AMD User manual
Contents
1. AMD SERIES MAGNETICALLY DRIVEN CHEMICAL PUMP USER MANUAL S Roll IL AMD SERIES Table of Contents VP ORC eeraa E mane 2 2 Inspecting the Pump Prior to Installation cooooncccnnnnnnnnc ccoo 2 3 Notes for Opera O Mardel 2 4 Installation Piping and Wiring occccccnnnnnoonononnnnnnnnnnnanannnannnnnnoss 4 5 Operating Procedure and Notes cnica dci 7 6 Maintenance and Inspection ccccnconoooooonnncnnnccnnnnananonnnnnnncncnnnnn 8 7 Incorrect Usage and Selecionar 9 8 Repair and Warranty AA A 10 Appendix A Disassembling the AMD PuMP cccccnnnoncccnnnnnnnnnnos 11 Appendix B Exploded View and Parts LiSt ooooonoocccncnonnn 12 AMD SERIES 1 Foreword Thank you for purchasing an ASSOMA pump To ensure proper operation and maximum efficiency please read this instruction manual carefully Failure to follow the recommended operating conditions outlined in this manual may result in serious personal injuries and or equipment damage 2 Inspecting the Pump Prior to Installation 1 Check the pump exterior for any physical damage that may have been incurred during shipping 2 Use a small screwdriver to rotate the impeller of the motor s cooling fan The fan should turn easily If the fan feels tight or if there are unusual sounds the interior of the pump may have been damaged during shipping 3 Ifthere is any dama2. problem Ifthe problem cannot be found or if replacement parts are needed please call the distributor and give them the following information 1 The pump model and manufacturing serial number indicated on the nameplate 2 The operating condition 3 The situation under which the pump fails Please refer to the warranty card for details of the warranty terms and conditions 10 AMD SERIES Appendix A Disassembling the AMD Pump A 1 Preparing for Disassembly 1 The magnets used in our AMD magnetic drive seal less pumps have very strong magnetic strength Take extra precautions when disassembling the pump to prevent personal injury and damage to electronic and magnetic equipments like diskettes magnetic stripe cards etc 2 For personal safety wear protective gear like corrosive resistant aprons and protective eyeglasses during disassembly to prevent injuries caused by spilled chemicals A 2 Assembly Please follow the reverse procedure for disassembly to assemble the AMD pump However during assembly please pay attention to the following points 1 To attach the outer magnet to the motor shaft apply some grease to the shaft and using a mallet drive the magnet down the shaft via a thick plastic plate see Fig A 1 A 2 and A 3 2 The front thrust ring should be placed on the pump shaft prior to pressing it into the shaft support 3 Use a hand press to gradually and firmly press the shaft into the shaft s
3. 1 Ville SG NS Wy Bad Piping Designs WUE y Y a EEE XY Fig 4 3 4 3 Wiring Bad MT WN 0 01 0 02 slope Good A Uji We Ui Fig 4 2 gt 0 5m or gt 2D Y gt 1 5D D Diameter gt 1 5D Fig 4 4 The wiring system should be done properly using premium equipment and complying with rules and standards set by the electrical company The following recommendations should also be implemented 1 Please use magnetic relays that have the same power ratings as the pump s motor 2 When using the pump for outdoor applications please make sure the switch is protected from rain 3 Magnetic relays and on off switches should be installed properly and away from the pump AMD SERIES 5 Operating Procedure and Notes 5 1 Notes Prior to Starting the Pump 1 Check the motor s power rating including frequency voltage and wiring 2 Recheck to make sure all the parts flange pump casing base plate etc are securely fastened 3 Fill the pump with liquid priming to remove any air within the pump and suction piping 4 Check to ensure the inlet valve is open 5 Using a screwdriver rotate the motor s cooling fan to ensure it is not too tight or stuck 5 2 Starting Up the Pump 1 Check the direction of rotation of the motor by rapidly switching on and off the power 2 Close the outlet valve and start up the pump 3 Slowly open the outlet val
4. Specific Gravity 1 A change in a fluid s concentration will usually affect its viscosity and specific gravity Other physical properties like corrosiveness may also change with the fluid s concentration therefore the selected pump material should be able to withstand the corrosive properties of the fluid 2 When the fluid s viscosity and or Specific Gravity differ from that of water the shaft power flow rate and pump head may change also 3 4 Particle Size Sludge 1 The service life of a pump can be greatly shortened by pumping fluids that carry small particles or sludge Its service life is dependent on the concentration of the particles its size and hardness 2 For particle concentration less than 5 particle size smaller than 50 y m and hardness within 80Hs our SV model which has SiC bushings can be used However a shorter than normal service life can be expected 3 5 Maximum Operating Pressure The pump s maximum operating pressure is dependent on the operating temperature and the structure of the pump Please refer to table 3 1 for the recommended maximum operating pressure for our AMD SERIES pumps Unit kg cm Operating Temperature C 20 40 60 80 AMD 440 441 3 5 3 3 3 2 5 AMD 552 553 555 4 5 4 3 4 3 6 Table 3 1 3 6 Minimum Flow Our pump uses the pumped fluid as its cooling and lubricating system A low flow rate may result in increasingly high temperature within
