Instruction Manual for

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1 Manual No.: SIKO-MPD-003 Instruction Manual for MPD Mechanical Diaphragm Metering Pump Important! Read and understand this manual prior to operating this product! Thank you for having selected the SIKOPUMP MPD Mechanical Diaphragm Metering Pump. This instruction manual deals with the correct handling, maintenance, inspection and troubleshooting procedures for the MPD Mechanical Diaphragm Metering Pump. Please read through it carefully to ensure the optimum performance, safety and long service of your pump. Contents 1. SAFETY INSTRUCTION...Page 1 2. TO THE USERS Page 2 3. ATTENTION Page 2 4. SUMMARIZE OF THE MPD METERING PUMP. Page 2 5. MODEL IDENTIFICATION GUIDE.. Page 3 6. SPECIFICATIONS.. Page 3 7. STRUCTURAL PRINCIPLES OF THE PUMP Page 4 8. THE USE OF PUMP Page 4 9. PUMPS DAILY MAINTENANCE Page INSTALLATION.. Page FAILURE ANALYSIS AND ELIMINATION.. Page 8 APPENDIX ASSEMBLY DIAGRAM..Page 9 to Page 12

2 1. SAFETY INSTRUCTIONS Turn off the power supply Working without disconnecting the power supply may cause an electrical shock. Before performing any assembly or maintenance procedures involving the pump, make sure to turn the power supply switch off and to stop the pump and other related devices. Terminate operation When you detect any signs of abnormal operation, terminate pump operation immediately Modification Never modify the pump. will not be responsible for any accident or damage of any kind caused by the user remodeling the pump without first obtaining permission or instructions from. Protective clothing If application involves the handling of hazardous liquids, protective gear(gloves,glasses, clothing,etc) must be worn before performing any maintenance on the pump. Please follow safety guidelines established for such applications. Operation Operation of the pump and related system must be by experienced or knowledgeable persona. The pump operator or pump operation supervisor must not allow any personal who have little or no knowledge of the pump to operate the unit. Power Do not operate the pump at a different voltage than specified on the nameplate. This may result in damage to the unit or fire. Only the specified voltage must be used. Spill accident Protective measures should be taken against any accidental spill or leakage of any hazardous liquids as a result of unexpected damage to the pump or the related piping. Please follow safety guidelines established for such occurrences. Operating site must be free of water and humidity The pump is not designed to be water-proof or dust-proof. The use of the pump in places with splashing water or humidity above 90% may result in an electrical shock or short circuit. Do not damage power cord Do not cut, abrade or forcibly pull the power cord. Excessive heat or heavy load applied to the cable may damage the cable and finally result in a fire or an electrical shock. Do not cover the motor Covering the motor during operation may result in an accumulation heat inside the motor and cause a fire or a mechanical failure. Proper ventilation is necessary for the motor. Grounding Do not operate the pump without proper grounding; otherwise an electrical shock may result. Follow all local, state and government regulations for the installation and wiring of the pump. Location and storage Do not install or store the pump in the following places: ---Places where a flammable gas or material is used or stored. ---Places where the ambient temperature is extremely high (104. F or higher) or extremely low (32. F or lower). --- Chemical Handing Pump Solutions Page 1

