Sliding Vane Pumps-ProVane Model

BLACKMER POWER PUMPS 965820 Page 1/16 INSTRUCTIONS NO. 111-B00 INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS ProVane® Models: PV6B, 8B Section Effective Replaces 111 Feb 2013 Dec 2007 Patent Protected by U.S. Patents 7134855 & 7316551 B2 and Related Foreign Patents. TABLE OF CONTENTS Page General Safety Data ................................................1-2 PUMP DATA Initial Pump Start Up Information ................................ 2 Technical Data ........................................................... 2 INSTALLATION Pre-Installation Cleaning ............................................ 3 Location and Piping .................................................... 3 Mounting .................................................................... 4 Coupling Alignment .................................................... 4 Pump Rotation............................................................ 4 To Reverse Pump Rotation ........................................ 4 Check Valves ............................................................. 4 OPERATION Pre-Start Up Check List .............................................. 5 Start Up Procedures ................................................... 5 Running the Pump in Reverse .................................... 5 Flushing the Pump ..................................................... 6 Optional Pump Relief Valve........................................ 6 Optional Relief Valve Setting and Adjustment ............ 7 MAINTENANCE Torque Table ................................................................. 8 Lubrication ..................................................................... 8 Strainers ........................................................................ 8 Vane Replacement ........................................................ 8 Pump Disassembly ....................................................... 9 Parts Replacement ........................................................ 9 Pump Assembly .......................................................... 10 TROUBLE SHOOTING ...................................................... 13 ONLY Pump models listed below are covered in this Manual Cylinder Type Models Material Parts List PV6B, PV8B Ductile Iron 111-B01 Blackmer manuals and parts lists may be obtained from Blackmer's website (www.blackmer.com) or by contacting Blackmer Customer Service. Numbers in parentheses following individual parts indicate reference numbers on Blackmer Part Lists. SAFETY DATA This is a SAFETY ALERT SYMBOL. When you see this symbol on the product, or in the manual, look for one of the following signal words and be alert to the potential for personal injury, death or major property damage Warns of hazards that WILL cause serious personal injury, death or major property damage. Warns of hazards that CAN cause serious personal injury, death or major property damage. Warns of hazards that CAN cause personal injury or property damage. NOTICE: Indicates special instructions which are very important and must be followed. NOTICE: Blackmer Pumps MUST only be installed in systems, which have been designed by qualified engineering personnel. The system MUST conform to all applicable local and national regulations and safety standards. This manual is intended to assist in the installation and operation of the Blackmer ProVane pumps, and MUST be kept with the pump. Pump service shall be performed by qualified technicians ONLY. Service shall conform to all applicable local and national regulations and safety standards. Thoroughly review this manual, all instructions and hazard warnings, BEFORE performing any work on the pump. Maintain ALL system and pump operation and hazard warning decals. 111-B00 Page 2/16 SAFETY DATA Failure to disconnect and lockout electrical power or engine drive before attempting maintenance can cause severe personal injury or death Failure to disconnect and lockout electrical power before attempting maintenance can cause shock, burns or death Hazardous machinery can cause serious personal injury. Hazardous voltage. Can shock, burn or cause death. If pumping hazardous or toxic fluids, system must be flushed and decontaminated, inside and out, prior to performing service or maintenance Disconnecting fluid or pressure containment components during pump operation can cause serious personal injury, death or major property damage Hazardous or toxic fluids can cause serious injury. Hazardous pressure can cause personal injury or property damage Operation without guards in place can cause serious personal injury, major property damage, or death. Failure to relieve system pressure prior to performing pump service or maintenance can cause personal injury or property damage. Do not operate without guard in place Hazardous pressure can cause personal injury or property damage PUMP DATA PUMP IDENTIFICATION A pump Identification tag, containing the pump serial number, I.D. number, and model designation, is attached to each pump. It is recommended that the data from this tag be recorded and filed for future reference. If replacement parts are needed, or if information pertaining to the pump is required, this data must be furnished to a