Water Process Solutions Encore 700 Operation & Maintenance Manual
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Water Process Solutions Encore 700 Operation & Maintenance Manual

Diaphragm metering pump
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®
ENCORE
700 DIAPHRAGM
METERING PUMP
MANUAL NO. WT.440.400.001.UA.IM.1012
V 2.0

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Summary of Contents for Water Process Solutions Encore 700

  • Page 1 ® ENCORE 700 DIAPHRAGM METERING PUMP MANUAL NO. WT.440.400.001.UA.IM.1012 V 2.0...
  • Page 3 ® ENCORE DIAPHRAGM METERING PUMP MANUAL NO. WT.440.400.001.UA.IM.1012...
  • Page 4 ® ENCORE 700 METERING PUMP EQUIPMENTSERIAL NO. _____________________________ DATE OF START-UP ________________________________ START-UP BY ____________________________________ Prompt service available from nationwide authorized service contractors. ORDERING INFORMATION In order for us to fill your order immediately and correctly, please order material by description and part number, as shown in this manual.
  • Page 5 ® ENCORE 700 METERING PUMP INTRODUCTION This manual provides installation, operating, and maintenance instructions for the Encore® 700 Diaphragm Metering Pumps, here in after referred to as the "pump" or "metering pump". The pump provides accurate metering and transfer of a wide variety of chemicals. It is available in six head sizes, three gear ratios, direct and pulley drive configurations, and a single or double simplex configuration.

  • Page 6: Table Of Contents

    ® ENCORE 700 METERING PUMP Table of Contents Very Important Safety Precautions ........SP-1,-2,-3 Preventive Maintenance Schedule and Record of Performance ................1.010-13 Notes on Protective Equipment and Clothing ......1.010-6 Protect Your Equipment Investment ........1.010-5 Headquarters ................1.010-1 Technical Data ..............Section 1 Installation .................

  • Page 7: Very Important Safety Precautions

    ® ENCORE 700 METERING PUMP VERY IMPORTANT SAFETY PRECAUTIONS This page provides very important safety information related to safety in installation, operation, and maintenance of this equipment. WARNING TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVE THE FOLLOWING: THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED AND SERVICED ONLY BY TRAINED, QUALIFIED PER- SONNEL WHO ARE THOROUGHLY FAMILIAR WITH THE ENTIRE CONTENTS OF THIS INSTRUCTION MANUAL.
  • Page 8 ® ENCORE 700 METERING PUMP VERY IMPORTANT SAFETY PRECAUTIONS (CONT'D) CONSULT YOUR REPRESENTATIVE IF THE PUMP IS TO BE USED UNDER CONDITIONS OTHER THAN ORIGINALLY SPECIFIED AND IF THERE IS ANY QUESTION REGARDING THE SIZE OF THE DISCHARGE LINE. USE RIGID PIPE WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED PRESSURE/TEMPERA- TURES ARE ENCOUNTERED.
  • Page 9 DO NOT DISCARD THIS INSTRUCTION MANUAL UPON COMPLETION OF INSTALLATION. INFORMATION PROVIDED IS ESSENTIAL FOR PROPER AND SAFE OPERATION AND MAINTENANCE. ADDITIONAL OR REPLACEMENT COPIES OF THIS INSTRUCTION MANUAL ARE AVAILABLE FROM: Water Process Solutions Unit 10 Mill Hall Business Estate Aylesford, Kent, ME20 7JZ Phone: +44(0) 1622719945 Email: enquires@waterprocesssolutions.com...

  • Page 10: Preventive Maintenance Schedule And Record Of Performance

    ® ENCORE 700 METERING PUMP PREVENTIVE MAINTENANCE SCHEDULE AND RECORD OF PERFORMANCE This equipment should receive preventive maintenance on a one (1) year cycle.* It is recommended that the following table be used to plan, schedule, and record this important work. Date of Installation Preventive Maintenance Log Schedule Date...

