Service instructions. Table of contents. DMX and DMH

Transcription

1 Service instructions DMX and DMH Table of contents 1. Type identification Nameplate Type key Torques and lubricants Lubricants Service tools Spare parts Dismantling and assembly General information Interval between cleaning and maintenance Dismantling and assembly of dosing head Oil change (DMH) Fault finding charts DMX DMH Drawings DMX DMH GB 13 1 / 13

2 1. Type identification 1.1 Nameplate DMX4-10 B-PP / E / T-X-4144X S / N : L / hr, bar, 50 Hz 230 / 400V50 / 60HZ 440 / 480V 60HZ P Made in Germany Fig. 1 DMX, DMH nameplate TM Pos. Description Pos. Description 1 Type designation 7 Country of origin 2 Model 8 Year-week code 3 Max. capacity [l/h] 9 Marks of approval, CE-mark, etc. 4 Voltage 10 Max. pressure [bar] 5 Frequency 11 Serial number 6 Product number 2 / 13

3 2. Type key Example: DMX B PP /E /T -X -E 1 QQ X E0 Type range Motor variant DMX E0 PTC motor for frequency control DMH Motor type EEx de C T3, 3 x 400 V, E1 50 Hz (only DMX-B or DMX-AT) Maximum flow [l/h] Motor type EEx de C T4, 3 x 400 V, E2 50 Hz (only DMX-B or DMX-AT) Maximum pressure [bar] E3 Mains plug API approval Control variant X No plug B Standard F EU (Schuko) AR* Etron E26 (analog/pulse control) B USA, Canada AT3 AT4 AT5 AT6 AT7 Servomotor, 1 x 230 V, 50/60 Hz supply, 4-20 ma control Servomotor, 24 V, 50/60 Hz supply, 4-20 ma control Servomotor, 1 x 115 V, 50/60 Hz supply, 4-20 ma control Servomotor, 1 x 230 V, 50/60 Hz supply, 4-20 ma control, EEx d II BT 4 Servomotor, 1 x 115 V, 50/60 Hz supply, 4-20 ma control, EEx d II BT 4 I E Australia, New Zealand, Taiwan Switzerland Connection, suction/discharge B6 Pipe 4/6 mm 4 Tube 6/9 mm 6 Tube 9/12 mm B9 Tube 19/27 mm, PVC Q Tube 19/27 mm and 25/34 mm S Tube 0.375"/0.5 A Threaded Rp ¼" Dosing head variant A1 Threaded Rp ¾" PP Polypropylene A2 Threaded Rp 1 ¼" PV PVDF (polyvinylidene fluoride) V Threaded NPT ¼" PVC Polyvinyl chloride A9 Threaded NPT ½", male SS Stainless steel, DIN A3 Threaded NPT ¾" Y Hastelloy C A7 Threaded NPT ¾", male PV-R PVDF + integrated relief valve A4 Threaded NPT 1 ¼" PVC-R PVC + integrated relief valve A8 Threaded NPT 1 ¼", male PP-L PP + integrated diaphragm leakage detection K Cementing d. 40 mm PV-L PVDF + integrated diaphragm leakage detection Cementing d. 40 mm B8 PVC-L PVC + integrated diaphragm leakage detection and flange DN 32 SS-L SS + integrated diaphragm leakage detection B1 Tube 6/12 mm/cementing d. 12 mm Y-L Y + integrated diaphragm leakage detection PV-RL B2 Tube 13/20 mm/cementing d. 25 mm PVDF + integrated relief valve and diaphragm leakage detection B3 Welding d. 16 mm PVC + integrated relief valve and B4 Welding d. 25 mm PVC-RL diaphragm leakage detection B5 Welding d. 40 mm SS-H SS + heating flange in dosing head (electric) B7 Welding d. 40 mm and flange DN 32 Gasket material E EPDM (ethylene propylene diene monomer) Valve type V FKM (fluorocarbon) T PTFE (polytetrafluoroethylene, also called Teflon ) 1 Standard C1 Welding flange DN 32, SS P Flange 1 ¼" 2 Spring-loaded Valve ball material Spring-loaded, 3 C Ceramic 0.05 bar suction, 0.8 bar discharge G Glass 4 Spring-loaded, discharge side only T PTFE (polytetrafluoroethylene (Teflon )) Supply voltage SS Stainless steel, DIN Y Hastelloy 0 Without motor, IEC flange Control panel position G H 1 x 230 V, 50/60 Hz 1 x 120 V, 50/60 Hz X No control panel 230/400 V, 50/60 Hz E F Front-mounted or 440/480 V, 60 Hz W Wall-mounted F Without motor, NEMA flange (US) 3 / 13

