Flotronic ‘One-Nut’ Pumps – 10” Slimline Stainless Steel
Installation, Operation and Maintenance Manual
Page 1: ...Flotronic One Nut Pumps 10 Slimline Stainless Steel Installation Operation and Maintenance Manual ...
Page 2: ...AMENDMENT RECORD Issue No Date Signature Issue No Date Signature 1 06 02 2020 D GILES 2 09 11 2020 D GILES 3 10 03 2021 D GILES 4 26 05 2021 D GILES 5 27 05 2021 D GILES ...
Page 3: ... 0 6 9 Preventing the build up of explosive mixtures 10 0 6 10 Preventing sparks 10 0 6 11 Preventing leakage 10 0 6 12 Maintenance to the double diaphragm pump to avoid potential hazards 10 0 6 13 Additional safety instructions 11 1 Installation 12 Packaging and Shipping Inspection 12 Storage 12 Installing the Slimline Pump 12 1 3 1 Foundation 12 1 3 2 Connection of suction and delivery pipes 13 ...
Page 4: ... 29 3 5 1 Air valve unit inspection and replacement 29 4 Spare parts 32 F Series Slimline metallic pump 32 Ordering spares 33 5 Data 34 Technical data 34 Tightening torques 34 Dimensions 35 6 Warranty 36 Warranty 36 Returning parts 37 6 2 1 Disclaimer 37 www unibloctech com ...
Page 5: ...ompetent to carry out the procedures detailed within this manual 3 Do not operate this equipment if it has a known fault 4 Only original Flotronic Pumps spare parts should be used in the repair and maintenance of this equipment 5 Do not exceed 7 2 Barg 105PSI air supply pressure and ensure the compressed air supply is filtered dry and oil free to the specifications detailed in section 1 3 5 6 Do n...
Page 6: ... is the installer s responsibility to ensure that these maximum temperatures are not exceeded under any circumstances Performance figures provided by Flotronic Pumps against individual enquiries are estimates only and are subject to variations depending upon air pressure and volumes of air provided by the client head losses due to pipework valves and any other installation factors which may be unk...
Page 7: ...trofit from Flotronic Pumps or the silencers must be removed and replaced by pipework which can carry the leakage to a safe place Please note that wherever the media is piped pulses of mixed air and media will occur at the end of the pipework when diaphragm failure has occurred Provision must be made to accept the volumes of air media mixture that may be present WARNING MEDIA MAY REMAIN INSIDE THE...
Page 8: ...sh if the equipment is CE marked for ATEX observe the equipment nameplate and the certification provided It is the responsibility of the user to ensure that the equipment is correctly rated for the environment in which it is to be used A technical file is lodged with Intertek Italia S P A notified body 2575 under document number 3010075 0 6 3 Personnel qualifications and training All personnel inv...
Page 9: ...able atmosphere where applicable 0 6 7 Avoiding excessive surface temperatures WARNING ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE 0 6 8 Pump media temperature Pumps have a temperature class as stated on the nameplate These are based on a maximum ambient of 40 ºC 104 ºF Refer to Flotronic Pumps if higher ambient temperatures are to be considered Where there is any risk o...
Page 10: ... only be used to handle media for which it has been approved to have the correct corrosion resistance Avoid entrapment of media in the pump and associated piping due to closing of suction and delivery valves which could cause dangerous excessive pressures to occur if there is heat input to the media 0 6 12 Maintenance to the double diaphragm pump to avoid potential hazards WARNING CORRECT MAINTENA...
Page 11: ...and renew the complete thrust tube if any sign of excess wear or damage is apparent 6 Inspect the diaphragms and renew if any sign of damage is apparent 0 6 13 Additional safety instructions When installing a pump either for the first time or after maintenance a check must be made to ensure that the earth connection terminal on the pump and any external metalwork is at ground potential Ensure that...
Page 12: ...ature of 15 C 59 F to 25 C 77 F and relative humidity below 65 Do not remove the protective covers from the suction delivery and air connections which have been fastened to keep pump internals free of debris Installing the Slimline Pump 1 3 1 Foundation The pump will operate properly without being fixed to a foundation however if the pump is required to be fixed in position all Flotronic Pumps are...
