PD Pump Systems
Contents
1. b hk Ta aa va 33 Pressure Adj stMment b aaa 34 as trao an 37 Motor lei ARE SE eee eee 38 Stramer a a 40 Strainers PDZ M 42 P rts NI epe 44 PROCON PUMP MFD BY PROCON PROD MURFREESBORO TN PD 1 PROCON PUMP MFD BY PROCON PROD MURFREESBORO TN PD 2 5530 Figure 1 Identification This section is for maintenance of positive displacement pumps manufactured by PROCON These are brass pumps which match one of the above drawings PRESSURE Application The pump type used in a recirculating chiller system is determined by the requirements of flow and pressure This chart illustrates which pump family is suitable for various combinations of flow and pressure Ifthe pump system does not deliver the required flow and pressure on initial installation the requirements should be compared to the catalog pump curves to confirm the pump is correctly sized to the application If the pump system has delivered the required flow and pressure in the past and the application installation is unchanged it is safe to assume a degradation in performance has occurred and can be corrected PUMP SELECTION CHART POSITIVE DISPLACEMENT MED 0 MED HIGH 5065 Figure 2 0906 i19nno PL sinsselJ E eqn Agde ZL XH MOJI LL2. Jay OL JSUIENS cdd 6 BUJ91UI BABA 181 2H 8 INVd9VIO MO14 IN31SAS dd duund g uon229 918UJ9 1941815 0 aules 20 D gt 495 OSU d d uonegabuJ9H d QN CO sf LO tO Figure 3 Theory of Operation The PD Positive Displacement pump is a type of rotary vane pump known as a carbonator pump due to its widespread use in the beverage industry Four vanes are captive to a rotor which connects to the motor shaft The rotor spins inside a liner The rotor and liner are on different centers providing an eccentric cavity Opposing vanes are connected by push rods As one vane is pushed into the rotor slot by the approaching liner the opposing vane is pushed out of the rotor slot maintaining firm contact with the retreating liner Figure 4 4 T M 1 H 037 NAEDRN NUT 0 RING ADJUSTING PUSH R D SCH M ROTOR SPRING vine RELIEF VALVE FLUID CAVITY LINER 5057 Fluid enters the liner cavity and is trapped between two vanes As the vanes rotate inside the liner the eccentric alignment gradually decreases the volume available to contain the fluid When the rotating trapped fluid finally encounters an outlet it is squeezed out athigh pressure The result is a consistent flow rate essentially regardless of sys tem pressure The pump curve approximates a straight line
3. Place back in service Nete 1 Winding resistance for 1 3 HP 208v 6 3 Ohms Winding resistance for 1 4 HP 115v 1 9 Ohms Note 2 WARNING Thermal protector is automatic reset Motor may restart at any time without warning Figure 12 17 Motor Temperature Many times users are concerned that motors are operating too hot It should be understood that a properly loaded motor will reach a shell temperature hot enough to cause burns if touched This is a normal condition The nameplate of the motor may have a specification for RISE This is the temperature the shell of the motor will attain above ambient inside the case of the machine not room ambient For example if the nameplate RISE is 90 C 194 F and the motor is operating in a 30 86 F ambient the shell of the motor may attain 120 C 248 which is well above the boiling point of water In the absence of a RISE specification the nameplate will specify the motor as Class A or B Class A motors may not exceed 105 C 221 F Class B motors may not exceed 130 C 266 F Single phase motors used by NESLAB are all internally thermally protected The motor nameplate should carry the legend Ther mally protected f the motor is still running it is below the trip point of the thermal protector and therefore is within operating range If the motor is indeed too hot it will cycle on and off on the thermal protector and flow will be observed to stop