4 2.1 Torques and lubricants This section shows the screws and nuts to be tightened to a certain torque as well as the lubricants to be used. After approx. 6 to 10 working hours or two days, tighten the dosing head screws crosswise using a torque wrench. Pump Torque [Nm] Lubricant DMH 251, 10 bar DMH Thread Eze DMH 251, 16 bar DMH Thread Eze DMH 251, 25 bar Thread Eze DMH 254 DMH Thread Eze DMH 257 DMX 6-7 Thread Eze Thread Eze, part no (0.5 l). 2.2 Lubricants DMH Pump type Model Quantity [l] One dosing head Product number Quantity [l] Two dosing heads Product number Oil type DMH white oil DMH 252, 10 bar white oil DMH 252, 16 bar DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 DMH DHG 68 Alternatives to white oil (Paraffin 55 DAB7) Alternatives to DHG 68 Manufacturer Designation Manufacturer Designation ARAL Autin PL (DAB7) ARAL Degol BMB 68 BP BP-Energol WM2 BP BP-Energol GR-XP 68 ESSO Esso Marcol 82 (M82) Chevron Chevron NL gear compound 68 Fina Fina Vestan A 70 B ESSO Spartan BP 68 Texaco Texaco white oil pharmaceutical 70 Fina Fina Giran 68 Shell Odina 15 Mobil Oil Mobilgear 626 Texaco Texaco Meropa 68 Shell Tellus 68 elf Reductelf SP DMX Change of gear grease should be performed by authorized, qualified personnel only. For change of grease, contact Grundfos. To ensure trouble-free operation, we recommend that you change the gear grease after 5 years or 20,000 operating hours. 4 / 13

5 3. Service tools The following drawings and tables show standard and torque tools for pump service.. A B C Pos. Description Suppl. information Part no [Nm] SV0292 A Torque wrench [Nm] SV0269 B Ratched insert tool Part for torque wrench SV0295 C M6-5 mm SV0296 Hexagon head driver M8-6 mm SV0297 M10-8 mm SV / 13

6 4. Spare parts Kit type Contents Valve kit: Valve Diaphragm/valve parts Diaphragm Valve parts kit Two complete valve kits (suction and discharge) Diaphragm and internal valve components Diaphragm TM TM Diaphragm TM TM TM Material Type Model Flow [l/h] Dosing head/gasket/valve balls DMX 221 DMX 226 4, 8, 16 7, 14, 27 12, 26, 50 17, 39, 75 25, 60, , 52, 67, 100, 132, 142, , 82, 95, 160, 199, 224, , 130, 152, 255, 321, 380, , 315, 525, 765 DMH 251 All DMH 252 All DMH 253 All DMH 254 All DMH , 270, 332, DMH 257 All DMH 280 All Diaphragm/ valve parts Product numbers Diaphragm Valve PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel Stainless steel/fkm/stainless steel PP/EPDM/PTFE PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel PP/EPDM/GLAS Stainless steel/fkm/stainless steel PP/EPDM/PTFE Stainless steel/fkm/stainless steel 6 / 13

7 Material Type Model Flow [l/h] Dosing head/gasket/valve balls Diaphragm/ valve parts Product numbers Diaphragm Valve DMH 281 All PP/EPDM/PTFE Stainless steel/fkm/stainless steel DMH 283 All PP/EPDM/PTFE Stainless steel/fkm/stainless steel DMH 285 All PP/EPDM/PTFE Stainless steel/fkm/stainless steel DMH 287 All PP/EPDM/PTFE Stainless steel/fkm/stainless steel DMH 288 All PP/EPDM/PTFE Stainless steel/fkm/stainless steel 7 / 13