  • Page 11: Notes On Protective Equipment And Clothing

    ® ENCORE 700 METERING PUMP NOTES ON PROTECTIVE EQUIPMENT AND CLOTHING The following Warning appears in several locations in this manual. It is general in nature due to the variety of hazardous liquids this equipment is capable of handling. WARNING: WHEN DEALING WITH HAZARDOUS MATERIAL, IT IS THE RE- SPONSIBILITY OF THE EQUIPMENT USER TO OBTAIN AND FOLLOW ALL SAFETY PRECAUTIONS RECOMMENDED BY THE HAZARDOUS MATERIAL MANUFACTURER/SUPPLIER.
  • Page 12 ® ENCORE 700 METERING PUMP Quality Preventive Dependable Operation Equipment Maintenance Minimum Downtime There's no question about it. Equipment that is properly maintained is dependable equipment. It will give optimum performance with minimum unscheduled downtime. WPS manufactures quality equipment designed for performance and reliability. Each product is carefully tested and inspected before shipment to ensure that it meets our high standards.

  • Page 13: Headquarters

    Direct any questions concerning this equipment that are not answered in this instruction manual to the reseller from whom the equipment was purchased. If the equipment was purchased directly from WPS, contact the office indicated below. UNITED Kingdom Water Process Solutions Unit 10 Mill Hall Business Estate Aylesford, Kent, ME20 7JZ Phone: +44(0) 1622719945 Email: enquires@waterprocesssolutions.com...
  • Page 14 ® ENCORE 700 METERING PUMP WT.440.400.001.UA.IM.1012...

  • Page 15: Illustrations

    ® ENCORE 700 METERING PUMP SECTION 1 - TECHNICAL DATA List of Contents PARA./DWG. NO. Technical Data ............1.1 Material Identification/Composition ......1.2 Pump Capacity ............1.3 Pump Compatibility ..........1.4 Illustrations Chemical Compatibility of Metering Pumps - Performance ..........440.050.190.010A-F WT.440.400.001.UA.IM.1012...

  • Page 16: Technical Data

    ® ENCORE 700 METERING PUMP Technical Data The overall technical characteristics of the Encore® 700 Series Metering Pumps are listed in Table 1.1. Material Identification/Composition The chemical composition of materials used in the manufacture of the metering pump is listed in Table 1.2. Pump Capacity The pump capacity for the direct and pulley drive configurations are listed in Table 1.3.
  • Page 17 ® ENCORE 700 METERING PUMP Table 1.1 - Encore® 700 Series Metering Pump - Technical Data Pump Type Non-Loss Motion, Mechanical Diaphragm Metering pump. Simplex and double simplex capabilities. Diaphragm Type Teflon®-faced single piece mechanical diaphragm, Six sizes: 1-3/8", 2", 3", 4", 5" and 6-1/2". Service Metering of mild to very corrosive chemicals;...
  • Page 18 ® ENCORE 700 METERING PUMP Table 1.2 - Encore 700 Series Metering Pump - Material Identification/Composition COMMON TERM COMPOSITION Ceramic 99% aluminum oxide. Hypalon®* A chlorosulphonated polyethylene. Kynar®** (PVDF) Polyvinylidene fluoride. Polyvinyl chloride. Stainless 316 AISI 316 - Cr 16-18% Ni 10-14%, C 0.08%, Mn 2%...

  • Page 22: Chemical Compatibility Of Metering Pumps

    ® ENCORE 700 METERING PUMP WARNING: WHEN DEALING WITH HAZARDOUS MATERIALS, IN ALL CASES THE HAZARDOUS MATERIAL SUPPLIERS OR MANUFACTURERS' RECOMMENDATIONS FOR SAFETY PROCEDURES MUST BE OBTAINED AND FOLLOWED. CHEMICAL COMPATIBILITY OF METERING PUMPS - PERFORMANCE 440.050.190.010A ISSUE 0 8-95 WT.440.400.001.UA.IM.1012...
  • Page 23 ® ENCORE 700 METERING PUMP CHEMICAL COMPATIBILITY OF METERING PUMPS - PERFORMANCE 440.050.190.010B ISSUE 0 8-95 WT.440.400.001.UA.IM.1012...
  • Page 24 ® ENCORE 700 METERING PUMP CHEMICAL COMPATIBILITY OF METERING PUMPS - PERFORMANCE 440.050.190.010C ISSUE 0 8-95 WT.440.400.001.UA.IM.1012...
  • Page 25 ® ENCORE 700 METERING PUMP CHEMICAL COMPATIBILITY OF METERING PUMPS - PERFORMANCE 440.050.190.010D ISSUE 0 8-95 WT.440.400.001.UA.IM.1012...
  • Page 26 ® ENCORE 700 METERING PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT WHEN DEALING WITH ANY CHEMICAL, IT IS THE RESPONSIBILITY OF THE EQUIPMENT USER TO OBTAIN AND FOLLOW THE SAFETY PRECAUTIONS OF THE MANUFACTURER OF THE CHEMICAL. RATING KEY ACCEPTABLE SATISFACTORY WHERE MINOR ATTACK IS ACCEPTABLE...
  • Page 27 ® ENCORE 700 METERING PUMP WARNING: DRIED RESIDUE OF SPILLED 30. HYPALON TO 130°F SOLUTIONS IS EXPLOSIVE. 31. PVC TO 100°F, 50%, SS TO 100°F, 50% SS TO180°F 32. PVC TO 70°F, 10%, SS TO 70°F, 10% PVC TO 125°F 34.
  • Page 28 ® ENCORE 700 METERING PUMP WT.440.400.001.UA.IM.1012...
  • Page 29 ® ENCORE 700 METERING PUMP SECTION 2 - INSTALLATION List of Contents PARA./DWG. NO. General Information ............2.1 Unpacking ................. 2.2 Mounting the Pump ............2.3 Pipe Line Diameter ............2.4 Tubing ................... 2.5 Installation ..............2.6 Illustrations Typical Installation Simplex Manual Arrangement .......

