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Installation, Operation & Maintenance Manual (IOM)

1. E 8 1 2 H TTT ae A A A AT sen eee See ee o o EN Y 1 1 4 3 Adjustable motor slidebase Use four 1 2 anchor bolts me 7 1 2 19 31 1 2 80 m 34 86 All dimensions are in inches centimeters 34 Appendix D Outline Dimensions for Z4500 103 Mounting Inlet 4 3002 ANSI f f f CMI y 4 10 16 AN Baseplate web fe 1 1 2 3 81 ee 12 1 4 81 12 47 43 18 m Se 20 50 80 Beltguard 8 1 2 _ 1718 Discharge Electric motor 21 59 4 76 aie egies I OUTLET Nu H Q 10 3 4 O E 27 31 q CORK O i Y B 1 E 1 d O 10 1 2 Mary A 26 67 9 1 2 gt r mn 4
2. Appendix C Performance Curves 23500 gpm L min 120 4 378 5 420 RPM 1004 378 5 kW 804 302 8 14 9 604 227 1 7 5 404 151 4 0 0 0 20 1 38 40 2 76 60 4 14 80 5 52 100 6 89 120 8 27 140 9 66 Differential Pressure psid bar gpm L min 1404 529 9 520 RPM 1204 4542 1004 378 5 kW 804 302 8 14 9 604 227 1 7 5 409 151 4 0 0 0 20 1 38 40 2 76 60 4 14 80 5 52 100 6 89 120 8 27 140 9 66 a Differential Pressure psid bar gpm L min 160 4 605 7 640 RPM 1404 529 9 kW 1204 4542 14 9 1004 378 5 7 5 804 302 8 0 0 0 20 1 38 40 2 76 60 4 14 80 5 52 100 6 89 120 8 27 140 9 66 Differential Pressure psid bar gpm L min 200 4 757 0 780 RPM kW 180 681 4 22 4 160 605 7 14 9 1404 529 9 7 5 120 454 2 0 0 0 20 1 38 40 2 76 60 4 14 80 5 52 100 6 89 120 8 27 140 9 66 Differential Pressure psid bar hp 20 10 hp 20 10 hp 20 10 hp 30 20 10 24 Appendix C Performance Curves 24500 gpm L min 206 780 204 772 202 765 200 757 198 750 196 742 194 734 192 727 190 719 188 712 186 704 gpm L min 256 969 254 961 252 954 250 946 248 939 246 931 244 924 242 916 240 908 238 901 236 893 gpm L min 316 1 196 314 1 189 312 1 181 310 1 173 308 1 166 306 1 158 304 1 151 302 1 143 300 1 136
3. SZ OS O ring Code A Buna N B Neoprene 34 D Viton E Teflon Note Hydraulic motor is not shown See page 15 for repair re build kits CAUTION Always relieve pressure in the unit before attempting any repairs nel Part No Description Qty mer Part No Description Qty No No 1 4442 Case 1 20 3253 Cam key pin 5 2 4443 Cam 1 21 4462 Grease seal 2 3 4444 X2R Rotor shaft assembly 1 22 4463 Grease seal 2 4 4445 Head 2 23 4464 X 2 Mechanical seal assembly 2 5 4446 Sideplate 2 1172 2 Aux inlet flange 2 NPT 1 6 4448 Vane 6 24 1172 2S Aux inlet flange 2 WF 1 T 4449 X Vane driver 5 1920 3 Aux inlet flange blind 1 8 4450 Relief valve cap 1 25 4479 28 Discharge flange 2 WF 2 9 4451 Relief valve spring 1 4981 2 Discharge flange 2 NPT 10 4452 Shim 1 26 2649 Nameplate 1 11 4453 Thrust bearing assembly 2 27 4248 Relief valve nameplate 1 12 4454 Bearing race mounting ring 2 28 1359 Lubrication instruction plate 2 13 4455 Cam key 1 29 1343 1 8 NPT relief fitting 4 14 4456 Bearing cap 2 30 2158 1 8 NPT grease zerk 2 15 4457 Relief valve 1 31 2159 Lubricap 2 4458 Bearing cap shim 002 red 32 3442 1 4 NPT pipe plug 2 16 4458 1 Bearing cap shim 010 brown Se 33 2 231_ O ring discharge flange 2 4458 2 Bearing cap shim LOGO yellow 34 2 234 O ring auxiliary inlet flange 1 17 4459 Shaft key 5 16 x 1 3 4 1 35 2 270 O ring case 2 18 4460 X Roller b
4. Suction pipe too small or restricted Indicated by pump inlet pressure dropping several pounds when pump is started Remove restriction or modify piping Worn vanes Replace Pump without vapor return Worn sideplates Without vapor equalization a pump can remove only about 396 of the truck tank capacity per minute without severe cavitation and capacity loss Reverse or replace sideplates Check universal drive assembly to make sure angularity is within limits yokes are parallel and slip joint is greased Check bearings Check pulley alignment on belt drive pumps Vanes sticking Remove vanes and clean out foreign matter check strainer Replace vanes if swollen Pump runs but no flow Valve closed Check valves Make sure internal tank excess flow valve is open Refer to manufacturer s instructions Excess flow valve slugged Broken shaft Stop pump until valve opens If problem continues slow pump down or install a new or larger excess flow valve Disassemble and inspect pump Repair if necessary Defective meter Service meter Pump will not turn Foreign matter in pump Clean out the pump check strainer in suction line low Worn vanes and or sideplates locked up Vanes broken Clean out pump carefully and replace vanes Has pump been operated dry Then check for damage to cam and rotor shaft assembly Bearing seized Replace pump bearings Grease monthly Use bal
5. o g g of a multitude of load unload operations Be sure and check all 9 CORKEN B177 Automatic Bypass federal state local laws and codes to ensure that all piping Valve components are in accordance 10 Hydrostatic Relief Valve 11 Swing Check Valve 8 Open any shut off valves between the bypass valve and the storage tank 9 Make a note of all pressure gauge readings especially the pressure gauge located at the discharge of the pump Start the pump and circulate the liquid through the bypass system back to the storage tank 10 Verify the proper pump rotation direction There is an arrow cast in the pump case 11 An ammeter may be used by adjusting the bypass valve until the ammeter indicates the full load motor amperage rating shown on the motor nameplate or maximum rated differential whichever comes first Permit the pump to circulate liquid for half an hour or more If the motor overload protection device stops the motor in this period the bypass valve setting is too high and should be readjusted until the motor will run for half an hour After a satisfactory setting is achieved seal the valve adjusting stem to prevent tampering with the adjustment See Important Instructions IH102 and Installation Operation and Maintenance IOM Manual IH106 for more details on the use of the Corken bypass valves 12 Your pump has an internal relief valve it must be set higher than the external bypass setting The internal relief val
6. to prevent overgreasing the bearings Overgreasing can cause seal failure if grease passageways are blocked in some way Clean each fitting before lubricating the bearings This practice helps to prevent foreign material contamination of the bearings and accidental over pressurization of the mechanical seals Use only ball bearing grease MIL G 10924C with a temperature rating of 65 F Normal wear parts are the mechanical shaft seals bearings vanes and sideplates All of these parts plus O rings and grease seals are offered in the Corken repair kit listed in this manual directly after the Seal Replacement Instruction on page nine Use only genuine Corken replacement parts when repairing your Corken Z Series pump Follow the instructions provided with the parts When it becomes necessary to repair your pump or remove it from the system you must be absolutely certain that all propane anhydrous ammonia or whatever product being pumped is bled from the pump and connecting piping Once all the product has safely been bled from the pump and connecting piping make certain no pressure is left in the system SPECIAL CARE MUST BE TAKEN DURING THE BLEED DOWN PROCESS TO AVOID DANGER TO PERSONNEL AND PROPERTY IN THE AREA Bleeding a system too fast is a common mistake and may result in refrigerated liquid being left in the pump and piping even though the pressure gauge shows no pressure As the refrigerated liquid begins to warm more gas
7. 1 8 NPT relief fitting 4 12 4454 Bearing race mounting ring 2 30 2158 1 8 NPT grease zerk 2 13 4455 Cam key 1 31 2159 Lubricap 2 14 4456 Bearing cap 2 32 3442 1 4 NPT pipe plug 2 15 4457 Relief valve 1 33 2 231_ O ring discharge flange 2 4458 Bearing cap shim 002 red 34 2 234_ O ring auxiliary inlet flange 1 16 4458 1 Bearing cap shim 010 brown Ge 35 2 270_ O ring case 2 4458 2 Bearing cap shim 020 yellow 36 7001 037NC150A Bolt hexagon head 24 17 4459 Shaft key 5 16 x 1 3 4 1 37 7001 062NC125A Bolt hexagon head 16 18 4460 X Roller bearing 2 38 7012 006SF019E Screw 8 Registered trademarks of the DuPont company 39 7206 037A Lockwasher 8 2 _ denotes o ring code See chart above 40 4985 Shaft cover 1 3Slots in vanes must face TOWARDS the direction of rotation 41 7012 010SFO50E Screw 2 40 Appendix F V Belt Selection for Stationary Coro Vane Pumps 1 450 RPM Motor e 1 750 RPM Motor Belt Sheave Pitch Diameter Z Beie Sheave Pitch Diameter Belt Number Pump Motor Pump Motor Number B64 B15 4 B7 4 2 420 1 3V14 0 1 3V3 35 3V600 B60 B13 6 B4 2 470 1 3V10 6 1 3V2 80 3V530 B60 B12 4 B4 2 520 1 3V10 6 1 3V3 15 3V530 B55 B11 0 B4 2 580 1 3V10 6 1 3V3 65 3V560 B56 B11 0 B4 8 640 1 3V8 0 1 3V3 00 3V500 B64 B15 4 B4 4 3 420 2 3V10 6 2 3V2 65 3V530 B64 B15 4 B4 8 470 2 3V10 6 2 3V2 80 3V530 A5
8. 25 50 75 100 125 Differential Pressure psid The chart shows approximate delivery rates as seen in vapor equalized propane systems at 70 F 21 C with no pressure loss in pump suction piping The following will cause increased vaporization of the liquid in the pump suction adversely affecting the delivery 1 Restrictions in the suction piping such as internal valves excess flow valves elbows etc 2 Restriction or lack of a vapor return line 3 Temperatures below 70 F 21 C This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases See the GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT CP226 for additional information 22 Appendix C Performance Charts 22000 ZH2000 ZX2000 and ZXH2000 Coro Vane Truck Pumps Pump Differential Approximate Delivery of Brake hp Pump Torque Speed Pressure Propane Required Required RPM psid kPa gpm L min bhp kW ftelb NeM 750 50 345 82 309 2 9 2 2 20 4 27 7 750 100 689 77 291 5 8 4 3 40 8 55 3 750 150 1 034 75 284 8 9 6 63 62 2 84 3 650 50 345 69 261 2 5 1 9 20 4 27 7 650 100 689 64 242 5 1 3 8 40 8 55 3 650 150 1 034 63 238 7 7 5 7 62 2 84 3 600 50 345 63 238 2 3 1 7 20 4 27 7 600 100 689 58 219 4 6 3 5 40 8 55