Blackmer representative. TECHNICAL DATA Pump Size 6, 8 Maximum Pump Speed 3600 RPM Flow Rate at Max. Pump speed 6-8 GPM (23-30 LPM) Maximum Operating Temperature 240°F (116°C) Maximum Viscosity 5, 000 SSU (1100 cP) Maximum Differential Pressure 125 psi (8.6 Bar) Maximum Working Pressure 200 psi (13.8 Bar) Technical Data is for standard materials of construction. Consult Blackmer Material Specs for optional materials of construction INITIAL PUMP START UP INFORMATION Model No.: ______________________________________ Serial No.: ______________________________________ ID No.: _________________________________________ Date of Installation: _______________________________ Inlet Gauge Reading: ______________________________ Discharge Gauge Reading: _________________________ Flow Rate: ______________________________________ 111-B00 Page 3/16 INSTALLATION NOTICE: Blackmer pumps must only be installed in systems designed by qualified engineering personnel. System design must conform to all applicable regulations and codes and provide warning of all system hazards. NOTICE: This pump shall be installed in accordance with all applicable local, state and national regulations. Install ground and wire to local and National Electrical Code requirements. Install an all-leg disconnect switch near the unit motor. Disconnect and lockout electrical power before installation or service Hazardous voltage. Can shock, burn or cause death. Electrical supply MUST match motor nameplate specifications. Motors equipped with thermal protection automatically disconnect motor electrical circuit when overload exists. Motor can start unexpectedly and without warning. An external bypass valve and/or internal relief valve MUST be installed in the system to protect the pump from excessive pressure. Hazardous pressure can cause personal injury or property damage Incorrect bypass valve or internal relief valve settings can cause pump component failure, personal injury, and property damage. Hazardous pressure can cause personal injury or property damage NOTICE: Blackmer ProVane pumps may or may not be fitted with an internal relief valve. If an internal relief valve is not supplied, an external bypass valve MUST be used. PRE-INSTALLATION CLEANING NOTICE: This pump contains some residual test fluid and rust inhibitor. If necessary, flush pump prior to use. Foreign matter entering the pump WILL cause extensive damage. The supply tank and intake piping MUST be cleaned and flushed prior to pump installation and operation. LOCATION AND PIPING Pump life and performance can be significantly reduced when installed in an improperly designed system. Before starting the layout and installation of the piping system, review the following suggestions: 1. Locate the pump as near as possible to the source of supply to avoid excessive inlet pipe friction. 2. The inlet line should be at least as large as the intake port on the pump. It should slope downward to the pump, and should not contain any upward loops. Eliminate restrictions such as sharp bends; globe valves, unnecessary elbows, and undersized strainers. 3. Install a system bypass valve that returns excess flow to the supply tank or pump inlet piping as appropriate for the pumping system. Insure that the bypass valve pressure setting is appropriate for the pump and system component working pressures. 4. It is recommended a strainer be installed in the inlet line to protect the pump from foreign matter. The strainer should be located at least 24" (0.6m) from the pump, and have a net open area of at least four times the area of the intake piping. Strainers must be cleaned regularly to avoid pump starvation. 5. The intake system must be free of all leaks. 6. When pumping liquids at elevated temperature, provisions should be made to compensate for expansion and contraction of the pipes, especially when long pipe lines are necessary. Steel pipe expands approximately 3/4” (1.9 cm) per 100 feet (30.49 m) per 100°F (37.8°C) rise in temperature. 7. Expansion joints, placed at least 36" (0.9m) from the pump, will compensate for expansion and contraction of the pipes. Contact the flexible connector/hose manufacturer for required maintenance/care and design assistance in their use. 8. ALL piping and fittings MUST be properly supported to prevent any piping loads from being placed on the pump. 9. Install pressure gauges in the NPT ports provided in the pump casing (if equipped) to check pump at start up. 10. Check alignment of pipes to pump to avoid strains which might later cause misalignment. See Figure 1. Unbolt flanges or break union joints. Pipes must not spring away or drop down. After pump has been in operation for a week or two, completely recheck alignment. Figure 1 111-B00 Page 4/16 INSTALLATION PUMP MOUNTING A solid foundation reduces noise and vibration, and will improve pump performance. On permanent installations it is recommended the pumping unit be secured by anchor bolts as shown in Figure 2. This arrangement allows for slight shifting of position to accommodate alignment with the mounting holes in the base plate. Figure 2 - Pipe Type Anchor Bolt Box For new foundations, it is suggested that the anchor bolts be set in concrete. When pumps are to be located on existing concrete floors, holes should be drilled into the concrete to hold the anchor bolts. When installing units built on channel or structural steel type bases, use care to avoid twisting the base out of shape when anchor bolts are tightened. Place shims as needed under the edges of the base prior to tightening of the anchor bolts to prevent distortion. COUPLING ALIGNMENT The pump must be directly coupled to a gear reducer and/or driver with a flexible coupling. Verify coupling alignment after installation of new or rebuilt pumps. Both angular and parallel coupling alignment MUST be maintained between the pump, gear, motor, etc. in accordance with manufacturer’s instructions. See Figure 3. 