Page 13: ...ould be the same or larger than that of the suction connection to maintain efficient suction capability 3 Ensure connections to the pump are flanged screwed or clamped to appropriate standards 4 Ensure connections are completely tight and that bends and or restrictions to the pipework are kept to a minimum 5 Any leakage in the suction pipework will dramatically reduce the suction capability of the...
Page 14: ...n 1 metre of the pump Do not over tighten or force pipes into threads 1 3 4 Air Pressure WARNING OPERATING THE PUMP AT A HIGHER PRESSURE THAN INSTRUCTED BELOW CAN DAMAGE THE PUMP AND MAY CAUSE INJURY TO PERSONNEL Maximum air pressure must not exceed 7 2 bar 105 psi and the pump should be operated at the lowest pressure to achieve adequate performance from the pump 1 3 5 Air condition A clean suppl...
Page 15: ...elivery side of the fluid pipework this can be used to control flow Alternatively the pump may be controlled by adjusting the air supply Noise levels Noise levels from the Flotronic Pumps pump will generally not exceed 85 decibels at one metre distance Hearing protection may be required Recommendations for Best Pump Performance The following points should be observed to achieve the best results fr...
Page 16: ...on of the pump operation is recommended to optimise performance Complete inspection The intervals for a complete inspection depend upon the operating conditions of the pump the characteristics of the media temperature and running time It s recommended that a complete inspection is carried out at least once per year If a problem has occurred or if the pump is in need of a complete inspection refer ...
Page 17: ...Maintenance 17 Fig 4 2 Remove the dome washer assembly Fig 5 3 Remove the secondary air dome www unibloctech com ...
Page 18: ...screw and remove either diaphragm from the thrust tube Fig 8 6 Withdraw the other diaphragm with the thrust tube attached 7 Unscrew the second diaphragm from the thrust tube It is recommended that the thrust tube is held in a vice using soft jaws to aid diaphragm removal and prevent damage to the thrust tube surface www unibloctech com ...
Page 19: ... and removed The groove in the body is machined so that it is deeper towards the top of the pump Fig 11 9 Snap Fit Divider Seal The divider seal may be pushed out with a suitable blunt tool whilst taking care not to damage the face of the body Fig 12 10 Unscrew the two bolts and remove the delivery manifold 11 Remove the two delivery balls www unibloctech com ...
Page 20: ...O rings per seat Fig 16 14 Unscrew and remove the two bolts securing the suction manifold to the main body Example shown in Fig 16 is 1 to 2 versions to 1 versions have two manifold securing bolts through the centre of the footplate and manifold to retain the body 15 Lift the main body off the suction manifold and remove the two suction balls www unibloctech com ...
Page 21: ...9 17 Pumps fitted with optional replaceable seats will have 2 O rings per seat Fig 20 18 The Flotronic Slimline pump is now disassembled with the exception of the air valve Please see section 3 5 for air valve removal Check all components for wear or damage and replace if necessary www unibloctech com ...
Page 22: ...are present and check for wear or damage replace if necessary Clean parts prior to assembly using appropriate cleaning agents Special attention should be paid to the diaphragm sealing faces on body and thrust tube Fig 22 2 Install the two suction manifold O rings ensuring sufficient care is taken not to damage the O rings Pumps fitted with optional replaceable seats will have 2 O rings per seat Fi...
Page 23: ... the centre of the footplate and manifold to retain the body Fig 25 6 Install the two delivery manifold O rings ensuring sufficient care is taken not to damage the O rings Pumps fitted with optional replaceable seats will have 2 O rings per seat Fig 19 Fig 26 7 Install the two delivery balls Fig 27 8 Install the delivery manifold and tighten the two retaining bolts to the torque value specified in...
Page 24: ... as shown Fig 30 11 Install the divider seal by pushing the seal up into the groove The groove in the body is machined so that it is deeper towards the top of the pump Fig 31 12 Push the bottom of the seal into place and reshape the divider seal by pressing the sides into the groove www unibloctech com ...
Page 25: ...ool T 020 apply a sharp tap with a light mallet or similar ensuring that the seal is held central and square to the body Fig 34 15 Divider seal should snap into position The raised edges of the seal must be checked to ensure that they have engaged fully and correctly on the body faces Insertion tool is designed to stop the seal being pushed too far www unibloctech com ...