  • Page 30: General Information

    ® ENCORE 700 METERING PUMP General Information To provide satisfactory service, the metering pump must be installed in accordance with the instructions that follow. Operational difficulties, lack of accuracy, and possible damage to the pump mechanism may occur if these instructions are not followed properly. Unpacking When the pump is unpacked, check all items against the packing list to make sure that no parts are discarded with the packaging material.

  • Page 31: Pipe Line Diameter

    ® ENCORE 700 METERING PUMP d. If a pulsation dampener is required to reduce pressure peaks, install it in the discharge line. Refer to Dwgs. 440.400.110.010, 020, 030, and 040. The dampener will minimize vibrations and reduce wear due to long lines and/or high stroking speeds. NOTE: Take care not to drip pipe primer or cement into valves.

  • Page 32: Installation

    ® ENCORE 700 METERING PUMP Table 2.1 - Pressure/Temperature Ratings for Suction and Discharge Tubing Maximum Working Pressure (psi) at HEAD TUBE SIZE MATERIAL 60°F 73°F 100°F 120°F 1-3/8" 1/4" x 3/8" Polyethylene 2" 3/8" x 1/2" Polyethylene NOTE: Tubing connection is available on 1-3/8" and 2" heads only. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED PRES- SURE/TEMPERATURES ARE ENCOUNTERED, USE RIGID PIPE.

  • Page 33: Simplex Manual Arrangement

    ® ENCORE 700 METERING PUMP NOTES: ( ) INDICATES DIMENSIONS IN MILLIMETERS. RECOMMENED MINIMUM HEIGHT FROM FLOOR TO VALVE CONNECTIONS SHOULD BE 12" (305). SIMPLEX MANUAL ARRANGEMENT - SPACE RECOMMENDATIONS 440.400.110.010 ISSUE 2 2-98 WT.440.400.001.UA.IM.1012...

  • Page 34: Double Simplex Manual Arrangement

    ® ENCORE 700 METERING PUMP NOTES: ( ) INDICATES DIMENSIONS IN MILLIMETERS. RECOMMENED MINIMUM HEIGHT FROM FLOOR TO VALVE CONNECTIONS SHOULD BE 12" (305). DOUBLE SIMPLEX MANUAL ARRANGEMENT - SPACE RECOMMENDATIONS 440.400.110.020 ISSUE 2 2-98 WT.440.400.001.UA.IM.1012...

  • Page 35: Suction Lift

    ® ENCORE 700 METERING PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED TEMPERATURES/PRESSURES ARE ENCOUNTERED, USE RIGID PIPE. METERING PUMPS - TYPICAL INSTALLATION - Suction Lift 440.400.110.030 ISSUE 1 2-98 WT.440.400.001.UA.IM.1012...

  • Page 36: Flooded Suction

    ® ENCORE 700 METERING PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED TEMPERATURES/PRESSURES ARE ENCOUNTERED, USE RIGID PIPE. METERING PUMPS - TYPICAL INSTALLATION - Flooded Suction 440.400.110.040 ISSUE 1 2-98 WT.440.400.001.UA.IM.1012...

