagger ends), then one bull ring. 4. Reinstall packing gland. Tighten snug only. Do not overtighten. 5. Readjust valve seat with stem coupling. See instructions sent with valve. Stem Note: During operation of valve, packing will require adjustment periodically. Tighten only enough to prevent leakage in 1/8 turn increments. Packing Computer Bull Ring Packing Assembly No. No. Two Required Two Required V S10000 CSS TE CSS TK V S10025 CSS TE CSS TK V S10050 CSS TE CSS TK * V S10075 CSS TE CSS TK MATERIAL: Packing Crane Style K17-60 Teflon Filled Kevlar with Break-in Lube TEMPERATURE: -100 F to 600 F Bull Ring 1/16 Thick Virgin Teflon * For all 600 Series Solenoid Valves which use bracket SV-603-1, new packing nut SV ( ) must be furnished with new packing.

30 NOTES: FAC ELECTRODE LENGTHS ERC-ERS NEW STYLE LMH GAUGE GLASS LEVELS ELECTRODES GAUGE GLASS LEVELS SIZE TOP BOTTOM SHORT LONG TOP BOTTOM 5 N/A N/A N/A All levels shown are nominal dimensions. 2. All high level alarm electrodes 1 shorter than short electrode. 3. All low level alarm electrodes 1 longer than long electrode. 4. Holder meets NEMA 1 and NEMA 4 requirements for NEMA 7 applications An intrinsically safe relay must be used with this holder. 5. All ground electrodes are 2 longer than long electrode.