8 5. Dismantling and assembly 5.1 General information If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the following sections. Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section 3. Service tools Before dismantling the pump When dosing dangerous liquids, always refer to the corresponding safety data sheets. Wear protective clothing (goggles and gloves) when working on the connections and cables. Maintenance should only be carried out by authorized specialists. Flush and clear all parts before dismantling. Disconnect the electricity supply to the motor. Remove the electric cable in accordance with local regulations. Close the isolating valves, if fitted, to avoid draining the system. Note the centre of gravity of the pump to prevent it from overturning Before assembly Clean and check all parts. Order the necessary service kits. Replace defective parts by new parts. Always replace gaskets and O-rings when the pump is overhauled During assembly Lubricate and tighten screws and nuts to correct torque as stated in section Interval between cleaning and maintenance DMX Clean the overflow valve and replace the diaphragm, if necessary, every 12 months, or if faults occur. Gear grease see page Lubricants Clean the valves: At least every 12 months or after 4000 operating hours, or if the pump is not performing, or in the event of a fault DMH Check the oil level and add oil if necessary: Check the oil level every two weeks and add oil, if necessary. Clean the valves: At least every 12 months or after 4000 operating hours, or if the pump is not performing, or in the event of a fault. Clean the valves and replace, if necessary (for stainless steel valves: inner parts of valve). Change diaphragms and gear oil every 12 months, change the dosing liquid and gear oil in dusty installation sites, change gear oil every 3000 operating hours. Clean ball check of the double diaphragm after a diaphragm breakage, remove the ball check immediately and clean it. 8 / 13

9 5.3 Dismantling and assembly of dosing head The drawings in this section are schematic drawings. Consequently, the number of screws and appearance of parts may differ according to pump type. Step Action 1 Remove the valves Stop the pump. Remove the connections. Unscrew valves counter-clockwise. See Clean the valves, page Clean the valves. TM TM Remove the dosing head Loosen the locking screw. While the pump is running, set the stroke-length adjusting knob to 100%. Tighten the locking screw. Stop the pump. Remove the connections. Loosen the socket head screws. Remove the dosing head. Note the position of the dosing head in order to refit it correctly. 3 Remove the diaphragm Insert a screwdriver through the centre of the label showing the motor direction of rotation. Turn the fan blades until the diaphragm reaches the front dead centre (the diaphragm detaches itself from the diaphragm flange). Screw the diaphragm counter-clockwise. 4 TM Check the support plate, If any Check the support plate for damage/wear. Check the adaptor ring (only DMX) Check the adaptor ring for damage/wear. Fitting the diaphragm TM Fit the adaptor ring (only DMX) Position the adaptor ring in the gearbox with the curvature against the dosing head. Fit the support plate and ring, If any Ensure that the support plate behind the diaphragm rests in the groove of the new diaphragm. Fit the diaphragm Screw the new diaphragm completely into position, then rotate back until the holes in the diaphragm and flange coincide. Turn the fan blades until the diaphragm reaches the bottom dead centre. (The diaphragm is pulled onto the diaphragm flange.). 5 TM Fit the dosing head Fit the dosing head in the correct position on the gear housing by means of the screws and tighten according to the table in section 2.1 Torques and lubricants. 9 / 13

10 Step Action 6 TM TM Clean the valves Dismantle/assemble the valves as shown in the drawing to the left. Clean all parts and replace faulty parts by new ones. 7 Fit the valves Fit the valves so that the arrows point in the flow direction. Screw the valves clockwise. Fit the connections. TM Commissioning TM TM Fill the dosing head (only for systems without flooded suction) Unscrew the discharge valve (pos. 5). Add the dosing liquid to the dosing head. Screw the discharge valve (pos. 5) back in. Deaerate the dosing pump Open the deaeration valve (pos.11) of the dosing line (if installed), or remove pressure on the discharge side so that the liquid is able to issue without counter pressure. Run the pump for approx. one minute or until the air has escaped from the dosing head. Close the deaeration valve (pos.11) of the dosing line. 10 / 13