4. push any debris inside the gauge where it will be trapped out of trouble System pressure will prevent any such trapped dirt from backing up into the orifice Reconnect fittings and test the gauge PANEL CAPILLARY TUBE GAUGE FITTING NUT X DIAPHRAGM FERRULE 2 pcs RIFICE PLATE GAUGE NIPPLE ADAPTER am FITTING S A A O PN A pn 2 T ARA WEE A 4 N B as an f e j V N HR a A AN a SM n me DU N M Figure 16 26 Check Valve Installed on HX units only The check valve is intended to keep the tank from siphoning dry if the hose is removed from the return fitting The valve is lo cated upstream from the return fitting There are two styles of checkvalves used The mechanism of the style shown in Figure 17 consists of a Teflon amp seat on a weighted hinged flapper the one shown in Figure 18 is of a spring loaded metal to metal design The mechanism is acces sible through the access cover This need not be opened under normal use as there is no periodic maintenance required on either style checkvalve CHECK VALVE LOCATION typical CHECK VALVE ACCESS COVER gt ay agni Figure 17 Check Valve Figure 18 27 Testing the Check Valve 1 Remove the hose from the return fitting If the return line drains at this point the valve is stuck open Figure 19 2 Insert a hose
5. Thus this pump family is designed to deliver low flow rates and high pressures Disassembly of the pump is not recommended Restoration of performance is unlikely due to high machining tolerances required Any internal pump failure should be resolved by replacing the pump The manufacturer Procon accepts removed pumps for rebuilding PRESSURE PSI PRESSURE FLOW FLOW LITERS PER MINUTE 2 38 5 7 15 9 5 113 13 15 17 FLOW GALLONS PER MINUTE CURVE PD1 PUMP 50 Hz CURVE PD1 PUMP 60 Hz 5117 CURVE PD2 PUMP 50 Hz CURVE D PD2 PUMP 60 Hz PRESSURE BAR Figure 5 Fluids This is a list of some typical fluids which may be used in a PD pump system Glycol ethylene up to a 5096 concentration in water Labora tory or reagent grade is typically used Automotive antifreeze is not recommended Glycol propylene up to a 5096 concentration in water Labora tory or reagent grade is typically used Automotive antifreeze is not recommended Water deionized up to a resistivity of 1 8 megohm cm Water single distilled Water tap Wetted Parts The following materials are in contact with the circulating fluid in a PD pump system PVC Copper Bronze Brass Stainless Steel Teflon amp thread sealing tape Nickel plated copper Carbon graphite pump vanes and liner Troubleshooting chart No Flow PSI may exceed capacity Disconnect load Direct flow from unit into a
6. and start Internal thermal protectors are all automatic reset The motor will restart without warning when the thermal protec tor resets The thermal protector has a wide hysteresis dead band and the motor must cool down almost to ambient before reset This may take considerable time due to the mass of the motor One exception Certain blue IMOFA brand motors used in CFT units for export to Europe have no internal thermal protector but rather an external circuit breaker mounted in the control box Pump Replacement Tools required Bucket Nut driver 5 16 Wrench Adjustable Bench Vise Torque type screwdriver capable of 30 in Ib 170 cm kg Torque type wrench 5 16 capable of 50 in Ib 280 cm kg Dee GOV de Disconnect unit from line voltage Drain the fluid from the system Loosen the hose clamp on each of the pump fittings using a 5 16 nut driver as soon as practical Hose removal will be much easier if the hose is allowed to relax for 10 15 minutes after each clamp is loosened Loosen the V band clamp and slide it up against the motor Pull the hoses off the hose fittings Remove the pump from the unit with the fittings intact Place the pump in a vise and remove the fittings from the pump They can generally be unscrewed without desoldering Don t squeeze the round part of the pump in the vise The vise should hold the pump by the square boss area just below the fittings Install the fittings in the ne
7. bucket gt 80 PSI 550 kPa system pressure lt 80 PSI 550 Air in pump G0 to Priming Did pump ever work YES Is the pump turning YES NO UNSURE Separate pump from motor Is the ca OK Can you turn pump using a screwdriver YES NO TES Replace coupling Pump seized Replace it NO Go to Motor troubleshooting YES Problem is external to pump and motor Does the motor turn alone YES an you turn pump with inger 9 Figure 6 Troubleshooting chart No Flow continued Can you turn pump using a screwdriver Is fluid stained unsure see note 1 fb Manually close both aL Try again if pump internal amp external bypass Pump is seized can be loosened up see Pressure Adjustment nate 2 Inspect for missing or damaged Strainer screen Bypass path was apen Replace pump Note 1 Collect a fluid sample in a glass container Stained or tinted fluid may indicate a vane failure Go to Allow sample to sit undisturbed If vane particles Pressure Adjustment are present thay will settle oul to the bottom Pump vane failure Note 2 Only reuse the pump if it can be turned smoothly through a full revolution with no rough spats encountered Figure 6a Troubleshooting chart Pump Noise Close outlet valve Minimum 10 PSI 70 kPa