5. reduced flow E 1 Corrosion and cracking S Wrong pump material selected 2 Rapid corrosion and wearing of bearing E 3 Corrosion of the O ring resulting in leakage Table 7 1 Abnormal Condition Possible Effect Damage ae S 1 Produce high frequency vibrations and noise Inlet pipe not submerged E 2 Fracturing of the bearing and thrust rings sufficiently into the fluid or air gt sueked inte pipnie systcni 3 Reduced pump performance en y 4 Serious cases can lead to dry running ae sate 1 Reduced pump performance e pump p a a 2 Serious cases can lead to dry running z a Leaking foot valve or inlet piping Fluids within pump leaks during shut down period resulting in dry running when pump is restarted Table 7 2 Abnormal Condition Possible Effect Damage Starting the pump without priming Dry running causing damage to pump Low speed or wrong rotation Low fluid flow direction Incorrect motor frequency or Overloading of the motor voltage 1 Low performance and vibrations caused by Low inlet tank fluid level a Improper Operation 2 Fracturing of the bearing and thrust rings 3 Dry running Foreign objects stuck in impeller 1 Produce vibrations and noise 2 Reduced efficiency and flow Serious cases may result in dry running 9 AMD SERIES 1 Insufficient cooling of pump 2 Excessive radial and axia
6. Appearance 1 Check for oxidation or corrosion of the front casing bracket and base plate 2 Check for leakage of the pump and the piping system Operation 1 Check for irregular sounds and vibrations 2 Check the in tank fluid levels and inlet outlet pressures 3 Check the power supply and motor loading 4 Check and test run backup pumps regularly to ensure they can function properly when needed Table 6 1 6 2 Periodic Maintenance 1 The following parts should be inspected quarterly 2 Refer to Appendix B for the part names Part Name Inspection Item Solution 1 Cracks 1 Replace Front 2 Scratch marks except when pumping 2 Contact the distributor And particle laden fluids Rear Casing 3 Crystallization or sludge 3 Clean 4 Shaft support loose or deformed 4 Contact distributor dls one 1 Deformed corroded or swollen 1 Replace O ring 1 Scratch marks or cracks 1 Contact distributor 2 Cracked bearing or crystallization 2 Contact distributor Impeller f a d 3 Bearing displays signs of some wear 3 Replace if worn Magnet and tear excessively Assembly 4 Crystallization and other sludge 4 Clean l 5 Foreign objects stuck in impeller 5 Remove the objects 6 Impeller deformed 6 Contact distributor Shaft and l Scratch marks 1 Contact distributor Thrust Ring 2 Cracks 2 Replace Table 6 2 6 3 Preventive Maintenance Operational data like vibration flow
7. ct air The inlet piping should also have a 0 01 0 02 slope increase towards the pump see Fig 4 2 There should not be any elbows for at least 5 times the pipe diameter from the opening of the pump The elbow closest to the pump opening should be a long radial elbow Inlet Piping There should be at least a 1 5 diameter distance between the pipe inlet and the closest tank wall to prevent circulation see Fig 4 4 The submerge depth of the inlet should be at least 0 5m or at least twice the pipe diameter below the liquid surface see Fig 4 4 There should be a distance of at least 1 5D between the bottom of the tank and the beginning of the inlet pipe opening see Fig 4 4 If there are two or more inlet piping in the same tank they should be placed at least 3D apart to prevent mutually disrupting each other s flow Foot Valve ER Please install a foot valve if upward suction is used see Fig 4 1 Self Priming Cylinder If suction method is upward suction please install a self priming cylinder to prevent dry running due to a leaking foot valve The size of the self priming cylinder should have a minimum liquid level of at least 0 5m above the opening of the pump Control Valve Acontrol valve should be installed to make disassembling of the pump easier The valve should only be shut off when the pump is to be detached for maintenance or repairs 2 W