  • Page 37: Flooded Suction & Vent Riser

    ® ENCORE 700 METERING PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED TEMPERATURES/PRESSURES ARE ENCOUNTERED, USE RIGID PIPE. METERING PUMPS - TYPICAL INSTALLATION - Flooded Suction & Vent Riser 440.400.110.050 ISSUE 1 2-06 WT.440.400.001.UA.IM.1012...

  • Page 38: Installation Wiring

    ® ENCORE 700 METERING PUMP NOTES: FIELD WIRING (NOT BY WPS ) MUST CONFROM TO LOCAL ELECTRICAL CODES. ALL VOLTAGES SHOULD BE 50/60 HZ. METERING PUMPS - INSTALLATION WIRING - For Intermittent Start-Stop Operation 440.400.130.010 ISSUE 3 4-09 WT.440.400.001.UA.IM.1012...
  • Page 39 ® ENCORE 700 METERING PUMP SECTION 3 - OPERATION List of Contents PARA. NO. Preparation for Operation ............3.1 Starting and Stopping the Pump ..........3.2 Intermittent Start-Stop Operation ........... 3.3 Adjustment of Feed Rate ............3.4 Frequency of the Pump Stroke ..........3.4.1 Length of the Pump Stroke .............

  • Page 40: Preparation For Operation

    ® ENCORE 700 METERING PUMP Preparation for Operation a. Fill the solution container with solution. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, USE EX- TREME CARE TO AVOID CONTACT WITH THE MATERIAL. CONSULT YOUR CHEMICAL SUPPLIER FOR INSTRUCTIONS IN THE PREPARATION OF SOLUTIONS AND THE HANDLING OF CHEMICALS.

  • Page 41: Intermittent Start-Stop Operation

    Frequency of the Pump Stroke Thefrequencyofthepumpstrokeisdeterminedbythe gearratioof the speed reducer. Available speeds for the Encore 700 are listed in Table 3.1: Table 3.1 - Pump Gear Ratios and Speeds Available Number of Strokes...

  • Page 42: Strength Of The Solution

    ® ENCORE 700 METERING PUMP the stroke length. Numbers on the scale represent percent stroke. Each full turn of the knob will result in a 10% change of the stroke length. Each graduation on the circular scale on the knob is equal to 0.25%.

  • Page 43: Theory Of Operation

    ® ENCORE 700 METERING PUMP Theory of Operation The theory of operation for the Encore® 700 Mechanical Diaphragm Metering Pump is addressed by discussing the operation and interrela- tionships of the following assemblies: • Pump Drive Mechanism • Speed Reducer •...

  • Page 44: Liquid Ends

    ® ENCORE 700 METERING PUMP Combination of a linear scale (0 to 100%) on the stroke control housing and a circular scale (0 to 10) provides an accurate micrometer-type set- ting of the stroke, with a resolution of 0.25%. Liquid Ends NOTE: Refer to the List of Contents for Section 5 - Illustrations to identify the applicable drawings.
  • Page 45 ® ENCORE 700 METERING PUMP SECTION 4 - SERVICE List Of Contents PARA./DWG. NO. General ................4.1 Periodic Cleaning ............4.2 Cleaning Pumping Head Parts ........4.2.1 Cleaning Clogged Solution Tube ........4.2.2 Periodic Preventive Maintenance ......... 4.3 Gearbox Lubrication ..........4.3.1 Priming Troubles or Loss of Suction ......

  • Page 46: General

    ® ENCORE 700 METERING PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP- MENTDAMAGE FROM BEING SPRAYED WITHLIQUID UNDER PRESSURE, PRIOR TO DISASSEMBLY OF PIPE CONNECTIONS, REFER TO DETAILED INSTRUCTIONS ON RELIEVING PRESSURE AND DRAINING. General Routine maintenance of the metering pump consists of two operations: •...

  • Page 47: Cleaning Clogged Solution Tube

    ® ENCORE 700 METERING PUMP Cleaning Clogged Solution Tube Where solution joins water being treated and that water contains consid- erable hardness, there may be a deposit formed inside the solution tube at the point of application. In time, this can completely plug this tube and the deposit must be removed.

