SINCE 1882

MITCHELL LEWIS & STAVER CO.PUMPS AND INDUSTRIAL PRODUCTS DIVISION

STOCKING DISTRIBUTORS:

YAMADAAir Operated Diaphragm

FDA-AOD PumpsPulsation DampnersBarrel AOD Pumps

PEERLESSAnsi Process Pump

Paper StockSelf Priming

Horizontal Split CaseVertical Multi-Stage

Vertical TurbinesEnd Suction

GORMAN RUPPSolids-Handling Self-PrimersSubmersible De-Watering

Rotary GearEngine-Mounted Self Primers

HYDROMATICSubmersible Non Clog

Grinder PumpSubmersible Vortex

MYERSSubmersible Non-Clog

Grinder PumpsSelf-PrimingCentrifugal

Reciprocating

TOYOSubmersible Solids

Handling SlurryVertical Cantilever Sump

DredgingMixers

OBERDORFERChemsteel

Rotary GearMag Drive

AMPCO3A Sanitary Pumps

CIP PumpsGeneral Industrial Centrifugal

PRICECentrifugal

VerticalSelf-Priming

DURAMETERMetering Pumps

Accessories

MONOFLOProgressive Cavity Pumps

Metering PumpsMacerators

Main Office9935 SW Commerce CircleWilsonville, OR 97070

50348231 72866-748-807.7

Fax 503-682-0719

PACIFIC NORTHWE$TSALES 4 SERVICE LOcATIöN5Spokane Office

____

Redmond Office25O2East-TrentAve 2753 l52ndAve NESpokane, WA 99202 Redmond, WA 98052

509-5341068800-365-7683

FAX 509-755-0853

425.882-22OQ

FAX 425-867-1118

Website www mitchellewis .comE-Mail 2sales@mitchellewis corn

SINCE 1882

MITCHELL LEWIS & STAVER CO.PUMPS AND INDUSTRIAL PRODUCTS DIVISION

STOCKING DISTRIBUTORS:

MITCHELL SYSTEMS SAHARAIHENDERSON AURORAPackaged Lift Stations Compressed Air Filters Fire PumpsCustom Control Panels Air Dryers Fire SystemsFire System Packages Breathing Air Purifiers and Filters

BERKELEY CORI(EN DELTECHEnd-Suction Oil Free, Air Cooled Air Dryers

Submersible Turbine Air/Gas Compressors Air FiltrationLow Viscosity Pumps Breathing Air

FINISH THOMPSON COMPAIR/LEROI I(AESERStamped Stainless Air Compressors Rotary Screw

Mag-Drive Gas Compressors Air DryersNon-Metallic Filters

Blowers

Also Available: FYBROC*SUNDSTRAND*WARREN RUPP*WORTHINGTON* INGERSOLL-RAND * IMO *ALLWEILER

COMPLETE REPAIR & FABRICATION

Large Partslñventory *7 Service & Machine Tool Operators*All Types of Weldiñg. &Fabricatlon*Repalr all Types of Pumps

Note Not all products are sold in all locations

www, mitchellewis. corn

J’7/04.]M

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241i 320 480 51i0 640 721) 800 880FLOWRATE U. S . GALLONS PER MINUTE

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ToDEL: S[43C10

PIONEER PUMP,INC STANDARD CENTRIFUGAL ES3

PUMP STATION INDEX

SECTION 1 TEST DATA

SECTION 2 PRIMING INSTRUCTIONS

SECTION 3 PUMP CURVE / PUMP MANUAl

SECTION 4 MOTOR DATA / MANUAL

SECTION 5 ELECTRICAL DIAGRAMS

SECTION 6 SOLENOID VALVE MANUAL

SECTION 7 SOLENOID CONTROL VALVE

SECTION 8 PRESSURE REDUCING VALVE

SECTION 9 SELF CLEANING SUCTION SCREEN

SECTION 1

MITCHELL LEWS & STAVER CODistributors Since 1882 n925 c w Commec c;rc!e. V scnvIIe Omnon 97070

- Phone (03) 2-IPGV • Ex ç07) h2163

Start-up for Oswego Lake Country Club

3 each SC43C10L73-B @ 10.25” Trim520 gprn @420 tdh [181.82 psi]

SCHF43I0-1 Pioneer Pump with Frame close coupled to a 100 hp BaldorMotor @ 3540 rpm, 3 phase, 230/460 volt, ODP premium efficiency,365TCs frame, 91% power factor, 94.1 efficiency, cat# EM2550T, withspec# 42F098W461-G1.

Pump 1Serial number 3902Motor Serial Number 7040116017088 amps = 80.4 hp

Pump 2Serial number 3900Motor serial Number 7040116018092 amps = 84.04 hp

Pump 3Serial Number 3901Motor Serial number 7040116017589 amps = 81,3

All pumps have been checked for the following:Proper installation, piping size, pump lubrication, pipe stress on flanges*,grouted base, line amps, rotation and rpm. Main disconnect service,individual pump motor low current monitors [loss of prime/failprotection, system high pressure cutout with manual reset and pressureswitch, and field adjusted staggered starting and stopping delays.Automatic and manual starts performed and pumps ran for at least onehour after start-up.

Crctmonn, VJasniroron Thcorna. Vv’anrtcn Spokane, Nas1ncTcn ‘erdan, nano

‘425; 882-2200 253 922-14a1 5C3 534-0343 208) 395-0

Priming Pump with outside sourceSee attached diagram

When priming pump from outside source such as garden hose make sureall discharge lines are closed. Remove gauge and petcock, open 1 / 4 turntop vent ball valve below the 6” wafer check valve, hook up the gardenhose to hose bib, make sure upper most 1 / 4” turn ball valve [on 3 / 4”from main discharge] is closed, turn water on then turn water facet valveopen to fill line. Wait for water to come thru the gauge line [1 52Ominutes], replace petcock and gauge, wait for water to come thru the topvent line, shut off water, then the vent line and start pump, slowly open fldischarge valve above the wafer check valve until fully open. Note if pumpcavitates close valve until cavitation stops and slowly open again until fullyopen, may take 10 to 15 minutes.

Priming Pump from TankWhen priming the pump from the tank be sure all discharge lines areclosed. Remove petcock and gauge, open 1 / 4 turn top vent valve belowthe 6” wafer check valve, and make sure the garden hose bib is closedalso. Use extra caution here/il! Crack the 1 / 4 turn ball valve just abovethe garden hose bib till you hear it and don’t turn full open [if you do youwill blow the suction line off]. Put your ear down next to the gaugeopening and listen for water flows and air escaping from the suction line.In about 10 to 15 minutes time you should get water from the gauge,reinstall petcock and gauge, then water will come from the top vent valve,shut off the 1 /4 turn ball valve and then top vent valve this is the properorder*. Start pump and follow the same procedures above slowly open thedischarge valve above the wafer check valve. *Never leave the fill linevalve open at any time without leaving the vent line open

Recommendations• *Recommend that suction piping have permanent support instead of

temporary support at this time.• Install drain line for C80 I Flomatic solenoid control valve.• Leave model 420 Bermad pressure reducing valve set at 50 psi. for

Clemons self cleaning suction screens.• Have 4” x 6” eccentric reducer line shortened or hard suction line

from pond shortened for easier installation in future.

Maintenance Reciuired

( Grease pumps and motors per manufacfures recommendationsCheck pressure aiid vacuum gauges to make sure pressure reducing

valve on the return line and self cleaning suction screens do not plugwith algae.Pumps have a mechanical seal and shouldn’t require service untilthe mechanical seal leaks.

Performance Test byDave KlingeleMitchell Lewis & StayerMarch 25, 2005

Witnessed byBob SensemanOswego Lake Golf & Country Club

(N March 25, 2005

Witnessed bySteve ThomasOswego Lake Golf & Country ClubMarch 25, 2005

SECTION 2

Priming Pump from TankWhen priming the pump from the tank be sure all discharge lines areclosed. Remove petcock and gauge, open I / 4 turn top vent valve belowthe 6” wafer check valve, and make sure the garden hose bib is closed also.Use extra caution here/i/f Crack the 1 / 4 turn ball valve just above thegarden hose bib till you hear it and don’t turn full open [if you do you willblow the suction line off]. Put your ear down next to the gauge openingand listen for water flows and air escaping from the suction line. In about10 to 15 minutes time you should get water from the gauge, reinstallpetcock and gauge, then water will come from the top vent valve, shut offthe 1 /4 turn ball valve and then top vent valve this is the proper order*.Start pump and follow the same procedures above slowly open thedischarge valve above the wafer check valve. *Never leave the fill linevalve open at any time without leaving the vent line open

0

C

PRHING FROM TANK

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Priming Pump with outside sourceSee attached diagram

When priming pump from outside source such as garden hose make sureall discharge lines are closed. Remove gauge and petcock, open I / 4 turntop vent ball valve below the 6” wafer check valve, hook up the gardenhose to hose bib, make sure upper most I / 4” turn ball valve [on 3 / 4”from main discharge] is closed, turn water on then turn water facet valveopen to fill line. Wait for water to come thru the gauge line [1 52Ominutesi, replace petcock and gauge, wait for water to come thru the topvent line, shut off water, then the vent line and start pump, slowly open thedischarge valve above the wafer check valve until fully open. Note if pumpcavitates close valve until cavitation stops and slowly open again until fullyopen, may take 10 to 15 minutes.

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9LiYLL±.LJ fK\/ii//7/ Thii/’/L—,tl, I LAKIE OSVVEGO COUNTRY CLUB

Drawn by: MW Rev #: JOhk by: I IJ ‘.ZuJ II PAGE 2 ol 2

Check&Iby:B1 ñEEE i J IRRIGA 770N PUI1P REPLACErAERIT

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IOEL:SC43[1O I SIZE: 411 x 311 IMPELLER OJA, VARIOUS I SPEED: 3570 IPM1

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(1 80 160 240 320 400 480 560 640 720 800 800FL[JWRATE EJ.S,GALL[]NS PER MINUTE

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FL1WRATE ClifliC METERS PER HOUR

I MODEL: S[43[10

PIONEER PUMP , INC STANDARD CENTRIFUGAL SERIES

U

C.

Pioneer Standard Centrifugal Series

Operation & Maintenance Manual(Open Bracket Style)

Manual #3001

Pioneer Pump, Inc.

Corporate Office

461 N.E. 3rd AvenueCanby, OR 97013

Phone (503) 266-4115Fax (503) 266-4116

Operation and Maintenance ManualTable of Contents

Introduction / Warnings Page 1 (Inspection Page 2

RecordsWarranty

Instaliation Page 3

Foundation I Baseplate / SkidLevelingGroutInstalling Pump

Installation Page 4

Suction PipingDischarge PipingSuction and Discharge FlangesScreeningSump DesignLifting

Installation Page 5

AlignmentRotationPriming

Operation Page 6

Pre-Start ChecklistStartingWarningCaution

Operation Page 7

Operation of a Pioneer PumpCautionWarning

Maintenance Page 8

WarningWarningWarningWarningCaution

Maintenance Page 9

WarningDisassembly

Maintenance Page 10

Suction Cover and Wear RingOne Piece Volute and Wear ring

C

Maintenance.Page 11

Impeller RemovalSeal RemovalBackplate RemovalBearing Housing

Maintenance Page 12

CautionWarningBearing Housing ReassemblyCautionCaution

Maintenance Page 13

CautionBrackplate to bearing housing reassembly

Maintenance Page 14

Seal reassemblyImpeller Reassembly

Maintenance Page 15

Volute reassemblyLubrication — Bearing frame

Maintenance Page 16

Lubrication — Seal oil reservoir

Maintenance Page 17

Torque specificationsSpare Parts

Maintenance Page 18

Spare partsTroubleshooting Page 19

Storage Page 20

Conditions and Terms of Sale Page 21

Figure A2048A, Instructions Suction cover & wear-ring

Figure A2049A, Instructions Volute & wear-ring removal

Figure A2050A, Instructions Impeller removal

Figure A2051A, Instructions Mechanical seal removal

Figure A2052A, Instructions Brackplate removal

Figure A2053A, Instructions Brackplate disassembly

Figure A2054A, Instructions Bearing frame disassembly

Figure A2055A, Instructions Drive-end bearing assembly

Figure A2056A, Instructions General parts identification

Model specific parts pageBarrier Fluid information and MSDS (For Hot oil and other specialty pumps)

INTRODUCTION

Thank you for purchasing a Pioneer Bare Shaft Frame Mounted Centrifugal Pump. It is to be

used with Non-Volatile, Non-Flammable Liquids with specified entrained solids, except as

approved by the factory.

WARNING!!!This manual provides installation, operation and maintenance instructions for your Pioneer

Pump and is intended to make your personnel aware of any procedure that requires special

attention because of potential hazards to personnel or equipment. Read all instructions

carefully and remember, pump installations are seldom identical. Therefore, this manual

cannot possibly provide detailed instructions and precautions for each specific application.

Thus, it is the owner/installer’s responsibility to ensure that applications not addressed in this

manual are performed after establishing that neither operator safety nor pump integrity are

compromised by the installation.

WARNING!!!Centrifugal Pumps are designed for specific service and may or may not be suited for any other

service without loss of performance or potential damage to equipment/personnel. If there is

ever any doubt about suitability for a specific purpose; contact your Pioneer Pump, Inc.

representative or the flictory for assistance.

Remember: Pump performance may be affected by changes in pumpage such as, specific

gravity, viscosity, temperature, operating speed and NPSHA (net positive suction head

available).

1

C

INSPECTION

INSPECTION

All equipment is inspected at the factory prior to shipment. However, you should inspect all

equipment upon arrival for shipping damage and item shortages from the packing slip. Report

any damage or shortages to the carrier and Pioneer Pump, Inc.

RECORDING MODEL & SERIAL NUMBERS

Please record the model and serial number for your Pioneer Pump in the spaces provided

below. The factory will need this information when you require parts or service.

Pump Model:

___________________________________________

Pump Serial Number:

____________________________________

Engine/Motor Serial #:

__________________________________

Engine/Motor Model Mgf:

__________________________

WARRANTY INFORMATION

LIMITED WARRANTY: Seller warrants for two years from the date of shipment Seller’s manufactured

products to the extent that Seller will replace those having defects in materials or workmanship when used for the

purpose and in the manner which Seller recommends. If Seller’s examination shall disclose to its satisfaction that

the products are defective, and an adjustment is required, the amount of such adjustment shall not exceed the net

sales price of the defective products and no allowance will be made for labor or expense of repairing or replacing

defective products or workmanship or damage resulting from the same. Seller warrants the products which it sells

of other manufacturers to the extent of the warranties of their respective makers. Where engineering design or

fabrication work is supplied, buyer’s acceptance of Seller’s design or of delivery of work shall relieve Seller of all

further obligation, other than as expressed in Seller’s product warranty. THIS IS SELLER’S SOLE

WARRANTY. NO OTHER WARRANTIES, WRITTEN OR ORAL, EXPRESS OR IMPLIED,

INCLUDiNG THE WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND

MERCHANTABILITY, ARE MADE OR AUTHORIZED. NO AFFIRMATION OF FACT, PROMISE,

DESCRIPTION OF PRODUCT OF USE OR SAMPLE OR MODEL SHALL CREATE ANY

WARRANTY FROM MANUFACTURER, UNLESS SIGNED BY THE PRESIDENT OF TIlE

MANUFACTURER. Seller neither assumes, nor authorizes any person to assume for it, any other obligation in

connection with the sale of its engineering designs or products. This warranty shall not apply to any products or

parts of products which (a) have been repaired or altered outside of Seller’s factory, in any manner; or (b) have

been subjected to misuse, negligence or accidents; or (c) have been used in a manner contrary to Seller’s

instruction or recommendations. Seller shall not be responsible for design errors due to inaccurate or incomplete

information supplied by Buyer or its representative.

2

INSTALLATION

FOUNDATION/BASE PLATE/SKID

If using a concrete foundation it should be rigid enough to inhibit vibration. Pour the

foundation well in advance of installation of pump equipment to allow time for drying and

curing.