3 2. To the users Dear users: thank you for the purchase and use of Shanghai SIKO Pump Manufacture Co., Ltd. (hereinafter referred to as "SIKO") series products. For your safety and interests of your use of the equipment prior to carefully read the product brochures and enclosed all the information. If you are not in accordance with the product specification use and operation, which, led to the loss, we will assume responsibility. Brochures of the product (hereinafter referred to as "brochure") 1. The copyright belong to SIKO; 2. We have the right to explain if the brochure has difference with the actual products. 3. Brochure is an indivisible part of the product take good care of. If you have any unknown or disagreement, please inform us within7 days from the day you bought it, or we will think that you have accept all the content, thanks! 3. Attention 1. Adding #220 Worm Gear Oil or #50 gear oil to the standard before using the pump 2. Electrical wiring of the pump must conform to the electrical wiring Nameplate voltage. 3. Before using, ensure that the export pipeline is free (the valve is open) 4. During the welding, never drop the welding bits or sundries into the pipe or valve body (or it will cause the water can not come out, the pressure and Flow turn to small).to stop working close the metering pump first, then closed the valve exit. 5. Export pipeline pressure must be higher than the import pipeline pressure, if it is lower than the import, pressure, we must install back-pressure valve, to prevent Siphon. 6. Export pipeline diameter must be greater than or equal to the corresponding standard metering pump connection. 4. Summarize of the MPD metering pump The main product of the MPD mechanical diaphragm metering pump is a reciprocating pump, the pump cylinder can be divided into single-cylinder, twin-cylinder, and other types of triplex. The pump can be used in the oil, chemical, textile, food, paper, nuclear technology, plant, plastics, pharmaceuticals, water, and environmental protection industry and technology sectors. They are used in transporting solid particles of liquid of the pressure and pipeline with precise quantities. Its flow can boot (or fixed) are from 0-100% within step less adjustment. (According to the characteristics of metering pump, general itinerary at least not less than the total trip of 10%) applied to single-cylinder pump liquid single occasion; double cylinder pump for use ratio pump can also use parallel; triplex pump can be used as three percentage pump, but also triplex parallel, --- Chemical Handing Pump Solutions Page 2

4 to achieve greater emission, increased the liquid pulse frequency, promote continuous liquid smooth accession; six-cylinder pump up triplex pump twice effects. This type of pump can transport temperature of -30 degree to 70 degree, the viscosity of mm2/s solid particles and other non-corrosive and non-corrosive liquid medium. Different models of the metering pump can be used in accordance with requirements inverter motor assembly (will receive 4-20mA current signal) or explosion-proof--machine. Pump model parameters and specifications please refer to the company's product samples selection. 5. MODEL IDENTIFICATION GUIDE 6. SPECIFICATIONS Please refer to our Pump catalogue check valve assembly pump head assembly diaphragm fig 1, structure of mechanical diaphragm metering pump --- Chemical Handing Pump Solutions Page 3

5 7. Structural principles of the pump 2.1) Structure: The pump is made of the motor, gear box, the cylinder three parts, etc Wheel box part is made of cam, stroke adjustment and body composition ratio worm; by rotating the hand wheel to adjust to regulate in Tappet itinerary changes from the surface membrane telescopic distance to change the flow purposes Cylinder is composed of cylinder block components, valve block inhaling and exhaling valve block, the diaphragm base membrane components. 2.2 Principle: Motor driven by coupling through the worm and worm wheel spindle and deceleration so eccentric rotation rotary movement, led by the eccentric Tappet guide bore for reciprocating movement. Together with the membrane, through a one-way so they created a vacuum, inhalation valve, the progressive cavity pump valve is opened, inhaling liquids; when the diaphragm dead point forward movement, this time inhalation valve closure discharge valve is opened, the liquid membrane from the promotion. By adjusting the pump in a certain itinerary also work with reciprocating consecutive formation pressure, quantitative emission liquid. 2.3 Flow regulation characteristics: Pump flow control regulation is on hand wheel rotation, driven adjustment screw rotation, Tappet thereby changing the pitch, the change diaphragm pump cavity mobile itinerary to determine the size of flows. Adjust hands round of the calibration decision patch itinerary, precision rate of 95%. Flow repeatability accuracy of 1%. 8. The use of pump 8.1) Pump operation before the inspection and preparations 8.1.1) Check the bolts connecting whether tightening, whether the foot-adjusted fair, a loose nut not allowed ) Cleaning of the movements of the face Machining antirust oil when use at the first time, shovelment not allowed ) According to the temperature of environmental and transmit and adding #220 worm Gear Oil or #50 Gear oil to the oil standard ) Reciprocating diaphragm moving around several times, without any blocking, smooth touch ) Check regulator hand wheel is going to zero. it should be up to 0 (so-scale should be zero especially, as it will affect range starting drift when in the transport process) ) Check whether electrical lines then in the corresponding electro, (wiring, made famous motor voltage on calibration requirements make pump according to the rotation direction of rotation. --- Chemical Handing Pump Solutions Page 4