9. 3 600 150 1 034 56 212 74 5 3 62 2 84 3 500 50 345 52 197 1 9 1 4 20 4 27 7 500 100 689 46 174 3 9 2 9 40 8 55 3 500 150 1 034 44 166 5 9 4 4 62 2 84 3 Z3200 and ZH3200 Coro Vane Truck Pumps Pump Differential Approximate Delivery of Brake hp Pump Torque Speed Pressure Propane Required Required RPM psid kPa gpm L min bhp kW ftelb NeM 750 50 345 112 424 6 2 4 6 43 4 58 9 750 100 689 99 375 9 9 7 4 69 3 94 0 650 50 345 95 360 5 2 3 9 42 0 57 0 650 100 689 84 318 8 2 6 1 66 3 89 9 600 50 345 86 326 5 0 3 7 41 3 56 0 600 100 689 76 288 7 8 5 9 64 8 87 9 500 50 345 70 265 3 8 2 8 39 9 54 1 500 100 689 62 235 5 8 4 3 60 9 82 6 24200 ZH4200 and Z4500 Coro Vane Truck Pumps Pump Differential Approximate Delivery of Brake hp Pump Torque Speed Pressure Propane Required Required RPM psid kPa gpm L min bhp kW ftelb NeM 750 50 345 369 1 397 12 5 9 3 87 118 0 750 100 689 325 1 230 25 1 18 6 175 237 3 650 50 345 316 1 196 10 8 8 0 87 118 0 650 100 689 278 1 052 21 7 16 1 175 237 3 600 50 345 289 1 094 9 9 7 3 87 118 0 600 100 689 254 961 20 0 14 8 175 237 3 500 50 345 236 893 8 3 6 2 87 118 0 500 100 689 208 787 16 7 12 4 175 237 3 Delivery times are approximate see note on page 22 for further explanation Applies to ZX ZXH2000 models only 23
10. 6 3 4 17 14 Y mss 14 15 164 37 94 5 12 70 1 4 NPT Y Internal y 5 8 4 13 relief 2 NPT valve Y discharge 5 11 32 13 57 9 84 3 300 lb ANSI flange inlet 6 5 8 BC 8 1 4 D 18 89 20 95 1 4 square keyway All dimensions are in inches centimeters 27 Appendix D Outline Dimensions for Model Z3500 H i H 1 125 29 A d d ule CORN ul 1 H 7 188 1 4 18 3 keyway col a 5 500 A 14 0 L 3 000 1 3 000 7 6 7 6 4425 y 4 125 10 5 10 5 la 7 188 Pals 5 375 18 3 13 7 All dimensions are in inches centimeters 28 Appendix D Outline Dimensions for Model Z4200 1 3 16 3 01 Internal relief valve 2 NPT 1 4 NPT auxillar wei B 8 20 32 2 5 8 13 13 16 687 35 08 a e A 3 1 4 8 26 Ge 1 4 NPT Y lt gt 7 3 4 17 78 19 69 16 31 32 CS 43 08 S 19 1 2 pe 49 53 SI 7 7 8 BC 10 1
11. 8 D 20 00 25 72 Inlet 2 1 8 4 300 Ib ANSI 5 40 flange Leg pr E gt 1 1 4 3 18 1 1 4 3 17 BN 5 16 square key 5 16 square key Eight 7 8 2 22 diameter holes d Outlet 2 NPT Outlet 2 NPT y I rt Dn al D 4 4 10 16 10 16 All dimensions are in inches centimeters 29 Appendix D Outline Dimensions for Model Z4500 8 0 875 2 2 H on a 6 5 8 B C NE A B Outlet r1 3 R F 3004 ANSI flange E d Inlet 4 R F 3004 Hy ANSI flange 10 75 27 3 8 5 16 square key Dr ii l E i E nee 1 0 2 5 6 5 165 1 prom T 1 CT TuS To ass Tass 8 0 875 2 2 4 5 8 1 587 4 688 4 688 7 3 7 3 on a 7 7 8 B C mounting holes 11 9 11 9 p 21 121 6 125 53 6 15 6 All dimensions are in inches centimeters 30 Appendix D Outline Dimensions for Model ZH2000 square keyway Hydraulic drive adapter asse
12. B6 6 640 QD3A18 0 B18 4 QD3A6 0 B6 4 3 B78 B68 QD3A12 0 B12 4 QD3A6 2 B6 6 780 QD3A15 0 B15 4 QD3A6 4 B6 8 3 B73 B65 QD3A10 6 B11 0 QD3A6 0 B6 4 860 QD3A13 2 B13 6 QDA6 2 B6 6 3 B70 B78 QD4A18 0 B18 4 QD4A6 0 B6 4 25 520 QD3 5V18 70 QD3 5V5 50 3 5VX800 B80 QD3A18 0 B18 4 QD3A7 6 B8 0 640 QD3A18 0 B18 4 QD3A6 2 B6 6 3 B78 B75 QD3A15 0 B15 4 QD3A7 6 B8 0 780 QD3 5V10 90 QD3 5V4 90 5VX650 B72 QD3A13 2 B13 6 QD3A7 6 B8 0 860 QD3A13 2 B13 6 QD3A6 2 B6 6 3 B70 Appendix G Troubleshooting Guide In diagnosing pump and system troubles record the following data during product transfers 4 Pressure in tank being filled 5 Pipe size and length of suction and discharge lines 1 Pressure at pump suction 6 Size and length of vapor equalizing line 2 Pressure at pump discharge 7 Pump speed if practical 3 Pressure in truck tank Solution Check engine speed and PTO on pulley ratio Consult pump performance curve Use tachometer on pump if speed is questionable Restriction in discharge piping or hose too small Vapor equalization lines too small or not used Readjust repair or replace valve Cause Pump speed too slow Problem Low capacity High differential pressure External bypass valve stuck open or set too low Clogged strainer Clean strainer 42 Appendix G Troubleshooting Guide continued Problem Cause Solution Low capacity continued
13. before attempting any repairs id Part No Description Qty i Part No Description Qty 1 4495 X2R Rotor shaft assembly 1 26 2158 1 8 NPT grease zerk 2 2 4242 Cam 1 27 1343 1 8 NPT relief fitting 4 3 4232 Vane 6 Bolt 1 2 13 x 1 1 2 hex 28 7001 050NC150A 16 4 4231 Sideplate 2 C head 5 4488 nee 2 29 7001 081Nc125a POR 5 16 36 x 1 14 hex 6 4239 Case 1 head 7 4417 Bearing cap 2 30 1241 Relief valve 1 8 4438 Grease seal 2 1172 1 5 Outlet flange 1 5 NPT 1 9 4435 Mounting ring 2 1172 1 5S Outlet flange 1 5 WF 1 4439 Bearing shim 002 red au Lee Outlet flange 2 NPT 1 10 4439 1 Bearing shim 010 brown e 1172 25 Outlet flange 2 WF 1 4439 2 Bearing shim 020 yellow 1947 Outlet flange 1 5 NPT ell 1 11 2270 Shaft key 2 4243 Outlet flange 2 NPT ell 1 12 4431 X 2 Mech seal assembly 2 32 4241 Cam key 1 13 2754 Bearing outer race 2 33 3253 Cam key pin 1 14 4432 Thrust bearing assembly 2 34 3442 1 4 NPT pipe plug 1 15 2760 244 Retainer ring 2 35 4262 X Vane driver 3 16 1174 2 Relief valve cap 1 36 2 234_ O ring flange 1 17 1359 Lubrication instruction plate 2 37 2159 Lubricap 2 18 4441 Grease seal 2 1172 1 5 Aux inlet flange 1 5 NPT 1 19 7012 006SF019E Screw 8 1172 158 Aux inlet flange 1 5 WF 1 20 Not shown m 38 1172 2 Aux inlet flange 2 NPT 1 21 Not shown 1172 28 Aux inlet flange 2 WF 1 22 2 262 O ring case 2 1920 3 Aux inle
14. early failure The engine loses 396 of its power for every 1 000 ft 305 m above sea level so if your installation is at a higher altitude than normal consult the factory Motor Recommended wire size AWG Approximate Length of run ft Hp es Volts full load We p amperes 0 100 to 200 to 300 3 1 115 34 0 6 4 2 220 17 0 12 8 8 3 230 9 6 12 12 12 460 4 8 12 12 12 5 1 115 56 0 4 1 1 0 230 28 0 10 6 4 3 230 15 2 12 12 10 460 7 6 12 12 12 7 1 2 1 230 40 0 8 6 4 3 230 22 0 10 10 8 450 11 0 12 12 12 10 3 230 28 0 8 8 8 460 14 0 12 12 12 15 3 230 42 0 6 6 6 460 21 0 10 10 10 20 3 230 54 0 4 4 4 460 27 0 8 8 8 25 3 230 68 0 2 2 2 460 34 0 6 6 6 30 3 230 80 0 1 1 1 460 40 0 6 6 6 40 3 230 100 0 2 0 2 0 2 0 460 52 0 4 4 4 50 3 230 130 0 3 0 3 0 3 0 460 65 0 2 2 2 Based upon 3 voltage loss copper wire type TW Single phase motor calculations are based on two times distance Operation of Your Z Series Stationary Coro Vane Pump Performance curves and charts are provided in Appendix C The following steps should be performed for the initial pumping operation 1 2 Verify the strainer screen is clean Rotate the pump by hand Check V belt drive or direct drive coupling alignment Misalignment will cause accelerated wear of the drive system motor bearings and pump Check motor for proper wiring Review complete system to make certain th
15. elements in the vicinity etc Qualification of the personnel Type of liquid being transferred e Specific safety measures to be applied e g gas detection automatic shut off valves personal protection equipment etc See Appendix A for shipping weight and Appendix D for outline dimensions A rotation arrow is located on the side of the pump so check the PTO to determine its direction of rotation The Z Series pump will match either PTO rotation Connect the drive shaft to the pump shaft that turns the pump in the direction of the arrow The PTO selection is important The pump requires a PTO with an average output speed of 500 to 800 RPM when the truck engine is operating at the proper speed to maintain oil pressure and water circulation The DRIVESHAFT connecting the pump to the PTO should be of the splined or slip type This type driveshaft permits the shaft to adjust for PTO movement and twisting of the truck frame A fixed driveshaft transfers the forces directly into the pump and PTO and will shorten the life of both considerably The yokes of the driveshaft universal joints must be positioned as shown Improper positioning will soon wear them out and potentially destroy the bearings in the pump and PTO INLET PIPING should be as short as possible with minimum restrictions so that the pressure drop is limited Inlet Piping is not generally required on the Z3200 or Z4200 These pumps are bolted directly to the tank
16. gpm L min 386 1 461 384 1 454 382 1 446 380 1 438 378 1 431 376 1 423 374 1 416 372 1 408 60 80 4 14 5 52 Differential Pressure psid bar 100 6 89 18 6 14 9 40 2 76 60 80 4 14 5 52 Differential Pressure psid bar 100 6 89 120 8 27 20 1 38 40 2 76 60 80 4 14 5 52 Differential Pressure psid bar 100 6 89 20 1 38 40 2 76 60 80 4 14 5 52 Differential Pressure psid bar 100 6 89 120 8 27 hp 25 20 15 10 hp 30 25 20 15 10 10 25 Appendix D Outline Dimensions for Model Z2000 6 gt 40 61 2 1 8 5 40 3 1 4 ns Outlet Internal Relief Valve 2 NPT 5 15 16 ya 15 08 11 59 1 4 NPT 2 38 M Inlet 2 NPT Four 7 16 1 11 diameter holes All dimensions are in inches centimeters 26 Appendix D Outline Dimensions for Model Z3200 T 10 15 16 Ala 2 86 a 8 3 4 ae 1 22 23 hd i 3 7 16 8 73
17. i 24 13 Ee P i o ajo El FRERES EK RE r IL al ES 1 2 s 2 2 I 11 i n a Le_95 16 23 65 Adjustable motor slide base Use for 1 2 3 18 anchor bolts 30 7 8 78 44 39 1 2 100 33 42 106 68 All dimensions are in inches centimeters 35 Appendix E Parts Details for Models Z ZH ZX ZXH2000 37 45 ft lb A 5 33 35 15 ftelb Ne 36 25 ft lb 14 45 ftelb O ring Code A Buna N B Neoprene a Note Hydraulic motor is not shown D Viton See page 15 for repair re build kits E Teflon E 56 25 ftelb CAUTION Always relieve pressure in the unit before attempting any repairs Part No Description Qty dad Part No Description Qty 1 4413 Case 1 19 2754 X Bearing 2 2 4414 Cam 1 20 3253 Cam key pin 2 3 4416 Head 2 21 2760 244 Retainer ring 2 4 4417 Bearing cap 2 22 4441 Grease seal 2 5 1174 3 Relief valve cap 1 23 2270 Shaft key 1 4 x 1 9 16 2 6 4282 Shim Z2000 ZH2000 1 24 4479 2 Flange 2 NPT 2 Shim ZX2000 ZXH2000 3 4479 28 Flange 2 welded T 4424 Cam key 1 25 2649 Nameplate 1 8 4425 Relief valve 1 4248 Relief valve nameplate 4 Relief valve spring Z2000 22000 ZH2000 4426 1 26 9 ZH2000 4248 1 Relief valve nameplate 4 T210 Relief valve spring ZX2000 ZX2000 ZX