If the pump is to be mounted on a steel frame, or similar structure, it should be set directly over

the supporting beams. These beams and the structure must be rigid enough to prevent

distortion and potential misalignment due to movement within the structure or base.

The location of this structure should be as close as possible to the pumpage source. Provide

adequate space for operation, maintenance and inspection of the pump and equipment.

The concrete foundation should be provided with anchor bolts for attachment to the base plate.

If required, provide adequate drainage to keep pump and motor dry and clean. Also, provide

either leveling nuts or leveling wedges for mounting the base plate to the foundation.

LEVELING

When mounting the base plate to the foundation use the leveling nuts or wedges to provide a

level, flat base plate. Use a machinist’s level on the mounting pads and make adjustments as

necessary as the anchor bolts are tightened. This will provide the true alignment between the

pump and motor.

GROUT

If this base plate is to be grouted insure that you have the mounting surface flat and level for

correct alignment of pump and motor. Build a dam around the base plate perimeter that is to be

watertight. Use standard grouting practice and be sure to protect (cover) the leveling wedges

with caulk or plastic tape if they are to be removed later. After the grout has thoroughly

hardened, remove forms. If the wedges are removed, fill holes with grout. Seal grout by

covering with a quality paint or sealer.

INSTALLING PUMP

Insure that all foreign material has been removed from the pump before mounting. Be sure to

remove all shipping protection prior to operation.

NOTE: Many of the bare pumps are shipped with protective guards and coatings.

3

INSTALLATION

C’: SUCTION PIPING

For best performance the suction piping should be at least as large as the pump flange, never

smaller. Use an eccentric reducer at the suction flange with the straight side up. The use of

flow-retarding fittings is to be avoided and if necessary should never be placed closer to the

pump suction than four (4) times the pipe diameter. The pump should be at the highest point of

the piping. Slope the piping up to the pump to prevent air pockets and avoid changing pipe

size with the exception of the eccentric reducer mentioned above. All suction piping and

fittings are to be checked for any foreign material (rocks, bolts, wire, etc.) and also any sharp

burrs that could disrupt the flow.

DISCHARGE PIPING

Use a concentric taper on the discharge side to increase discharge pipe diameters. All valving

and additional fittings should be the same size as the discharge main-line. The discharge size

should be adequate to maintain reasonable velocities and reduce friction losses.

SUCTION & DISCHARGE PIPE FLANGES

All piping is to be supported, braced and lined up square before connection to the pump

flanges. A flexible fitting is recommended on both suction and discharge, to eliminate any

piping strains being transmitted to the pump.

NOTE: Flexible pipe couplings must be restrained so as not to transmit any strain to the pump

flanges when expanding or contracting under pressure. Unrestrained expansion fittings can

transmit enonnous forces to the pump flanges.

SCREENING

Make provisions for the installation of a suction screen or strainer to prevent any debris from

clogging the impeller. The open area of the strainer should be equal to at least four (4) times

the area of the pipe. The screen should be rigid enough to prevent collapse when flow is

reduced due to clogging.

SUMP DESIGN

The submergence of the suction pipe into the liquid should be at least four (4) to five (5) times

the pipe diameter. If this is not possible then provide a baffle or a floating board. This is to

prevent any vortex action allowing air into the pipe. For best performance a bell mouth fitting

is recommended. Refer to the Hydraulic Institute Handbooks or other Hydraulic Data books

for detailed sump design information.

LIFTINGAny lifting equipment is to be rated for at least five (5) times the weight of the item being

lifted. Use oniy established methods when lifting or moving any heavy components.

4

INSTALLATION

ALIGNMENT OF PUMP AND MOTOR

Precise alignment is mandatory to achieve correct performance of the system. Every time a

component is moved this alignment will have to be checked. The alignment can be checked

with a straight edge and an outside caliper, taper thickness gauge, dial indicators or, for best

results, use a laser alignment tool. Use the straight edge across the outside diameters of the

coupling to ensure that the two halves are concentric and parallel. The outside calipers or the

taper thickness gauge is to correct for any angular misalignment and to verify the correct gap

between the coupling flanges. Use a laser alignment tool or dial indicators to adjust for

concentric and angular displacement. With dial indicators, rotate shafts together and take

readings every ninety (90) degrees. Make adjustments by placing shims under the driver, and

be sure that the mounting bolts are properly tightened while taking readings and after final

a4justment then install coupling guard.

ROTATION

Before the pump is started correct rotation must be confirmed. If the rotation is not correct

then interchange any two of the leads on a three (3) phase driver. For a single-phase driver

refer to the wiring diagram.

PRIMING

With a flooded suction use a bleed valve at the top of the volute to allow trapped air to escape.

If you are using a foot valve, then fill the suction line and pump case with water and use a bleed

valve for trapped gas as above. Rotating the pump shaft will release trapped gas in the

impeller.

5

C.

OPERATIONPRE-START

(N. 1) Verify that rotation is correct and that the shaft rotates freely.

2) Check all piping connections for tightness.

3) Inspect all accessories and make sure they are appropriate for your installation.

4) Verify that the driver and coupling are aligned correctly and that all guards are in place.

5) Ensure that all bearings and grease seals are lubricated.

6) If vacuum assisted, check the vacuum pump oil level as well as the oil level in the

backplatelbracket reservoir.

7) Oil levels should also be checked and maintained during pump operation.

8) Follow the instruction on all tags, labels and decals attached to the equipment.

STARTING

WARNING!!!This pump is designed to handle most non-volatile, non-flammable liquids containing specified

entrained solids and corrosives. Do not attempt to pump volatile, corrosive, or flammable

liquids which may damage the pump or endanger personnel as a result of pump failure.

C CAUTION!!!Pump speed and operating condition points must be within the continuous performance range

shown on the Performance Curve in the separate Part List Manual for your specific pump

model.

Any centrifugal pump must be primed before starting unless it is of a self-priming design. See

preceding section on priming and ensure suction pipe is filled with liquid.

With discharge valve closed, start the pump and slowly open valve. Throttle the flow gradually

to fully open. Avoid any abrupt changes in the discharge flow rate to prevent pressure surges

in the piping. If the design pressure is not achieved shut the pump down immediately. Ensure

that pump is adequately primed and restart.

Never run the pump with the discharge valve closed for extended periods of time. Never use

the suction valve to throttle the flow. Check all suction and discharge piping for leaks.

If a suction strainer is installed, check the pressure drop across the strainer. If the differential

in pressure exceeds five (5) PSI have the strainer cleaned.

6

OPERATION

OPERATION OF A PIONEER PUMP

Before Starting

Check oil and grease levels in the pump bearing housing and seal chamber (backplate/bracket

reservoir)

CAUTION!!!Make sure the pump is level.

WARNING!!!Do not operate the pump without guards in place over the rotating parts. Exposed rotating

parts can catch clothing, fingers or tools, causing severe injury to personnel.

C

MAINTENANCE

WARNING!!!Before attempting to service this pump, read this manual carefully. Operators and maintenance

personnel should have a good understanding of all aspects of this pump and the pumping

conditions. Failure of operating personnel to be familiar with all aspects of pump operation

outlined in this manual could contribute to equipment damage, bodily injury or possible death

WARNING!!!Before any servicing:1) Read this manual careftilly.

2) Shut down driver and lock out incoming power to ensure that the pump will remain

inoperative.3) If the pump or components are hot, allow adequate cooling prior to servicing the unit.

4) Close the suction and discharge valves.

5) Vent the pump slowly and drain completely.

WARNING!!!If this pump is used to handle any hazardous materials that can cause illness, either directly or

indirectly, take precautions by wearing approved protective clothing and use appropriate safety

equipment. Also, review section on Vacuum Pump venting.

WARNING!!!Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries

(N to personnel or damage to equipment. Attach lifting equipment to the lifting device fitted to the

pump. If chains or cable are wrapped around the pump to lift it, make certain that they are

positioned so as not to damage the pump, and so that the load will be balanced. The bail on

trailer or skid mounted units is intended for use in lifting the pump assembly only. Suction and

discharge hoses and piping must be removed from the pump before lifting.

CAUTION!!!When servicing this pump, use only components provided by Pioneer Pump, Inc. Any use of

non-authorized parts could result in sub standard performance, damage to equipment and

possible injury to personnel. Non-authorized parts will also void the warranty.

When using this manual any reference to part numbers or names will be directed to the

applicable cross section drawing. These parts will also be called out in the bill of materials for

full description.

Drain volute case of pumpage when pumping unit is idle to avoid freezing and possible thermal

cracking of pump case, etc.

8

MAINTENANCE

This manual also provides a troubleshooting section to diagnose many operational or

performance problems. The equipment covered in this section is limited to the pump only.

Refer to the applicable vendor’s manual for motors, engines and other accessory equipment.

Use the troubleshooting section to help determine the cause of any problems, and only

disassemble the pump components required to remedy the existing condition.

This manual provides installation, operation and maintenance instructions for your Pioneer

Pump. The manual will also make your personnel aware of any procedure that requires special

attention because of potential hazards to personnel or equipment. Read all instructions

carefully and remember this manual cannot anticipate or warn of every situation that could

occur. Because of this the owner is responsible that only safe procedures be used, if not

addressed in this manual. If any question regarding the pump is not covered adequately please

contact Pioneer Pump, Inc.

WARNING!!!Select a clean suitable location for any required maintenance and note that all work must be

performed by qualified personnel.

An ongoing record of performance will assist in any troubleshooting and/or analysis of

problems. A pressure gauge can be installed on the suction and discharge side of the pump to

monitor any changes in differential pressure. Differential pressure is useful in monitoring and

diagnosing any possible degradation in pump performance.

DISASSEMBLY

VerifS’ the following:1) Driver is shut down and power is locked out.

2) If pump components are hot, allow to adequately cool.

3) Suction and discharge valves are shut.4) Pump is drained.

Review all safety information and follow the instructions in this manual, as well as, all tags,

labels and decals attached to the pump or related equipment.

Under normal conditions this pump is designed to run maintenance free, because of its rugged

construction, for extended periods of time. However, all centrifugal pumps contain wear parts

that will gradually deteriorate, which will affect pump performance. This pump does contain

wear parts and these parts should be replaced as required to maintain optimum performance.

General maintenance can be performed without removing the pump from the driver. The

instructions below assume a complete disassembly of the pump is required.

C:

MAINTENANCE

(Parts names in bold type refer to Figures A2048A through A2056A and specific pages noted)

SUCTiON COVER AND WEAR RING

___

Figure A2048A

If the pump is equipped with an external balance line it must be removed prior to removing

the suction cover. Disconnect the balance line from either the suction cover, suction spool or

the backplate.

Support the suction cover using a suitable sling. Remove the capscrews between the suction

cover and vohite. Jackscrew holes are provided in the suction cover to aid removal from the

volute. Insert two of the capscrews attaching the Suction cover to the volute into the jackscrew

holes, and tighten them evenly to jack the suction cover free of the volute. If the suction wear

ring shows grooves or uneven wear it should be replaced. Minor irregularities can be dressed

with a fme file and crocus cloth. Wear rings may be reworked by light machining, if proper

equipment is available to correct minor irregularities. After the removal of any stock, the ring

must remain within allowable clearances for maximum performance. (Consult factory for

clearances for specific models).

When the pump performance drops below acceptable limits the suction wear-ring and hub

wear ring (if so equipped) should be replaced. These rings can be removed by drilling two

holes of the adequate size, axially, through the ring 180° apart. The ring can now be collapsed

and removed.

Tap new ring into place evenly around circumference with chamfer toward suction flange.

Anti-seize lubrication should be applied to the “OD” of the ring prior to installation in suction

cover. Make sure wear ring is installed tight against shoulder.

ONE PWCE VOLUTE AND WEAR RG

Figure A2049A

Support the volute using a suitable sling and remove the capscrews between the volute and

backplate. There are jackscrew holes in the backplate flange to aid in removal of the volute.

Insert two of the volute capscrews in the jackscrew holes, and tighten them evenly to push the

volute free of the backplate. If the suction wear ring shows grooves or uneven wear it should

be replaced. Minor irregularities can be dressed with a fme file and crocus cloth. Wear rings

maybe reworked by light machining, if proper equipment is available to correct minor

irregularities. After the removal of any stock, the ring must remain within allowable clearances

for maximum performance. When the pump performance drops below acceptable limits the

volute wear ring should be replaced. This ring can be removed by drilling two holes, of the

proper size, axially, through the ring 180° apart. The ring can now be collapsed and removed.

Tap new ring into place evenly around circumference with chamfer toward suction flange.

Anti-seize lubrication should be applied to the outside diameter of the ring prior to installation

in volute, make sure wear ring is installed tight against shoulder.

NOTE: If this pump is equipped with Pioneer’s run-dry feature for mechanical seal protection,

then, prior to any further disassembly of this pump, the external oil reservoir and auxiliary

gland should be drained. First drain the reservoir via the plug in the bottom. Then disconnect

the oil line from the reservoir, and lower this disconnected end into a suitable container.

10

IMPELLER REMOVALFigure A2OSOA

Remove the impeller lockscrew and washer at the center of the impeller. Utilizing a properly

sized gear puller, evenly pry between the back shroud of the impeller and the backplate. Take

care not to lose or damage any impeller shims that may be inside the impeller bore, and do not

lose the impeller key. As the impeller is being removed from the shaft ensure that the seal

spring, if present, is not lost or damaged. Inspect the impeller and replace or repair if

warranted.

SEAL REMOVAL (Rotating Element)

Figure A2051A

Once the impeller is removed, the rotating assembly of the seal (bellows, spring and retainer)

can slide off of the shaft as a unit. Apply a light coat of oil to the shaft to help free the rotating

assembly. Take care to protect this assembly from any foreign matter or damage. For hot oil

pumps: Note the position of the tail of the seal on the shaft so that seal can be reinstalled to

the exact same location on the shaft. Loosen the set screws securing the metal bellows seal to

the shaft and pull the seal off the shaft by grasping the seal at the “face end” and compressing

the bellows. Do not pull the seal off from the set screw end as this may stretch and

permanently deform the bellows.

BRACKPLATE REMOVALFigure A2052A / Figure A2053A

The “brackplate” can now be removed by removing the capscrews between the brackplate

and the bearing housing. A sling or other support should be attached to the brackplate prior to

its removal. Slide the brackplate straight off of the shaft to prevent any damage to the (stationary seal seat or the surface of the shaft. Care should also be taken to avoid damaging

the brackplate lipseal(s) or the run-dry gland lipseal. The stationary seal seat can now be

pressed out of the brackplate bore, taking care not to break the seat. The entire seal assembly

can now be inspected for any damage that will require replacement or reconditioning.

BEARING HOUSINGFigure A2054A

If the frame bearings require servicing it will be necessary to remove the bearing housing

from the driver and the pump end from the bearing housing. Remove the coupling guard as

necessary. With the bearing housing supported with a hoist and sling remove bolts holding the

housing to the baseplate. Now the bearing housing can be moved away from the driver for

further servicing.

On the drive-end of the bearing housing remove the capscrews holding the bearing housing

cover or the SAE bracket to the housing. Gently slide the housing cover or the SAE bracket

off of the shaft to protect the lip seal(s) if it is to be reused.

11

Now the shaft assembly, including the shaft, bearings and the bearing locknut and washer

can be removed through the drive-end of the bearing housing. This operation may require

placing a block of wood against the impeller-end of the shaft and tapping with a “dead blow”

( hammer or using a mechanical or hydraulic press against the impeller end of the shaft. If the

bearings are to be re-used, the shaft should be pressed out rather than tapped out with a

hammer. With the shaft and bearing assembly out of the housing the bearings can be inspected

and replaced as necessary.

CAUTION!!!Any work on the shaft and bearing assembly should be done in a properly equipped shop by

experienced personnel. We recommend that the bearings be replaced any time they are

removed from the bearing housing. Clean the bearing housing and the shaft and other

components except the bearings, with cleaning solvent and a string I lint free cloth. Inspect all

parts and blow components dry with compressed air. If the bearings are to be replaced, the old

bearings can be removed using a suitable gear puller. It is recommended that brackplate and

bearing cap lip seals also be replaced at this time. These lip seals can be driven out of their

bores with a drift, punch or screw driver. Before removing the lip seals note the orientation of

the lips, and be certain to install the new seals with the same orientation. When driving or

pressing in the lip seals use a flat block or plate which applies pressure around the entire

circumference of the seal — do not drive the seal in with a drift or punch.