8. e recommend the use of valves that have the least loss when fully opened like a gate valve AMD SERIES Filter 1 It is generally not recommended to install a filter in front of a pump which can unpredictably increase suction system resistance 2 If a filter has to be used it should be cleaned regularly to ensure a smooth flow Vacuum Gauge 1 The material used should be corrosion resistant otherwise a pressure gauge diaphragm should be used 2 During operation if the vacuum gauge reading fluctuates either there are air bubbles in the system or cavitation has occurred Outlet Piping 1 The weight of the outlet piping should be properly supported to prevent putting excessive stress on the pump see Fig 4 1 2 A priming piping must be installed if the suction system does not General fas A Requirements employ positive pressure i e upward suction see Fig 4 1 3 The flow rate in the outlet piping should not exceed 3m sec 4 The ability for each component in the piping system to withstand pressure should be calculated to determine the maximum allowable operating pressure Prine Pipi 1 Upward suction pumps that do not have a self priming cylinder should have a priming piping system Pressure Gauge 1 Pressure gauge used should be able to read beyond the maximum operating pressure 2 Pressure gauge should be made of material that is corrosive resistant otherwise a diaphrag
9. ge to the pump contact the shipping company and the distributor immediately to determine who should pay for the damage and to arrange for replacement parts 4 Each pump has a nameplate indicating the pump model MFG number rated head flow rate and motor power voltage and frequency Check these data to ensure they comply with your order and application 3 Notes for Operation 3 1 Dry Running 1 Our pump use the transfer fluid as its internal cooling system therefore dry running the pump can cause the temperature to rise to a dangerous level that may seriously damage the pump 2 If dry running occurs switch off the pump immediately let it cool for at least an hour before priming the pump to prepare it for normal operation NOTE Do not subject the pump to rapid cooling which may damage the internal parts 3 We recommend using a dry run protector to detect dry run occurrences to avoid causing unnecessary damage to the pump 3 2 Operating Temperature 1 Operating temperature may change the fluid s viscosity vapor pressure and corrosiveness Please ensure that your pump is operating within the proper temperature range 2 The optimal temperature range for pumping pure water is 5 C 80 C Please consult the distributor for the temperature range suitable for your chemicals 3 We recommend the operating environmental temperature to be between 5 C 40 C 2 AMD SERIES 3 3 Concentrations Viscosity and
10. l force reducing service life of bearing and thrust rings Inlet valve closed Dry running seriously damaging the pump 1 Low NPSHa resulting in cavitation 2 Reduced strength of the magnet resulting in decoupling 1 Rapid wearing of the bearing 2 Wearing of the impeller and casing surfaces Low flow over extended period of time Transfer fluid temperature too high Fluid carries hard particles Table 7 3 Abnormal Condition Possible Effect Damage Deformation of the O ring Result in leakage Pamasedimpeller 1 Resulting in vibrations and noise 2 Reduced pump performance and fluid flow 1 Produce vibrations and noise ES Damaged motor bearings 2 Overloads the motor 3 3 High Motor temperature 3 Wear ri fe 1 Produce vibrations and noise 5 it RTS 2 Overloads the motor E i 1 Produce vibrations and noise a WAE INC TORU CE beanies 2 May result in fracturing of the impeller shaft S Pump s base screws loose Produce vibrations and noise Hidekase ofinletpipinpier foot 1 Reduced pump performance and low flow rate or i may result in cavitation valve 7 f 2 Serious cases may result in dry running 1 Low flow or no flow Lol 2 Pump unable to dissipate heat eps 3 nad cases may i in overheating of the pump and outlet piping Table 7 4 8 Repair and Warranty When a problem arises please read this instruction manual and try to troubleshoot the
11. m should be used 3 A valve can be installed on the piping that leads to the pressure gauge to facilitate maintenance and to lengthen the gauge s service life 4 During operation if the pressure gauge reading fluctuates either there are air bubbles in the system or cavitation has occurred Check Valve A check valve should be installed in the following situations 1 Discharge pressure exceeds 2kg cm and flow rate exceeds 3m sec 2 Two or more pumps share the same outlet piping system 3 To prevent back flow water hammer from damaging the pump during unexpected power outages Control Valve 1 Acontrol valve can be used for controlling the flow of fluids Do not run the pump with the control valve closed for an extended period of time 2 When starting the pump always start with a closed valve and then slowly open the valve to obtain the desired operating pressure and flow Always open or close the valve gradually Exhaust Valve 1 A vent should be installed if the horizontal section of the outlet piping is very long AMD SERIES 1 Outlet Piping 2 Throttle Valve 3 Priming Piping 4 Priming Valve 5 Check Valve 6 Outlet Pressure Gauge 7 Motor 8 Pump 9 Inlet Pressure Gauge 10 Inlet Piping 11 Inlet Piping Support 12 Vibration Damper 10 13 Filter 14 Inlet Tank 13 15 Foot Valve 7214 Jy 15 A 12 N A U AK nN T Su 9 o 1b yd O ETT Fig 4