18. internal valve and must be installed in accordance with the valve manufacturer s instructions These shafts must be parallel 15 maximum operating angle U joint yokes must be inline and parallel splined slip joint Figure 1 Shaft Alignment The Outlet Piping Should Include the Following 1 A pressure gauge should be installed in the pump outlet or near it A pressure gauge is necessary to determine the efficiency of your pumping system 2 A hydrostatic relief valve is required by most state laws and for your own safety 3 If a meter with a vapor eliminator is installed pipe the eliminator outlet to the top of your tank Never pipe the eliminator into the pump inlet piping or into the liquid part of the system at any point 4 The meter back pressure valve may be piped into the tank top or into the pump inlet piping 5 The discharge piping should be at least the same size as the meter The Bypass System The internal safety relief valve is intended as a safety device and not as an operational bypass valve The external bypass valve should be set at a differential pressure lower than the internal relief valve and may be connected to the tank at any convenient point liquid or vapor All Z Series pumps except ZX2000 which is set at 175 psid are set near 150 psid ZH2000 Foot mounted hydraulic drive with NPT connections ZX2000 Foot mounted with NPT connections and high pressure internal relief
19. is recommended Preventive Maintenance guidelines are provided in this manual and are to be followed for the proper operation and performance of the pump Sound Levels When properly installed and operated these pumps do not exceed 85 dbA noise levels at a distance of one meter 3 281 ft from the surface of the pump This value is highly dependent upon the installation and may vary from installation to installation Piping Forces and Moments Maximum Allowable Pipe Torque Z ZH ZX ZXH2000 Inlet Size 2 in 50 mm Torque 1 650 inelbs 186 Nem Outlet Size 2 in 50 mm Torque 1 650 inelbs 186 Nem Z ZH3200 and Z3500 Inlet Size 3 in 80 mm Torque 1 800 inelbs 203 Nem Outlet Size 2 in 50 mm Torque 1 650 inelbs 186 Nem Auxiliary Size 2 in 50 mm Inlet Torque 1 650 inelbs 186 Nem Z ZH4200 Inlet Size 4 in 100 mm Torque 1 900 inelbs 215 Nem Outlet Size 2 in 50 mm Torque 1 650 inelbs 186 Nem Auxiliary Size 2 in 50 mm Inlet Torque 1 650 inelbs 186 Nem Preventative Maintenance Pump Maintenance Schedule Daily Monthly 3 Months Lubricate bearings X Inspect drive couplings X Clean inlet strainer X Check for leaks X Inspect hose and fittings X Principles of the Z Series Coro Vane Pump The Corken Z Series truck pump is a special type of rotary positive displacement pump kno
20. must assure and declare full compliance with this Directive before the machine in which the pump will be incorporated or of which it is a part is put into service Contacting the Factory Before you contact the factory note the model number and serial number of your pump The serial number directs us to a file containing all information on material specifications and test data applying to your specific pump When ordering parts the Corken service manual or Operations Installation and Maintenance IOM manual should be consulted for the proper part numbers ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS The model and serial numbers are shown on the nameplate of the unit Record this information for future reference Model No Serial No Date Purchased Date Installed Purchased From Installed By Table of Contents Applicable Notice of ATEX Contormitv eee 4 Principles of the Z Series Coro Vane Pump ehh n 5 Exclusive Features of Your Z Series Coro Vane Pump occoccoc en 5 Installation of the Z Series Coro Vane Truck Pumps hh nn 5 Outlet Piping Should Include the Following 6 Bypass St aspirar ta ar a wipes pep eir ate eara 6 Power Take off Drive Systems scie hears eee Re xe RARE EGG E EE eu eng E nia eed iege 6 Hydraulic Drive Systems 4 asma ce da ea dio 7 Operation of Your Z Series Coro Vane Truck Pump ooccoccc e 7 How to Transfer From the Truck Tank at Full
21. note If you pressurize with liquid it will sometimes refrigerate even though it enters the pump slowly As a result the seal elastomers will not seal properly thereby causing them to leak 14 Repair Re build Kits 22000 ZH2000 ZX2000 ZXH2000 Repair Kit 3193 X1 24200 ZH4200 24500 Repair Kit 3197 X1 2 224A O ring Buna N 1 2 231A O ring Buna N 1 2 231A O ring Buna N 2 2 234A O ring Buna N 2 2754 X Roller bearing 2 4460 X Roller bearing 2 4262 X Vane driver 3 4449 X Vane driver 5 4428 Vane 6 4448 Vane 6 4431 XA2 Seal assembly 2 4464 XA2 Seal assembly 2 4432 Thrust bearing 2 4453 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4454 Thrust bearing mounting ring 2 4439 Bearing cap shim 0 002 8 4458 Bearing cap shim 0 002 8 4439 1 Bearing cap shim 0 010 2 4458 1 Bearing cap shim 0 010 2 4439 2 Bearing cap shim 0 020 2 4458 2 Bearing cap shim 0 020 2 4441 Grease seal 2 4463 Grease seal 2 2270 Shaft key 1 4459 Shaft key 1 23200 ZH3200 Repair Kit 3195 X1 2 224A O ring Buna N 1 2 234A O ring Buna N 2 2754 X Roller bearing 2 4262 X Vane driver 3 4232 Vane 6 4431 XA2 Seal assembly 2 4432 Thrust bearing 2 dac sean une 2 22000 ZH2000 ZX2000 ZXH2000 Re Build Kit 3194 X1 4439 Bearing cap shim 0 002 8 Includes all items in the Repair Kit pl
22. 5 2A10 6 2A3 6 520 1 3V14 0 1 3V4 12 3V630 B55 2B11 0 2B4 2 580 1 3V14 0 1 3V4 75 3V630 B60 B12 4 B5 4 640 2 3V8 0 2 3V3 00 3V500 B56 B11 0 B5 2 710 2 3V6 9 2 3V2 80 3V475 B53 B9 4 B4 8 780 1 3V8 0 1 3V3 65 3V500 B53 B8 6 B5 0 860 2 3V5 3 2 3V2 65 3V450 B51 B7 4 B4 8 950 1 3V6 5 1 3V3 65 3V475 B64 2B15 4 2B4 4 5 420 3 A13 2 3 A3 2 A60 B60 2B13 6 2B4 2 470 2 A13 2 2 A3 6 A60 B60 2B12 4 2B4 2 520 2 A12 0 2 A3 6 A56 B55 2B11 0 2B4 2 580 2 3V10 6 2 3V3 65 3V560 B56 2B11 0 2B4 8 640 3 3V8 0 3 3V3 00 3V500 B56 2B11 0 2B5 2 710 2 3V8 0 2 3V3 35 3V500 B53 2B9 4 2B4 8 780 2 3V6 9 2 3V3 15 3V475 B53 2B8 6 2B5 0 860 2 3V6 5 2 3V3 15 3V475 B51 2B7 4 2B4 8 950 2 3V6 0 2 3V3 35 3V475 B64 3B15 4 3B4 4 7 1 2 420 4 A13 2 4 A3 2 A60 B64 2B15 4 2B4 8 470 3 A13 2 3 A3 6 A60 B60 3B12 7 3B4 2 520 3 3V14 0 3 3V4 12 3V630 B55 3B11 0 3B4 2 580 2 3V14 0 2 3V4 75 3V630 B56 3B11 0 3B4 8 640 2 3V14 0 2 3V5 30 3V630 B56 3B11 0 3B5 2 710 2 3V10 6 2 3V4 50 3V560 B53 3B9 4 3B4 8 780 3 3V6 9 3 3V3 15 3V475 B53 3B8 6 3B5 0 860 3 3V6 5 3 3V3 15 3V475 B51 3B7 4 3B4 8 950 2 3V8 0 2 3V4 50 3V530 B71 3B18 4 3B5 2 10 420 3 3V19 0 3 3V4 50 3V710 B71 2B18 4 2B5 8 470 3 3V19 0 3 3V5 00 3V710 B60 4B12 4 4B4 2 520 3 3V14 0 3 3V4 12 3V630 B55 4B11 0 4B4 2 580 3 3V14 0 3 3V4 50 3V630 B56 4B11 0 4B4 8 640 2 3V14 0 2 3V5 30 3V630 B62 3B12 4 3B5 8 710 2 3V14 0 2 3V5 60 3V630 B56 3B11 0 3B5 8 780 2 B12 4 2 B5 6 B60 B62 3B12 4 3B7 0 860 2 3V10 6 2 3V5 30 3V560 B60 3B9 4 3B6 0 950 2 3V10 6 2 3V5
23. 60 3V560 B71 4B18 4 4B5 2 15 420 4 3V19 0 4 3V4 75 3V710 B71 3B18 4 3B5 8 470 4 3V19 0 4 3V5 00 3V710 B62 5B13 6 5B4 8 520 3 3V19 0 3 3V5 60 3V750 B60 5B12 4 5B4 8 580 4 3V14 0 4 3V4 75 3V630 B56 5B11 0 5B4 8 640 3 3V14 0 3 3V5 30 3V630 B56 5B11 0 5B5 2 710 3 3V14 0 3 3V5 60 3V630 B53 5B9 4 5B4 8 780 3 B12 4 3 B5 6 B60 B53 5B8 6 5B5 0 860 2 B12 4 2 B6 0 B60 B51 5B7 4 5B4 8 950 2 B11 0 2 B6 0 B56 B75 4B18 4 4B6 6 20 520 4 3V19 0 4 3V5 60 3V750 B68 4B15 4 4B6 8 640 4 3V14 0 4 3V5 30 3V630 B64 4B12 4 4B6 6 780 3 B13 6 3 B6 0 B62 B68 3B13 6 3B8 0 860 4 3V10 6 4 3V5 30 3V560 B65 3B12 4 3B8 0 950 3 B11 0 3 B6 0 B56 5VX680 4 5V15 00 4 5V5 50 25 520 4 B18 4 4 B5 2 BX76 5VX700 3 5V14 0 3 5V6 30 640 4 B16 0 4 B5 6 BX70 5VX680 3 5V12 5 3 5V6 70 780 3 B15 4 3 B7 4 BX71 5VX660 3 5V11 3 3 5V6 70 860 4 B15 4 4 B6 6 BX70 41 Appendix F V Belt Selection for the Z 4500 1 450 RPM Motor 1 750 RPM Motor Belt Sheave Pitch Diameter psg aten Sheave Pitch Diameter Belt Number Pump Motor Pump Motor Number 3VX690 QD3 3V14 00 QD3 3V4 12 7 5 420 QD3 3V19 00 QD3 3V4 75 3 3V800 3VX710 QD3 3V14 00 QD3 3V4 50 470 QD2 3V19 00 QD2 3V5 30 3VX800 3VX710 QD3 3V14 00 QD3 3V5 00 520 QD3 3V14 00 QD3 3V4 12 3VX690 3VX630 QD3 3V10 60 QD3 3V4 12 580 QD3 3V14 00 QD3 3V4 50 3VX710 3VX650 QD3 3V10 60 QD3 3V4 75 640 QD2 3V14 00 QD2 3V5 30 3VX710 2 3VX710 QD2 3V14 00 QD2 3V6 90 710 QD3 3V10 60 QD3 3V4 50 3V
24. 650 3VX650 QD2 3V10 60 QD2 3V5 60 780 QD2 3V14 00 QD2 3V6 50 2 3VX710 3VX600 QD3 3V8 00 QD3 3V4 75 860 QD2 3V10 60 QD2 3V5 30 3VX650 3VX580 QD3 3V6 90 QD3 3V4 50 950 QD2 3V10 60 QD2 3V6 00 3VX670 3VX690 QD3 3V14 00 QD3 3V4 12 10 420 QD3 3V14 00 QD3 3V3 35 3VX690 3VX710 QD2 3V14 00 QD2 3V4 75 470 QD3 3V14 00 QD3 3V3 65 3VX690 3VX710 QD2 3V14 00 QD2 3V5 00 520 QD3 3V10 60 QD3 3V3 15 3VX616 3VX710 QD2 3V14 00 QD2 3V5 60 580 QD2A15 6 B16 0 QD2A4 8 B5 2 2 B72 3VX650 QD2 3V10 60 QD2 3V4 75 640 QD2A15 0 B15 4 QD2A5 0 B5 4 2 B71 3VX650 QD2 3V10 60 QD2 3V5 30 710 QD1A15 6 B16 0 QD1A6 0 B6 4 B74 3VX570 QD3 3V6 90 QD3 3V3 65 780 QD2 3V10 60 QD2 3V4 75 3VX650 3VX600 QD2 3V8 00 QD2 3V4 75 860 QD2 3V10 60 QD2 3V5 30 3VX650 3VX580 QD2 3V6 90 QD2 3V4 50 950 QD3 3V6 00 QD3 3V3 35 3VX550 3 3VX800 QD3 3V19 00 QD3 3V5 60 15 420 QD3 3V25 00 QD3 3V6 00 3 3V900 3 3VX800 QD3 3V19 00 QD3 3V6 00 470 QD3 3V19 00 QD3 3V5 30 3VX800 3V830 QD3 3V19 00 QD3 3V6 90 520 QD3 3V19 00 QD3 3V5 60 3 3VX800 3VX710 QD3 3V14 00 QD3 3V5 60 580 QD3 3V19 00 QD3 3V6 50 3V810 3V730 QD3 3V14 00 QD33 3V6 00 640 QD3 3V14 00 QD3 3V5 30 3 3V710 3 3VX710 QD3 3V14 00 QD3 3V6 90 710 QD3 3V14 00 QD3 3V5 60 3VX710 3VX650 QD3 3V10 60 QD3 3V5 60 780 QD3 3V10 60 QD3 3V4 75 3VX650 3 3VX670 QD3 3V10 60 QD3 3V6 50 860 QD3 3V10 60 QD3 3V5 30 3VX650 3 3VX670 QD3 3V10 60 QD3 3V6 90 950 QD3 3V10 60 QD3 3V6 00 3VX670 B78 QD3A18 0 B18 4 QD3A6 0 B6 4 20 520 QD3A18 0 B18 4 QD3A5 0 B5 4 3 B77 B73 QD3A15 0 B15 4 QD3A6 2
25. All Steel Seal seat All Gray iron Stainless steel amp Ni Resist Z ZH ZX ZXH2000 Seal metal parts Z ZH3200 Z3500 Steel Z ZH4200 Z4500 Shaft All 8620 steel Vanes and vane drivers All Advanced polymers Z ZH3200 Steel cadmium plated Relief valve spring Z ZH ZX ZXH2000 Z3500 Stainless steel Z ZH4200 Z4500 Z ZH3200 Z3500 Steel Relief valve Z ZH ZX ZXH2000 Stainless steel Z ZH4200 Z4500 Bearing All Steel Thrust bearing All Steel O rings All Buna N PTFE Viton Neoprene Retainer rings All Steel O Viton and Neoprene are registered trademarks of the DuPont company 19 Appendix C Z2000 ZH2000 ZX2000 and ZXH2000 Performance Curves 90 80 750 RPM 0 650 RPM 60 600 RPM Capacity gpm 50 500 RPM 40 30 25 50 75 100 125 150 Differential Pressure psid The chart shows approximate delivery rates as seen in vapor equalized propane systems at 70 F 21 C with no pressure loss in pump suction piping The following will cause increased vaporization of the liquid in the pump suction adversely affecting the delivery 1 Restrictions in the suction piping such as internal valves excess flow valves elbows etc 2 Restriction or lack of a vapor return line 3 Temperatures below 70 F 21 C This loss of delivery is not caused by the pump but is a result of the natural the