WARNING!!!When using cleaning solvent be sure to have adequate ventilation, as most solvents are toxic

and flammable. Follow all precautions pertaining to the solvent and keep area free from

excessive heat, sparks and flame.

Rotate the bearings by hand and check for any roughness or wear. If any roughness, wear or

discolored areas are present, replace the bearings. Also, check the fit between the bearings and

shaft for a tight press fit and between the bearings and the housing for a snug slip fit. If the fits

are not correct then replace the bearings, shaft or the bearing housing as indicated by wear. If

bearings are to be replaced use a bearing puller to remove then from the shaft.

BEARING HOUSING REASSEMBLY

Figure A2054A I A2055AAfter all components have been inspected, repaired, and or replaced ensure all parts are clean

and ready for assembly as indicated above. Use extreme caution, during assembly, to protect

all parts from dirt and damage. The bearings should be installed using the bearing

manufacturer’s recommended installation procedure.

CAUTION!!!If heat is used to install the bearing use an induction heater, electric oven or hot plate. Do not

use a direct flame. Heat the bearings to a uniform temperature of 220E F (1 O5EC) maximum,

and slide each bearing onto the shaft until firmly seated against the shaft shoulder. Once the

bearing is removed from the beat it must be placed over the shaft and seated against the

shoulder very quickly or it will seize to the shaft in the wrong position. After the bearings have

cooled; ensure that they are still seated against the shaft shoulder. If they are not seated use a

sleeve, of the correct size, and a press to seat bearing. This sleeve and press can be used if

heating the12

bearing is not practical, but only press against the inner race of the bearing.

CAUTION!!!With the Drive-End bearing firmly seated against the shaft shoulder install the bearing

lockwasher and the bearing locknut. Refer to figure A2055A for the correct orientation.

Ensure the washer tab on the inside diameter is engaged in the slot in the shaft and the tab

pointed toward the bearing. After the bearing nut has been tightened, bend one of the tabs on

the outside diameter of the washer to engage one of the slots in the nut.

Some pumps are equipped with double angular contact bearings at the drive end. It is

imperative that these bearings be installed in the correct orientation relative to one another.

When installing the first of the two angular contact bearings onto the shaft make certain that the

side of the inner race with the largest diameter is located against the shaft shoulder. The next

bearing must be installed with smaller diameter side of the inner race against the first bearing.

Refer to ifiustration A2056A.

Check that the bearing housing is clean and that the bearing bores are free of any burrs or

nicks. Ensure that the bearing housing spacer (not used with double drive-end bearings) is

installed in the drive-end bore of the housing. Wait for bearing to cool, then, from the drive-

end of the bearing housing, slide the shaft/bearing assembly into the drive-end of the housing.

Press the drive end of the shaft until the drive-end bearing contacts the housing or bearing

spacer shoulder. Apply a light coat of oil or grease to the bearing cap lipseal(s) that is

installed in the or SAE bracket lip seal(s). Slide the bearing cap or SAE bracket over the drive

end of the shaft taking care to protect the lip seal. Secure the bearing cap to the bearing

housing using the capserews. For oil lubricated bearing frames make sure that the bearing cap

0-ring 1S installed on the bearing cap register. Moving the shaft in both axial directions should

produce a total endplay between 0.002”and 0.010”. Use bearing shims to limit endplay to this

range.

BRACKPLATE TO BEARING HOUSING REASSEMBLY

Apply a coat of oil or grease to the brackplate lip seal(s) and to the run-dry gland lip seal (if

present). Slide the brackplate over the pump-end of the shaft, protecting the lip seals. Check

that the brackplate drain port is located in the bottom position. Secure the brackplate to the

bearing housing using capscrews provided.

Ifpump is grease lubricated both bearings should be initially packed with grease before

reinstalling the bearing cap and brackplate. For oil lubricated bearing housings note that there

is a grease fitting on the face of the brackplate. This fitting is there to allow grease to be

injected between the two brackplate lipseals so as to provide lubrication for the outermost of

the two lip-seals. A hand operated grease gun should be used, after reassembly of the

brackplate to the bearing housing, to inject two or three “pumps” of grease between these seals.

For Hot Oil pumps this should be a high temperature grease.

‘3

SEAL REASSEMBLYFigure A2051A

Always handle all seal parts with extreme care to prevent damage. Be especially cautious not

to contaminate the precision finished mating faces as even fingerprints can shorten seal life. If

required, clean the faces with a non-oil based solvent and a clean, lint-free cloth. Use a

concentric pattern while wiping to prevent scratching the faces.

Carefully inspect all seal parts for any damage or wear. Any scoring or grooves in the mating

faces could cause the seal to leak, so it should be refurbished and mating faces relapped or

replaced with a new complete seal assembly.

Clean the shaft and remove any nicks, cuts or burrs. Lubricate the outside diameter of the seat

0-ring with 30 wt. to 80 wt. motor oil or hydraulic hose assembly lube and apply a drop of light

lubricating oil to the seal faces.

Slide the stationary seat over the shaft and carefully press into the bore of the brackplate.

Ensure that it is squarely seated into the brackplate. Lubricate the shaft surface and the inside

diameter of the rubber bellows. Now slide the rotating element over the shaft up to the

stationary seat. With the polished face (primary ring) of the rotating element toward the

polished face of the seat. Slide the spring over the outside of the seal assembly up to the

retainer flange.

For Rot Oil pumps refer to figure A2019A. Measure from the installed stationary seat face a

distance of 1.562”, and mark the shaft. Lubricate the rotating element o-ring, and install the

metal bellows seal onto the shaft, and compress the bellows until the back-end of the seal

assembly is even with the mark made at 1.562”. Tighten the seal set screws.

IMPELLER REASSEMBLYFigure A2050A

Inspect the impeller for any cracks or badly worn areas. Replace if necessary. Install the

impeller key and slide impeller over the shaft. Ensure that the seal spring is in place over the

outside diameter of the impeller hub (this does not apply for hot oil pumps with metal bellows

seals). Install the impeller washer and impeller lockscrew (use #262 red loctiteTM on threads

of the impeller lockscrew when reinstalling in the shaft) and tighten (See torque specs, page

17).

For impellers that are equipped with “backvanes” rather than a hub wear-ring, use the

following procedure:

With the impeller firmly against the shaft end, measure the gap between the back vanes of the

impeller and the face of the brackplate. Remove the impeller and place impeller shims

(0.005, 0.010 and 0.0 15 thick) in the bore of the impeller until the gap is the same as it was

when originally removed. Each time the impeller is installed on the shaft make sure the seal

spring is in place over the outside diameter of the impeller hub (not applicable for hot oil

pumps). Once the desired gap between the back vanes and backplate is attained, install the

impeller washer and impeller lockscrew (use #262 red loctiteTM on threads of the impeller

lockscrew when reinstalling on the shaft) and tighten (See torque specs, page 17).

C 14

VOLUTE REASSEMBLY

Figure A2049A

For a one-piece volute and suction cover, inspect the suction wear-ring and review the wear

ring section in this manual if replacement is required. Slide a new 0-ring over the register of

the brackplate. Make sure the o-ring is up against the face of the brackplate flange. Lubricate

the 0-ring with grease. Position the volute, with the discharge nozzle in the same orientation as

the piping, and secure with capscrews.

For separate volute and suction cover, check on the wear ring section in this manual for

replacement, if required. Place a new 0-ring over the register of the suction cover, lubricate

with grease and seat it against the cover face. Secure to volute with appropriate capscrews.

LUBRICATION - BEARING FRAME

The lubrication of the ball bearings will depend on speed, load, ambient temperature,

contamination, moisture, intermittent or continuous service and other factors. These regreasing

recommendations are general in nature and are to be used with good judgment and

consideration of the pump service. The following is a suggested lubrication interval chart:

Pioneer Frame Size 2200 RPM 1800 RPM 1200 RPM

8.5 AK Frame 5,000 hrs. 7,500 hrs. 10,000 hrs.

12.5 AK Frame 2,500 3,500 5,000

To lubricate the ball bearings, remove the plastic covers from the zerk fittings. Ensure that the

zerk fitting and the end of the grease gun are clean. Use only a hand-operated grease gun with

ball bearing grease as shown below, or equal:Texaco Starplex Moly 2Mobile MobiLux No. EP2Shell Alvania EP2

Chevron SRI

For Hot Oil pumps the bearing frame will be oil lubricated. An oil level gauge is attached to

the bearing frame and marked at the factory for proper oil level. ISO viscosity grade 32 turbine

oil is installed at the factory. This oil is suitable for a wide range of temperatures. However,

during operation temperature measurements should be taken on the bearing frame at the oil

sump location. If the indicated temperature is greater than 160°F then the oil should be

changed to an ISO viscosity grade 68 turbine oil at the next maintenance interval. Oil should

be changed approximately every three months of continuous operation.

15

(\‘

MAINTENANCE

LUBRICATION - SEAL OIL RESERVOIR See Drawing #s A2049A I A2056A

This pump is provided with a seal oil reservoir that permits this unit to run dry. The reservoir

supplies lubrication and cooling to the outboard side of the mechanical seal without any liquid

in the pump. For filling the run-dry reservoir (see Drawing # A4135A), open 1/4 NPT bleed valve.

Open filler cap I gauge on run-dry reservoir and add oil until oil comes out of the 1/4’ NPT

bleed valve. Close bleed valve and finish filling run-dry reservoir. (It is necessary to open the 1/4”

bleed valve initially to assure that any air bleeds off.) Monitor the oil level sight gauge and add oilas indicated. During normal operation it is suggested to change this oil every three (3) months. Ifthe sight gauge shows indication of contamination or discoloration change oil more frequently.Use turbine oil with an ISO rating of 32 or lower. If you have unusual pumping conditions consultPioneer Pump, Inc. Drain oil from the reservoir by removing the 1/2” NPT pipe plug connected tothe 1/2” tee below the reservoir. Most of the remaining oil in the seal gland can be drained by openingthe 1/4’ bleed valve next to the seal gland. The capacity of this reservoir is approximately 1 quart.

Oil used in the reservoir should be ISO VG 32 Turbine Oil or Automatic transmission oil,equivalent to one of the following manufacturer’s products: (for hot cooking oil applicationssee paragraph below)

Chevron Turbine oil GST 32Mobile DTE 797Shell Turbo T oil 32

For Hot Cooking Oil pumps the seal oil reservoir must be filled with with a USDA H-I. non

toxic fluid capable of operating at pumping temperature without boiling off or burning.

Pioneer Pump, Inc has approved Oils noted below for cooking oil applications Substitutions

can be used if they comply to USDA H-I non-toxic fluids as stated above. Substitutions are at the

discretion of the end-user, and it is the end-users responsibility to determine compatibility with the

application as it pertains to Federal and State regulations. If there are questions regarding a

different type of oil being used, consult Pioneer Pump, Inc. for assistance. The fluid in the

seal oil reservoir extends mechanical seal life by keeping atmosphere away from the seal faces and

thus greatly reducing carbon build-up at the faces and inside diameter of the seal bellows. The seal

oil reservoir also provides greatly improved seal lubrication during caustic boil out of the pump and

fryer system. It is strongly recommended, for the above mentioned reasons, that the seal oilreservoir be kept filled.

Paratherm NF 76 Lubricants 76 Food Machinery Oil Grade 68www.paratherm.com www. 761 ubricants .com800-222-361 1 800-435-7761

Royal Purple Barrier Fluid - FDA & Polyguard FDA Dow Chemical Ucon Lubricantswww.royalpurple.com/prodsi/bffda/htrnl www.dow.com/polyglycols/carbowax/app/food.htm988-382-6300 800-447-4369

Cameo FMO PAG 53-100 Summit Industrial Products, Inc. Barrier Fluid E & 5

www.camcolubricants.com www.klsumrnit.com651-489-8828 800-749-5823

Shell Cassida Fluid RT 32 16

www.shelllubricants.com800-782-7852

TORQUE VALUESMAINTENANCE

The above values are general in nature. If a grade 2 or 5 capscrew is threaded into stainless

steel, use the lower value i.e. 304 stainless.MAINTENANCE

PARTS ORDER

When ordering parts from Pioneer Pump, Inc. please provide the following infonnation:

1) Pump serial number2) Pump model3) Cross section drawing number4) Part number from cross section drawing5) Description of part6) Quantity required7) Package VIN (Vehicle Identification Number)

17

C

SIZE MATERIALTJNC

GRADE 5 GRADE 8

304 SS BOLTS BOLTS

% 3.0 lb-ft 9 lb-ft 13 lb-ft

5/16 7.0 lb-ft 19 lb-ft 27 lb-ft

3/8 13 lb-ft 34 lb-ft 48 lb-ft

7/16 20 lb-ft 54 lb-ft 77 lb-ft

1/2 31 lb-ft 83 lb-ft 117 lb-ft

9/16 45 lb-ft 120 lb-ft 170 lb-ft

5/8 63 lb-ft 165 lb-ft 234 lb-ft

3/4 112 lb-ft 293 lb-ft 415 lb-ft

7/8 180 lb-ft 474 lb-ft 670 lb-ft

1 270 lb-ft 710 lb-ft 1000 lb-ft

1 1/4 540 lb-ft 1421 lb-ft 2000 lb-ft

C

SPARE PARTS

S pare parts should be kept on hand to reduce downtime. Service of a particular pump

determines the quantity and range of spares. At a minimum the following parts should be

stocked.

Suction wear ringAll 0-ringsSet of bearingsMechanical sealSet of grease seals

If you have unusual pumping conditions, consult Pioneer Pump, Inc. for additional

recommended spare parts.

(L

18

TROUBLESHOOTING

1. Pump not primed

2. Suction line not filled

3. Air pocket in suction line

4. Suction inlet or foot valveobstructed, insufficientlysubmerged, or too small

5. System head higher than pumpdesign bead

6. System head lower than pumpdesign head

7. Insufficient NPSH

8. Parallel pump application isincorrect

9. Suction pressure to vapor pressurebelow minimum

10. Suction lift too high

11. Excess vapor in pumpage

12. Specific gravity of pumpagedifferent than design

13. Viscosity of puznpage differentthan design

14. Operation at below rated capacity

15. Cavitation

16. Electrolysis

17. Impeller obstructed withforeign material

18. Rotation direction wrong

19. Low speed

20. Air leak into Suction line

21. Air leak through mechanical seal

22. Seal fluid contaminated, hot orinsufficient

23. Seal fluid system not vented

24. High speed

25. Mechanical seal insufficient

26. Bearing housing excessivelycooled

27. Low oil pressure(oil lube bearings)

28. Improper or poor lubrication

29. Lubrication defective

30. Dirt in lubricstionlbearings

31. Moisture in lubricautibearinghousing

32. Lubricant excess

33. Pipe strain

34. Temperature growth

35. Misalignment

36. Coupling improperly installed

37. Impeller installed backwards

38. Worn wear rings

39. Impeller damage

40. Improper balance (after repair)

41. Bent shaft

42. Excessive thrust

43. Rotational element dragging

44. Worn or incorrectly installedbearings

45. Mechanical seal not properly set,0-rings damaged or hardened

46. Shsft scored at seal

47. Volute 0-ring

48. Foundation not rigid or settled

Symptom Possible Causes Symptom Possible Causes

No Discharge 1,2,3,4,5,7,8,9,10,17,18,19,20, Vibration and noise 2,4,9,10,14,15,17,26,27,28,29

37 30,31,32,33,34,35,36,39,40,

41,42,43,44,48

Reduced Capacity 2,3,4,5,7,8,9,10,11,17,19,20,21,383

9,40,47 Seal: excessive leakage, 22,23,25,33,34,35,36,41,44,

short life, seal housing 45,46

Reduces Pressure 5,7,8,1 1,13,18,19,38,39,40,47 overheating

Loss of Prime 2,3,4,7,10,1 1,20,21,22,23 Bearings: over heating, 26,27,28,29,30,31,32,33,34,

short life, noise 35,36,41,42,43,44

Power consumption 6,12,13,17,18,19,24,33,34,35,3637,

excessive, driver runs 38,41,42,43,44 Pnmp overheating, seizes 1,8,9,14,33,34,35,36,41,42,43,

hot 44

Corrosion, erosion, 7,8,11,14,15,16

pitting, oxidation or otherloss of material

U

19

STORAGE

STORAGE

(. This is adequately prepared for outside storage prior to shipment, but use the following list of

additional suggestions for extended storage.