6 8.2) Start 8.2.1) Open the valve and make sure the pipeline if free before starting up the motor ) After starting roll a few times first, then put into use as needed ) Based on the needs of process, check certification provided in the flow calibration curve and with the actual conditions retrial flow calibration curve, come to the itinerary should be relative percentile, relax locking nut, hands rotate adjust to the designated calibration; Rotating hand wheel adjustment, attention should not be too fast and too aggressive, according to the flow from large flow direction of regulation, which require from large, to small-conditioned, hands should be several rounds of spin lattice, large flow again to the direction of rotation calibration, after the regulation was required to adjust lock to prevent loosening ) The pump stroke can adjust during stopping or in operation; the pump flow will take about 1-2 minutes to stabilize the trip length, the greater stability longer flow time ) Check the temperature of regulator and other campaign not exceeding 65 C degree ) The operator should be smooth, no unusual noise; otherwise, if not, check it then put into operation. 8.3) Stop 8.3.1) Cut power to stop motor functioning ) Close import pipeline valves, but it should be opened when working. 9. Pumps daily maintenance 9.1) Check 9.1.1) Check of rotating inside the designated oil line not too much or too little regularly, lubricants should be clean without impurities, pay attention to the oil change (#50gear oil and #220 worm gear oil were suggested). Please refer to the oil-period as following table: Lubricants replacement period Cycle Within one month of Within two to six More than six months the beginning months Hour per time h h h 9.1.2) Check the internal parts after the pump operate hours and repair or replace the right-link bushings and other easy broken parts ) Clean the cylinder when the pump stops for a long time, if the liquids is strongly corrosive, it should be running water 5 minutes to rinse tanks of the liquid to prevent the corrosion. 9.2) Maintenance solution demolition and assembly sequence 9.2.1) Liquid cylinder demolition components:1, First removed with a one-way valve connected to the pipe and accessories; 2, The cylinder block removed. Spin out membrane (At this point the best way is to contact with the technique of the manufacture), then remove the cylinder head gear box; 3, According with the following order of removing all the tappet assembly of the parts; A, unload the spring shoot, take out spring beat, spring, tappet, if the composite bearings as a change of the grinding removed, using the same models replaced. B, turn off the inlet and outlet valve, valve fit, spacing unit, valve seats, valve ball. --- Chemical Handing Pump Solutions Page 5

7 9.2.2) Gearbox disassembly: 1, Led out lubricants 2, take the motor, motor block, pull coupling and bearing seat, raid the worm components. 3, discard the adjustment assembly and from the assembly within lending hand wheel adjustment, regulating, 4, remove the worm gear, eccentric spindle and principal axis after unload the two ends of the principal axis 9.2.3) The assembly should be according to the contradictorily order, and pay attention: the assembly components should be checked after the assembly space, the assembly should be complete without a comfortable rotation for jamming. The slide assembly seat at the regulator must regulate stem rotation to death, while regulating hand wheel rotation to 20 on the scale, fine-tuning hand wheel adjustment cylindrical shoot coincides with the slide. 10. Installation fig 2 typical metering pump installation 10.1) Pump installation ) Pumps should be installed above ground mm high mixed suspected soil, or the corresponding solid-chair, put the pump to the level state; multi pump installment should be pay attention to the correction phase coupling of benchmarks, Care Deviation not more than 0.15 mm (elastic coupling), and the steel couplings within 0.05 mm; ) Suction tube should not have sharp bend (not more than 90C degree) and should minimize bending pipeline and increased resistance of components ) Do not install the pump and medicine shafts in direct sunlight ) For fitted with a barrel to the drug the height should not than 1.5M, or it will affect the inhalation of the pump, as the equipment needs maintenance check please put it in capacious --- Chemical Handing Pump Solutions Page 6