1. Parallel alignment: The use of a laser alignment tool or dial indicator is preferred. If a laser alignment tool or dial indicator is not available, use a straight edge. Turn both shafts by hand, checking the reading through one complete revolution. Maximum offset should be less than .005" (.127 mm). 2. Angular alignment: Insert a feeler gauge between the coupling halves. Check the spacing at 90° increments around the coupling (four checkpoints). Maximum variation should not exceed .005" (.127 mm). Some laser alignment tools will check angular alignment as well. 3. Replace the coupling guards after setting alignment. Figure 3 – Alignment Check PUMP ROTATION PV6,8 pumps will ALWAYS operate in the clockwise rotation when viewed from the driven end. See Figures 4 and 5. TO REVERSE PUMP FLOW To reverse FLOW direction in a ProVane pump. The pumps rotation WILL NOT CHANGE for PV 6&8. See Flow Direction Options in the Maintenance section of this manual. If the rotation of the electric motor driving the pump is incorrect; see the motor manufacturer’s instructions to change the rotation of the electric motor to match it to the rotation of the pump. CHECK VALVES The use of check valves or foot valves in the supply tank is not recommended with self-priming, positive displacement pumps. If the possibility of liquid backflow exists when the pump is off, a check valve in the system is recommended because the pump can motor in the reverse rotation and create undue stress on all attached components. Never start a pump when it is rotating in the reverse rotation as the added starting torque can damage the pump and related equipment. If a check valve is used, install it at the pump discharge. 111-B00 Page 5/16 OPERATION Operation without guards in place can cause serious personal injury, major property damage, or death. Do not operate without guard in place Disconnecting fluid or pressure containment components during pump operation can cause serious personal injury, death or major property damage Hazardous pressure can cause personal injury or property damage Failure to relieve system pressure prior to performing pump service or maintenance can cause personal injury or property damage. Hazardous pressure can cause personal injury or property damage Pumps operating against a closed valve can cause system failure, personal injury and property damage Hazardous pressure can cause personal injury or property damage An external bypass valve and/or internal relief valve MUST be installed in the system to protect the pump from excessive pressure. Hazardous pressure can cause personal injury or property damage Incorrect bypass valve or internal relief valve settings can cause pump component failure, personal injury, and property damage. Hazardous pressure can cause personal injury or property damage PRE-START UP CHECK LIST 1. Check the alignment of the pipes to the pump. Pipes must be supported so that they do not spring away or drop down when pump flanges or union joints are disconnected. 2. Verify proper coupling alignment. 3. Check the entire pumping system to verify that the proper inlet and discharge valves are fully open, and that the drain valves and other auxiliary valves are closed. 4. Install inlet and discharge pressure gauges on the pump in the threaded connections provided. These can be used to check actual suction and discharge conditions after pump start-up. 5. Check the wiring of the motor, and briefly turn on the power to make sure that the pump rotates in the direction of the rotation arrow. START UP PROCEDURES NOTICE: Consult the "General Pump Troubleshooting" section of this manual if difficulties during start up are experienced. 1. Start the motor. Priming should occur within one minute. 2. Check the suction and discharge pressure gauges to see if the pump is operating within the expected conditions. 3. Check for leakage from the piping and equipment. 4. Check for overheating of the pump, reducer (if equipped), and motor. 5. If possible, check the flow rate. 6. Check the pressure setting of the system bypass valve by slowly restricting a valve in the discharge line and reading the pressure gauge. This pressure should be 20 psi (1.4 bar) higher than the intended operating pressure. RUNNING THE PUMP IN REVERSE NOTICE: When pumps are operated in reverse a separate pressure relief valve must be installed to protect the pump from excessive pressure. NOTICE: Pump should be operated in reverse rotation for no more than 10 minutes and only when a separate pressure relief valve is installed to protect the pump from excessive pressure. It may be desirable to run the pump in reverse rotation for system maintenance. The pump will operate satisfactorily in reverse rotation for a LIMITED time, at a reduced performance level. 