1) Store the unit off the ground so no water will accumulate around the equipment.

2) Protect unit from blowing sand and dirt.

3) Stack no other items on top of pump/equipment.

4) Protect unit from the entry of any animals.

5) Periodically rotate shaft to lubricate bearings and protect bearings from brinelling.

6) Protect unit with approved drying agents.

7) Ensure all bare metal areas are coated with a rust preventive.

8) Inspect unit every four (4) weeks and replace drying agents (Silica Gel) as required or a

minimum of ever six (6) months.

9) Keep and inspection record showing dates of inspection with any maintenance preformed

and condition of drying agents.

( 10) Before installation ensure that all rust protection has been removed. Also, remove any• foreign material that may have accumulated during storage.

11) Before installation remove all drying agents (Silica Gel).

20

Conditions and terms of sale

CONTROLLING PROVISIONS: These terms and conditions

shall control with respect to any purchase order or sale of Seller’s

products. No waiver, alteration or modification of these terms

and conditions whether on Buyer’s purchase order or otherwise

shall be valid unless the waiver, alteration or modification is

specifically accepted in writing and signed by an authorized

representative of Seller.

DELIVERY: Seller will make every effort to complete delivery

of products as indicated on Seller’s acceptance of an order, but

Seller assumes no responsibility or liability, and will accept no

backcharge, for loss or damage due to delay or inability to deliver

caused by acts of God, war, labor difficulties, accident, delays of

carriers, by contractors or suppliers inability to obtain materials,

shortages of fuel and energy, or any other causes of any kind

whatever beyond the control of Seller. Seller may terminate any

contract of sale of its products without liability of any nature, by

written notice to Buyer, in the event that the delay in delivery or

performance resulting from any of the aforesaid causes shall

continue for a period of sixty (60) days. Under no circumstances

shall Seller be liable for any special or consequential damages or

for loss, damage, or expense (whether or not based on negligence)

directly or indirectly arising from delays or failure to give notice

of delay.

SELLER’S LIABILITY: Seller will not be liable for any loss,

damage, cost of repairs, incidental or consequential damages of

any kind, whether based upon warranty (except for the obligation

accepted by Seller under “Warranty” above), contract or

negligence arising in connection with the design, manufacture,

sale, use or repair of the products or of the engineering designs

supplied to Buyer.

RETURNS: Seller cannot accept return of any products unless

its written permission has been first obtained, in which case same

will be credited subject to the following: (a) All material returned

must, on its arrival at Seller’s plant, be found to be in first-class

condition; if not, cost of putting in saleable condition will be

deducted from credit memoranda. (b) A handling charge

deduction of twenty percent (20%) will be made for all credit

memoranda issued for material returned. (c) Transportation

charges, if not prepaid, will be deducted from credit memoranda.

CANCELLATION OR ALTERATION: Cancellation or

alteration of an order by Buyer may not be made without advance

written consent of Seller and shall be subject to a cancellation

charge. The cancellation charge will be a minimum of fifteen

percent (15%) or actual cost incurred by Seller at the time of

cancellation or alteration, whichever is greater.

SHIPMENTS: All products sent out will be carefully examined,

counted and packed. The cost of any special packing or special

handling caused by Buyer’s requirements or requests shall be

added to the amount of the order. No claim for shortages will be

allowedunless made in writing within ten (10) days of receipt of a

shipment. Claims for products damaged or lost in transit should

be made on the carrier, as Seller’s responsibility ceases, and title

passes, on delivery to the carrier.

SPECIAL PRODUCTS: Orders covering special or non

standard products are not subject to cancellation except on such

terms as Seller may speeir on application.

QUOATIONS: All quotations are subject to approval,

acceptance and correction at the home office. Any errors in

quotations resulting in orders will be corrected and re-submitted

to the customer for their acceptance or refusal. All quotations are

valid for 45 days from the date on the quotation.

PRICES AND DESIGNS: Prices and designs are subject to

change without notice. All prices are F.O.B. Point of Shipment,

unless otherwise stated.

TAXES: The amount of any sales, excise or other taxes, if any,

applicable to the products covered by this order, shall be added to

the purchase price and shall be paid by Buyer unless Buyer

provides Seller with an exemption certificate acceptable to the

taxing authorities.

TERMS OF SALE: For value received, Buyer agrees to honor

all terms of the sale, as outlined on the reverse hereof, including,

but not limited to the following:

• 3% 10, net 30 days unless otherwise specified in wnting.

+ Buyer agrees and understands that payments will beconsidered past due if payment is not received within thirty

(30) days of the invoice date.

• Buyer agrees that all past due payments shall bear interest at

the rate of 1.5% per month (18% per annum) until paid in

full.

+ Buyer agrees that it is the intention of Buyer and Seller to

conform strictly to all usury laws now in force and effect in

the state of purchase.

• Buyer further agrees not to suffer or permit any charge, lien,

security interest, adverse claim or encumbrance of any andevery nature whatsoever against the equipment until theindebtedness secured thereby is satisfied in full.

+ Minimum invoice amount will be no less than $25.00 plus

transportation.

USE OF EQUIPMENT: Buyer agrees to maintain and use the

equipment solely in the conduct of its own business, in a careful

and proper manner and in conformity with all applicable permits,

licenses, statues, ordinances, regulations and laws.

INSURANCE: Buyer shall have and maintain at all times with

respect to all equipment insuring against risk of fire, theft and

other risks as Seller may require, until the indebtedness secured

thereby is satisfied in full.

0

21

U

I A2048M

SUCTIIJN WEAR RING

IDTI I IIei mii iii I

L’.;: r[MJAL ILLIIS.— SIITILII COVER AI() VEAR RING RE1]VALIxa.m

SUCTION COVER 0-RING7

REFERENCE ORAVINGS .1 DRAJING CONTAINS PROPRIETARY DATAI NO DISCLOSURE TITHOUT IRITTEN1 AUThORIZATION PROU PIONEER PUMP, INC.

SUCTION COVER

i R1QA 1 1.4

T2eMI PIONEER PUMP. INC. - CANBY. OREGON

OIL RESERVOIR

OIL LINE—

DISCONNECT BALANCE LINE AT BRACKPLATE

DRAJINC CONTAINS PROPRIETARY DATANO DISCLOSURE TIT]IOUT IRITTENAUTIJORIZATION PROM PIONEER PUMP, INC.

I I IIEl G1I IFI,ic1

‘:a Jr.I[I4ANLJAL ILLUSTRATION — IMPELLER RE’VVAL-

K I P 611Sd01 I1 1,5

0

METAL

UPPER HALF [IF DRAWING SHOWSOIL LUBRICATED FRAME WITH METALBELLOWS SEAL (HOT OIL)

1A2050A

IMPELLER KEYIMPELLERIMPELLER SCREW

LOWER HALF [iF DRAWING SH1]WSGREASE LUBRiCATED FRAME WITHRUBBER BELLOWS SEAL (STO.)

IMPELLER WASHER

REFERENCE DRAWINGS

SEAL SPRING

I1_.

— I

ILIC.

*_ I

RUBBER BELLOWS SEAL

DRATING CONTAINS PROPRIETARY DATANO DISCLOSURE JITBOUT TRITTENAUThORIZATION FROM PIONEER PUMP, INC. I PIONEER PUMP. INC. - UANIST. (JIOIIJN r

CCC

I A2052A

HUB WEAR-RING

AIJXILLIARY GLANDAUXILLIARY GLANO LIP SEAL(FOR ‘RuN—DRY1 ONLY)

REFERENCE DRAWINGS -] DEAlING CONTAINS PROPRIETARY DATAj NO DISCLOSURE JIThOUT TRITTEN

AUTHORIZATION FROM PIONEER PUMP, INC.

I ia I II’ UU1 SFIFXB,.m.I

j

‘ ‘MANUAL ILLUSTRATION — BRACKPLATE RE1]VALIIXIR

F 1 F I’IWIR I 3/5

I PIONEER PUMP. INC. - CANBY. OREGON I A2052A

UPPER HALF [F DRAWING SHOWS BRACPLATE 0-RINGOIL LUBRICATED FRAME WITH METALBELLOWS SEAL (HOT OIL)

DUAL BRACKPLATE LIPSEALS(OIL LUBE BEARINGS ONLY)

SINGLE BRACKPLATE LIP SEAL(GREASE LUBE BEARINGS)

LOWER HALF OF DRAWING SHOWSGREASE LUBRICATED FRAME WITHRUBBER BELLOWS SEAL (STO.)

rrn,I —.

ii m.

WEAR—RING

AIJXILLIARY GLAND0-RING

AUXILLIARY RAND RING(USED W/ ‘.{)y’ (]I[y)

AUXILLIARY GLAND

1A2053A

ITII II1FIeJ I

j JMAMML ILLUSTRATIIJ - BACKPLATE.DI.;

nyn.,a.. ——-— — — -

————

P’ a’i RUt: IA..

INC. - CANBY...- w-iur4 --A2O5.

DOUBLE LIP SEALS WITHOIL LUBED BEARINGS

SINGLE LIP SEAL W/ GREASELUBEO BEARINGS

REFERENCE DRAWINGS DRATING CONTAINS PROPRIETARY DATANO DISCLOSURE UThOUT TRITTENAUTHORIZATION FROK PIONEER PUMP, INC.

•6- nI..riuri&ic PUMP.

I1aNcI I 1IRBI DflVI SEa:IFIB),je.I I ‘‘

jcJ MANUAL ILLUSTRATION - BEARING FRAME DISASSEMBLYp a r wiww I 1/5 1•

TIIONRER PUlP, INC.-CtANliY. OREGON I A2054A

BEARING CAP

BEARING CAP El—RING(OIL LUBED BEARINGS ONLY)

fl2oA

DRIVE-END BEARINGS(DOUBLE ANGULAR CONTACT )

UPPER HALF OF DRAWING SHOWSOIL LUBRICATED FRAME WITH METALBELLOWS SEAL (HOT OIL)

SHAFT

BEARING HOUSING

SINGLE, DEEP GROOVEBALL BEARING

PUMP—END BEARING

LOWER HALF OF DRAWING SHOWSGREASE LUBRICATED FRAME WITHRUBBER BELLOWS SEAL (STO.)

REFERENCE DRAWINGS I DRATING CONTAINS PROPRIETARY DATA1 NO DISCLOSURE JITUOUT JRITTEN

1 AUTHORIZATION FROI PIONEER PUMP, INC.

* .IB. .*.oin.

IT) NL

1A2055M

BEARING LOCKNUTDRIVE—END BEARING( S)

BEARING LOCKNUT

BEARING WASHER

BEARING WASHER

ENGAGE TAB ON INSIDE DIAMETER OF BEARINGWASHERIN THIS SLOT. BEND TAB ON 0,0. OF WASHER INTOSLOT ON BEARING NUT

REFERENCE DRAWINGS

*,1E.‘mii e.

DRATING CONTAINS PROPRIETARY DATANO DISCLOSURE JITHOUT IRITTENAUTHORIZATION FROM PIONEER PUMP, INC.

n

iaI I Iiiei ani I

MANUAL ILLUSTRATION - IVE- AING ASSEMBLYP’ a: I’ V1 14

PIONEER PUMP. INC. - CANDY. OREGoN I A2055M

BEARING SHIllS AS NGEOED0.005 THICK0010 THICK0.015 THICKLIP SEAL CARRIER(NOT ALL N118.S)

LIP SEALBEARING PillBEARING WASIERGEARINGO-PINGPIPE PLUG ER EREASE FTGFRAPt I4II4TINB FOOT

1A2056A

SOCKET PEAD [APSCREWIPFELLER KEY

///SPilL (NOT ALL PQ]ELS)

1ECHANICAL SEALSEAL flE(

LIP SEAL (P1)1 ALL IIJ)ELS)RAPE I4IJITING FOOT

0/1/02

SEAL SETTING (PETAL BELLOWS SEALS CRY)N0TES— CAPSCPEWS NOT LISTED, USE GRADE 5 MATERIAL.— BALA?(E LIIE (MiT SHOWN), IPCLIJS )E EACH

PIPE NIPPLE90 ELB1NOSE FITTINGHE ASSELY

BAI..AP(E LflE NOT USED C)1 ALL ME1)ELS

SEAL OIL RESERVOIR0-RING0-RINGVBT

BEARING PUlSINGBEARING CAP

0-PINGIPWELLER

TEFLOR CORD

OIL LEVEL GAUGE

I1FELLER SCREWIPiELLER WASI-ERGREASE FITTING

f PIONEER PUMP, INC MODEL: FRAME MOUNTED ‘BRACKPLATE STYLE” 1A2056A

FILLER CAP / GAUGE

1 35A

RUN-DRY RESERVOIR

1/2 NPT CLOSE

TUBE FITTING

MECHANICAL SEAL

SEAL GLAND

1/21/4 NPT BLEEO VALVE

STAINLESS STEEL 1/4 NPT 45° ELBOW

1/4 NPT x 3.O NIPPLE

4/I 8/2005

iW IONEER RY RESERVOIR ILLUSTRATION (HOT O 1M135APUMP, INC RUt

SECTION 4

Products: AC Motors: EM2550T: Baldor Electric Company, a leader in energy effident electric ... Page 1 of:

Product Quick Search

i. ‘B)81J’Y :ONTACI.u5 SITE

I Information

Overview

AC Motors Premium Efficiency

Product Overview: EM2550T-i Specifications

Performance Data

J Parts List

-j Layout Dwg

Connection Diag

Product Literature

More Information

- Locate Distributor

Catalog Number: EM2550T

Description:

Ship Weight:

View Specifications

Baldor Sales Offices

I Return to List• Heavy duty frames

• Bali bearings

Moisture resistant ISR® (Inverter SpikeResistant) copper windings

• Low-loss electrical lamination grade steel

• Three year warranty,

.y

Typicai applications include operations wherecontinuous or frequent duty is required. Super-EMotors are designed to conserve energy overextended time periods. Inverter rated per NEMAMGi Part 31.4.4.2. SuitaDle for variable torqueapplications and 20:1 constant torque speed rangewith properly sized and adjusted variable frequencydrives.

NEMAPremiumi

Products Support News/Events i About Baldor Investor Relations homeCopyright 2001-2005 Baldor Siectric Company, All rights reserved.

This site works best with Internet Explorer and Netscape 4.x and above.

• ORIVES • OENERATOR$ EM2550T

100HP,3540RPM.3PH,6OHZ,365TS,4264M,OPSB

810 lbs.

Click for Larger Image

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Products: AC Motors: EM2550T: Baldor Electric Company, a leader in energy efficient electric Page 1 of I

Product Quick Search

• •EM2550T

IICME WHE.Rt0 1I I ThtCf US 5TE 1P

,J____:. -‘ irr--4

General Information AC Motors Premium Efficiency

Specifications: EM2550Ti Specifications Catog Number: EM2550T

Performance Data Specifcahon Number: 42F098W461G1

Horsepower: 100Parts List

Voltage: 230/460LayoutDwg Hertz: 60

i Connection Diag Phase: 3

Full Load Amos: 218/109. Product LiteratureUsable at 208 Volts: N/A

More Information RPM: 3540

Frame Size: 365TSLocate Distributor

Service Factor: 1.15i Baidor Sales Offices Rating: 40C AMB-CONT

Locked Rotor Code: C

I Return to List NEMA Design Code: B

Insulation Class: F

Full Load Efficiency: 94.5

Power Factor: 91

Enclosure: OPSB

Balder Type: 4264M

DE Bearing: 6313

ODE Beanng: 6311

Electrical Specification Number: 42WGW461

Mechanical Specification Number: 42F98

Base; RG

Mounting: Fl

‘ For certified information, contact your local Baldor office.