8. from a pressurized gas source such as nitro gen or compressed air into the return fitting Cup your hand around the fitting to provide a seal 3 Apply a burst of gas into the fitting You should hear a click click sound as the seat flops up and down Note If there is fluid trapped in the return line between the valve and the tank it will drain out during this step 28 Replacing the Check Valve NOTE Any soldering to the check valve body must be done carefully to avoid melting the Teflon amp seat 1 Open the service access cover 2 Insert a bent wire such as a coat hanger to pull the seat open and secure it This keeps the Teflon from contacting the hot valve body 3 Wrap the valve body with a damp rag 4 Usealow temperature solder such as 95 5 or 50 50 Use a hot flame and work quickly 5 Do not release the seat until the body is cool CHECK VALVE CROSS SECTION CLOSED OPEN 21137 Figure20 29 Ball and Spring Type Check Valves Older check valves use a mechanical ball and spring arrange ment Performance of this type can usually be restored by polishing the ball using Scotch Brite amp or a similar abrasive pad Repair of this type beyond cleaning is not practical If a failed valve of this type is found it should be replaced by the current Teflon seat type Lubrication A small amount of molybdenum lubricant see Coupling Lubrica tion on the access cover threads will assist in
9. slightly to obtain load recommended 10 PSI 70 kPa 0 10 PSI 0 70 kPa Does noise vary with PSI YES Noise occurs at 40 PSI 275 kPa Bypass valve s may 10 40 PSI 70 275 kPa be opening Ga to Pressure Adjustment you cleanad strainer 7 Go ta Strainer Cleaning check for constrictions in fluid path NO Mac GE Emerson Imofa Dayton Other Loosen realign This is hall This is a sleeve tighten v hand bearing motor bearing motor Are bearings Ga to Motor lubricated Lubrication YES Resilient motor mounts must nat be avertightenad Back nuts off slightly v Next Next page page c 1 2 Figure 7 11 Troubleshooting chart Pump Noise continued YES NO Separate pump from motor Is mator noisy alone YES Mechanical failure pump slot Replace motor Replace YES pump coupling omo NO Realign and reconnact Place unit back in service J Figure 7a Troubleshooting chart Low Flow and or Pressure C id Fill tank YES Change fluid to water Time flow into an open container Does flaw match the hart NO Pump is OK Problem if any 18 external to the chiller YES NO Is the fluid water YES Have you cleaned trainer YES NO Go to Adjustments amp M
10. D 0 075 0 191 cm was chosen because the O D Outside diameter of 0 125 0 32 cm provides a snug fit in the adapter fitting The gauge indicates system back pressure not pump capacity A unit connected to a low back pressure system parallel manifolds or short lines of large diameter may indicate 0 or a very low pressure In other words the gauge indication reflects reflects system demand not pump supply 32 Priming The pumps are self priming only if plumbed in a flooded suction configuration i e the fluid flows continually downhill from the tank to the pump inlet NESLAB CFT and HX applications are not plumbed flooded suction so priming may not be automatic If flow does not start immediately shut the unit off Remove the fitting nut from the rear of the adapter fitting on the pressure gauge The fitting nut is held captive to the cap tube by a ferrule This allows the cap tube to become a vent for the discharge line providing an escape path for air trapped in the pump Place a rag over the end of the cap tube Start the unit When fluid is observed flowing steadily from the cap tube reseat it in the adapter fitting and tighten the fitting nut When installing a new pump add a small amount of fluid to the inlet of the pump during installation to assist priming See PUMP REPLACEMENT for details Pressure Gauge Fittings PANEL A GAUGE CAPILLARY TUBE BRACKET FITTING NUT GAUGE NIPPLE i i ADAPTER FI