  • Page 48: Gearbox Lubrication

    ® ENCORE 700 METERING PUMP Gearbox Lubrication (Refer to Dwg. 440.400.000.010) The gearbox is filled with approximately two quarts of mineral oil SAE85W90 gear oil. This lubricant must be replaced annually to realize optimum performance of the mechanism. The first oil change is recom- mended after six months of operation.

  • Page 49: Hazardous Properties Of Sodium Chlorite

    ® ENCORE 700 METERING PUMP the pump will not reprime itself due to compression and re-expansion of the air trapped in the pump head. If the system is installed in accordance with Dwgs. 440.400.110.030 or 440.400.110.040 (located in Section 2 - Installation) using a backpres- sure valve and/or pressure relief valve, the discharge drain valve may be opened to allow the pump to prime against atmospheric pressure.

  • Page 50: Cleaning The Pump

    ® ENCORE 700 METERING PUMP Sodium chlorite dissolves easily in water at ordinary temperatures to form a cloudy, white solution. This solution is chemically stable under ordinary conditions of temperature and pressure. When received in loose flake form in metal containers, sodium chlorite will stand considerable rough handling.

  • Page 51: Inspection

    ® ENCORE 700 METERING PUMP and the discharge line shut-off valve. e. Remove the pump head. Flush away any spilled solution not caught in the container with ample quantities of water. f. Immerse the pump head, valves, and lines that were removed in lukewarm water for two minutes.

  • Page 52: Removing Pump From Service And Disassembling Valves, Head, And Diaphragms

    ® ENCORE 700 METERING PUMP leaks when they are found, to avoid corrosion damage. Flush away spilled solution with water and wipe the parts clean and dry. Maintain gasketed joints in good condition. Keep an adequate supply of gaskets and O-rings available so that repair of leaks can be accomplished without delay.

  • Page 53: Removing Suction And Discharge Valves

    ® ENCORE 700 METERING PUMP Removing Suction and Discharge Valves WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY, USE EX- TREME CARE TO AVOID CONTACT WITH LIQUID PRESENT IN THE HEAD. ALLOW THE SUCTION VALVE TO FALL INTO A SUITABLE CONTAINER AND CATCH THE LIQUID.

  • Page 54: Valve And Diaphragm Replacement

    ® ENCORE 700 METERING PUMP Valve and Diaphragm Replacement NOTE: The 1-3/8", 2", 3", and 4"diaphragms utilize a circular back-up ringscrewed onthe diaphragm insert. When replacing the diaphragm, unscrew the back-up ring for reuse. A Teflon disc is inserted between the diaphragm and the back-up ring.
  • Page 55 ® ENCORE 700 METERING PUMP h. Clean the bellow clamp and remove any sharp edges along the area that makes contact with the bellow seal. Do the same to the plunger. Apply silicone grease to the O-ring and position it into the gearbox. Hold and centralize the plunger while inserting the adapter.

  • Page 56: Disassembly Of Complete Pump

    ® ENCORE 700 METERING PUMP Disassembly of Complete Pump WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP- MENT DAMAGE, TURN POWER OFF BEFORE SERVICING. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM BE- ING SPRAYED BY LIQUID UNDER PRESSURE, ALLOW SYSTEM TO DRAIN FULLY BEFORE ATTEMPTING TO DISASSEMBLE PIPING AND REMOVING VALVES OR HEADS.
  • Page 57 ® ENCORE 700 METERING PUMP a. Remove the gearbox cover, as described in step a, above. b. Drain the gearbox oil. c. Remove the worm shaft assembly (51) by pulling it up. NOTE: Two bearings (6) and (7) and a shim combination (12-15) come out with the assembly.
  • Page 58 ® ENCORE 700 METERING PUMP NOTE: The set screws (48) are coated with Nylok to seal. If set ™ screws were removed or are leaking, replace with a new one. c. With a 6mm Allen wrench, remove one M8 screw (21) from the eccentric shaft (45), which is accessible through the carrier bear- ing (22) end opening.
  • Page 59 ® ENCORE 700 METERING PUMP • Eccentric Assembly, Taper Roller Bearings, Connecting Rod, Stroke Control Housing, and Knob Replacement (refer to Dwg. 440.400.000.010B) Reverse the removal procedures for the replacement of the item mentioned above, however, the following additional procedures must be adhered to: a.
  • Page 60 ® ENCORE 700 METERING PUMP Figure 4-1. Eccentric Shaft Alignment h. Rotate the eccentric shaft assembly (45) and take the indicator reading at two locations, 180° apart, and along the eccentric travel of the sheave. Both readings must be the same. If the readings are different, turn the carrier bearing clockwise or counterclockwise until a point is found where the readings are the same.
  • Page 61 ® ENCORE 700 METERING PUMP Figure 4-2. Stroke Control Alignment n. Push the knob past the O-ring for manual position (quad-ring for automatic position) until the front edge of the knob is in line with the zero percent line on the stroke control housing scale. o.
  • Page 62 ® ENCORE 700 METERING PUMP screws to the outside, shorter screws to the inside). Position the rubber coupling to the coupling flange. k. Measure the distance from the top surface of the motor support to the top surface of the rubber coupling ("A" dimension) and add to this dimension the depth of the groove ("B"...
  • Page 63 ® ENCORE 700 METERING PUMP g. Install the cover and tighten all bolts. h. Install the bigger pulley, smaller step on top, to the worm shaft all the way against the shoulder, and tighten the two set screws. Thread the three stand-offs tight against the shoulder to the gearbox cover.