Products I Support News/Events I About Baldor Investor Relations HomeCopyriaht ; 2001-2005 3ldor Electric Ccmpanv. All rights reserved.

This site works best with Internet Explorer and Netscape 4.x and above.

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NOTES:

LOW VOLTAGE(2D)

1. INTERCHANGE ANY TWOROTATION.

HIGH VOLTAGE(1 D)

LINE LEADS TO REVERSE

2. OPTIONAL THERMOSTATS ARE PROVIDED WHENSP E CI El ED.

3. ACTUAL NUMBER OF INTERNAL PARALLEL CIRCUITSMAY BE A MULTIPLE OF THOSE SHOWN ABOVE.

4. LEAD COLORS ARE OPTIONAL. LEADS MUST ALWAYS BENUMBERED AS SHOWN.

1—BLU

OPTIONALTHERMOSTATS

r J—BRN

2—WHT

L

4—YE L

V9—GRY

(9

5

3

6

, ,/ /

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j4 ±5±6

T’ 12 iLI NE

3—ORG

REV. DESC: REVISE TO SHOW OPTIONAL_COLORS I

REV. LTRC1: JLP RE’iSE. 01/21/99 2:28 TDR: 0171435 BALDOR ELECTRIC Co.TILE: AAA00005148 MDL: —

021.000PMTL -

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MOTORS AND DRIVES

Integral Horsepower

AC Induction Motors

ODP, WPI, WPII Enclosure

TEFC Enclosure

Explosion Proof

Installation & Operating Manual

7/02 MN400

Table of Contents

Section 1

W General Information 1-1Overview 1-1Limited Warranty 1-1Safety Notice 1-2Receiving 1-4Storage 1-4Unpacking 1-4Handling 1-4

Section 2Installation & Operation

Overview 2-1Location 2-1Mounting 2-1Alignment 2-1Doweling & Bolting 2-2Power Connection 2-2

Conduit Box 2-2AC Power 2-2

First Time Start Up 2-4Coupled Start Up 2-4Jogging and Repeated Starts 2-4

Section 3Maintenance & Troubleshooting 3-1

General Inspection 3-1Lubrication & Bearings 3-1

Type of Grease 3-1Lubrication Intervals 3-1Lubrication Procedure 3-3

Accessories 3-4Troubleshooting Chart 3-5

tT s

MN400 Table of Contents i

e

C• 0. •

aii Table of Contents MN400

Section 1General Information

Overview This manual contains general procedures that apply to Baldor Motor products. Be sure to read andunderstand the Safety Notice statements in this manual. For your protection, do not install, operate orattempt to perform maintenance procedures until you understand the Warning and Caution statements. AWarning statement indicates a possible unsafe condition that can cause harm to personnel. A Cautionstatement indicates a condition that can cause damage to equipment.

Important: This instruction manual is not intended to include a comprehensive listing of all details for allprocedures required for installation, operation and maintenance. This manual describes generalguidelines that apply to most of the motor products shipped by Baldor. If you have a questionabout a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldordistributor for more information or clarification.

Before you install, operate or perform maintenance, become familiar with the following:• NEMA Publication MG-2, Safety Standard for Construction and guide

for Selection, Installation and Use of Electric Motors and Generators.• The National Electrical Code• Local codes and Practices

Limited Warranty

1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factorywarehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and toprovide one year of actual service, the warranty period is extended for an additional period of six (6) months for atotal of eighteen (18) months from the original date of shipment from the factory or factory warehouse stock. In nocase will the warranty period be extended for a longer period. Baldor extends this limited warranty to each buyerof the electric motor for the purpose of resale and to the original purchaser for use.

2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during thewarranty period if:

a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansasor one of the Baldor Authorized Service Centers and

b. the purchaser gives written notification concerning the motor and the claimed defect including the datepurchased, the task performed by the Baldor motor and the problem encountered.

3. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith,Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resultingfrom the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequentialdamages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited tothe duration of the warranty period hereunder. (Some states do not allow limitations on how long an impliedwarranty lasts, so the above limitation may not apply to you.)

4. Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects inmaterial or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfillBaldor’s warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor’s warranty repairallowance. Baldor will not pay overtime premium repair charges without prior written authorization.

5. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paidunless first authorized in writing by Baldor.

6. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed intoservice are not always justified. Therefore, Baldor Authorized Service Centers must determine from the conditionof the motor as delivered to the center whether or not the motor is defective. If in the opinion of a BaldorAuthorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is toproceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, thepurchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center’s signedservice report to Baldor for further consideration.

7. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.Note that Baldor Super—E® Premium Efficiency electric motors are warranted for a period of three (3) years.Baldor IEEE 841 electric motors are warranted for a period of five (5) years.All other terms and conditions of the Limited Warranty statement apply.

MN400 General Information 1-1

Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.

Only qualified personnel should attempt installation, operation and maintenance of

electrical equipment.

Be sure that you are completely familiar with NEMA publication MG-2, safety standards

for construction and guide for selection, installation and use of electric motors and

generators, the National Electrical Code and local codes and practices. Unsafe

installation or use can cause conditions that lead to serious or fatal injury. Only qualified

personnel should attempt the installation, operation and maintenance of this equipment.

WARNING: Do not touch electrical connections before you first ensure that

power has been disconnected. Electrical shock can cause serious

or fatal injury. Only qualified personnel should attempt the

installation, operation and maintenance of this equipment.

WARNING: Be sure the system is properly grounded before applying power.

Do not apply AC power before you ensure that all grounding

instructions have been followed. Electrical shock can cause

serious or fatal injury. National Electrical Code and Local codes

must be carefully followed.

WARNING: Avoid extended exposure to machinery with high noise levels. Be

sure to wear ear protective devices to reduce harmful effects to

your hearing.

WARNING: This equipment may be connected to other machinery that has

rotating parts or parts that are driven by this equipment. Improper

use can cause serious or fatal injury. Only qualified personnel

should attempt to install operate or maintain this equipment. 4WARNING: Do not by-pass or disable protective devices or safety guards.

Safety features are designed to prevent damage to personnel or

equipment. These devices can only provide protection if they

remain operative.

WARNING: Avoid the use of automatic reset devices if the automatic restarting

of equipment can be hazardous to personnel or equipment.

WARNING: Be sure the load is properly coupled to the motor shaft before

applying power. The shaft key must be fully captive by the load

device. Improper coupling can cause harm to personnel or

equipment if the load decouples from the shaft during operation.

WARNING: Use proper care and procedures that are safe during handling,

lifting, installing, operating and maintaining operations.

Improper methods may cause muscle strain or other harm.

WARNING: Before performing any motor maintenance procedure, be sure that

the equipment connected to the motor shaft cannot cause shaft

rotation. If the load can cause shaft rotation, disconnect the load

from the motor shaft before maintenance is performed. Unexpected

mechanical rotation of the motor parts can cause injury or motor

damage.

WARNING: Disconnect all electrical power from the motor windings and

accessory devices before disassembly of the motor. Electrical

shock can cause serious or fatal injury.

WARNING: Do not use these motors in the presence of flammable or

combustible vapors or dust. These motors are not designed for

atmospheric conditions that require explosion proof operation.

1-2 General InformationMN400

Safety Notice Continued

WARNING: Motors that are to be used in flammable and/or explosiveatmospheres must display the UL label on the nameplate.

Specific service conditions for these motors are defined inNEC 70-599.

WARNING: UL rated motors must only be serviced by authorized BaldorService Centers if these motors are to be returned to a flammableand/or explosive atmosphere.

Caution: To prevent premature equipment failure or damage, only qualifiedmaintenance personnel should perform maintenance.

Caution: Do not lift the motor and its driven load by the motor liftinghardware. The motor lifting hardware is adequate for lifting only themotor. Disconnect the load from the motor shaft before moving themotor.

Caution: If eye bolts are used for lifting a motor, be sure they are securelytightened. The lifting direction should not exceed a 20° angle fromthe shank of the eye bolt or lifting lug. Excessive lifting angles cancause damage.

Caution: To prevent equipment damage, be sure that the electrical service isnot capable of delivering more than the maximum motor rated ampslisted on the rating plate.

Caution If a HI POT test (High Potential Insulation test) must be performed,follow the precautions and procedure in NEMA MG-i and MG-2standards to avoid equipment damage.

If you have any questions or are uncertain about any statement or procedure, or if yourequire additional information please contact your Baldor distributor or an AuthorizedBaldor Service Center.

MN400 General Information 1-3

Receiving Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for

shipment. When you receive your motor, there are several things you should do

immediately.

1. Observe the condition of the shipping container and report any damage

immediately to the commercial carrier that delivered your motor.

2. Verify that the part number of the motor you received is the same as the part

number listed on your purchase order.

Storage If the motor is not put into service immediately, the motor must be stored in a clean, dry

and warm location. Several precautionary steps must be performed to avoid motor

damage during storage.

1. Use a “Megger” periodically to ensure that the integrity of the winding insulation

has been maintained. Record the Megger readings. Immediately investigate

any significant drop in insulation resistance.

2. Do not lubricate bearings during storage. Motor bearings are packed with

grease at the factory. Excessive grease can damage insulation quality.

3. Rotate motor shaft at least 10 turns every two months during storage (more

frequently if possible). This will prevent bearing damage due to storage.

4. If the storage location is damp or humid, the motor windings must be protected

from moisture. This can be done by applying power to the motors’ space

heater (if available) while the motor is in storage.

Unpacking Each Baldor motor is packaged for ease of handling and to prevent entry of

contaminants.

1. To avoid condensation inside the motor, do not unpack until the motor has

reached room temperature. (Room temperature is the temperature of the room

in which it will be installed). The packing provides insulation from temperature

changes during transportation.

2. When the motor has reached room temperature, remove all protective wrapping

material from the motor.

Handling The motor should be lifted using the lifting lugs or eye bolts provided.

1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the

motor and additional equipment connected to the motor by this method. The

lugs or eye bolts provided are designed to lift only the motor. Never lift the

motor by the motor shaft or the hood of a WPII motor.

2. When lifting a WPII (weatherproof Type 2) motor, do not lift the motor by

inserting lifting lugs into holes on top of the cooling hood. These lugs are to be

used for hood removal only. A spreader bar should be used to lift the motor by

the cast lifting lugs located on the motor frame.

3. If the motor must be mounted to a plate with the driven equipment such as

pump, compressor etc., it may not be possible to lift the motor alone. For this

case, the assembly should be lifted by a sling around the mounting base. The

entire assembly can be lifted as an assembly for installation. Do not lift using

the motor lugs or eye bolts provided.

If the load is unbalanced (as with couplings or additional attachments)

additional slings or other means must be used to prevent tipping. In any event,

the load must be secure before lifting.

1-4 General InformationMN400

Section 2Installation & Operation

Overview Installation should conform to the National Electrical Code as well as local codes andpractices. When other devices are coupled to the motor shaft, be sure to installprotective devices to prevent future accidents. Some protective devices include,coupling, belt guard, chain guard, shaft covers etc. These protect against accidentalcontact with moving parts. Machinery that is accessible to personnel should providefurther protection in the form of guard rails, screening, warning signs etc.

Location The motor should be installed in an area that is protected from direct sunlight, corrosives,harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these canreduce the operating life and degrade performance. Be sure to allow clearance forventilation and access for cleaning, repair, service and inspections. Ventilation isextremely important. Be sure the area for ventilation is not obstructed. Obstructions willlimit the free passage of air. Motors get warm and the heat must be dissipated to preventdamage.

These motors are not designed for atmospheric conditions that require explosion proofoperation. They must NQI be used in the presence of flammable or combustible vaporsor dust.

1. ODP motors are suitable only for indoor applications.

2. TEFC and WPII motors are suitable for indoor or outdoor standard serviceapplications.

Mounting The motor must be securely installed to a rigid foundation or mounting surface tominimize vibration and maintain alignment between the motor and shaft load. Failure toprovide a proper mounting surface may cause vibration, misalignment and bearingdamage.

Foundation caps and sole plates are designed to act as spacers for the equipment theysupport. If these devices are used, be sure that they are evenly supported by thefoundation or mounting surface.

After installation is complete and accurate alignment of the motor and load isaccomplished, the base should be grouted to the foundation to maintain this alignment.

The standard motor base is designed for horizontal or vertical mounting. Adjustable orsliding rails are designed for horizontal mounting only. Consult your Baldor distributor orauthorized Baldor Service Center for further information.

Alignment Accurate alignment of the motor with the driven equipment is extremely important.

1. Direct CouplingFor direct drive, use flexible couplings if possible. Consult the drive orequipment manufacturer for more information. Mechanical vibration androughness during operation may indicate poor alignment. Use dial indicators tocheck alignment. The space between coupling hubs should be maintained asrecommended by the coupling manufacturer.

2. End-Play AdjustmentThe axial position of the motor frame with respect to its load is also extremelyimportant. The motor bearings are not designed for excessive external axialthrust loads. Improper adjustment will cause failure.

3. Pulley RatioThe pulley ratio should not exceed 8:1.

4. Belt DriveAlign sheaves carefully to minimize belt wear and axial bearing loads (seeEnd-Play Adjustment). Belt tension should be sufficient to prevent belt slippageat rated speed and load. However, belt slippage may occur during starting.

Caution: Do not over tension belts.

5. Sleeve bearing motors are only suitable for coupled loads.

MN400 Installation & Operation 2-1

Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet

into the foundation. This will maintain the correct motor position should motor removal be

required. (Baldor motors are designed for doweling.)

1. Drill dowel holes in diagonally opposite motor feet in the locations provided.

2. Drill corresponding holes in the foundation.

3. Ream all holes.

4. Install proper fitting dowels.

5. Mounting bolts must be carefully tightened to prevent changes in alignment.

Use a flat washer and lock washer under each nut or bolt head to hold the

motor feet secure. Flanged nuts or bolts may be used as an alternative to

washers.

Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding

should conform to the National Electrical Code and local codes and practices.

Conduit Box For ease of making connections, an oversize conduit box is provided. The box can be

rotated 360° in 90° increments. Auxiliary conduit boxes are provided on some motors for

accessories such as space heaters, RTD’s etc.

AC Power Connect the motor leads as shown on the connection diagram located on the name plate

or inside the cover on the conduit box. Be sure the following guidelines are met:

1. AC power is within ±10% of rated voltage with rated frequency. (See motor

name plate for ratings).OR

2. AC power is within ±5% of rated frequency with rated voltage.

OR

3. A combined variation in voltage and frequency of ±10% (sum of absolute (values) of rated values, provided the frequency variation does not exceed ±5%

of rated frequency.

Performance within these voltage and frequency variations are shown in Figure 2-1.

Id

2-2 Installation & OperationMN400

i;

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Voltage Variations (%)

Figure 2-1 Motor Performance VS Voltage Variations

a)C)C

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+20

+15

+10

+5

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—10

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—20

MaximumFull -Load TorqueCurrent \%%\%•\\\\

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—15 —10 —5 0 +5 +10 +15

MN400 Installation & Operation 2-3

First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is

disconnected from the load and will not cause mechanical rotation of the motor shaft.

1. Make sure that the mechanical installation is secure. All bolts and nuts are

tightened etc.

2. If motor has been in storage or idle for some time, check winding insulation

integrity with a Megger.

3. Inspect all electrical connections for proper termination, clearance, mechanical

strength and electrical continuity.

4. Be sure all shipping materials and braces (if used) are removed from motor

shaft.

5. Manually rotate the motor shaft to ensure that it rotates freely.

6. Replace all panels and covers that were removed during installation.

7. Momentarily apply power and check the direction of rotation of the motor shaft.

8. If motor rotation is wrong, be sure power is off and change the motor lead

connections. Verify rotation direction before you continue.

9. Start the motor and ensure operation is smooth without excessive vibration or

noise. If so, run the motor for 1 hour with no load connected.

10. After 1 hour of operation, disconnect power and connect the load to the motor

shaft. Verify all coupling guards and protective devices are installed. Ensure

motor is properly ventilated.