11. PD Pump Systems NESLAB P N 000878 Rev 08 15 96 Service Manual Contents General Information ize Gea JaNoS ers MO MD MM d ua A Flowdiagraltr s Theory Operation art oe Cr rt Press re TOW CU Jio p dE Tor DRIN HU ORE WeitedipartS ENERO gt Troubleshooting NO FIOW us eios bi tetti opu in DLE PUMP i i up UAE M ME M EU i 10 Low Flow and or Pressure zi scatet cuu AT DAD LA Qu ALME 12 E MU LS 13 Pressure gauge always Zero 14 Pressure dallgedieolTObl i ik 15 Motor Cm 16 Motor Temperature s okol teer O na 17 Component Repair and Replacement Pump Replacement sedet beet hn Zl 18 Motor Replacement 20 elsi PVP E s 22 Pressure Gauge Replacement eesesssssssssssesssee eene 24 Pressure Gauge Once rear vaca Eee Reo ote qum arae Hi 25 Check 26 Testing the Check eee ette a OR Re ufi ea D UR REUS 27 Replacing the Check Valve neuer editt tiet n sre ine peed d dee ee 28 Check Valve CIOSS SGCHOfl oot er oo eae Exe da Ere 28 Relief Valve Adjustment nennen 30 Capillary TADE Pc HH 31 Adjustments and Maintenance E M 32 Relief Valve
12. TTING LOO n FERRULE 2 nes o nie 5034 Figure 22 33 Relief Valve Internal The relief valve built into the pump temporarily protects against dangerous overpressure The relief valve is set at the pump factory and confirmed at NESLAB The relief valve setting appears stamped in the brass as shown The illustration shows the posi tion of the stamping only your actual value may differ The flow will fully bypass from the outlet to the inlet at the specified relief valve setting The relief valve actually begins to crack open and allow bypass flow approximately 50 PSI 345 kPa below the stamped relief valve setting Turning the pressure adjustment screw clockwise will increase the relief valve setting NESLAB supplies an additional external relief valve set to a lower setting to provide primary pressure control The internal relief valve is a safety feature and should not be relied on to provide primary pressure control Changing the setting on this internal relief valve is not recommended See PRESSURE ADJUSTMENT for details on balancing the settings of both internal and external relief valves RELIEF VALVE SETTING v T NRW qu CORN NUT D RING DJUSTING PROCON PUMP SCREW SPRING BY PROCON PROD MUR FREES B RQ TN RELIEF VALVE 5182 Figure 23 34 Pressure Adjustment mp 0 a 1 Inlet 2 Check valve 3 Reser
13. aintenance Strainer re both bypass valves et correctly NO Go to Pressure Adjustment YES Disconnect pump from motor Motor tum OK lone YES Go to troubleshooting motor operation Vane wear or damage Go to pump replacement Figure 8 13 Leaks The flange area of the pump has assembly holes at the top and the bottom Fluid leaking out of either hole indicates a shaft seal failure The seal has a limited ability to seat around imperfections If this is a new pump allow it to run for 24 hours and re inspect A continuous leak will require pump replacement Field replacement of the shaft seal is not practical Certain fluids will deteriorate the pump shaft seal Highly deionized water will leach ions out of the seal material causing it to lose flexibility This will cause leaks Deionized water must be used with caution and with monitoring of the deionization level See FLUIDS for further details PD PUMP AND MOTOR ASSEMBLY RELIEF VALVE INTERNAL SSEMBLY HOLE OIL PORT uc 5047 V BAND CLAMP May be only one or one on each end depending an motor manufacturer Figure 9 Troubleshooting chart Pressure gauge always zero TO Disconnect cap tube from adapter fitting Turn unit on Is there flaw fram cap tube Cap t
14. alve Figure 26 36 Internal Relief Valve Adjustment 4 Remove the acorn nut on the side of the pump Adjust the pump pressure adjustment screw under the acorn nut until the gauge indicates the value stamped on the pump If no value is shown adjust to 90 PSI 620 kPa Turning the screw CW will increase the pressure setting Replace the acorn nut RELIEF VALVE SETTING 1 a Ev wi du 2 N ACORN NUT 0 RING ADJUSTING SCREW SPRING MFO BY FROO MURFREESBORO TN RELIEF VALVE __ 22 E162 Internal Relief Valve Figure 27 External Relief Valve Adjustment 5 Back out the threaded stem on the external relief valve CCW As the setting drops below the internal valve setting the gauge will now indicate the external valve setting Continue until the gauge indicates 80 PSI 550 kPa or desired setting Tighten the lock nut 6 The external relief valve is intended for coarse pressure limiting not regulation For precise pressure regulation an external bypass type regulator is recommended NOTE The minimum pressure achievable using the provided external relief valve is about 35 45 PSI 240 310 kPa If lower operating pressures are required the addi tion of an external bypass type regulator is recommended NESLAB sells various EPR External Pressure Regulator kits for this purpose Contact a NESLAB sales represen tativesfor information Coup