26. Capacity 2 20 7 Installation of Your Corken Z Series Coro Vane Stationary Pump 0 8 The Inlet Piping Should Include the Following 228 8 The Outlet Piping Should Include the Following 8 The Bypass System Must Include the Following 9 A Vapor Equalizing System Should Include the Following 9 Driver Installation 5552 Prat hd HE Ripe NS Ue ENEE 9 Operation of Your Z Series Stationary Coro Vane Pump o oocccccc rne 9 Maintenance of Your Z Series Coro Vane Truck Pump System 11 Lubrication c rm 11 Pump Maintenance Schedul ta Le son narnr aus ges retiennent ae se eile MOEE PR ofa gine aa 11 Preventive Maintenance Program 12 Z Series Coro Vane Seal Replacement Instructions 13 Re pair He bulld Kits 4 55 mee EG EE X RIO A ed eet Mite d e 15 Pump Assembly Instructions For Z Series Truck Pumps 16 Appendices A Model Number and Identification Code 22220 17 B Features Benefits and Operations and Material Specifications 19 C Performance Curves and Charts i saresge iastan ehh hr nn 20 D Outline Dimensions nop A S e eMe go urea bare E be
27. EPLATES are easily replaced should the need arise Sideplates may be reversed for extended service life The MECHANICAL SEAL is designed for longer life under greater loads and may be inspected or replaced without disturbing the piping of the pump No special tools are needed BEARINGS are heavy duty roller type for long bearing life PRESSURE GAUGE connections 1 4 in pipe thread are provided The RELIEF VALVE is built in and nonadjustable The valve is preset at the factory NOTE EVEN WITH THIS INTERNAL SAFETY VALVE AN EXTERNAL BYPASS VALVE MUST BE INSTALLED Installation of Your Corken Z Series Coro Vane Truck Pump Before installing of your pump remove all temporary plastic plugs The installation of the Z Series CORO VANE pump is simple However in order for the pump to deliver optimum performance the principles discussed in this book should be followed The piping details are furnished to illustrate methods proved by hundreds of installations Your own needs may require slight variations but every effort should be made to follow the recommendations identified in this manual For the transfer of flammable liquids like LPG the pump must be installed according to the applicable local safety and health regulations The installer and or the user must take into account the following Potential risk due to local conditions regarding the installation and operation e g poor ventilation and additional risks due to other
28. H2000 ZXH2000 27 1359 Lubrication instruction plate 2 10 4427 Sideplate 2 28 1343 1 8 NPT relief fitting 4 11 4428 Vane 6 29 2158 1 8 NPT grease zerk 2 12 4262 X Vane driver 3 30 2159 Lubricap 2 13 4430 X2R Rotor shaft assembly 1 31 3442 1 4 NPT pipe plug 2 14 4431 X 2 Mechanical seal assembly 2 32 2 2831 O ring flange 2 15 4432 Thrust bearing assembly 2 33 2 224 O ring relief valve cap 1 16 4435 Bearing race mounting ring 2 34 2 261_ O ring case 2 17 4438 Grease seal 2 35 7001 031 NC125A Bolt hexagon head 4 4439 Bearing cap shim 002 red 36 7001 037 NC150A Bolt hexagon head 16 18 4439 1 Bearing cap shim 010 brown E 37 7001 043 NC125A Bolt hexagon head 16 4439 2 Bearing cap shim 020 yellow 38 7012 006 SF025E Screw 8 Registered trademarks of the DuPont company 39 7206 037A Lockwasher 8 Slots in vanes must face TOWARDS the direction of rotation 3 denotes O ring code See chart above 36 Appendix E Parts Details for Models Z ZH3200 28 60 ftelb 25 25 ft lb 28 60 ft lb O ring Code 25 ft lb A Buna N Note Hydraulic motor is not shown 27 B Neoprene m See page 15 for repair re build kits D Viton E Teflon CAUTION Always relieve pressure in the unit
29. ID105J Installation Operation amp Maintenance Manual Z Series Truck and Stationary Pumps Model Z2000 Truck Pump Z3500 Truck and Stationary Pump T d Model 24200 Truck Pump Model Z4500 Stationary Pump Warning 1 Periodic inspection and maintenance of Corken products is essential 2 Inspection maintenance and installation of Corken prod ucts must be made only by experienced trained and qualified personnel 3 Maintenance use and installation of Corken products must comply with Corken instructions applicable laws and safety standards such as NFPA Pamphlet 58 for LP Gas and ANSI K61 1 1972 for Anhydrous Ammonia 4 Transfer of toxic dangerous flammable or explosive substances using Corken products is at user s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards Solutions beyond products CORKEN Warning Install use and maintain this equipment according to Corken s instructions and all applicable federal state local laws and codes Periodic inspection and maintenance is essential Corken One Year Limited Warranty Corken Inc warrants that its products will be free from defects in material and workmanship for a period of 12 months following date of purchase from Corken Corken products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced at Corken s opt
30. OT EFFICIENT AND THE CONDITIONS THAT CAUSE THE NOISE ALSO CAUSE WEAR TO INTERNAL PARTS OPERATE THE PUMP AT SPEEDS THAT RESULT IN A QUIET TRANSFER NOTE EVENWITHTHISINTERNALSAFETY VALVE AN EXTERNAL BYPASS VALVE MUST BE INSTALLED Installation of Your Corken Z Series Coro Vane Stationary Pump NOTE All pumps should be installed in a well ventilated area The installation of the Coro Vane pump is simple However in order for the pump to deliver optimum performance the principles discussed in this book should be followed The piping details are furnished to illustrate methods proved by hundreds of installations Your own needs may require slight variations but every effort should be made to follow the recommendations identified in this manual No pump can discharge more liquid than it receives so the pump location and the inlet piping must be given careful attention If the inlet piping is inadequate to supply the demand of the pump you may expect trouble For the transfer of flammable liquids like LPG the pump must be installed according to the applicable local safety and health regulations The installer and or the user must take into account the following e The pump must be located as near the storage tank as possible The complete inlet line including the vertical line from the tank must not exceed 12 feet 3 7 m in length e The bottom of the tank must be no less than two feet Pump base E 1 2 x 8 a
31. PT threaded hole and turn the head over After lubricating the mechanical seal seat with light oil press the seal seat into the head using your fingers Make sure the seal seat is fully seated and the shiny side faces up Apply a generous amount of light oil to the seal seat to remove any remaining debris and fingerprints Install the case O ring around the pilot OD of the head Press the outer grease seals into each of the bearing caps Press the spring pins into each of the cam key holes 8 Install the cam key into the pump case Slide the cam into the pump case aligning the long inlet slots to the inlet portion of the case 9 Install one sideplate and bolt one head into place with two bolts 10 Turn the pump onto the assembled head Ensure there is enough room to allow the shaft to extend through the assembled head by six inches 1 While holding the rotor shaft vertical install the vane drivers Vertically install the rotor shaft into the unit Slide the vanes into each rotor slot ensuring the rounded tip contacts the cam and the vane slots face into the direction of rotation as shown in each parts detail drawing 12 Install the remaining sideplate 13 Lubricate the pump shaft and seal carbon with light oil Install the seal retainer assembly by aligning the retainer slot onto the seal alignment pin Carefully press the seal carbon into the retainer assembly with the polished face oriented outward by al
32. a flexible connection in the pump inlet and outlet piping to compensate for piping strains 5 Use an eccentric swage at the pump inlet nozzle to change the line size flat side up 6 Make the inlet line level or slope it downward to the pump The Outlet Piping Should Include the Following 1 A pressure gauge should be installed in the pump outlet or near it A pressure gauge is necessary to determine the efficiency of your pumping system 2 A hydrostatic relief valve is required by most state laws and for your own safety 3 If the outlet piping exceeds 50 ft 15 2 m in length a check valve should be installed near the pump outlet The Bypass System Must Include the Following 1 A pump bypass system must be installed If the pump discharge is shut off before the driver is stopped dangerously high pressures can develop unless a bypass valve is installed to permit the pump to discharge back to the supply tank at a predetermined pressure 2 The pump may have an internal relief valve but it is intended as a safety relief valve device and not an operational bypass 3 Always install an external bypass relief valve such as the Corken ZV200 or B177 in the pump discharge line The bypass valve may discharge into the tank at any convenient opening either liquid or vapor however it should not connect into the pump inlet piping system A Vapor Equalizing System Should be Included To obtain maximum performance fr
33. back to the storage tank through the bypass valve Then slowly close the valve downstream of the bypass valves The discharge pressure of the pump should increase to the maximum differential pressure of the pump at no flow conditions see Appendix C Performance Curves Ifthe maximum differential pressure is not obtained the pump must be serviced See Appendix G Troubleshooting Guide for additional help d Replace vanes or sideplates if worn Tighten all holdown bolts Inspect motor starter contact points This must be performed by an authorized and qualified electrician based on the electric motors manufacturer s guidelines 12 Z Series Coro Vane Seal Replacement Instructions Please Note The photos listed below contain a 22000 however all Z Series pumps use the same procedures for seal replacement To determine the parts needed for repair refer to Appendix A Model Number and Identification Code and Appendix E Parts Details CAUTION BLEED ALL PRESSURE FROM THE PUMP AND PIPING BEFORE STARTING TO INSTALL YOUR SEAL ASSEMBLY Step 1 Depressurize and open the pump Loosen the head bolts and remove one head with the bearing cap attached while holding in on the shaft Step 2 Seal seat and grease seal removal 9 NOTE The above photo is of a cutaway for better details Remove the head O ring and place head on the workbench as shown Lightly tap the seal out of the head with a long screwd