Coupled Start Up This procedure assumes a coupled start up. Also, that the first time start up procedure

was successful.

1. Check the coupling and ensure that all guards. and protective devices are

installed.

2. Check that the coupling is properly aligned and not binding.

3. •The first coupled start up should be with no load. Apply power and verify that

the load is not transmitting excessive vibration back to the motor though the

coupling or the foundation. Vibration should be at an acceptable level.

4. Run for approximately 1 hour with the driven equipment in an unloaded

condition.

The equipment can now be loaded and operated within specified limits. Do not exceed

the name plate ratings for amperes for steady continuous loads.

Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor

winding insulation. A much greater amount of heat is produced by each acceleration or

jog than than by the same motor under full load. If it is necessary to to repeatedly start or

jog the motor, it is advisable to check the application with your local Baldor distributor or

Baldor Service Center.

Heating - Duty rating and maximum ambient temperature are stated on the motor name

plate. Do not exceed these values. f there is any question regarding safe operation,

contact your local Baldor distributor or Baldor Service Center.

2-4 Installation & Operation MN400

Section 3Maintenance & Troubleshooting

WARNING: UL rated motors must only be serviced by authorized BaldorService Centers if these motors are to be returned to a flammableand/or explosive atmosphere.

General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation orevery 3 months, whichever occurs first. Keep the motor clean and the ventilationopenings clear. The following steps should be performed at each inspection:

WARNING: Do not touch electrical connections before you first ensure thatpower has been disconnected. Electrical shock can cause seriousor fatal injury. Only qualified personnel should attempt theinstallation, operation and maintenance of this equipment.

1. Check that the motor is clean. Check that the interior and exterior of the motoris free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. canaccumulate and block motor ventilation. If the motor is not properly ventilated,overheating can occur and cause early motor failure.

2. Use a “Megger” periodically to ensure that the integrity of the winding insulationhas been maintained. Record the Megger readings. Immediately investigateany significant drop in insulation resistance.

3. Check all electrical connectors to be sure that they are tight.

Lubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly. The lubricatingability of a grease (over time) depends primarily on the type of grease, the size of thebearing, the speed at which the bearing operates and the severity of the operatingconditions. Good results can be obtained if the following recommendations are used inyour maintenance program.

Type of Grease A high grade ball or roller bearing grease should be used. Recommended grease forstandard service conditions is Polyrex EM (Exxon Mobil).

Equivalent and compatible greases include:Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

— Maximum operating temperature for standard motors = 1100 C.— Shut—down temperature in case of a malfunction 1150 C.

Lubrication Intervals Recommended lubrication intervals are shown in Table 3-1. It is important to realize thatthe recommended intervals of Table 3-1 are based on average use.

Refer to additional information contained in Tables 3-2 and 3-3.

Table 3-1 Lubrication Intervals *

Rated_Speed - RPMNEMA / (IEC) Frame Size 10000 6000 3600 1800 1200 900

Upto 210 md. (132) ** 2700 Hrs. 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.Over2lOto28O mcI. (180) ‘ 3600Hrs. 9500Hrs. l5000Hrs. l8000Hrs.Over 280 to 360 mcI. (225) * 2200 Hrs. 7400 Hrs. 12000 Hrs. 15000 Hrs.Over 360 to 5800 mcI. (300) *2200 Hrs. 3500 Hrs. 7400 Hrs. 10500 Hrs.

* Lubrication intervals are for ball bearings. For roller bearings, divide the listed lubrication interval by 2.** For 6205 and 6806 bearings. For 6807 bearings, consult oil mist lubrication (MN4O1).

Relubrication interval for 6205 bearing bearing is l55OHrs. (using grease lubrication).Relubrication interval for 6806 bearing bearing is 72OHrs. (using grease lubrication).

MN400 Maintenance & Troubleshooting 3-1

Table 3-2 Service Conditions

Severity of Service Ambient Temperature Atmospheric Type of BearingMaximum Contamination

Standard 40° C Clean, Little Corrosion Deep Groove Ball Bearing

Severe 50° C Moderate dirt, Corrosion Ball Thrust, Roller

Extreme >50° C* or Severe dirt, Abrasive dust, All Bearings

Class H Insulation Corrosion

Low Temperature <—30° C **

* Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does

not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.

** Special low temperature grease is recommended (Aeroshell 7).

Table 3-3 Lubrication Interval Multiplier

Severity of Service MultiplierStandard 1.0Severe 0.5Extreme 0.1

Low Temperature 1.0

Table 3-4 Bearings Sizes and Types

Frame Size Bearing DescriptionNEMA (IEC) (These are the “Large” bearings (Shaft End) in each frame size)

Bearing OD Width Weight of Volume of greaseD mm B mm Grease to to be added

add* teaoz (Grams) I spoon

Up to 210 mcI. (132) 6307 80 21 0.30 (8.4) 0.6 2.0

Over 210 to 280 mcI. (180) 6311 120 29 0.61 (17) 1 .2 1 39

Over 280 to 360 mcI. (225) 6313 140 33 0.81 (23) 1.5 5.2

Over 360 to 449 mcI. (280) — 6319 200 45 2.12 (60) 4.1 13.4

Over 5000 to 5800 mcI. (355) 6328 300 62 4.70 (130) 9.2 30.0

Over 360 to 449 mcI. (280) NU319 200 45 2.12 (60) 4.1 13.4

Over 5000 to 5800 mcI. (355) NU328 300 62 4.70 (130) 9.2 30.0

Spindle Motors76 Frame 6207 72 17 0.22 (6.1) 0.44 1.4

77 Frame 6210 90 20 0.32 (9.0) 0.64 2.1

80 Frame L 6213 120 23 0.49 (14.0) 0.99 3.3

* Weight in grams = .005 DB

Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the

grease volume for the next larger size bearing.

3-2 Maintenance & Troubleshooting MN400

Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease alreadyin the motor. Consult your Baldor distributor or an authorized service center if a greaseother than the recommended type is to be used.

Caution: To avoid damage to motor bearings, grease must be kept free of dirt.For an extremely dirty environment, contact your Baldor distributor oran authorized Baldor Service Center for additional information.

With Grease Outlet Plug

1. Clean all grease fittings.

2. Remove grease outlet plug.

3. If motor is stopped, add the recommended amount of grease.

If motor is to be greased while running, a slightly greater quantity of grease willhave to be added. Add grease slowly until new grease appears at shaft hole inthe endplate or purge outlet plug.

4. Re-install grease outlet plug.

Without Grease Outlet Plug

1. Disassemble motor.

2. Add recommended amount of grease to bearing and bearing cavity. (Bearingshould be about 1/3 full of grease and outboard bearing cavity should be about1/2 full of grease.)

Note: Bearing is 1/3 full when only one side of bearing is completely full of grease.

3. Assemble motor.

Sample Lubrication Determination

Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambienttemperature of 430 C and the atmosphere is moderately corrosive.

1. Table 3-1 list 9500 hours for standard conditions.

2. Table 3-2 classifies severity of service as “Severe”.

3. Table 3-3 lists a multiplier value of 0.5 for Severe conditions.

4. Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.

Note: Smaller bearings in size category may require reduced amounts of grease.

.04n ‘)X ‘ “* ‘

()

MN400 Maintenance & Troubleshooting 3-3

Accessories The following is a partial list of accessories available from Baldor.Contact your Baldor distributor for availability and pricing information.

Note: Space heaters and RTD’s are standard on some motors.

Bearing RTDRTD (Resistance Temperature Detector) devices are used to measure ormonitor the temperature of the motor bearing during operation.

Bearing ThermocouplesUsed to measure or monitor bearing temperatures.

Bearing ThermostatTemperature device that activates when bearing temperatures are excessive.

Used with an external circuit to warn of excessive bearing temperature or toshut down a motor.

Conduit BoxesOptional conduit boxes are available in various sizes to accommodateaccessory devices.

Cord & Plug AssemblyAdds a line cord and plug for portable applications.

Drains and BreathersStainless steel drains with separate breathers are available.

Drip CoversDesigned for use when motor is mounted in a vertical position. Contact yourBaldor distributor to confirm that the motor is designed for vertical mounting.

Fan Cover & Lint ScreenTo prevent build-up of debris on the cooling fan.

NameplateAdditional stainless steel nameplates are available.

Roller BearingsRecommended for belt drive applications with a speed of 1800 RPM or less.

Rotation Arrow LabelsRotation arrows are supplied on motors designed to operate in one direction

only. Additional rotation arrows are available.

Space HeaterAdded to prevent condensation of moisture within the motor enclosure during

periods of shut down or storage.

Stainless HardwareStainless steel hardware is available. Standard hardware is corrosion resistant

zinc plated steel.

Winding RTDRTD (Resistance Temperature Detector) devices are used to measure ormonitor the temperature of the motor winding during operation.

Winding ThermocouplesUsed to measure or monitor winding temperatures.

Winding ThermostatTemperature device that activates when winding temperatures are excessive.

Used with an external circuit to warn of excessive winding temperature or toshut down a motor.

Note: On some motors, leads for accessory devices are brought out to a separate

conduit box located on the side of the motor housing (unless otherwisespecified).

3-4 Maintenance & Troubleshooting MN400

Table 3-5 Troubleshooting Chart

Sniptom Possible Causes Possible SolutionsMotor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,

as, single phasing at the starter, controls, etc.Excessive humming High Voltage. Check input line connections.

Eccentric air gap. Have motor serviced at local Baldor service center.Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in

(measured) with nameplate rating. motor or load.Reduce load or replace with motor of greater capacity.

Single Phasing. Check current at all phases (should be approximatelyequal) to isolate and correct the problem.

Improper ventilation. Check external cooling fan to be sure air is movingproperly across cooling fins.Excessive dirt build-up on motor. Clean motor.

Unbalanced voltage. Check voltage at all phases (should be approximatelyequal) to isolate and correct the problem.

Rotor rubbing on stator. Check air gap clearance and bearings.Tighten “Thru Bolts”.

, Over voltage or under voltage Check input voltage at each phase to motorf.

Open stator winding. Check stator resistance at all three phases for balance.Grounded winding Perform dielectric test and repair as required

- Improper connections. Inspect all electrical connections for propertermination, clearance, mechanical strength and

-•—••--•---•- electrical continuity. Refer to motor lead connection

diagram.Bearing Over Heating Misalignment. Check and align motor and driven equipment.

Excessive belt tension. Reduce belt tension to proper point for load.Excessive end thrust. Reduce the end thrust from driven machine.

.. Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.Dirt in bearing. Clean bearing cavity and bearing. Repack with correct

- grease until cavity is approximately 3/4 filled.Vibration Misalignment. Check and align motor and driven equipment.

Rubbing between rotating parts and Isolate and eliminate cause of rubbing.stationary parts.Rotor out of balance. Have rotor balance checked are repaired at your

Baldor Service Center.Resonance. Tune system or contact your Baldor Service Center for

assistance.Noise Foreign material in air gap or Femove rotor and foreign material. Reinstall rotor.

ventilation openings. Check insulation integrity. Clean ventilation openings.Growling or whining Bad bearing. [ Replace bearing. Clean all grease from cavity and new

bearing. Repack with correct grease until cavity isLapproximatey 3/4 filled.

MN400 Maintenance & Troubleshooting 3-5

Most large frame AC Baldor motors with a 1.15 service factor are designed to operate

below a Class B (80°C) temperature rise at rated load and are built with a Class Hwinding insulation system. Based on this low temperature rise, RTD (ResistanceTemperature Detectors) settings for Class B rise should be used as a starting point.

Some motors with 1.0 service factor have Class F temperature rise.

The following tables show the suggested alarm and trip settings for RTDs. Proper

bearing and winding RTD alarm and trip settings should be selected based on these

tables unless otherwise specified for specific applications.

If the driven load is found to operate well below the initial temperature settings under

normal conditions, the alarm and trip settings may be reduced so that an abnormal

machine load will be identified.

The temperature limits are based on the installation of the winding RTDs imbedded in the

winding as specified by NEMA. Bearing RTDs should be installed so they are in contact

with the outer race on ball or roller bearings or in direct contact with the sleeve bearing

shell.

Winding RTDs — Temperature Limit In °C (40°C Maximum Ambient)

0

0

Suggested bearing and winding RTD setting guidelines 0

Motor Load (T1D)Class F Temp Rise 105°C Class H Temp Rise 125°C

Alarm Trip Alarm Trip Alarm Trip

Rated Load 130 140 155 165 175 185

Rated Load 140 150 160 165 180 185

to 1.15 SF.

Note: • Winding RTDs are factory production installed, not from Mod—Express.

• When Class H temperatures are used, consider bearing temperatures and lubrication requirements.

Bearing RTDs — Temperature Limit In OC with 40°C Max Ambient

Bearing Type Anti—Friction Sleeve

• Oil or Grease Alarm Trip Alarm Trip

Standard* 95 100 I 85 95

High Temperature** 110 115 105 110

Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise.‘° High temperature lubricants include some special synthetic oils and greases.

Greases that may be substituted that are compatible with Polyrex EM (but considered as “standard”

lubricants) include the following:— Texaco Polystar— Rykon Premium #2— Chevron SRI #2

See the motor nameplate for replacement grease or oil recomendation. Contact Baldor

application engineering for special lubricants or further clarifications.

3-6 Maintenance & Troubleshooting MN400

0

MOTORS AND DRIVES

BALDOR ELECTRIC COMPANYP.O. Box 2400

Ft. Smith, AR 72902—2400(479) 646—4711

Fax (479) 648—5792

© Baldor Electric Company Printed in USA 0MN400 7/02 C&J10000

SECTION 5

120 VOLTW CONTROL POWER

Ri FUNCTL

50J 8FUNCTL

SUCTION SCREEN

TOG SOLENOID VALVE

F-1v-SThJNER

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SECTION 6

1A576 THRU 1A581, 3A433, 3A434,Operating Instructions & Parts Manual3A436, 4A697. 4A699 and 4A700

ptease read and save th.se Instruttians. Read cacehdly before attempting to ais.nble, install, operate or maintain the product desa’ihed.Protect yourself nd oth.r by observing all safety information. Failure to comply with insctlons could reault In personal in/wy andiorproperty damage! Retain instructions for fuWre reference.

Dayton® General Purpose SolenoidValves Normally Closed, 2-WayDescriptionDayton solenoid valves are pilot operated 2-way, normally closed valves designedfor use irs industrial applications. All solenoid valves have a defined operatingpressure range.

Valves feature a standard junction box. Class F molded coil (order separately),Buna-N diaihragm or piston, stainless steel plunger and tube. Valves are equippedwith a brass body capable of handling noncorrosive and nonflammable liquids andgases such as air, water.

Dayton solenoid valves are rated in accordance with standards sanctioned by FluidControls Institute, Inc. Valves are UL Listed.

Figure 1

Specifications and Performance

Mm. Flow—Maximum——— —Required-.-.-—

Inlet OPtI— Max. Air Water Max. Air Waterand Range Working Flow Flow Fluid Flow - FlowModel Outlet Orifice PSI CA Pressure CFMt GPMIt5 Temp. CFMt GPMIt

14576 3/8 5/8w 5-150 2.8 300 PSI 226 34.5 180F 61.6 6.31A577 1/2 5/8 5-150 3.6 300PSl 292 43.8 180 79.2 8.01A578 3/4 3/4 5-125 5.5 300 PSI 280 61.5 180 121.0 12.314579 1 1 5-125 13.0 250 PSI 910 14S.S 180 286.0 29.11A580 1’1 1 I 5-250 16.0 250 P51 2110 253.0 180 352.0 35.81A581 Vt I’h 5-250 2S.0 2SOPSI 3300 395.0 180 550.0 55.934433 1/4 1/4 2-150 1.2 350 P51 127 14.4 180 14.4 1.734434 1/2 5/8 0-100 3,6 300 PSI 205 36.0 180 28.8 2.53A436 3/4 3/4 0-100 53 300 PSI 314 55.0 180 44.0 3.944597 3/8 5/8 0-100 2.8 300 PSI 160.0 28.0 180 22.4 2.04A699 3/8 1/4 2-150 1.2 350 PSI 120.0 14.0 180 14.4 1.74A700 318 3/8 2-150 2.2 350 PSI 189.2 25.0 180 26.4 3.1

(t) Cubic Feet Minute (tt) Gallons Per MinuteC.) Operating Pressure Differential (Maximum rating must not be exceeded or valve will fail to open.)(A) Amount of water in GPM at standard conditions (60F specific gravity — 1) which wilt pass through the valve with a one

PSI pressure drop with valve in full open position.(*) Maximum flow rates at maximum operating pressure drops across valve.