111-B00 Page 6/16 OPERATION FLUSHING THE PUMP NOTICE: If flushing fluid is to be left in the pump for an extended time, it must be a lubricating, non-corrosive fluid. If a corrosive or non-lubricating fluid is used, it must be flushed from the pump immediately. To flush the pump, run the pump with the discharge valve open and the intake valve closed. Bleed air into the pump through the intake gauge plug hole or through a larger auxiliary fitting in the intake piping. Pump air for 30 second intervals to clean out most of the pumpage. 1. Run a system compatible flushing fluid through the pump for one minute to clear out the remainder of the original pumpage. The valve in the discharge line should be restricted to build up 10 psi (0.7 bar) to force flushing liquid through the bearing seal chamber. 2. To remove the flushing fluid, follow step 1 above. 3. After flushing the pump some residual fluid will remain in the pump and piping. 4. Properly dispose of all waste fluids in accordance with the appropriate codes and regulations. OPTIONAL PUMP RELIEF VALVE: An external bypass valve and/or an internal relief valve MUST be installed in the system to protect the pump from excessive pressure. Hazardous pressure can cause personal injury or property damage Incorrect bypass valve or internal relief valve settings can cause pump component failure, personal injury, and property damage. Hazardous pressure can cause personal injury or property damage. 1. Blackmer ProVane pumps may or may not be fitted with an internal relief valve. If an internal relief valve is not supplied, an external bypass valve must be used. 2. The pump’s internal relief valve is designed to protect only the pump from excessive pressure and must not be used as a system pressure control valve. 3. Internal bypassing of liquid elevates liquid temperature. Internal relief valve should only be used for brief periods and for differential pressures below 125 psi. For extended periods, an external bypass returned to source must be used. 4. The pump relief valve cap must be on the inlet side of the pump. If pump relief valve is installed improperly, it will not operate and a component failure may result. See Figures 4 and 5. Fig 4 Right Hand Orientation Fig 5 Left Hand Orientation 111-B00 Page 7/16 OPERATION OPTIONAL RELIEF VALVE SETTING AND ADJUSTMENT The relief valve pressure setting/range is marked on a metal tag attached to the valve cover. The relief valve should be set at 20 PSI (1.4 Bar) higher than the operating pressure or system pressure control valve, but no higher than the maximum working pressure of the pump. Incorrect settings of the pressure relief valve can cause pump component failure, personal injury, and property damage. Hazardous pressure can cause personal injury or property damage Relief valve cap is exposed to pumpage and will contain some fluid. Hazardous or toxic fluids can cause serious injury. DO NOT remove the R/V cap OR adjust the relief valve pressure setting while the pump is in operation. 1. To INCREASE the pressure setting, remove the relief valve cap (1) and O-ring (88). Loosen the locknut (3). Turn the adjusting screw (2) inward, or clockwise. Inspect R/V cap O-rings and replace as required. Reattach R/V cap O-ring and RV cap. 2. To DECREASE the pressure setting, remove the relief valve cap (1) and O-ring (88). Loosen the locknut (3). Turn the adjusting screw (2) outward, or counterclockwise. Inspect R/V cap O-rings and replace as required. Reattach R/V cap O-ring and RV cap. Refer to the individual Blackmer pump parts lists for various spring pressure ranges. Unless specified otherwise, pumps are supplied from the factory with the relief valve adjusted to the mid-point of the spring range. MAINTENANCE: Failure to disconnnect and lockout electrical power or engine drive before attempting maintenance can cause severe personal injury or death Disconnecting fluid or pressure containment components during pump operation can cause serious personal injury, death or major property damage Hazardous machinery can cause serious personal injury. Hazardous pressure can cause personal injury or property damage Failure to disconnect and lockout electrical power before attempting maintenance can cause shock, burns or death If pumping hazardous or toxic fluids, system must be flushed and decontaminated, inside and out, prior to performing service or maintenance Hazardous voltage. Can shock, burn or cause death. Hazardous or toxic fluids can cause serious injury. Failure to relieve system pressure prior to performing pump service or maintenance can cause personal injury or property damage. NOTICE: Maintenance shall be performed by qualified technicians only. Follow the appropriate procedures and warnings as presented in this manual. Hazardous pressure can cause personal injury or property damage 111-B00 Page 8/16 MAINTENANCE: Torque Table 1 Pump Size PV6B, 8B Head / Casing Cap Screws in-lbs 42 N-m 4.75 Rotor Capscrews in-lbs 34 N/m 3.84 