11 5.4 Oil change (DMH) Step Action b Drain the gear oil Stop the pump. Unscrew the oil plug (pos. 1) inclusiv the gasket (pos. 1b) and collect the gear oil in a container. Screw the oil plug and the new gasket back in and tighten well. Note: Risk of leaks and damage caused by oil loss. For each oil change, use a new flat gasket (pos. 1b). Fill the gear oil Check that the oil plug(pos. 1) is tightened. Unscrew and remove the aeration screw and oillevel gauge (pos. 2). Set the stroke-length adjusting knob (pos. 3) to 0. Slowly add the hydraulic oil through the aeration screw opening (pos. 2), until the oil reaches the mark on the oil-level gauge. For amount of oil, see section 2.1 Torques and lubricants. Wait 30 minutes. Run the pump for approx. 5 minutes with a stroke adjustment of 0%. Run the pump for approx. 10 minutes with a stroke adjustment of 40%. Check the oil level Switch off pump. Unscrew and remove the aeration screw and oillevel gauge (pos. 2), check the oil level and add oil if necessary. Fit the aeration screw and oil-level gauge (pos. 2). TM Vent the dosing pump (for pumps with air vent screw (pos. 4)) Remove cover (pos. 7) from the stroke-length adjusting knob (pos. 3). Loosen the locking screw (pos. 6). Set the stroke-length adjusting knob (pos.3) to 15%. Loosen the degassing valve (pos. 4) by one rotation to the left. Run the pump for approx. 5 minutes. Tighten the degassing valve (pos. 4). Set the stroke-length adjusting knob (pos.3) to the duty point. Tighten the locking screw (pos. 6). Refit cover (pos. 7). 11 / 13

12 6. Fault finding charts 6.1 DMX Fault Cause Remedy Pump does not run. Pump does not suck. Pump does not dose. Dosing output of pump is inaccurate. Pump not connected to mains. Wrong mains voltage. Electrical failure. The empty-tank indicator light is flashing in the display. The integrated diaphragm leakage detection is activated. ERROR and MBS are flashing in the display. Suction line leaking. Cross-section of suction line too narrow or suction line too long. Suction line clogged. Foot valve covered by sediment. Suction line buckled. Crystalline deposits in valves. Diaphragm broken or diaphragm tappet torn out. Air in suction line and dosing head. Stroke adjustment set to zero. Liquid too viscous or density too high. Crystalline deposits in valves. Valves not correctly assembled. Injection point blocked. Inexpert installation of lines and peripheral equipment. Dosing head not fully vented. Degassing liquid. Valves partially soiled or incrusted. Zero point misadjusted. Counter pressure fluctuations. Suction height fluctuations. Siphon effect (pre-charge pressure higher than counter pressure). Leaky or porous suction line or discharage line. Parts in contact with pumped liquid not resistant. Dosing diaphragm worn out (incipient tears). Mains voltage fluctuating. Variation of the dosing liquid (density and viscosity). Connect the pump to the mains. Replace the pump. Return the pump to the service centre for repair. Remove the cause. Replace the diaphragm. Replace or seal the suction line. Check recommended installation specifications in the installation and operating instructions. Rinse or replace the suction line. Suspend the suction line at a higher position. Lay the suction line correctly and check for damage. Clean the valves. Replace the diaphragm. Vent the pump. Wait until the pump has been vented. Turn the stroke-length adjusting knob in the direction of the "+". Check the installation. Clean the valves. Assemble the inside parts of the valve in the correct order and check or possibly correct the flow direction. Check and possibly correct the flow direction, or remove the clog. Check for leakages and correct installation. Repeat the venting. Check the installation. Clean the valves. Adjust the zero point to the actual counter pressure. Use a counter-pressure valve and a pulsation damper. Keep the suction level constant. Install a counter-pressure valve. Leaky or porous suction line or discharage line. Replace with resistant materials. Replace the diaphragm in accordance with the maintenance instructions. Decrease the counter pressure of the pump. Examine the concentration, possibly use an agitator. 12 / 13