COIL ELECTRICAL RATINGS (50/60 HZ) 24 VAC COIL ELECTRICAL RATINGS (50/60 HZ) @ 120 VACInrush @60Hz Holding @60HzVolt Current Volt Current

Models Amps (Amps) Amps (Amps) Watts.

Inrush’6OHz Holdisg@6OHrVolt Current Volt Current

Models Amps (Amps) Amps (Amps) Watts1A576, 14577, 1A578 53 2.21 16 0.67 12 14576, 14577, 1A578 57 0.48 19 0.16 1214579 27 1.13 15 0.67 12 14579 29 0.24 19 0.16 1214980, 1A581 24 1.00 18 0.75 12 14580, 14581 23 0.19 19 0i6 123A433, 3A434, 34436, 3A433, 34434, 3A439,

4A697, 44699, 44700 31 1.17 19 0.51 12 44697, 4A699, 44700 31 - 0.22 19 0.14 12

P4.00123-3Form 551873

Dayton

1A576 thru 1A581, 3A433, 3A434,Dayton Operang Instructions and Parts Mnu& 3A436 4A697, 4A699 and 4A700

•Daytöfla Géneràl Purpose Solenoid•Valves Normally Closed, 2-Way

General Safety information1. Read instructions thoroughly.

Failure to comply may result invalve failure, system damage orpersonal injury.

2. Use only fluids compatible withvalve materials of construction.

3. Do not use a solenoid valve on anysystem where system pressure canexceed maximum working pressureof the valve.

4. Do not utilize a solenoid valve as asafety shut off.

S. Do not exceed maximum operatingpressure differential; valve will failto open.

& Proper valve sizing is important. Anoversized valve may result in hamrnering or chattering. An undersized solenoid valve may considerably reduce system capacity.

7. 8efore energizing valve, be suresource voltage arid frequencymatches that on coil. Do notenergize coil unless coil is secarelyattached to valve. See Installation.

8. Do not use solenoid valve whereambient temperature may exceed40’C (104’F). Prolonged use inexcessive ambient temperature orhumidity may damage coils.

9. Do not dent or bend or useenclosing tube as lever. A damagedenclosing tube may result in coilburnout or inoperative valve.

10. Foreign matter iii the valve may

Figure a—Operational 5chematic

result in seat leakage, sticking openor closed, or coil burnout.

Disconnect power

_____________

and depressurizesystem before serv,dng. If the powerdisconnect is out-of s1ght lock it in theoffposition and tag to prevent

unexpected application af power.11. Follow all local electrical and safety

codes, the National Electrical Code(NEC) and the Occupational Safety& Health Act (OSHA).

12. The solenoid valve must be securelygrounded by connecting a groundwire to the bare metal of the valveand wiring it to a suitable electricalground, such as a grounded waterpipe, a grounded metallic racewayor a ground wire system.

13. Solenoid valves have a finite life.Norma! failure modes includevalve’s failure to open or valvesfailure to close. Installations whereproperty damage and/or personalinjury might result require furtherinstallation of back up systems.

AWARNING I with

explosive fluids or gases. Do not use inexplosive atmospheres as defined byThe National Electric Cede (NEC).14. NOTICE TO OWNERS: WARNING —

THIS PRODUCT CONTAINS A CHEMICAL KNOWN TO THE STATE OFCALIFORNIA TO CAUSE 8IRTh

DEFECTS OR OTHER REPRODIJCflVEHARM. Notice to California owners:Under California ballot measureproposition 65, California residentsmust be notified if a productcontains more than 1/1 000 of thesafe lifetime exposure level of acarcinogen or birth defect causingagent. More than 300 chemicals areon the list. This valve contains brassparts. Lead is present in all forms ofbrass. To minimize exposure to leadin all water systems, don’t drink hotwater and don’t drink the first glassof water from a system. Direct anyquestions to Grainger’s TechnicalSupport Department.

Installation1. For ease of installation, the Dayton

solenoid valve can be instailed in anyposition. Gravity will not affect valveoperation, as all Dayton valves arespring loaded.

NOTEr Valves can be operated in anyposition, but upright mounting reducesthe chance of malfunction caused bythe collection of foreign material in thetop of the enclosing tube.2. The solenoid coil can be rotated 360”

for ease of wiring. If possible, do notreduce the length of the solenoidcoil wire leads, so that if it becomesnecessary to remove coil at a laterdate (for valve deanout, etc.), wireleads will not have to bedisconnected.

3. To allow for removal of the solenoidcoil without removing the valve fromits piping, allow at least two inchesof clearance above the solenoid.

4. install the valve with the flow arrowart the valve body corresponding todirection of flow thru piping.

COIL INSTALLATION INSTRUCTIONS

[A WARNING J Defer moving

disconnect electrical power source!Failure to do so will cause coil to burnout or could result In personal Injury.1. Verify coil type, voltage arid

frequency. This information appearson the coil nameplate.

COIl. ELECTRICAL RATINGS (5Q160 HZ 208-240 VAC

Itirush ‘ 60 Hz Holding 60 HzVolt current Voft Current

Models Amps (Amps! Amps (Amp4 ‘Jatts

lA576thru 1A5791A580, 1A58134433. 34434, 3A43S,

4A697, 4A699, 4A700

24 0.10 19 0.08 9.026 0.11 19 0.08 9.1

31 0.12 19 0.08 12.0

2

2. Place coil over the enclosing tube andpress down firmly until clip engages.Coil may be rotated 3EO for easywiring.

WIRING

Be sure your wiring conforms to all localand national electric codes and that thevalve is grounded properly. Agrounding screw is provided in thejunction box for connecting the ground

• wire.

IA ‘AUTION DO not mistake apower lead for a

ground wire when making theconnection to the junction boxgrounding soew Be sure the wire youconnect to the grounding screw is theground wire.

TESTING1. Apply correct voltage to solenoid

valve and cycle solenoid severaltimes. A distinct click should be heardeach time the solenoid is energized.

2. Pressurize valve and check for leaks.NOTE: Solenoid valves are equippedwith a continuous-duty solenoid coil.which, when energized for an extendedperiod of time, becomes hot to thetouch. This is normal.

MaintenanceA WARNiNG Disconnect power

I and depressurizesystem before servicing. If powerdisconnect is out-of-sight. lock it in theoff position and tag to preventunexpected application of power.1. Periodically inspect valve for worn or

damaged parts.2. Replace parts when necessary. Refer

to parts illustration as an aid indisassembly and assembly.

CLEANINGPeriodically dean valve to maintainpeak operating conditions. Use Daytondegreasing solvent 2X726 or a similarsolvent. Remove other foreign matterand deposits with air and a crocus cloth.

INSPECTION1. All internal metal parts should be

clean and free of corrosion.2. All gaskets and diaphragms should

be clean and permanently set orbrittle.

3. Check the esidosing tube forexcessive wear, corrosion, and dentswhich would prevent free movementfor the plunger.

4. Check the valve seat for cleanlinessand corrosion.

5. Replace worn or damaged parts.Refer to parts list for orderinginformation.

Assembly1. Lubricate the gasket with a silicone

base or similar lubricant.2. Ensure that all moving parts do not

bind over the full length of travel.3. Assemble the valve as shown in the

parts illustration.4. Tighten the capscrews to the torque

valves given in the chart below.5. Test valve as indicated in Step 6 of

Installation.

CAPSCREW TORQUE CHARTMODELS TORQUE

Troubleshooting ChartSymptom

V Poscible cuse(s) j Corrctive ActionValve will not open 1. Valve improperly assembled

2. Movement of plunger or diaphragm restricted due to:a. Corroded parts:b. Dirt lodged inside of enclosing tube;c. Dented or bent enclosing tube;d. Distorted body due to:

1. Crushing in vise2. Excess or uneven torque on flange

bolts3. Overtightening of inlet or outlet

piping3. Coil burnout4. Damaged Wiring

5. Coil assembly improperly matched topower supply

3

1. Assemble parts in proper position, .makingcertain none are missing from valve assembly

2. a. Clean or replace as requiredb. Cleanc. Replace enclosing tubed. Replace valve body

3. See coil burnout, page 4. Replace coil as5embly4. Check for loose or broken connections. Repair asneeded5. Check coil assembly voltage, frequency, and

current ratings against power supply ratings.Replace improper coil assembly wrth assembly ofproper rating

Dayton

Dayton Operating Instructions and Parts Manual

Models 1A576 thru 1A581, 3A433, 3A434,•

3A436 4A697, 4A699 and 4A700V

V

V

V

V V

•VV

1 A576. 1 A577, 1 A5781 A5791A5&, 1A5813A433, 4A699, 4A7003A434, 3A43&, 4A697

40 In-lbs75 in-lbs

30-35 ft-lbs50 in-lbs40 in-lbs

1A576 thru 1A581 3M33, 3A434,Dayton Operating lnstructior and Parts Manual 3A436 4A697, 4A699 and 4A700

Dayton® General Purpose SolenoidValves Normally Closed, 2-Way

froubleshooting Chart (Continued)Syniptorn Pcs5ibIe Cause(5) Corrective ActionValve will not open 6. Faulty contacts on control source (relays 6. Check contacts in relays or thermostats. Clean as(Continued) or thermostats) required

7. Operating Pressure Differential higher 7. a. Replace valve with new valve having higherthan valve rating OPD7.b. Reduce system pressure

Valve will not close 1. Diaphragm or plunger restricted due to: 1.a. Corroded parts; a. Cleanb. Foreign material lodged in enclosing b. Clean

tube or valve seatc. DIstorted enclosing tube c. Replace enclosing tubed. Distorted body due to: d. Replace valve body1. Crushing invise

2. Excess or uneven torque on flange bolts3. Overtightening of inlet or outlet piping

2. Faulty control circuit 2. Check control circuit for shorts or fusedcontacts, causing power to be at the coilassembly at all times. Replace or repair3. Pressure at outlet of solenoid higher than 3. Install check valve in outlet line

Valve closes but flow 1. Foreign material lodged under seat 1. Clean all internal parts2. Synthetic seat material chipped, broken 2. Replace valve or affected partsor deformed3. Valve improperly assembled or applied 3. Consult manufacturer’s catalogue to determinefor given fluid if proper valve type and design is being used for

fluid application. Assemble with proper partsCoil burnout 1. Supply voltage at coil too low (below 85% 1. Locate cause of low voltage and correct (checkof rated coil voltage) transformer, wire size, control rating)2. Supply voltage at valve too high (more 2. Locate cause of high voltage and correct (installthan 10% above rated call voltage) proper transformer or service)3. Valve located in high ambient temperature 3. Ventilate or isolate the area from high ambient

V temperature4. Diaphragm or plunger cannot move due to: 4. Clean affected parts and replace parts as rea. Corroded parts; quired. Correct cause of corrosion or source ofb. Foreign material lodged in valve; foreign materials in systemc. Dented or bent enclosing tube

d. Distorted body5. Valve handlina fluids at temperatures which 5. Replace valve or valve coil with proper type forare in excess ol maximum temperature limit temperature range requiredof valve6. With valve closed, pressure difference 6. Replace valve with valve having higher MOPDacross valve too high, preventing valve rating

from opening7. Improper wiring: 7.

a. lnru5h voltage drop causing the a. Correct wiring. Check all electrical con-plunger to fail to pull into magnetic nectionsfield due to:1. Wiring the valve to the load side of

• motor starterV2. Wiring the valve in parallel with other

devices with high inrush current draw3. Inadequate transformer capacity

b. Wire size of electrIcal supply too small b. Use adequate wire size

4

Dayton Operating Instructions and Parts Manual 1A576 thru 1A579

For Replacement Parts, call 1-8OO323-O62OPfease provide follcng nfom,etion:-MoOelnun,ber-Serial number 14 any)-Part descriptions and rimber as shown a parts tst

Address pare correspondence to:Parts Company of Amenca1657 Shermer RoadNorthbrook, II. O062-5352

Replacement Parts List for Models 1A576 thru 1A578

2

4

5

6

7

48

Figure 3— Replacement Parts Iflustratlonfor Models 1A576 thru 1*578

Ref. PartNo. Oescription No.

Coil assembly 24 volts, 50160 Hz

1 (Standad) 5X54213A439/4A705Coil assembly 120 volts, 50/60 Hz 6X54313A440/4A706Coil assembly 208-240 volts, 50)60 Hz 6X54413A441/4A707

2 Enclosing tube assembly (Rune N) X22204-13 Capscrew (set 4) P51546-i

4 Plunger & spring assembly A

________

5 Diaphragm spring A6 Gasket A

________

7 Diaphragm A8 Valve body —

A Repair kit for Models 1A576 & 1A577 Ki 172A Repair kit for Model 1A578 K1233

(El) Not available as a replacement part. Purchase new unit.(t) Includes top plate assembly.

Replacement Parts List for Model 1A5791 Ref. PartI No. Oecripton No

Coil assembly 24 volts, 50/60 Hz(Standard) 6X542f3A439

I Coil assembly 120 volts, 50160 Hz 6X543/3A440Coil assembly 208-240 volts, 50160 Hz EX.5413A441

2 Capscrew P522386-i

3 Enclosing tube assembly X13781-I4 Plunger & spring assembly A5 Diaphragm spring A6 Gasket A7 Diaphragm AS Body

(El) Not available as a replacement part. Purchase new unit.

-‘f X+ ‘c i4/ /,9577

5

2

4

5

•8

Figure 4 Replacement Parts Illustrationfor Model 1A579

Dayton

Coil assembly 24 voLts, 50/60 Hz’ (Standard)Coil assembly 120 volt5, 50/60 Hz (Standard)Coil assembly 208-240 volts, 50160 HzCapscrew (set 4)Lockwasher (set 4)

10 Piston11 Valve body

Piston stern guide for IASBOPiston stem guide for 1 A581

A Repair kit for Model 1ASBOA Repair kit for Model lASS 1

(D) Not available as a replacement part. Purchase new unit.(A) lndudes top plate assembly.

• 6X54213A439/4A7055X543/3A44014A7066X54413M4114A707

Psi 60-5P51210-9

AD

112 10-3112 10-2

K 1282K1283

Figure 6 — Replacement Parts Illustrationfor Models3A433, 4A699 & 4A700

Dayton Operating lnstrudions and Parts Manual1A580, 1A581, 3A433,

3A434, 4A699 arid 4A7G0

For Replàcement Parts, call 1-800-323-0620.•Please prode following information:-Model r.umr-5erial number if any)-Part descriptions and number as shown in parts list

Address parts corresponPnce ro:Parts Company of America6S7 Sherrner RoadNorthbrook, IL 60062-5362

Replacement Parts List for Models 1A580 & 1A581Etef. PartNo. escription No.

fl12

34

6

10

ii

12

Figure 5— Replacement Parts Illustrationfor Models 1A580 & 1A581

234 tTube assembly for 1A580 X-13812-14

tTube assembly for 1 A581 X13816-125 Gasket A6 Plunger & spring assembly A7 Piston spring A8 Piston ring A9 Pistonringexpander A

Replacement Parts List for Models 3A433, 4A699 & 4A700

1 Coil assembly

Ref. PartNo. Oescrption No.

24 volt 6X542/3A439120 volt 6X543/3A440208-240 volt 6X544)3A441

2 Enclosing tube assembly3 Plunger & spring assembly4 0-ring5 Piston6 Body

A Repair kit

() Not available as a replacement part. Purchase new unit.(A) Includes top plate assembly.

X22039-7Xl 3805-1

AAF’.