34. bolts and torque in a crossing pattern 21 Install the remaining bearing race mounting ring and thrust bearing assembly on the opposite side of the pump 22 Perform step 19 again on the opposite side and install the measured shims plus 002 inch Install the four bearing cap bolts and torque in a crossing pattern 23 Install the shaft key and ensure shaft rotates smoothly 16 Appendix A Z Series Truck Pumps Model Number and Identification Code Base Model Z2000 ZH2000 ZX2000 ZXH2000 Z ZH3200 Z ZH4200 Inlet 2 NPT 2 NPT 3 ANSI 4 ANSI Outlet 2 NPT 2 NPT 2 ell Dual 2 NPT Auxiliary Inlet None None 2 NPT 2 NPT Internal Relief 150 psi 175 psi 150 psi 150 psi Weight Bare 100 100 140 275 Pump Ib kg 45 45 64 125 Vane 6 Vanes with Standard H Type Vane Drivers Vanes GCB 50 Standard G O ring Buna N Standard A Material Neoprene No charge option B 1Neoprene is a registered trademark of the DuPont company Flange Options WF Slip on weld flange ell Elbow All ANSI flanges are 300 indicates available flange connections Inlet Flange 2 NPT e E Standard 3 ANSI P 4 ANSI S Extra Cost 2 WF A F Options Outlet Flange 2 NPT E Standard 2 NPT el G No Cost 1 1 2 NPT C Options 2 NPT e E 1 1 2 WF D Extra Cost 2 WF S F Options 2 weld ell H Auxiliary Flan
35. ce Temperature Class rating is a range between T4 275 F 135 C and T5 212 F 100 C Nameplate O SORENE C A Unit Qf X OMA ASSBMBLED IN U S A R LP GAS OR ANHYDROUS AMMONIA MANUAL BEFORE OPBRATING D PAT PENDING zi ja ATEX and File number machinery directive Surface temperature range T4 275 F 135 C T5 212 100 C Explosion protection ATEX directive 94 9 EC marking Equipment classified as Group ll Catagory 2 Explosion gas atmosphere High level Training Instructions Instructions for the safe application and use of this product are provided in this manual Read this manual completely prior to installation and use of this product Only qualified and properly trained personnel should be allowed to install operate and maintain this equipment Mechanical Ignition Sources This equipment may be direct driven through a coupling by an electric motor or belt driven by an electric motor Guards for the drive mechanism in the assembly intended for personal protection are to be supplied by the customer The pump assembly including the drive system must be grounded to prevent possible electrostatic discharge Internal parts of the pump require fluid product being pumped or damage may occur Do not run the pump dry without liquid in the pump The application of liquid level controls in the pump system
36. e function of every valve and piece of equipment is clearly understood Everyone operating this system must be properly trained in normal operating procedures and emergency procedures in event of a malfunction Close all hose valves Slowly open the storage tank bottom shut off valve suction line to the pump Immediately check the System for leaks Connect to storage tank bottom opening with free flow type shut off valve Mount storage tank at least 4 feet above pump inlet FITTING NUMBER FITTING DESCRIPTION de Eccentric Swage Nipple when necessary flat side up 2 Flexible Connector Hose or Flexible Type Union Ball or Gate Valve Type 6 Swage Nipple 12 Globe Vaive Pipe bypass value bonnet opening to Pipe equalizing line to vapor vapor section of storage tank or equalizing Loading hose section of storage tank line Equalizing line must be same size or 5 Equalizing larger than bypass valve 3 CORKEN Flo Chek Valve or Flow Indicator This Typical Plant Arrangement will perform the following operations 4 Strainer 40 or 30 Mesh Screen 1 Unload Transport into Storage Tank 5 Shut off Valve 2 Unload Transport into Delivery Truck 3 Load Delivery Truck from Storage Tank 4 With addition of Bottle Filling Manifold will fill bottles from Storage A CORKEN Fio Chek Valve Tank Bs MER Sen ra rel NOTE This is a generalized bulk plant pump installation capable
37. earing 2 36 7001 037NC150A Bolt hexagon head 24 19 2760 283 Retainer ring 2 37 7001 062NC125A Bolt hexagon head 16 Registered trademarks of the DuPont company 38 7012 006SF019E Screw 8 denotes O ring code See chart above 39 7206 037A Lockwasher 8 3Slots in vanes must face TOWARDS the direction of rotation 39 Appendix E Parts Details for Model Z4500 O ring Code A Buna N Neoprene B D Viton E Teflon Note Hydraulic motor is not shown 30 36 39 25 ftelb See page 15 for repair re build kits 47 CAUTION Always relieve pressure in n Es the unit before attempting any repairs Ge y y 36 25 ftelb 8 38 Suc 23 SS Ref Part No Description Qty Ref Part No Description Qty No No 1 5522 Case 1 19 2760 283 Retainer ring 2 2 4443 Cam 1 20 3253 Cam key pin 5 3 4444 X2R Rotor shaft assembly 1 21 4462 Grease seal 2 4 4445 Head 2 22 4463 Grease seal 2 5 4446 Sideplate 2 23 4464 X_2 Mechanical seal assembly 2 6 4448 Vane 6 24 Inlet flange 4 ANSI 1 T 4449 X Vane driver 5 25 Outlet flange 3 ANSI 2 8 4450 Relief valve cap 1 26 2649 Nameplate 1 9 4451 Relief valve spring 1 27 4248 Relief valve nameplate 1 10 4452 Shim 1 28 1359 Lubrication instruction plate 2 11 4453 Thrust bearing assembly 2 29 1343
38. et flange 4 WF 1 30 4441 Grease seal 2 6 1207 2 Relief valve cap 1 31 4431 X2 Mechanical seal assembly 2 T 1208 1X6R Rotor shaft assembly 1 32 4985 Coro Vane shaft cover 1 8 1224 Relief valve 1 33 7001 037NC125A Hex head bolt 24 9 1309 Cam key 1 34 7001 037NC150A Hex head bolt 16 10 1343 Grease relief fitting 4 35 7001 043NC150A Hex head bolt 6 11 1359 Lubrication plate 2 36 7012 006SF019E Screw 9 12 2158 Grease zerk 2 37 7012 010SF050E Screw 2 13 2159 Lubricap 2 38 7206 037A Lock washer 0 375 8 14 2270 Shaft key 1 4 1 39 5534 Head 2 15 2649 Nameplate 1 40 5537 Case 1 16 2754 Outer bearing 2 41 5539 Cam 1 17 2760 244 Retainer ring 2 Outlet flange 3 NPT 5538 1 18 3253 Cam key pin 2 40 Elongated 19 3442 Pipe plug 1 4 NPT 2 5538 38 Outlet flange 3 WF 4 20 3935 Sideplate 2 Elongated 21 13936 Vane 6 43 5548 Spring 1 22 4248 Relief valve warning tag 1 44 5554 X Vane driver 6 Registered trademarks of the DuPont company denotes O ring code See chart above 3Slots in vanes must face TOWARDS the direction of rotation 38 Appendix E Parts Details for Models Z ZH4200 N Kei IL A Si IN J 36 29 25 ftelb 36 S M 25 ftelb a 36 pa 25 ftelb 10 1 Ax 24 ES NN an
39. etainer and carbon installation Clean the pump and apply a generous amount of light oil Install the new seal assembly by aligning the seal retainer slot with the seal drive pin on the shaft Step 6 Mechanical seal installation Install the new case O ring onto the head Apply a generous amount of light oil to each seal face and carefully install the head assembly over the pump shaft Step 7 Completing installation Torque the head bolts in a crossing pattern There is no need to disassemble or re shim the bearing caps Repeat all of the above steps when replacing the seal assembly on the opposite side Step 8 Lubrication amp re pressurizing Note Both sides of the pump are identical duplicate procedure to change the seal on the opposite side Lubrication Regrease the bearing after thoroughly cleaning the grease opening and fittings If dirt is forced into the bearings early failure will result Special relief fittings have been provided to help prevent over greasing the bearings Excessive grease may drip out after lubrication Over greasing can damage the pump bearings and cause seal leaks Use only a recommended ball bearing grease If you use a hand grease gun put the grease in slowly and stop as soon as the relief fitting opens Grease the U joints and the spline of the drive shaft when greasing the pump Re pressurize NOTE FOR BEST RESULTS SLOWLY PRESSURIZE WITH VAPOR PRESSURE Please
40. ge 2 NPT E Standard None U 1 1 2 NPT C No Cost Blind Flange e T Options 1 1 2 WF s B 2 WF F xtra Cost 5 NPT ell S G Options 2 weld ell H Part Number Test Options 3000 X1 Hydrostatic test Model Number Base XXX XXX 17 Appendix A Z Series Stationary Pump Model Number and Identification Code Base Model 23500 Z4500 Model Number Inlet 3 NPT Standard 4 300 ANSI BaseXXXXX Outlet 3 NPT Elongated Standard 3 300 ANSI Weight bare 160 265 pump Ib kg 73 120 Vane 6 Vanes with Standard H Type Vane Drivers Vanes GCB 50 Standard G O ring Buna N Standard A Material Neoprene No charge option B 1Neoprene is a registered trademark of the DuPont company Flange Options WF Slip on weld flange ell Elbow All ANSI flanges are 300 e indicates available flange connections Inlet Flange 4 ANSI s S tandard sranda 3 NPT M No Cost d Option PAPE Q Extra Cost 3 WF N Options 4 WF R Outlet Flange 3 ANSI P Standard 3 NPT A T Elongated Extra Cost 3 WF 8 V Options Elongated Mounting Options Description Model Part Number Maximum Driver hp Ship Weight mounting only Ib Mounting set up for V belt drive Includes steel Z4500 103 15 284T 630 baseplate adjustable motor slid base V belt drive and enclo
41. ice should also be protected as the rust particles can destroy the pump s seals almost immediately after startup 1 Fill or thoroughly flush the pump with a light rust inhibiting oil If the pump is flushed with oil placing some desiccant packets inside the pump will provide added protection 2 Plug all pump openings 3 Store in a dry location 4 Before placing the pump back into service drain the oil and remove any desiccant packets 5 Refer to the OPERATION OF YOUR PUMP section of this manual Appendix Hydraulic Motor Specifications Operating Specifications for Char Lynn Hydraulic Motor Mounting flange 2 bolt SAE A 1 in diameter Input shaft straight keyed Port KAN 7 8 14 O ring Port Bi 7 8 14 O ring Pilot diameter 3 250 3 245 in 57 15 57 02 mm Motor displacement 6 2 cubic in per revolution Maximum speed continuous 742 RPM duty Flow continuous duty 20 gpm 76 L min 3 500 inelb Torque continuous duty 395 5 NeM Case drain 7 16 20 O ring Recommended fluids EECHER quality anti wear Minimum viscosity 70 SSU 13 cSt Maximum operating temperature 180 F 82 C Data applies to this particular motor only Your application may vary please consult factory for details Solutions beyond products CORKEN 0 IBEX Corken Inc e A Unit of IDEX Corporation 3805 N W 36th St Oklahoma City OK 73112 Phone 405 946 5576 e Fa