13 6.2 DMH Fault Diagnosis Cause Remedy No dosing flow even at a low counter pressure. Pump makes no noise. No dosing flow even at a low counter pressure.. Pump produces high noise levels, although the pressurerelief valve is activated.. Pump does not deliver, or pressure relief valve opens. Pump delivers insufficient flow. Pump doses too much. No motor sound or vibrations. Fan is not rotating. When the aeration screw is removed, use the oil-level gauge to observe a calm oil surface. There is no sloshing. Oil level is too low, see oil-level gauge. ii the suction line is closed, the pressurerelief valve is not activated. No dosing flow on the discharge side. The pressure-relief valve is activated independently of the dosing flow setting (10%-100%). The AMS (diaphragm protection valve) responds and the pressure-relief valve is activated independently of the dosing flow setting (10%-100%). The AMS responds and the pressurerelief valve is activated at 100% dosing flow; When the flow is reduced by approx. 10%-20%, the pressure-relief valve is no longer activated. Suction valve: During the pressure stroke, the dosing liquid flows back into the suction line. Discharge valve: During the suction stroke, the dosing liquid flows back into the dosing head. The pump takes in less liquid. Dosing flow depends highly on the pressure; if the counter pressure is low, the dosing flow increases considerably. If the stroke frequency is increased, the dosing flow increases excessively. Manometer discharge line. Especially with stroke frequencies below 15 strokes/min., for example with frequency converter operation. Motor is not running. Motor runs, but the eccentric shaft is not rotating, no piston movement; spiral pin or motor shaft broken. Not enough oil in pump, air is penetrating the piston flange through the control holes. Dosing head not filled, suction line and tank empty. Valve on discharge side closed. Counter pressure is higher than the set pressure at the pressure-relief valve. Discharge valve installed in the opposite direction of the flow. Check arrow at valve. Valve on suction side closed. Suction filter obstructed. Suction valve blocked (does not open). Suction valve spring too strong. Suction valve installed in the opposite direction of the flow; check arrow at valve. Dosing head not completely vented. Pump running in cavitation (dosing liquid with too high viscosity; dosing liquid with too low steam pressure at operating temperature = degassing of the liquid; suction lift too high; wrong design of system on suction side). Diaphragm broken (not enough oil in enclosure of pump; piston flange). Pump discharge valve clogged or ball guide in valve worn due to corrosive or abrasive dosing liquid. Suction/discharge valves dirty or leaky. Too much clearance between piston and slide valve, or stroke frequency of pump too low (too much slip). Counter pressure has seriously increased; pressure-relief valve set too low. Pressure-relief an degassing valve (pos. 7) not working properly. Connect the motor to the power supply. Replace the motor if blown. Contact Grundfos service. Fill in oil and vent the pump. Vent the dosing head, fill/replace (tank) on suction side. Open the valve. Set the pressure-relief valve to a higher value, but only if the pump is designed for this. Do not block the pressure-relief valve. Install the discharge valve correctly. Open the valve. Clean the suction filter and replace it, if necessary. Dismantle and check the suction valve. Use the correct spring or double-ball valve for checking. Install the suction valve correctly. Fill the dosing head completely. Contact Grundfos service. Clean and grease well all parts using oil according to regulations, then install a new diaphragm. Remove the discharge valve, dismantle and clean it. If the bars of the ball guide are worn, replace the valve. Clean or replace the valves. Replace the piston and piston slide valves, use another hydraulic oil with a higher viscosity (mainly for frequency controller operation and higher counter pressure). Readjust the zero point. Correct the setting of the pressure-relief valve. Replace the valve or replace with ø8 ball, if necessary. Manometer dischargeline. Counter pressure has seriously dropped. Readjust the zero point. Heavy overdose. Overdosing at higher dosing flow adjustments and flows. Pre-charge pressure of suction line higher than counter pressure of discharge line. A positive pressure difference of min. 2 bar is required between suction valve and discharge valve for the pump to operate correctly. Excessive dynamics in suction line. Install a counter-pressure valve. Mount a suction pulsation damper. 13 / 13

14 7. Drawings 7.1 DMX TM DMH TM / 13