Relief Valve Capscrews in-lbs 15 N-m 20.3 Bearing Adjuster Set Screw (189) in-lbs 9.5 N-m 1.07 Suggested Tool List Allen Wrenches: 7/64”, 2mm - 5mm Combination Wrenches: 10mm - 12mm, 23mm Pliers: Standard & Long Nose Spanner Wrench Strap Wrench Ball Peen Hammer: 8oz. Ratchet & Socket Set: 10mm - 12mm, 23mm Mallet: shot loaded rubber Screwdrivers: (2), slot type SCHEDULED MAINTENANCE LUBRICATION The Blackmer ProVane pumps are equipped with ball bearings that require no additional lubrication. STRAINERS Strainers must be cleaned regularly to avoid pump starvation. Schedule will depend upon the application and conditions. VANE REPLACEMENT NOTICE: Maintenance shall be performed by qualified technicians following the appropriate procedures and warnings as presented in this manual. See the table on page 1 of this manual to determine what model you have. Figure 6 – Vane Replacement 1. Flush the pump per instructions in this manual. Drain and relieve pressure from the pump and system as required. 2. Remove the head cap screws (21). Gently pry the head away from the casing using two screwdrivers. The head O-ring should come off with the head assembly. 3. Turn the shaft by hand until a worn vane comes to the top (12 o'clock) position of the rotor. Remove the vane. 4. Install a new vane, ensuring that the rounded edge is UP, and the relief grooves are facing towards the direction of rotation. See Figure 6. 5. Repeat steps 3 and 4 until all vanes have been replaced. This method of vane installation ensures the push rods do not fall out of their rotor slots. 6. Carefully install the head (23) into the casing or cylinder. Install and tighten four head cap screws (21). If equipped with optional relief valve, to insure proper orientation see Figures 4 and 5 in Optional Pump Relief Valve section Torque per Table 1 shown at the beginning of the maintenance section. 111-B00 Page 9/16 MAINTENANCE: PUMP DISASSEMBLY NOTICE: Follow all hazard warnings and instructions provided in the “Maintenance” section of this manual. NOTE: The numbers in parentheses following individual parts indicate reference numbers on the Pump Parts List. 1. Flush the pump per instructions in this manual. Drain and relieve pressure from the pump and system as required. 2. Starting on the inboard (driven) end of the pump, clean the pump shaft thoroughly, making sure the shaft is free of nicks and burrs. This will prevent damage to the mechanical seal when removed. 3. Remove the head cap screws (21). Gently pry the head away from the casing using two large screwdrivers. The head O-ring should come off with the head assembly. 4. Remove locknut and lock washer (24A and 24B): a. Bend up the engaged lock washer tang and rotate the locknut counterclockwise to remove it from the shaft. b. Slide the lock washer off the shaft. Inspect the lock washer for damage and replace as required. 5. Remove the rotor and shaft (13) from the casing. While one hand is pushing the shaft, the other hand should be cupped underneath the rotor to prevent the vanes (14) and pushrods (77) from falling out. As the rotor & shaft are removed further, carefully support the shaft so it does not drop and damage the sleeve bearing or finished surfaces of the shaft or the rotating seal face as it is removed. Carefully set the rotor and shaft aside for future vane replacement and reassembly. 6. To remove the cylinder. Lay the pump on end with the bearing housing facing upward and remove the 4 cap screws (21). Lift off the bearing housing and remove the cylinder O-ring (71). 7. The mechanical seal rotating assembly will come out with the shaft. The stationary seat and stationary seal ring need to be removed from the bearing adjuster (188). 8. Carefully pry the stationary seal elements (153A) from the bearing adjuster (188). Be sure not to scratch the seal face or damage the elastomer seal seat. 9. Remove the ball bearing adjuster (188) by loosening the set screws (189) and turning it counter clockwise with a strap wrench or spanner wrench. 10. If necessary for replacement, remove the ball bearing (24C) from the bearing adjuster. Turn the bearing adjuster so the threaded side is up. Using an appropriately sized arbor press remove the bearing (24C) from the bearing adjuster. Discard old bearing and replace with new one. See step 2 of “Pump Assembly” 11. If the sleeve bearing is worn or damaged. a. Remove the sleeve bearing (24) from the bearing housing (57) using an appropriately sized arbor press. 12. Only disassemble rotor & shaft if necessary for part replacement. Disassemble the rotor (13B) and shaft (13A) by removing the six cap-screws (13C). See figure 7. Figure 7 PARTS REPLACEMENT 1. If any of the O-rings have been removed or disturbed during disassembly, they need to be replaced with new O-rings. NOTE: PTFE O-rings should be heated in hot water to aid installation. 2. Excessive or continuous leakage from around the seal housing or in the bearing housing may be an indication of a damaged mechanical seal. If a mechanical seal has been leaking, it is recommended the entire seal be replaced. Refer to "General Pump Troubleshooting" for possible causes of seal leakage. 3. Inspect bearings for wear and replace as necessary. 