K1262

2

3

4

6

6

1A576 ‘thru 1A581, 3A433.Dayton Operating nstrucons and Parts Manual 3A434, 3A436, 4A697, 4A699 and 4A?OO

Replacement Parts List

2Rep’acement Parts List for Models 3A434, 4A436 & 4A697

I

4

.7

Figure 7 — Replacement Parts Lllustrationfor Mode’s 3A434, 3A436 & 4A697

Limited Warranty

Ref. PartNo Oescr:ption No,

_______

I Capscrew (set 4) PSi 546-12 Coil assemWy:

24 voLt 6X54213A439120 volt 6X54313A440203-240 volt 6X544/3A441

_________

3 Enclosing tube asaembiy X22204-i

4 Diaphragm spring A5 Gasket A6 Plunger & diaphragm assembly A7 Body —

A Repair kit K1263

(D) Not available as a replacement part. Purchase new unit.

(A) indudes top plate assembly.

Dayton One-Year Limited Warranty- Dayton General purpose solenoid valves, Mod&s 1A576 thru 1451, 3.4433. 3A434 3A436 4A697, 4A699 & 4.4700, arewarranted by Dayton Electric Mfg. Co. (Dayton) to the original user against defects In workmanship or materials under normal use for one year after dateof purchase. Any part which is determined to be defective in material or workmanship and returned to an authorized serir!ce location, as Daytondesignates, shipping costs prepaid, will be. as the exclusive remedy, repaired or replaced at Dayton’s option. For limited warranty claim procedures, seePROMPT DlSP05ON below. This limited warranty gives purchasers specific legal rights which vary from state to state.Limitation of liability. To the extent allowable under applicable law. Dayton’s liability for consequential arid Inciderital damages is expressly thsdaimecI.(5aytons liability in all events i limited to and shall riot exceed the purchase pike paid.Warranty Disclaimer. Dayton hat made a diligent effort to illustrate and describe the products in this literature accurately however, such illustrations anddescriptions are for the sole purpose of identification. and do not express orimplya warranfythat the products are merchantable, orfit for a particularpurpose, or that the products will necessarily conform to the illustrations or descriptions.Except as prtsnded below, no warranty or affirmation of fact, expressed or impliea other than as stated in the LJMITED W,4RRANfl” above is made orauthorized by Dayton.Product Suitability. Many states arid localities have codes and regulations governing sales, constructiort installation. anchor use of products for Certainpurnoses which may vary from those in neighboring areas. While Dayton attempts to assure that its products comply with such codes it cannot guaranteecompliance, and cannot be responsible for how the product is installed or used Before purchase and use of a product, please reri’, the productapplication, and national and local codes arid regulations, arid be sure that the product instailation, and use will comply with them.Certain aSpects of disdairners are not anpilcable to consumerproducte e.g. (a) some states do not allow the exclusion or limitation of incidental orconsequential damages; so the above l1,7,ita tion or exclusion may not apply toyou (b) also, some states do not allow a limitation on how long art frnpliedwarranty lasts, consequentially the above limitation may not apply to you and Ic) bylaw, during the period of this limited warranty, any implied warrantyof implied merchantability or fit’ess for a particular purpose applicable to consumer products purchased by consumen. may not be excluded or otherwisedisclaimed.Prompt Di3pasition, Dayton will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to bedefective within limited warranty. For any product believed to be defective within limited warran hot write or call dealer from whom the producr waspurchased. Dealer wIll give additional directions. if unable to resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address dare,and numberof dealers invoice, and describing the nature of the defect Title anti risk of loss pass to buyer on delivery to common tamer, ifproduct wasdamaged in transit toyoi file claim with carrier.

Manufactured for Dayton Electric Mfg. Co., 5959 W. Howasrd St. Miles, Illinois 60714 U.S.A. - -

Dayton7

SECTION 7

C

Operation & Maintenance MnuaiPacethis rrtariuai with valve, or person. responsible for:rnaintenanceoftheialve.

YOUR PRODUCT INFORIA TION:Mødel Number: C. SD) V

Date: 412 CS

Serial Number:__________________Valve Size: 2LSolenoid:_______________________

High Quality Valves Built tu LasL..

F1_OMATK7VALVES15 PRLJYN’S ISLAND DRIVEGLENS FALLS, MY 12801

800-833-2040 * 518-761-9797 Fax; 518-761-9798worIawideweb:i/www.flomatccom e-maii: fIornatic@flomatic.com

Model CSO1/CF8UI & C8O2/CfO2-So1ezzoid Control Vaive(OnVjJ- Non-Throttling)

4

FILE; c;wI&:Rei- 2

CAUSEL Main valve is air bound.2. Shut-off (isolation) valve at the outlet side of control is

closed.3. Indicator stuffing box or sight glass is leaking.4. Rumured diaphragm- in pilot valve. (Evidenced by ieak

from -vent hole itt sormg chamber.)5. Fouledoriuice or needle valve.6. Fouiedstrainer.7. Damagedpilot valve seat.8. Ruptured-diaphragmin main valve.

V 9 Sticksor stones lodged under seat of rnaitr valve.10; Worn seat packing and/or seat ring in main valve.

• ii. incorrect:adfustmentofpunt valve (set too high).V 12. Leakagefrom-one-or more fittings in the controls.

13. Damaged 0-ring stem seal.

B. PROBLEM: Valve is dosed arid Will not open.

I. Incorrect adjusflnent ofpiiot valve (Set too low)2. Needle valve (if instalLed open too far.3. Shutoff (isolation) valve at the outlet side of the con

troig Es close±4. Fouled pilot valve5.• Worrior eroded oriflee (or needle valve seat).

1 Valve isoversized.2. Flow control vaive (or needle-valve atthe outlet side of

controls) is out of adjustment.3. Pilot valve seat packing is damaged.

CORRECTION1. Onen uS” air bleeder at the top -of valve to release air.2. Open shut-off valve.3. Tighten packing nut or replace packine seals.4. Replace dianhraawi.S. Open needle valve wide (counter ciockwise) to flush seat.

& after 4 or 5 seconds return to original- setting, or- removeand clean orifice.

6. Disassemble, clean or- replace screen7. Disassemble, clean and replace damaged parts.8. Disassemble and replacediaphragm.9 Disassemble- and.rernove.. Rez,lace damaged parts.

10 Disassemble and replace damaged parts.11. For back pressure valve turn adjusting screw counter

clockwise slowly until valve resumes control and- the desired outlet pressure is obtained.

12. Tighten or replace fitting.13. Disassemble and. replace Oring.

I. Turn pi-lot.vait’e adjusting screw clockwise slowly untilthe valve opens and the desired outlerpressure is obtained.

2. Tmn adjusting can clockwise slowly until valve opensand a reduced outlet pressure is- observed. Lock in -thispostion.

3. Open shut-off (isolation) valve.4. Disassemble and clean, replace seat ringJpacking is nec

essary.-

5. Replace orifice (-or needle valve).

1. Install; a smaller pressure reducing valve in a bypassaroundthe oversized valve to handle low flows and pro-side better control.

2. Slowly- turn adjusting cap counter clockwise until theoutlet pressure becomes steady.

3. Replace seat packing.

Test To Isolate Source Of Problem(After visual insoection of external leaks)

1. With the main line gate valves open and the reducing valve pressurized, close the control shut-off (isolation) valveat the outlet side of the pressure reducing pilot control. THE MAIN VALVE SHOULD CLOSE.

If the valve remains fully open the source of the problem could be:(A) fouled ordice or needle: (B)fou/ed strainer: (C) control shut offvaise at in/er is closed: (D) rziprured main valve diaphragm

If the-valve is partially closed the source of the problem could be:IA) damaged: main valve seat packing or seat ring: (B) debris under seat: (C) nyain a/re is air-hound: ID) damagcd srem

If the valve closes fully, the source of the problem could be:(4) astor ass r’ out ofad;ucirn ‘it (B) amagea puof a/se stem or Sc! dug ‘j ,arnalls loule’ sri aires ir seele ta/ic

2. With the main line gate valves open and the reducing valve pressurized, close both shut-off (isolation) valves andopen the air bleeder pet cock to release water out of the power chamber above the diaphragm of the reducing valve.Water will flow from the pet cock as the valve moves to the full open position.

If water continues to flow, the source of the problem could he:(A) damaged: maims salve diaphragm or stem seal 0-ring: (B) loose locknut.

TROUBLE SHOOTING GUIDEA. PROBLEM : Valve opens and will not close resulting in excessive outlet pressure.

C. PROBLEM: Valve hunts or chatters (evidenced by rapidly changing outlet pressure).

(

C.

0 cn 0 z

11

H

I p ii ii

0 (I)

I\)

0

C) O Fl’ 2. m z 0 C)

N (P I en

F! a a a

C)

1111 r

—

o

tn0 0 1

1J1

2n

00

n

C, SOLENOID CONTROL VALVE (ON/OFF - NON-THROTTLING)

The Model C801 Normally closed Solenoid Control Valve opens full when the solenoid control is energized andcldses drop tight when de-energized.

The Model C802 Normally open Solenoid Control Valve opens full when the three-way solenoid control is deenergized and closes drop tight when energized.

The solenoid pilot valve introduces control water to the diaphragm chamber of the main valve for closure andexhausts control water from the diaphragm chamber to open the valve. (The control fluid is usually water from thepipeline: however, a seoarate source of higher pressure may be used when desired.)

Part List

I. Shut-Off Valve2. Strainer3. OriflcefNeedle Valve)4. Solenoid5 Finger Strainer

SHIPMENT:

INSTALLATION:

START-UP:

When shipped, controls are usually mounted on the main valve. If controi subassembliesare shipped separately. all connectionsare tagged to insure correct assembly.

1. Flush the pipeline before inserting the valve.2. Install the valve with the “arrow’ on body pointing towards the reduced pressure area

(or with the flange tagged “INLET” toward the hign pressure area).3. Attach subasseniblies to main valve if necessary.4. Install 1/4” pet cocks at the backside of valve.5. Allow enough clearance above valve for removal of piston assembly.

1. Install pressure gauges to inlet and outlet pressures.2. Open both shut-off valves on the control assembly.3. Open 1/8” air bleeder at the top of the valve. (Re-close after step 4 or step 5.)4. Open main line shut-off valve (usually a gate or outterfiy valve) on the outlet side of the

main valve about 1/4 open.5. Slowly open main line shut-off valve on the inlet side and observe pressure gauges.

When the outlet pressure gauge shows that the downstream pressure is being controlled.this shut-off valve may be opened more rapidly.

6. If the outlet pressure requires adjustment. turn the adjusting screw of the pilot valvecounter cock’vise to decrease, clockwise to increase. CAUTION: any adjustmentshould be done slowly.

L

SECTION 8

MODEL fl -1/96

Installation, Operation, Maintenance Manual

Model 420 Pressure Reducing Valve

DESCRIPTION IN LINE STATIC TEST

The valve maintains a constant downstream pressureregardless ofdemand or changing upstream pressure.The reducing pilot senses downstream pressure andmodulates the main valve to maintain the setpoinr.

When downstream pressurefalls below the setting ofthe reducingpilot, the pilot opens allowing the mainvalve to open to increase pressure to the setpoint. Whendc tream pressure rises above the setting ofthere.. ng pilot, the pilot closes causing the main valve tothrottle toward a closed postion to maintain the setpoint.

A ball valve is incorporated to provide a means ofmanual shut-offfor drip-tight closure.

INSTALLATION

1. Ailow enough room around the valve assembly formaking adjustments and for future maintenance anddisassembly work.

2. Thoroughly flush the pipeline to remove dirt, scale, anddebris. Failure to perform this operation may render thevalve inoperable.

3. It is recommended that isolation gate valves be installedupstream and downstream of the Bermad control valve toallow for future maintenance operations.

4. Install the valve in the pipeline with the valve flow arrowon the body casting in the proper direction. Install thevalve horizontally with the cover up for best performance.Make certain the valve is positioned so the cover assemblycan be easily removed for future maintenance requirements.

5. After installation carefully inspect/correct any damagedaccessories, piping, tubing, or fittings.

c

Open Valve Static Test1. Remove a pipe plug or tube fitting on the top cover ofthe main valve.

CAUTION: This will allow the valve to fully open.Make sure this condition wil not cause system damage!

2. Check for leaks at the flange connection, fittings, etc.

Closed Valve Static Test1. Turn adjusting screw on reducing pilot fully counter

clockwise (CCW) and shut cock valve 1.2. Vent trapped air in the main valve cover by loosening a

tube fitting or pipe plug on the cover. This will trap themain valve in a closed position while the pipeline ispressurized.

3. Check the valve cover and diaphragm area for leaks.Tighten fittings and bolts if necessary.

START-UP OPERATION

NOTE: There must be flow/pressure through the valve andsystem to check and adjust the valve. Ensure that adownstream demand is created.1. Turn adjusting screw on reducing pilot fully counter

clockwise (CCW) until all spring tension is relieved.Main valve will close.

2. Open fully pipeline gate or butterfly valves if applicable.

Main valve should still remain closed.3. Vent trapped air in the main valve cover by loosening a

tube fitting or pipe plug on the cover.4. Slowly turn adjusting screw on reducing pilot (CW)

until the valve just begins to open. Continue to slowlyturn adjusting screw (CW) until desired setting isreached. Turning adjustment screw CW increases

downstream pressure and turning CCW decreases. Tightenlocknut.

-

I —

22

_—:..‘ Picstc :uie

S:nrer .•c’;e

:;onhrc,j Qrjfic — iosin; ::‘Afl /C/

MODEL 420 Pressure Reducing Valve :

--

29 -

TROUBLESHOOTING

SYMPTOM CAUSE REMEDY

Valve Fails to Open Insufficient inlet pressure. Check/create inlet pressure.

No downstream demand.

Insufficient spring compression onpressure reducing pilot 28A.

Ball valve 2 closed.

Create demand/flow.

Turn adjusting screw on pressure reducingpilot 28A clockwise.

Open ball valve 2.

Valve Fails to Closeor Regulate

Filter 4A plugged/Insufficient springtension on pilot 28A.

Orifice fitting 31 plugged.

Remove in-line filter 4A and clean screen/Turnadj. screw on pilot 28A CCW.

Remove orifice fitting 31 and clean.

Regulated pressure pulsates or hunts.

Debris trapped in main valve!Diaphragm in main valve leaking.

Bleed air from valve cover. Ensure flow rate isabove reconmiended minimum.

De-pressurize the system and remove valvecover and diaphragm to inspect/remove debris.Replace diaphragm if necessary.

Unwind adj. screw on pilot 28A filly CCW,shut bail valve 2 and remove control tubingbetween port #2 and ball valve 2. If leaklflowexists from the pilot, replace pilot/inspect fordebris or defective part.

—

__ Dr :

•!rrr i•(]e WOWfl3trm)

3 Cno rice — .1o;no .Decc

-‘I,-

7

Pilot 28A not serviceable.

4070 Leaverton Court - Anaheim, CA. 92807 - (714) 666-1100 C

SECTION 9

(h K t

iw .: :.;jSuction S;r n

Self-Cleaning Suction ScreenSpecs

aick Photo to view larger picturel1eaI’aff .ccaiw Sizgijri m1 If you irrigate, you know how

important it is to keepequipment runningsmoothly and water flowingfreely. Whether you arepumping water from a wastetreatment facility, manurelagoon, stream, canal, river,irrigationditch, pit or sump, or a golfcourse pond, you need thewater to be free of trash anddebris that could block waterflow and damage the pump ofclog water-distribution

The Clearwater Self-Cleaning Suction Screen is galvanized orepoxy coated and utilizes a heavy 10, 18, or 30 mesh stainlesssteel screen continuously removes trash and debris fromirrigation water that costs time and money in fuel, pumpingefficiency and maintenance costs. And it can be used foragricultural, turf, industrial, centrifugal turbine pumpapplications.The suction screen is attached to the end of thepump in the water source. All water pulled in must go throughthe screen before entering the intake pipe. The screen stopstrash and debris from entering, plugging lines and causingcostly maintenance repairs. The pump discharge return linedrives tvvo spray bars that continually rotate, jet water at thescreen at 35 to 100 PSI Operating Range.

The Clearwater screen- has no exterior moving parts that canbreak down or need repair. It can be installed at any attitudewithout the operation being affected and is un-collapsible and

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