15. ced hose tends to cold flow so the clamps will need to retorqued later The hose clamps do not actually loosen but rather the hose O D decreases It is best to give them a final torqueing just prior to leaving the job site Explain to the customer that a further torqueing may be required the fol lowing day and that a drip developing at a hose clamp is a result of cold flow and not poor workmanship 20 Motor Replacement Tools required Wrench 1 2 open end or combination Nut driver 5 16 Torque wrench capable of 30 in Ib 170 cm kg NOTE The motor may be replaced without opening the fluid system Draining the unit is not necessary Ensure the unit is physically disconnected from line voltage before attempting motor replacement Turning the unit s power switch off is not adequate to provide safety 1 Loosen the V band clamp between the pump and the motor Pull the pump away from the motor to separate them 2 Remove the nuts from the motor mounts using a 1 2 wrench If the top nuts are not accessible remove the bottom nuts by reaching under the shelf The motor will come out as long as one nut is removed from each motor mount it doesn t matter whether from the top or bottom 3 Jockey the motor off the shelf so the electrical connection box is accessible Remove the cover 4 Disconnect wires noting which terminals are used Remove old motor 5 bronze pump coupling is being used between the pump and m
16. e Figure 33 or it may be a basket type inside the reservoir on HX units STRAINER i SCREEN B 1 v Figure 33 43 Periodic cleaning of the screen is necessary The screen may be removed without significant fluid loss Turn the unit off and discon nect from the power source Have a clean rag handy which has been dampened and twirled into a pointy shape Remove the strainer cap using an open end or socket wrench Pull out the screen and quickly stuff the rag into the opening Some spillage will be unavoidable If a helper is available the helper could hold the rag tightly in place while you clean the screen You can tem porarily reinstall the strainer cap finger tight The debris will be inside the screen Clean the screen under running water A toothbrush is a handy tool for cleaning It will fit nicely inside the PD2 screen An alternative is to take a coarse paper towel the brown roll type dampen it and twist it into a spiral Pull it through the screen several times turning it as it passes Inspect the screen closely for damage particularly holes Itis advisable to keep a spare screen on hand The spare may be quickly substituted for the dirty screen minimizing downtime and fluid loss Then the dirty screen may be cleaned at your leisure and retained as the spare for next time A small amount of molybdenum lubricant See COUPLING LUBRI CATION on the PD2 strainer cover threads wi
17. ge 2 Remove fitting nut from the rear of the adapter fitting The fitting nut will be held captive to the capillary tube by the ferrule Remove the adapter fitting Remove clamp bracket s Pull the gauge out of the panel hole from the outside 3 4 5 6 Apply Teflon tape to the nipple of the new gauge 7 Mount the new gauge using the clamp bracket s 8 Install the adapter fitting 9 Retighten fitting nut Do not use Teflon tape here 10 Turn unit on and check for leaks PANEL GAUGE CAPILLARY TUBE BRACKET FITTING NUT GAUGE NIPPLE DAPTER FITTING jJ FERRULE 2 pcs Figure 14 Pressure Gauge Orifice The mini style pressure gauge 1 1 2in 4 cm diameter hasa small orifice plate between the gauge nipple and the diaphragm This is intended to dampen any needle vibration The orifice can become clogged by a small piece of dirt If this happens the gauge will read zero all the time Before disassembly confirm that the needle is on the correct side of the stop pin If incorrect the gauge has been destroyed by overpressure and will require replacement CORRECT INCORRECT P od E s N R 1 NG S N e m STOP PIN Figure 15 To clean the orifice remove the adapter fitting from the gauge Insert a small needle or similar probe into the gauge nipple Lo cate the orifice and twirl the needle in the opening This should