42. igning the carbon notches to the retainer pins Again apply a generous amount of light oil to remove any remaining debris and fingerprints 14 Carefully install the head over the pump shaft and seal assembly and torque the bolts in accordance with the appropriate bolt torque pattern drawing This pattern ensures even bolting of the head into the case without deforming the cam inlet port This is done by bolting those bolts over the solid portion of the cam port 15 Turn the pump over and remove the first head 16 Install the seal retainer assembly and carbon as outlined in step 13 above 17 Bolt head to case as described in step 14 above Ensure the rotor shaft turns freely in either direction 18 Slide the bearing race mounting ring onto one end of the shaft until contact with the main bearing inner race Mount the thrust bearing assembly onto the bearing race mounting ring and install the bearing cap 19 Lightly tighten the bearing cap with two opposed bolts until the rotor shaft cannot be freely turned Measure the gap between the head and bearing cap at four points around the bearing cap Adjustment may be necessary to contain the gap within 001 inch Round up the average measurement to the nearest even number This is the measured amount of bearing cap shims Refer to parts pages for shim measurements 20 Remove the two bearing cap bolts and install the measured amount of shims plus 006 inch Install the four bearing cap
43. ined or slip type to permit the shaft to adjust for PTO movement and twisting of the truck frame A fixed drive shaft transmits the forces directly to the pump and PTO which will shorten the life of both considerably Third the yokes of the drive shaft universal joints must be in a parallel position Figures one and two illustrate the proper arrangement Improper installation of the U joints will soon destroy them along with the bearings in the pump and PTO Properly mounted the second universal gives uniform motion to the drive shaft by compensating for the rotational error introduced by the first U joint An even number of universal joints two four six etc should always be used An odd number of U joints will cause unbalanced pump shaft rotation This problem becomes greater with increased angularity Other points to consider include the proper sizing of the shaft components with a maximum horsepower load to be expected good alignment of hanger bearings and proper pump coupling alignment Improper PTO systems count for a high percentage of truck pump failures Always remember to disengage the clutch before shifting the PTO into gear Shifting the PTO into gear without disengaging the clutch imparts an enormous shock on the PTO drive shaft pump and meter and will soon damage one or all of them For proper installation of pump drives follow the rules listed below 1 Driver shaft and pump shaft must be parallel plus o
44. ion when returned freight prepaid to Corken Inc 3805 N W 36th Street Oklahoma City Oklahoma 73112 Parts subject to wear or abuse such as mechanical seals blades piston rings packing and other parts showing signs of abuse are not covered by this limited warranty Also equipment parts and accessories not manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser must look to the original manufacturer s warranty if any This limited warranty is void if the Corken product has been altered or repaired without the consent of Corken ALL IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND SHALL IN NO EVENT EXTEND BEYOND THE EXPRESSED WARRANTY PERIOD Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken products Transfer of toxic dangerous flammable or explosive substances using Corken products is at the user s risk Such substances should be handled by experienced trained personnel in compliance with governmental and industrial safety standards Important notes relating to the European Union EU Machinery Directive Pumps delivered without electric motors are not considered as machines in the EU Machinery Directive These pumps will be delivered with a Declaration of Incorporation The fabricator of the machinery
45. l bearing grease manufactured for intended service Moisture frozen in pump Let thaw and break loose carefully Add methanol to tank on LP Gas Check with product supplier about possibility of water in gas Will not build Poor suction conditions Clean inlet strainer Increase pipe size pressure External bypass valve set too Set valve for higher pressure see instructions See IH102 and IH106 IOM manuals for more information Disassemble inspect and repair as necessary Do not run dry Pump is noisy Pump leaks around shaft Cavitation from poor suction conditions As above Vanes sticking As above Bearings worn Replace grease monthly Meter screen clogged Clean Very high differential pressure Check for restriction in discharge line Delivery hose too small and too long Slow down pump Check vapor release float assembly on meter and meter differential valve PTO shaft vibration Seal or O rings failed Inspect and repair driveline component Inspect seal assembly and replace if necessary Keep new seal very clean when replacing seal Recommend a light oil film on O rings Do not run pump dry 43 Appendix H Storage of the Z Series Coro Vane Truck Pumps If your Corken Z Series pump is to be removed from service for some time the pump must be protected as propane butane and anhydrous ammonia all leave the metal bare and open to corrosion Piping and tanks not in serv
46. mbly g 2 1 8 5 40 Hydraulic motor 13 16 fa L 10 1 2 jo UBI 8 26 63 20 30 i 17 11 16 44 90 5 15 16 4 9 16 15 08 met 11 59 a 23 8 7 Outlet 2 NPT 1 4 NPT 1 6 03 Internal relief valve 5 1 2 B 13 97 1 4 NPT Inlet 2 2 1 2 la 2 1 2 6 85 6 35 All dimensions are in inches centimeters 31 Appendix D Outline Dimensions for Model ZH3200 18 1 8 46 02 ma 8 3 4 22 22 E 40 15 16 27 75 gt Hydraulic motor Hydraulic drive adapter assembly 3 7 8 6 5 8 D B C TU 9 84 Ms 16 83 8 1 4D 2 76 20 96 6 24 Face y 1 1 8 2 86 1 1 4 square keyway Eight 8 7 8 2 22 3 300 Ib ANSI flange inlet diameter holes E 10 15 16 27 78 4 15 16 12 47 1 1 8 2 87 1 na 3 75 8 73 1 4 NPT 6 3 4 17 15 Y 14 15 16 37 94 E 5 Internal relief valve 4 12 70 1 4 NPT d 2 NPT J 1 5 8 4 13 discharge O Y I 5516 57 y 13 57 All dimensions are in inches centimeters 32 Appendix D O
47. nchor bolt d NOTE 24500 baseplate SSY SESS should be filled with groui Metal shim Large washer Concrete Figure 3 0 6 m above the pump inlet nozzle with four feet 1 2 m considered standard e The foundation for the pump is important The foundation must be firm level and preferably made of concrete The suggestions in figure three should be observed e Potential risk due to local conditions regarding the installation and operation e g poor ventilation and additional risks due to other elements in the vicinity etc Qualification of the personnel Type of liquid being transferred e Specific safety measures to be applied e g gas detection automatic shut off valves personal protective equipment etc The following table shows the weight of the bare pump for each model For handling a bare pump lifting slings should be used Web slings are preferred over metal slings to minimize damage to the paint See Appendix D for outline dimensions The Inlet Piping Should Include the Following 1 The tank excess flow valve EFV should have a flow rate of 1 1 2 to 2 times the capacity of he pump Do not use an EFV without knowing its flow capacity 2 The tank shut off valve must be a free flow type and not a standard globe valve 3 A strainer of the Y type with 30 to 40 mesh screen must be on the inlet line of the pump Mesh size indicates the number of openings per lineal inch 4 Use
48. om your Coro Vane pump a vapor equalizing system should be installed This system is simply a pipe connecting the vapor sections of the tank being unloaded and the tank being filled This equalizing line allows vapor to move freely between the two tanks in either direction and assures that both tanks remain at the same pressure As liquid is withdrawn from a tank it must be replaced by an equal amount of vapor or the pressure in the tank will drop If an equalizing line is not present this vapor is formed by boiling of the liquid and a reduction of the tank s pressure Meanwhile the tank being filled experiences a pressure increase as the rising fluid levels compresses the vapor space above it A vapor equalizing line will eliminate both of these problems and will reduce pumping time differential pressure noise and wear on the entire system Slow transfer rates will minimize these effects and reduce the need for a vapor equalizing line However today s high transfer rates require that a vapor equalizing line be installed Another way to consider this principle is to remember that it takes two holes in an oil can for oil to be poured smoothly from the can one for the oil to exit and the other for the air to enter Driver Installation The wiring of your electric motor is extremely important and must be done by a competent electrical contractor The following wire sizing chart indicates the minimum standards for wire sizes Im
49. proper motor wiring will cause expensive motor difficulties from low voltage If you suspect you have low voltage call your power company Connecting your motor for the voltage you have available is important too The motors furnished with the stationary pumps are usually dual voltage so you must be sure of the voltage your power company is supplying you Your motor will be completely ruined if it is connected to the wrong voltage A humid climate can cause problems particularly in explosion proof motor applications The normal breathing of the motor and alternating between being warm when running and cool when stopped often will cause moist air to be drawn into the motor housing This moist air will condense and may eventually add enough free water to the inside of the motor to cause it to fail To prevent this make a practice of running the motor and pump at least once a week on a bright dry day for an hour or so pumping through the bypass system In this period the motor will heat up and vaporize the condensed moisture and drive it out of the motor No motor manufacturer will guarantee an explosion proof or totally enclosed motor against damage from moisture Engine drivers pose a special consideration The manufacturer s instructions must be followed When the stationary pump is equipped with an engine from the factory the engine speed should normally not exceed 1 800 RPM Excessive engine speed will overload the engine and cause