111-B00 Page 10/16 MAINTENANCE: PUMP ASSEMBLY Before reassembling the pump, inspect all component parts for wear or damage, and replace as required. Wash out the bearing/seal recess of the head and remove any burrs or nicks from the rotor and shaft. Reassemble the BEARING Components first: To aid in the replacement of the sleeve bearing (24) the creation and use of a tool similar to the one shown in Figure 8 may be useful. Figure 8 – Sleeve Bearing Installation Bearing Bore Dia. “C” Tool Dim “A” Tool Dim “B” 1.26 in. (32mm) 2.05 in. (52 mm) 1.25 in. (31.75 mm) 1. Inspect the sleeve bearing (24) for wear or damage and replace as required. To replace sleeve bearing: a. Using an appropriately sized arbor press, remove the old bearing (24) from the bearing housing (57). b. To aid installation and prevent bearing damage, coat the bearing (24) with grease and place it on the face of the bearing housing (57). Align the seam in the bearing at 12:00 position (opposite the pump foot) c. Using an arbor press, press the bearing (24) into the housing (57) until it is flush with the face of the bearing housing. NOTE: Ensure the bearing does not become misaligned during the pressing motion 2. Inspect the ball bearing (24C) for wear or damage and replace as required. To replace ball bearing: a. Using an appropriately sized arbor press, remove the old bearing (24C) from the bearing adjuster (188). Discard the old bearing after removal. b. To aid installation and prevent bearing damage, coat the bearing with grease and place it on the face of the bearing adjuster (188) c. Using an arbor press which only contacts the outer race of bearing, press the OD of the bearing into the bearing adjuster until fully seated. 3. Cylinder O-ring installation a. Install a new O-ring (71) over the dowel of the Bearing housing (57). 4. Reassemble the cylinder to the bearing housing positioning it for the desired flow direction (see Flow Direction Options). Install cap screws (21A) through the bearing housing into the cylinder. Torque per Table 1. FLOW DIRECTION OPTIONS NO vane or rotational changes are required to reverse flow direction for the PV6, 8. The pump will have a CLOCKWISE ROTATION regardless of flow direction. For the pump to operate with the INTAKE port on the RIGHT as viewed from the driven end of the pump, position the cylinder with the pressure ports pointing up in relation to the feet. See Fig 4. For the pump to operate with the INTAKE port on the LEFT as viewed from the driven end of the pump, position the cylinder with the pressure ports pointing down in relation to the feet. See Fig 5. TO REVERSE FLOW DIRECTION Loosen cylinder cap screws (21A) to loosen cylinder from drive housing. Rotate cylinder on drive housing 180 degrees. Install cap screws (21A) through bearing housing and torque per table 1. 5. Assemble Rotor and Shaft (if disassembled). a. Loosely assemble rotor (13B) on to shaft (13A) securing with socket cap screws (13C). DO NOT damage the OD surface finish of the rotor and shaft. b. Secure a piece of steel sized to fit the width and length of a vane slot in a vise or other holding device. Place the loosely assembled rotor and shaft on to the piece of steel in one of the vane slots; completely filling the entire vane slot. c. Hold the assembly securely without damaging the OD of the rotor or shaft. d. Tighten the socket cap screws (13C). Torque per Table 1. Figure 10 – Rotor / Shaft Assembly Torque 111-B00 Page 11/16 MAINTENANCE: PUSHROD INSTALLATION Figure 11 – Pushrod Installation 6. Insert the vanes into the bottom three rotor slots with the relief grooves facing in the direction of pump rotation, and with the rounded edges outward. See Figures 6 & 11. 7. Hold the three bottom vanes in place while inserting the three push rods (77). See Figure 11. Note: A small amount of grease may be used to help hold the pushrod in the rotor during assembly. 8. Installing Seal Rotating Elements Refer to the seal manufacturer’s instructions for detailed removal and replacement instructions. Mechanical Seal type 8 or 9 a. Apply a small amount of Flowserve Pac-Ease™ or equivalent water based lubricant on the shaft between the shaft end and the rotor b. Slide the seal rotating assembly (153B) over the shaft with the rotating face away from the rotor until contact is made with the large diameter of the shaft. Seal spacer is not needed. c. Tighten set screws and remove seal spacer clips per manufacturer’s directions. d. After the bottom vanes and push rods are installed, carefully insert the driven end of rotor and shaft into the cylinder. e. Clean the polished face of the seal with a clean tissue and alcohol before reassembly. Mechanical Seal Type 16 a. After the bottom vanes and push rods are installed, carefully insert the driven end of rotor and shaft into the cylinder. b. Apply a small amount of Flowserve Pac-Ease™ or equivalent water based lubricant on the shaft between the shaft end and the rotor. c. Install the seal spacer (82) over the shaft until it bottoms out on the large diameter of the shaft. d. Slide the seal rotating assembly (153B) over the shaft with the rotating face away from the rotor until contact is made with the seal spacer. e. Clean the polished face of the seal with a clean tissue and alcohol before reassembly. 