8 site ) Do not install in easily touched by moisture or corrosive gases place ) Pump installed at a temperature of around -20C to 40C degree and the altitude should not exceed 1000M 10.2) Pipeline Installation ) Piping inhalation Path not less than pump inhalation valve diameter, and should try to shorten the length of pipeline inhaled, it is advisable general 1-2 meters; if it is necessary to increase the length but not longer than 4 meters (At this juncture, according to the corresponding installed filters bottom valve) (but at the start of inhalation liquid relatively extended) ) The pipeline which connect with inhaled valve and discharge valve should not integrate forcibly, the weight of the pipeline and valve can not be taken by the pump and adsorb-eject valve. Fix the pipe after the installation 10.3) Special liquid increase the flux of the pipeline MPDS2, MPDB, 2MPDB, MPDS2 Series diaphragm metering pump the replacement patch 1st step: rotating cylinder block under six screws and unloaded cylinder block lateral Flat-enhancer. Unloading cylinder block, with a counter-clockwise rotation out at the old patch 2ed step: pick up the new patch, patch enhanced bearing plate, and then aim at the screw thread of the mandrill, circle the diaphragm to bottom with a counter-clockwise rotation. 3rd step: installing the pump head and reinforce the screws MPDT1, MPDS1, MPDM1 Series diaphragm metering pump the replacement patch 1st step: first removed cylinder block connecting piece sets above transparent plastic sheeting 2nd step: spanner into the central cylinder block connectivity kits, Relax locking nut. 3rd step: rotating cylinder block under six screws and unloaded cylinder block, clockwise rotation from the old patch. 4th step: a hand rotating motor, while observing cylinder block connecting parts (referring to just under the diaphragm spin ejector), the most legitimate stem bothered extremity, stop motor rotation. 5th step: pick up the new membrane, the alignment rod thread to the anti-clockwise direction of rotation into the membrane, which means the degree" spin to the outer surface membrane connected with the cylinder block sets End 1mm whichever is worse, attention is concave into 1mm. While Alignment diaphragm cylinder block and screw holes connecting the hole. 6th step: Plate linking hands into the central cylinder block sets, locking nut. 7th step: connect bank onto cylinder block sets above the transparent plastic sheeting. --- Chemical Handing Pump Solutions Page 7

9 11. Failure Analysis and Elimination Feather Reason Method 1 No discharge 1. too high suction height 2. suction pipe clogging 3. suction pipe leakage 1. lowing the installation height 2. clean suction pipe 3. repair the pipe leakage 2 Not enough discharge 3 Discharge pressure not stable 4 Measuring precision lower 5 Noise when running 1. suction pipe partly clogged 2. suction valve or discharge valve clogged 3. ball valve seat wore 1. clean the suction pipe 2. clean the suction/discharge valve 3. repair or change the valve seat 4. lower speed 4. check the motor currency and voltage 1. leakage or clog in the 1. clean discharge/suction valve discharge or suction valve 2. add back-pressure valve 2. no back-pressure valve 1. leakage packing 1. repair or change the packing 2. wore suction/discharge 2. repair or change the valve valve 3. stable the power source 3. not stable speed frequency and voltage 4. adjustment wheel position 4. re-adjust the wheel position and changed fix it 1. movement part broken or lack or wore out 2. too high suction height 3. suction pipe leakage 1. change or fix the part 2. low the installation height 3. repair the leakage 4. push the air out 4. air inside the liquid 5. enlarge the suction pipe 5. suction pipe too small 6. low the discharge pressure 6. discharge pressure too high --- Chemical Handing Pump Solutions Page 8

10 Appendix-assembly diagram MPDS2 diaphragm metering pump assembly diagram --- Chemical Handing Pump Solutions Page 9

11 MPDB, 2MPDB, MPDS2, diaphragm metering pump assembly diagram --- Chemical Handing Pump Solutions Page 10

12 MPDS1, MPDM1, diaphragm metering pump assembly diagram --- Chemical Handing Pump Solutions Page 11

13 One way valve (PVC type) One way valve (SS304 type) --- Chemical Handing Pump Solutions Page 12

14 , specialized chemical handing pump manufacturer. Metering pump, magnetic driving pump, diaphragm pump, bellows pump, rotary pump and so on Address: No.518 Jinyuan Road(Jinyuan Industry Park), Shanghai, China Tel: (direct), Fax: Website: As we are constantly endeavoring to improve the performance of our equipment, The company reserves the right to make alteration from time to time and equipment will maybe differ from that detailed in this brochure.