50. quires that a condition be maintained within the truck tank that keeps the liquid and the vapors above the liquid in equilibrium to prevent violent boiling of the liquid As liquid is removed from the tank some of the liquid boils to form vapor to fill the space created as the liquid leaves If this action becomes too violent the pump will begin to make noise and the capacity will be reduced Truck pumps can lower the truck tank pressure from 5 psi to 10 psi below the starting tank pressure if there is no means provided for equalizing and then the trouble starts As the weather gets colder the worse this condition will become You can detect this pull down in pressure by observing your truck tank pressure gauge as the pump is operating To prevent this violent liquid boiling pressure in some form must be introduced into the truck tank The simple way to accomplish this is to equalize between the truck tank and the receiving tank Equalizing takes the higher pressure vapors from the receiving tank and returns them to the truck tank As a result the void left by the receding liquid is filled This in turn lessens the need for the liquid to boil excessively The equalizing principle is necessary for volatile liquids NOTE EQUALIZING BETWEEN TANKS OR THE ADDITION OF PRESSURE IS NOTALEGAL TRANSFER IN MOST STATES IF EQUALIZING LINES ARE NOT PERMITTED REMEMBER THAT A QUIET PUMP IS AN EFFICIENT PUMP A NOISY PUMP IS N
51. r minus one degree 2 Operating angle of the floating shaft must be 15 degrees maximum 3 Universal yokes must be in line and parallel 4 Splined slip joints must be used where needed 5 Use an even number of universal joints 6 Always use the least practical number of shafts PTO selection and drive system design is extremely important The PTO should have an average output speed of 500 to 800 RPM when the truck engine is operating at the recommended speed The designer of the drive system must select a PTO drive shaft capable of meeting the torque requirements of the pumping system Hydraulic Drive Systems Truck pumps are also driven by hydraulic systems consisting of an adaptor a motor a pump a cooler and connecting hoses The truck pump s shaft must be properly aligned with the hydraulic motor s shaft to avoid excessive stress on the truck pump s main and thrust absorbing bearings See Appendix D for outline dimensions The sizing of the hydraulic motor the hydraulic pump and the hydraulic oil cooler must be done using the operational requirements of the truck pump i e flow rate differential pressure pump speed required torque and power These data are on the performance charts in Appendix C Information on the Char Lynn hydraulic motor is found in Appendix l Operation of Your Z Series Coro Vane Truck Pump Performance curves and charts are provided in Appendix C The following steps should be pe
52. rformed for the initial pumping operation 1 Close the shutoff valve on the end of the delivery hose 2 Follow the instructions of the internal valve manufacturer for putting the valve into operation 3 Start the pump and circulate liquid through the external bypass system 4 f your system has a Corken T 166 bypass valve adjust the valve by turning the adjusting screw counter clockwise until the pump discharge pressure gauge shows nearly the same pressure it did before you started the pump Turn the adjusting screw clockwise until the gauge indicates about 100 to 115 psid above the tank pressure If a bypass valve of another make is used follow the instructions provided for adjusting the valve 5 You may increase the speed of your pump as long as it increases the capacity of the pump and does not exceed the excess flow valve or external bypass valve setting The one exception occurs when the pump is used to Pump On or to load the truck tank In this case the pump inlet conditions are poor at best so the pump should be operated at a slower RPM NOTE IF PUMP SPEED IS INCREASED BE CERTAIN THE METERING SYSTEM WILL HANDLE THE INCREASED FLOW WHEN PROPERLY INSTALLED AND OPERATED Z SERIES CORO VANE TRUCK PUMPS DO NOT EXCEED AN 88 dBA NOISE LEVEL AT A DISTANCE OF ONE METER 3 281 ft FROM THE SURFACE OF THE PUMP How to Transfer From the Truck Tank at Full Capacity To move volatile liquids rapidly from a truck tank re
53. river by reaching through the bearing cap opening Inspect the inner lip seal and remove if necessary using same process Cleanliness Even the smallest amount of dirt on your new seal can cause early failure Keep all parts tools and your hands clean while installing the seal Never touch the smooth lapped faces of the carbon rotor or seal seat For LP Gas anhydrous ammonia and similar liquids you are trying to seal a fluid that is 5 to 10 times thinner than water Your new seal needs every chance it can get so keep it clean Workmanship Your Corken pump is a precision piece of equipment with very close clearances Treat it as such Never use force during assembly or disassembly see steps 1 through 10 Step 3 Seal seat and grease seal installation NOTE The above photo is of a cutaway for better details Turn the head over and install the new grease seal face down by pressing into the bore behind the main bearing This can best be accomplished using the old seal seat with the O ring removed Apply a generous amount of light oil to the new seal seat Using the protective disc gently press seal into place Step 4 Seal retainer and carbon removal Remove the old seal assembly from the pump shaft while pressing against the sideplate This will allow the seal retainer assembly to be removed without pulling the rotor shaft out of the pump 13 Z Series Coro Vane Seal Replacement Instructions Step 5 Seal r
54. rmodynamic properties of liquefied petroleum gases See the GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT CP226 for additional information 20 Appendix C Z3200 and ZH3200 Performance Curves 120 750 RPM 110 100 650 RPM 90 600 RPM 80 Capacity gpm 70 500 RPM 60 50 25 50 75 100 125 Differential Pressure psid The chart shows approximate delivery rates as seen in vapor equalized propane systems at 70 F 21 C with no pressure loss in pump suction piping The following will cause increased vaporization of the liquid in the pump suction adversely affecting the delivery 1 Restrictions in the suction piping such as internal valves excess flow valves elbows etc 2 Restriction or lack of a vapor return line 3 Temperatures below 70 F 21 C This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases See the GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT CP226 for additional information 21 Appendix C Z4200 and ZH4200 Performance Curves 400 380 750 RPM 360 340 320 650 RPM 300 280 600 RPM Capacity gpm 260 240 220 500 RPM 200 180
55. sed beltguard Z3500 103 10 284T 560 Part Number 3000 X1 Test Options Hydrostatic test 18 Appendix B Specifications Equipment Type 8 Options Applications Truck sliding vane pump Propane bulk transfer Auto fuel pumping Multiple connection options NH nurse tanks Carousel cylinder filling Optional auxiliary inlet LPG cylinders Features amp Benefits Sliding vane type Positive displacement pump Heavy duty bearings Long bearing life Single mechanical seal Very easy seal replacement and maintenance Built in relief valve NPT models only Factory pre set added protection Pressure gauge connections Suction and discharge to reduce piping needs Reversible side plates Longer service life Operating Specifications RPM range 420 800 RPM Max differential pressure 125 psid 8 6 bar d for Z ZH2000 Z ZH3200 Z ZH4200 and 24500 150 psid 10 3 bar d for ZX ZXH2000 and Z3500 Max working pressure 400 psig 28 6 bar Temperature range 25 F 225 F 32 C 107 C Flow range 41 400 gpm 155 1 514 L min Internal relief valve Yes Material Specifications Part Model Standard Material Optional Material Cass Read Totor relist al Ductile iron ASTM A536 valve cap bearing cap Cam All Gray iron ASTM A48 Class 50 Sideplate All Gray iron ASTM A48 Class 30 Welding flange
56. t flange blind 1 23 2 224 O ring relief valve cap 1 4243 Aux inlet flange 2 NPT ell 1 24 1240 Relief valve spring 1 39 2649 Nameplate 1 3 8 1 9 40 4248 Relief valve nameplate 1 25 7001 037NC150A dn IA plete ie 16 Xs i 41 4282 Relief valve shim Registered trademarks of the DuPont company req denotes O ring code See chart above 42 7206 037A 3 8 lockwasher 8 3Slots in vanes must face TOWARDS the direction of rotation 37 Appendix E Parts Details for Models 23500 5 34 25 ftelb 34 25 ftelb O ring Code A Buna N B Neoprene Note Hydraulic motor is not shown D Viton See page 15 for repair re build kits E Teflon CAUTION Always relieve pressure in the unit before attempting any repairs bd Part No Description Qty Pot Part No Description Qty No No 1 2 228 O ring 1 23 4417 Bearing cap 2 2 2 245 O ring 1 24 4432 Thrust bearing assembly 2 3 2 259 O ring 1 25 4435 Thrust bearing mounting ring 2 4 2 268 O ring 2 26 4438 Grease seal Oil seal 2 1206 3 Inlet flange 3 NPT 1 27 4439 Bearing cap shim 0 002 2 5 1206 4 Inlet flange 4 NPT 1 28 4439 1 Bearing cap shim 0 010 2 1206 3S Inlet flange 3 WF L 29 4439 2 Bearing cap shim 0 020 2 1206 48 Inl