9. Install Stationary Seal Elements Mechanical Seal type 9, 16 a. Apply a small amount of lubricant in the seal access of the bearing adjuster (188) b. Install a new stationary seat and O-ring into the bearing adjuster until fully bottomed out. Type 9 only - align slot in stationary seat with anti-rotation pin (25A) in bearing adjuster (188) before inserting stationary seat. c. Clean the polished face with a clean tissue and alcohol. 10. Install a new O-ring (51) onto the bearing adjuster (188) 11. Lubricate the O-ring seal area on the bearing housing (57) with a light coating of oil. 12. Start the bearing adjuster (188) (with stationary seal elements installed) over the shaft, being careful not to damage the seal with the shaft end. 13. Screw the bearing adjuster (188) to the bearing housing (57) until they are flush. Be sure that the 2 setscrews (189) are not interfering with the flush fit of the bearing adjuster to the bearing housing. PUSHROD VANES111-B00 Page 12/16 MAINTENANCE: 14. LOCKNUT ADJUSTMENT It is important that the bearing locknut (24A) and lock washer (24B) be installed and adjusted properly. Over tightening the locknut can cause bearing failure or a broken lock washer tang. A loose locknut will allow the rotor to shift within the pump, causing wear. See Figure 12. Figure 12 – Locknut Assembly a. On the end of the pump shaft, install a lock washer (24B) with the tangs facing outward, followed by a locknut (24A) with the tapered end inward. Ensure the inner tang "A" of the lock washer is located in the slot in the shaft threads, bending it slightly, if necessary. b. Tighten the locknut to ensure that the bearing is bottomed in the recess. DO NOT over tighten and bend or shear the lock washer inner tang. Bearing Adjustment 15. Turn the bearing adjuster counterclockwise, as viewed from the driven end of the pump, until the shaft is snug and no longer turns. Mark a line across the bearing adjuster and drive housing. 16. Turn the bearing adjuster clockwise, as viewed from the driven end of the pump the distance prescribed per table 2. Measurement to be taken on outside of drive housing. Table 2 Pump size Distance on OD of Drive Housing PV 6,8 3/4” (19.05 mm) 17. Tighten the bearing adjuster lock setscrews and torque per table 1. 18. Install a new head O-ring (72) on the dowel of the head as shown in Figure 13. Figure 13 – Head O-ring Installation 19. Carefully install the head (23) into the cylinder. If pump is equipped with internal relief valve, orient the relief valve per instruction in PUMP RELIEF VALVE section of this manual. Install and tighten four head cap screws (21A). Torque per table 1. 20. RELIEF VALVE ASSEMBLY a. Insert the valve into the valve body with the fluted in inward. b. Install the relief valve spring onto valve and spring guide onto spring. c. Screw the adjusting screw into the valve cover until it makes contact with the spring guide d. Install the relief valve cap and O-ring after the relief valve has been properly adjusted. NOTICE: The relief valve setting MUST be tested and adjusted more precisely before putting the pump into service. Refer to “Relief Valve Setting and Adjustment”. 21. Reinstall coupling, shaft key, and coupling guards. Operation without guards in place can cause serious personal injury, major property damage, or death. Do not operate without guard in place 22. Refer to “Pre-Start Up Check List” and “Start Up Procedures” sections of this manual prior to restarting pump operation. 111-B00 Page 13/16 GENERAL PUMP TROUBLESHOOTING NOTICE: Maintenance shall be performed by qualified technicians only. Follow the appropriate procedures and warnings as presented in this manual. LEAKAGE Location Probable Cause/Corrective Action Between the head & casing Damaged head O-ring: Inspect and replace if necessary. Burrs/dirt in head O-ring groove or cylinder: File and clean as necessary. Around the shaft New Mechanical Seals: New seals may leak slightly at start up, but should seal up shortly thereafter. Damaged mechanical seals: Check for damaged O-rings or cracked, scratched or worn seal faces SHAFT BINDING Probable Cause Corrective Action Burrs, dirt or foreign particles on the heads or discs. During assembly, both heads and discs must be clean and smooth. Fileany burrs or rough spots, and wipe the discs with a clean cloth and alcohol to remove any dirt or foreign particles. Improper bearing adjustment. Bearings must be adjusted properly to center the rotor and shaft between the head & bearing housing. Refer to the "Pump assembly " section of this manual. Contaminated mechanical seal faces. Any trace of grease or dirt on the seal faces will prevent the faces from mating properly, causing the rotor and shaft to bind or turn hard. Use a tissue paper & alcohol to clean the seal faces. NOTE: Apply a light oil or suitable lubricant to bronze seal faces only. OTHER POSSIBLE CAUSES OF SHAFT BINDING: • Foreign particles on rotor, liner or vanes. • Damaged vanes or rotor. • Bent push rods. • Liquids that "set up" when inactive. OVERHEATING Probable Cause Corrective Action Pump is in bypass (internal or external) mode too long or the bypass loop is too short Adjust the bypass valve and/or