18. ling Lubrication NESLAB has found that providing lubrication to the bronze cou pling will extend its useful life NESLAB installs a heat shrink sleeve on the motor shaft as a cup to contain the lubricant If this cupis still intact it should be reused If the cup is frayed or other wise damaged it should either be replaced or removed com pletely Obtain a piece of 34 2 cm heat shrink tubing Cut the piece to 1 5 4 cm long Fully seat the tubing on the motor shaft Heat evenly with a heat gun Insert a small glob pea sized of lubricant NESLAB uses a molybdenum based lubricant with the trade name NEV R SEEZ This lubricant is intended primarily for use in automotive exhaust systems to allow future disassembly and is commonly available at automotive supply stores The grease base will eventually dry up and leave the molybdenum behind as a lubricant The intent is to provide lubricant between the coupling and the motor shaft Do not lubricate between the coupling and the pump Slot The nylon coupling does not require lubrication 38 Motor Lubrication OIL PORT May he only one or ang each end depending on motor manufacturer 5075 Figure 28 PD pumps are generally powered by sleeve bearing carbonator type motors NEMA type 48YZ These motors must be run on a horizontal shaft orientation due to the internal oil reservoir A wick runs from the reservoir
19. ll assist sealing and provide easier future service 44 Table 2 Part Usage Usage Number D2 e e aa 012869 009142 008123 008124 004185 013123 Heat Shrink 34 diameter 008445 008295 008125 008126 008120 009057 009212 009083 009200 008423 008142 Pump PD1 brass captive coupling Replaced by 008423 008576 X 008205 Pump PD1 brass optional hi temp Viton seal 008159 008143 008181 008155 008694 X 009058 009347 Strainer assembly bronze 013459 X 009384 Strainer screen PD2 replacement 004626 008899 ee ee _ _ _ U X X X v U CD 45 46 PD Pump Systems NESLAB P N 000878 Rev 08 15 96 Service Manual
20. ning A new coupling is supplied with replacement PD pumps It is temporarily held in place with a soft foam strip This strip should be removed and discarded The coupling is slightly asymmetrical The wide tab fits in the motor and the narrow tab fits in the pump NESLAB adds a lubrication cup to the motor shaft on PD pumps using bronze couplings This has been found to extend the useful life of the coupling See COUPLING LUBRICATION MOTOR END 0 480 in 1 22 PUMP FND m 0 425 in 1 08 cm Figure 13 23 Coupling Types continued 2 NYLON COUPLING Some PD pumps use a straight nylon coupling This coupling is slightly tapered The wide end fits in the motor and the narrow end fits in the pump It does not require the lubrication cup used with the bronze coupling The bronze and nylon couplings are interchangeable There is no particular advantage to using one or the other 3 CAPTIVE COUPLING Older PD 1 pumps have a captive tab emerging from the pump which is actually the end of the rotor shaft This tab mates directly with the motor slot There is no removable coupling on these pumps The current PD 1 pumps have the same removable coupling bronze or nylon which is used on the PD 2 pumps The captive coupling pumps are no longer available and may be directly replaced by the removable coupling style pumps 24 Pressure Gauge Replacement 1 Disconnect the unit from line volta