57. us the following 4439 1 Bearing cap shim 0 010 2 4414 Cam 1 4439 2 Bearing cap shim 0 020 2 4427 Sideplate 2 4441 Grease seal 2 Se Shaft key 1 23200 ZH3200 Re Build Kit 3196 X1 Includes all items in the Repair Kit plus the following 23500 Repair Kit 3195 X2 4242 Cam 1 2 228A O ring Buna N 2 4281 Sideplate 2 2754 X Roller bearing 2 SE Vane diver 3 23500 Re Build Kit 3196 X2 3936 Vane 6 Includes all items in the Repair Kit plus the following 4431 XA2 Seal assembly 2 5539 Cam 1 4432 Thrust bearing 2 3935 Sideplate 2 4435 Thrust bearing mounting ring 2 2436 Bearing cap shim 0 002 g 24200 ZH4200 24500 Re Build Kit 3198 X1 4439 1 Bearing cap shim 0 010 2 Includes all items in the Repair Kit plus the following 4439 2 Bearing cap shim 0 020 2 4443 Cam 1 4441 Grease seal 2 4446 Sideplate 2 2270 Shaft key 1 2270 Shaft key 1 SE Vb ER GE SEN O rings which are suitable for 15 Pump Assembly Instructions For Z Series Truck Pumps 1 Place the pump head on a clean work surface with the bolting flange down Press the inner grease seal in through the main bearing cavity until flush with the bottom of the bore Seal lips must be oriented down as shown in each parts detail drawing Press the main bearing into the head and install the retainer ring Install the relief fitting into 1 8 in N
58. utline Dimensions for Model ZH4200 19 9 16 S 9 3 4 Ad 49 69 15 3 9 24 77 31 43 UU i E EA il JH E o ES Hydraulic motor Hydraulic drive B i adapter assembly HET 10 16 10 16 10 1 8 D a A ps d 25 72 i Inlet 4 300 lb E pul 5 ANSI flange Q9 2 1 8 5 40 mle 1 1 4 3 18 5 16 square keyway Eight 7 8 2 22 diameter holes SR CH E LG Pansy on mm 9 C CH D ULL E H Outlet 2 NPT 7 e s P Outlet 2 NPT A i 2 NPT auxillary inlet 13 13 16 35 08 2 3 4 19 69 L4 7 17 78 16 31 32 43 08 l All dimensions are in inches centimeters 33 Appendix D Outline Dimensions for Z3500 103 Mounting 3 NPT outlet 3 NPT inlet I 18 1 8 1 E 46 i H d fcn 4 1 2 7t 444 77 1 1 2 3 8 I 42 30 5 15 38 1 5 3 16 13 2 P2 7 3 16 18 1 4 pipe plug Electric motor TT EEE EG i mad H 7 3 16 18 d i ATA AR 2 LI Ed INLET
59. valve spring 175 psid rather than the standard 150 psid ZHX2000 Foot mounted hydraulic drive with NPT connections and high pressure internal relief valve spring 175 psid rather than the standard 150 psid Correct assembly de ET aer Incorrect assembly Figure 2 Universal Joint Alignment Power Take off Drive Systems Proper pump operation and long life are directly dependent upon a good drive system Many truck pumps utilize a power train consisting of shafts and universal joints from a power take off shaft on the truck engine to the pump There are several basic principles that should be followed in laying out a PTO drive These principles should not be violated Following them will produce a workable power train that results in long pump life and reduced drive wear First the driver shaft and the driven shaft must be parallel to one another within plus or minus one degree Improper alignment will cause jerking and back and forth whip to the pump shaft thereby imparting a surging pulsation to the liquid flow which results in noise vibration and abnormal wear Second the angle of the floating shaft should be within the limits for the particular equipment being used usually a maximum of 15 at pump speeds up to 800 RPM To ensure that shaft expansion or contraction does not distort the drive system a splined slip joint should be placed between the two universal joints The drive shaft should be of the spl
60. ve is factory preset 13 After initial operation re check the strainer screen hose To Delivery Truck Keep pump foundation as close to grade level as practical Unloading hose Equalizing hose From Transport 10 Maintenance of Your Z Series Coro Vane Pump System All repairs to the pump must be performed by qualified personnel in a safe manner utilizing tools and or equipment that are free of hazards and follows the applicable safety codes of practice set by the local authorities having jurisdiction Make sure the system pressure has been relieved before attempting any repair to the pump Your Corken Z Series Pump requires regular maintenance and care like all mechanical equipment A neglected or improperly repaired pump will result in premature failure and cause unsafe conditions To promote product longevity and safety maintenance must be performed by properly trained technicians Make sure all safety systems are in place and the system pressure has been relieved before attempting ANY maintenance Make sure the transfer hoses are not kinked which can cause excessive pump discharge pressure Always make sure your hoses are not out of date Lubrication There are two lubrication points in which to grease the pump bearings one zerk per bearing cap located at opposite ends of the pump Four grease relief and seal ventilation fittings have been provided two at each end of the pump
61. vtr a Saleen ee 26 E Parts Betallss dis otro gx up bd a aston E aha Plats Te rcp d 36 F V Belt Selection for Stationary Coro Vane Pumps 41 G Troubleshooting CTT CEET 42 H Storage of the Z Series Coro Vane Truck Pumps 44 I Hydraulic Motor Specifications 24 288 44 Applicable Notices for ATEX 94 9 EC Conformity Product Type Coro Vane Rotary Vane Pumps Models Covered Z ZH2000 ZX ZXH2000 Z ZH3200 Z3500 Z ZH4200 and Z4500 Intended Application The pump models covered by this manual conform to the European Union ATEX 94 9 EC Directive for explosive gas atmospheres and transfer of liquefied gases such as Liquefied Petroleum Gas anhydrous ammonia freons etc Electric motors for these pumps in the assembly must comply with all applicable requirements for local federal and regional codes and regulations Possible Misuse Warning The designated pump models must only be installed in systems designed for its intended use similar to the examples presented in this manual ATEX Classification Group ll Category 2 G Temperature Class T4 T5 These products are classified under the ATEX directive as Equipment Group Il Category 2 equipment is intended for use in areas where explosive atmospheres caused by gases or vapors G may be present The surfa
62. which are free of hazards and following the safety codes of practice set by the authorities having jurisdiction These are general guidelines and are not intended to cover all the safety aspects that must be considered and followed while performing these procedures 1 Visual Inspection This includes checking for leaks corroded areas condition of hoses piping and fittings and any unsafe condition which may hinder the safety of the personnel and or the facility Clean Inlet Strainer Screen A clogged strainer screen will create too much flow restriction and vapor will be formed causing the pump to cavitate This reduces the pump s capacity and accelerates the wear of the internal parts Inspect Drive Coupling and Driveline Check the coupling alignment and the condition of the union for cuts broken sections and wear Lubricate Pump Bearings Use only ball bearing grease applied with a manual lubrication pump or gun Always clean the grease openings thoroughly before greasing 5 Lubricate Motor Bearing Follow the recommendations of the electric motor manufacturer for the type of grease to use and the lubrication frequency Performance Test a While transferring liquid with the pump check the pressure at the pump s inlet port The pressure drop in the inlet piping should not be greater than 3 psi While transferring liquid with the pump close the discharge valve s so the full flow will be directed
63. will escape causing a dangerous condition Take your time in bleeding your system and make proper provisions to vent or capture the gas in accordance with local regulations NOTE ONLY A PROPERLY TRAINED INDIVIDUAL SHOULD BE ALLOWED TO BLEED A PUMPING SYSTEM Pump Maintenance Schedule Daily Monthly 3 Months Lubricate bearings X Inspect drive coupling X Clean inlet strainer X Check for leaks X Inspect hose and fittings X 11 Preventative Maintenance Program for Z Series LPG Pumps Purpose By following an effective preventive maintenance program unscheduled downtime can be eliminated This program should be used by the Operation Manager to get a maximum utilization of manpower and equipment as well as to prevent possible unsafe situations and or production delays due to equipment breakdown Scope The Preventive Maintenance chart in figure four page 11 includes the items to be regularly checked and inspected with a recommended time schedule These are basic maintenance recommendations and each company should develop their own comprehensive preventive maintenance program schedule tailor made to their individual operational procedures and requirements Maintenance must only be performed by a properly trained and qualified individual that follows all the applicable safety procedures Procedures Every procedure herein recommended must be performed in a safe manner utilizing tools and or equipment
64. wn as a sliding vane pump Thesliding vane pump has many ofthe positive displacement advantages of the gear pump plus the ability to compensate for wear and operate at a lower noise level The sliding vane pump consists of a rotor turning in a cam liner machined eccentrically in relation to the rotor thereby displacing the liquid trapped between the rotor cam and vanes The Corken Z Series pumps are made with vanes produced from advanced polymers which exhibit extremely low coefficients of friction The vanes are self adjusting for wear which gives the pump long life Exclusive Features of Your Z Series Coro Vane Pump The pumping of volatile liquids is one of the most difficult of all pumping jobs and pumping from a delivery truck makes it even more difficult so more attention must be given to the design and manufacture of the pump and to its installation and operation In addition to being especially suited for handling volatile liquids your Z Series pump has a number of features to help make it more easily operated and maintained This model has been registered and listed by the UNDERWRITERS LABORATORIES INC for use in the handling of LP Gas and Ammonia The CASE AND HEADS are made of ductile iron for extra strength and toughness The VANES are manufactured of advanced polymers to provide excellent life and quiet operation After long service the vanes are simply and inexpensively replaced Both the CAM and the SID
65. x 405 948 7343 Visit our website at http www corken com or e mail us at info corken idexcorp com Printed in the U S A June 2010

Installation, Operation & Maintenance Manual (IOM)

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Installation, Operation &amp; Maintenance Manual (IOM)

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Installation, Operation & Maintenance Manual (IOM)