internal relief valve so that the pump does not operate in bypass mode so long. Route the external bypass line back to the supply tank. OTHER POSSIBLE CAUSES OF OVERHEATING: • Improper system bypass valve adjustment • Plugged discharge line. • Closed valve. LOW DELIVERY RATE Probable Cause Corrective Action Bypass valve setting too low, causing the liquid to bypass. The Bypass valve setting should be 20 psi (1.4 bar) higher than the differential pressure. OTHER POSSIBLE CAUSES OF A LOW DELIVERY RATE: ? Restriction in the suction line. ? Resistance in the discharge line. ? Air leaks in the suction line. ? Damaged or worn pump parts. ? Pump speed too low or too high. ? Bypass valve leaking. ? Bypass valve sticking open, or not properly seating. ? Dirty strainer. ? Liner installed backwards ? Pump running in reverse 111-B00 Page 14/16 GENERAL PUMP TROUBLESHOOTING EXCESSIVE NOISE AND VIBRATION Probable Cause Corrective Action Cavitation or vaporization of the liquid resulting from excessive vacuum on the pump due to starved suction. Check for: ? Inlet piping too long or too small in diameter. ? Strainer plugged or dirty. ? Undersized or restrictive fittings, such as globe valves or partially closed valves. ? Excessive amount of elbows. ? Suction lift too great. ? Pump speed too high for the viscosity of the liquid being pumped. Entrained air or vapors in the pump. Check pipe joints for leakage of air. Sometimes when recirculating liquid in a tank, the returning liquid falling through the air carries air down into the tank, which eventually gets back into the pump. Pump speeds exceed the recommended maximum. Check the recommended RPM for your specific application. Liner Installed Backwards The word “INTAKE”, which is cast on the liner MUST be towards the intake side of the pump Continual or long term bypassing of liquid through system bypass valve. Check for restriction in the discharge line, or an improper bypass valve adjustment OTHER POSSIBLE CAUSES OF NOISE AND VIBRATION: ? Excessively worn vanes ? Bearing Worn or Damaged. ? Loose or improperly installed piping. ? Misalignment of pump and driver. ? Pump base not properly mounted. POOR OR NO PRIMING Probable Cause ? Air leaks in the suction line. ? Restriction in the suction line. ? Damaged or worn pump parts. ? Too much lift for the vapor pressure of the fluid. ? A dirty or clogged strainer. ? Worn vanes. ? Suction Valve Closed. ? Incorrect pump rotation ? Bypass Valve partially open, valve not seating properly. DAMAGED VANES Probable Cause ? Foreign objects entering the pump. ? Running the pump dry for extended periods of time. ? Cavitation. ? Viscosity too high for the vanes and/or pump speed. ? Incompatibility with the liquids pumped. ? Excessive heat. ? Worn or bent push rods, or worn push rod holes. ? Settled or solidified material in the pump at start-up. ? Hydraulic hammer - pressure spikes. ? Vanes installed incorrectly (see “Vane Replacement"). BROKEN SHAFT Probable Cause ? Foreign objects entering the pump. ? Viscosity too high for the pump speed. ? Bypass valve not opening. ? Hydraulic hammer - pressure spikes. ? Pump/driver, driveline/drive shaft misalignment. ? Excessively worn vanes or vane slots. ? Settled or solidified material in the pump at start-up. SEAL LEAKAGE Probable Cause ? O-rings not compatible with the liquids pumped. ? O-rings nicked, cut or twisted. ? Shaft at seal area damaged, worn or dirty. ? Excessive cavitation. ? Mechanical seal faces cracked, scratched, pitted or dirty. ? Ball bearings worn. MOTOR OVERLOAD Probable Cause ? Horsepower of motor not sufficient for application ? Improper wire size / wiring and/or voltage to motor. ? Misalignment in pump drive system. ? Excessive viscosity, pressure or speed. ? Faulty or worn bearings. ? Rotor rubbing against head or liner. ? Dirty mechanical seal faces. 111-B00 Page 15/16 NOTES Sliding Vane Pumps: 5 to 2200 GPM Refined Fuels, Liquefied Gases, Solvents,Process Stainless Steel Sliding Vane Pumps 1 to 265 GPM: Acids, Brines, Sugars, Syrups, Beer, Beet Juice, Cider, Flavor Extracts, etc. System One® Centrifugal Pumps 10 to 7500 GPM; Process, Marine Magnetic Drive Pumps Stainless Steel: 14 to 215 GPM HXL 6, 8 & 10” Sliding Vane Pumps 130 to 2,220 GPM Refineries Terminals Barges Ships Reciprocating Gas Compressors Liquefied Gas Transfer, Boosting, Vapor Recovery Hand Operated Pumps Dispensing, Transfer, In-line Accessories Gear Reducers, Bypass Valves, Strainers Visit www.blackmer.com for complete information on all Blackmer products 1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A. Telephone: (616) 241-1611 • Fax: (616) 241-3752 E-mail: blackmer@blackmer.com • Internet Address: www .blackmer.com Index Safety Data Pump Data Technical Data Initial Startup Information Installation Pre-Installation Cleaning Location & Piping Pump Mounting Coupling Alignment Pump Rotation To Reverse Pump Flow Check Valves Operation Pre-Startup Checklist Startup Procedures Running the Pump in Reverse Flushing the Pump Optional Relief Valve Setting & Adjustment Maintenance Torque Table Tool List Scheduled Maintenance Lubrication Strainers Vane Replacement Disassembly Parts Replacement Assembly Flow Direction Options Troubleshooting Contact Blackmer