Page 26: ...t tube take note of the bearing position within the tube Bearing stack should be closest to Air Valve Fig 37 18 Install the diaphragm and thrust tube into the main body of the pump Ensure that the thrust tube is inserted with the bearings nearest to the air valve side of the pump as shown in Fig 36 Fig 38 19 Screw the second diaphragm onto the thrust tube ensure thread is lubricated 20 Grip both d...
Page 27: ...Ensure that the air system is inserted with the bearings nearest to the air valve side of the pump as shown in Fig 36 Fig 40 23 Fit the secondary air dome Take care not to damage the O ring located in the centre of the air dome Fig 41 24 Fit the dome washer and rod washer www unibloctech com ...
Page 28: ...e main nut Fig 43 26 Using a torque wrench tighten the main nut to the torque specified in Section 5 2 Table 3 It is recommended that the air valve is positioned with the silencers pointing down before final tightening of main nut www unibloctech com ...
Page 29: ...PENDING ON PUMP SPECIFICATION BUT DESIGN IS FUNDAMENTALLY THE SAME Fig 44 1 Loosen the 4 fixing bolts holding the valve unit to the air assembly and main dome Fig 45 2 Remove the air valve unit Fig 46 3 Dismantle the valve unit by removing the cover plate 4 Replace air valve if internal spool does not move freely when manual override buttons are pressed or there are signs of media within www unibl...
Page 30: ...e Fig 48 6 Check all holes on the cover plate for signs of media If media is apparent clean using a suitable cleaning agent Fig 49 7 Install the cover plate and four fixing bolts Fig 50 8 Secure the replacement air valve unit to the air system tightening the four fixing bolts www unibloctech com ...
Page 31: ...h hole Air should flow from the corresponding small hole in the tie rod One of these holes is shown in Fig 52 If a blockage is suspected clean using a suitable cleaning product 10 Check the larger air passages for contamination and clean if required Fig 51 and Fig 53 Fig 54 11 Air valve can now be reattached to the Air Assembly ready for use www unibloctech com ...
Page 32: ...Data 32 4 Spare parts F Series Slimline metallic pump Fig 55 F Series Slimline Pump www unibloctech com ...
Page 33: ... Dome Washer 1 13 Air Valve Cover Plate 1 14 Dome O Ring 2 15 Divider Seal 1 16 Balls 4 17 Manifold O Rings delivery 2 18 Manifold O Rings suction 2 19 Silencers exhaust 2 20 Ball Valve Pump On Off 1 21 Footplate 1 22 Suction Manifold Bolts 2 23 Delivery Manifold Bolts 2 24 Washer 4 Ordering spares When ordering spare parts contact Flotronic Pumps with the model number serial number and the item n...
Page 34: ...epending on diaphragm material Suction Lift Dry 3 6m 12ft Wet 8m 26ft Average Volume per Stroke 0 90 litres Tightening torques Before the pump is put into service and after any maintenance tighten the fastenings to the torque figures given in Table 3 ensuring fasteners are suitably lubricated TABLE 3 TORQUE FIGURES Diaphragm Material LB FT Nm KGM Tie Rod Nut Stainless Steel Mild Steel PTFE Nitrile...
Page 35: ...70 159 454 151 217 127 109 203 26 10 1 320 113 409 145 217 127 109 203 27 10 1 320 128 433 163 242 127 109 203 28 10 2 304 199 504 157 242 127 109 203 28 10 Pump footplate securing holes for all connection sizes Diameter 12 7 mm All dimensions quoted are for guidance only and will be dependent upon specification chosen General arrangement drawings available on request www unibloctech com ...
Page 36: ...aged or used in any way so as to adversely affect its performance or condition we shall not be liable for any fault arising from its use e We shall not be liable for faults arising from the use of any spare or replacement parts not authorised or recommended by us f Any equipment or defective part replaced by us shall become our property g The decision whether to repair or replace a defective part ...
Page 37: ...be liable in any respect as a result of the purchaser s failure to observe the conditions a to d set out above Returning parts When returning parts to Flotronic Pumps the following procedure should be adhered to 1 Consult Flotronic Pumps for shipping information and a returns form and decontamination declaration 2 Make sure the part pump is safe for handling and transport 3 Pack the return article...