21. otor install a lubrication cup on the motor shaft as described in COUPLING LUBRICATION This step is not required if a nylon coupling is used 6 Turn the shaft of the new motor a few revolutions by hand 21 7 Connect wires to the new motor Position new motor in the unit A Eye protection must be worn during this step 8 10 11 12 13 Temporarily provide power to the motor Jog the motor briefly and observe that the direction of rotation matches the arrow on the front of the pump The motor shaft should turn clockwise as viewed from the pump end Check that the slot in the pump is sharply rectangular without undue wear Be aware that the coupling is not symmetrical The wide end fits in the motor and the narrow end fits in the pump Ensure mating flanges of both pump and motor are clean and free of burrs Join pump and motor guiding coupling into place Check that flanges align tightly Tighten V band clamp to 15 30 in Ibs 85 170 cm kg of torque 22 Coupling Types 1 BRONZE COUPLING The bronze coupling is a sacrificial coupling It is a softer metal than either the steel pump bearing race or the steel motor shaft The coupling will wear to avoid wearing these more critical components The coupling is also intended to shear in two in the event the pump stops unexpectedly due to foreign matter in the pump or seizure This protects the motor by unloading it and allowing it to continue tur
22. sealing and provide easier future service 30 Relief valve adjustment external Leaks occurring at the locknut generally may be solved by tighten ing the locknut The locknut serves two functions It prevents the adjustment stem from moving and it tightens against the packing gland inside the valve to preventleaks Leaks occurring at the large nut labelled DO NOT ADJUST in the diagram should be solved by replacing the valve Replacement of the valve is done by removing any hoses then transferring the fittings to a new valve Teflon amp tape should be used on the threaded fittings Replacement of the valve will re quire the system pressure to be reset Refer to ADJUSTMENTS and MAINTENANCE PRESSURE ADJUSTMENT for details on setting the system pressure Relief valve adjustment DD NOT ADJUST INLET LOCKNUT STEM uv OUTLET Wie Figure 21 31 Capillary Tube The pressure gauge is connected to the pump discharge line by a capillary tube of 0 075 0 191 cm I D Inside Diameter The length is determined by measuring the distance of the path from the discharge line to the pressure gauge and adding 27 68 cm This additional length will allow a 3 turn coil of approximately 3 7 6 cm diameter to be included This coil will dampen any needle vibration and allow future service TIP A 3 7 6 cm diameter coil may be formed easily using an aerosol can as a winding form The capillary tube I
23. to each bearing The motor will have either one or two lubrication ports depending on the manufacturer A good source of oil is the 3 IN ONE brand squeeze cans manufactured by Boyle Midway Inc It should be available at hardware stores or electrical supply E houses MOT R OIL SAE 20 SPECIAL ELEND FOR Figure 29 exception Blue IMOFA brand motors and grey MAC brand motors are ball bearing and require no periodic lubrication 39 The motor should be oiled periodically in accordance with the nameplate directions In the absence of legible lubrication instruc tions add 30 35 drops of SAE 20 non detergent oil to each oil port Use the following table as a frequency guide Regularly Every 2 years Table 1 9 Pon May be only one or ane each end depending on manufacturer 5075 Figure 30 40 Strainer PD1 All PD pumps require a 100 mesh strainer on the inlet side of the pump Particles that are trapped are of sufficient size to destroy the vanes of the pump Never run the pump with a missing or damaged strainer screen The PD1 pump has an internal strainer screen _ 5 2 C 1 I 7 M A U SCREEN CORN NUT gt ame X Figure 31 41 Periodic cleaning of the screen is necessary The screen may be removed without significant fluid loss Turn the
24. ube clogged Trim back ends replace YES Turn unit aff Reconnect Constrict discharge by using valve or squeezing hose Gauge indication rise ND 2 in 1 5 in 5 em 3 8 YES Gauge diameter ave you cleaned the arifice Clean orifice Gauge is destroyed Replace gauge Place unit back in service Normal response Figure 10 15 Troubleshooting Chart Pressure gauge incorrect Turn unit off 5 the gauge on zero YES Install reference gauge on outlet line Turn unit an Unit gauge is correct 1 5 3 8cm What is gauge diameter This type cannot Gauge is be recalibrated damaged 2 Turn unit off Replace gauge Unscrew bezel Repasition pointer to zero Place unit back in service Figure 11 Troubleshooting Chart Motor operation pply voltage to motar Measure voltage at matar terminals applied voltage withir range supply voltage is incorrect motor turn YES when discannected from pump Thermal protector is open Allow motor to winding resistance cool Nate 2 Is motor hot YES Does therma protector reset close Malar failure Replace motor Mechanical failure Mator is good Winding or thermal protector failed open