12. rate voltage etc can be collected and upper and lower limits can be set for each of the values The collected data can be used for trend analysis see Fig 6 1 which can be a basis in which to determine when to carry out preventive maintenance UCL LCL Measured Date UCL Upper contorl Limit LCL Lower contorl Limit Fig 6 1 Time AMD SERIES 7 Incorrect Usage and Selection Abnormal Condition Possible Effect Damage Parallel pumps improperly installed Improper suction resulting in low efficiency insufficient flow cavitation or dry ruming E System resistance too high 1 Insufficient or no flow 3 or 2 Pump unable to effectively dissipate heat a Pump head too low 3 Excessive wear on bearing and thrust rings E Resistance lower than expected 1 Excessive flow 3 or 2 Overloading of the motor E Pump head too high 3 NPSHa too low resulting in cavitation E 1 High frequency vibration and noise 5 NPSHa too low 2 Fracturing of the bearing and thrust rings resulting in cavitation 3 Decreased pump performance and low flow rate 5 4 Serious cases may result in dry running 3 Specific Gravity higher than 1 Motor overloading 5 anticipated 2 Decoupling of the magnetic drive I 1 Motor overloading 2 Viscosity higher than anticipated 2 Decoupling of the magnetic drive N 5 3 Decreased pump performance and
13. the pump and increased radial and axial force thus affecting the pump s performance and service life Please use table 3 2 for the recommended minimum flow rate Unit l min Operating Temperature C 20 40 60 80 AMD 440 441 15 20 25 30 AMD 552 553 555 20 25 35 50 Table 3 2 Note The above data is based on water For volatile or viscous fluids consult your local distributor AMD SERIES 4 Installation Piping and Wiring 4 1 Installation Location 1 The pump should be close to the ground and located near the inlet tank 2 There should be sufficient space reserved around the pump to facilitate future maintenance and repairs 3 The pump and its wiring should be placed in a relatively dry environment protected from possible flooding 4 2 Notes for Installing the Piping System Procedure Items to Note Inlet Piping General Requirements l 2 3 4 5 6 Suction condition must satisfy NPSHa gt NPSHr 0 5m Reduce inlet Head as much as possible Use straight and short piping The pipes should have adequate structural support and shouldn t use the pump as its primary support see Fig 4 1 When designing supports consider the effects of temperature changes on the supports to avoid thermal stress Inlet piping and connectors should be installed properly to prevent sucking in air The piping system should not have upward bumps that may colle
14. upport 4 The shiny surface of the front and rear thrust rings should be facing inwards towards the shaft 5 When pressing the shaft bearing into the impeller make sure the cut ledge of the bearing matches the straight edge inside the impeller 6 When fastening the different parts of the pump make sure to fasten the corresponding opposite screws in turn to ensure a uniform tightness 7 After the entire pump is assembled use a small screwdriver to rotate the motor cooling fan to ensure everything is installed correctly The interior bottom of Model h mm drive magnet of AMD 440 AMD 441 131 should be higher than the AMD 552 184 5 top of motor shaft by 2 AMD 553 184 5 mm AMD 555 187 5 S Fig A Fig A 2 i Fig A3 11 AMD SERIES Appendix B Exploded View and Parts List F21 Inlet Flange S21 Bushing Impeller Rear Thrust Ring O ring Disc Flange Rear Casing Assembly 9 Cushion Packing S11 N Ww 12
15. ve when the motor has reached a stable speed Adjust the outlet valve to obtain the desired operating pressure or flow rate 5 3 Operating the Pump 1 Shut down the pump immediately in the case of cavitation or dry running 2 If decoupling should happen shut down the pump to prevent reducing the magnet s strength 3 During power outages shut off the pump s power supply and close the outlet valve 4 When switching on the pump with the outlet valve closed the outlet pressure should increase Ifthe pressure fails to rise or if the pressure is too low shut down the pump and check the piping and wiring NOTE Outlet Pressure Inlet Pressure Pump Pressure Pump Pressure kg cm Fluid Specific Gravity Pump Head 10 5 4 Shutting Down the Pump 1 Close the outlet valve slowly to prevent damage to the pump due to reverse fluid flow water hammer 2 Shut off the pump It should stop gradually If not check the interior of the pump for problems 3 The pump should be checked periodically If the pump is used in a cold operating environment relative to the fluid s freezing point the fluid may crystallize even if the pump is shut down for a very short amount of time To prevent crystallization a drain plug should be included in the piping system or a heating system could be used to maintain the temperature during shutdown AMD SERIES 6 Maintenance and Inspection 6 1 Daily Inspection See Table 6 1
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