25. unit off and discon nect from the power source Have a clean rag handy which has been dampened and twirled into a pointy shape Remove the strainer cap using an open end or socket wrench Pull out the screen and quickly stuff the rag into the opening Some spillage will be unavoidable If a helper is available the helper could hold the rag tightly in place while you clean the screen You can tem porarily reinstall the strainer cap finger tight The debris will be inside the screen Clean the screen under running water A toothbrush is a handy tool for cleaning Trim the bristles to 1 2 length for a PD1 screen An alternative is to take a coarse paper towel the brown roll type dampen it and twist it into a spiral Pull it through the screen several times turning it as it passes Inspect the screen closely for damage particularly holes Itis advisable to keep a spare screen on hand The spare may be quickly substituted for the dirty screen minimizing downtime and fluid loss Then the dirty screen may be cleaned at your leisure and retained as the spare for next time 42 Strainer PD2 All PD pumps require a 100 mesh strainer on the inlet side of the pump Particles that are trapped are of sufficient size to destroy the vanes of the pump Never run the pump with a missing or damaged strainer screen The PD2 pump has an external strainer screen located on the pump inlet line It may be a brass body type Figure 32 a plastic typ
26. voir 4 Refrigeration coil b PD2 strainer strainer alternate ocation 7 PD pump gt The fluid system contains two relief valves An internal in the pump and an external one on the pump discharge line Because of their ability to interact adjustment must be done in a certain sequence PD PUMP SYSTEM FLOW DIAGRAM 2 he PE NT al oe VA iw 8 Rel ef valve in enal PLA strainer 16 Relief valve external 11 Flew valve HX 12 Capillary tube 13 Pressure gauge 14 Qut el om 5060 Figure 24 35 1 Turn unit off Locate the external relief valve Loosen the locknut Turn the threaded stem all the way in clockwise This manually closes the valve by setting it to an infinite value 00 NOT ADJUST INLET LOCKNUT STEM 5064 External Relief Valve Figure 25 2 If the unit is not plumbed to an application install a loop of hose between the supply and return fittings Turn unit on NOTE The external relief valve may drip while the locknut is loose This is normal 3 CFT units Crimp the loop of hose flat using a pair of vise grips HX units Turn flow control valve completely clockwise if a round handle or fully if a lever handle The pressure gauge should rise to a high value It is now indicating the internal relief valve setting MFD BY PROCON PROD MURFREESBDRD TN PD 1 PD 2 buc Internal Relief V
27. w pump using Teflon tape as a sealant Support the pump body in a vise or use a backup wrench If soldering must be done on the fittings do so before installing them in the pump Solder balls dropping into the pump will destroy the vanes If soldering must be done to the fittings while on the pump orient the pump so the openings face downwards Always use a soft solder either 50 50 or 95 5 is acceptable Check the lubrication cup on the motor shaft Refer to COUPLING LUBRICATION for details 11 12 13 14 15 16 17 18 Check that the slot in the motor shaft is sharply rectangular without undue wear The motor should also be replaced if its slot is worn Be aware the coupling is not symmetrical The wide end fits in the motor and the narrow end fits in the pump Add some circulating fluid into the pump inlet fitting now to assist in priming later Ensure mating flanges of both pump and motor are clean and free of burrs that may have occured during handling File any burrs smooth Remove and discard the foam shipping strip from the coupling if it is present Attach pump to motor guiding coupling into place Observe that flanges mate squarely Tighten V band clamp to 15 30 in Ibs 85 170 cm kg of torque Install hoses onto fittings If they do not slide on easily apply a small film of liquid hand detergent to the hose barbs Torque hose clamps to 50 in lbs 280 cm kg NOTE Nylon reinfor
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