  • Page 64: Troubleshooting

    Troubleshooting Troubleshooting of the Encore 700 Series Metering Pump consists of pro- cedures and instructions for repair and/or replacement of subassemblies and components. The troubleshooting procedures are limited to fault isolation toa defective item.
  • Page 65 ® ENCORE 700 METERING PUMP Table 4.3 - Troubleshooting Fault Condition Possible Cause Corrective Action No Feed Rate or Zero or insufficient stroke Adjust to proper stroke length. Insufficient Feed Rate. length. Ball valves on suction or Replace balls in valves. Remove discharge side do not close possible deposits in valves or pump tightly.
  • Page 66 ® ENCORE 700 METERING PUMP Table 4.3 - Troubleshooting (Cont'd) Motor is Hot, But Starts Overload protector has opened. Check supply voltage. Check When Cool. excessive pressure at point of application. Check binding pump mechanism. Belt is Noisy. Worn belt. Pulley misaligned. Replace belt.
  • Page 67 ® ENCORE 700 METERING PUMP WARNING LABELS AND TAGS The following warning labels and tags are attached to the equipment: ---------------------------------------------------------------------------------------------------- AAA3769: THIS EQUIPMENT MAY HANDLE HAZARDOUS MATERIALS WHICH CAN CAUSE SEVERE PERSONAL INJURY. OBSERVE THE FOLLOWING: THIS EQUIPMENT MUST BE INSTALLED, OPERATED, SERVICED BY TRAINED QUALIFIED PERSONNEL, WHO ARE THOROUGHLY FAMILIAR WITH THE CONTENTS OF THE INSTRUCTION BOOK.

  • Page 68: Automatic Slurry Flushing System - Service

    ® ENCORE 700 METERING PUMP AUTOMATIC SLURRY FLUSHING SYSTEM - SERVICE 440.400.150.010 ISSUE 1 10-12 WT.440.400.001.UA.IM.1012...
  • Page 69 ® ENCORE 700 METERING PUMP SECTION 5 - ILLUSTRATIONS List of Contents DRAWING NO. Parts AIC3021 Direct Drive........440.400.001.010A&B AKG3009 (W2T417632) Pulley Drive ....440.400.001.020A&B ANM4784 Pump - Simplex Gearbox Assembly .............440.400.000.010A-D AAA1445 Pump - Double Simplex Gearbox Assembly .............440.400.000.020A-D AAB5792 (W2T9612) Detent Stroke Adjustment Kit ..........
  • Page 70 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST, SEE DWG. 44.400.001.015B. DIRECT DRIVE - PARTS 440.400.001.015A ISSUE 0 02-06 CF.440.400.0AB.IM.1114...

  • Page 71: Aic3021 Direct Drive

    W2T11128 Anti-Seize NI Lube 771  AAA1902 W2T11026 Label, Nameplate, Encore 700 NOTE:  Part of AAA9602 (W3T99430).  Part of API3492 (W2T417670)..Part of AOO4751. WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AIC3021 DIRECT DRIVE - PARTS LIST 440.400.001.010B...

  • Page 72: Akg3009 (W2T417632) Pulley Drive

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST, SEE DWG. 44.400.001.020B. AKG3009 (W2T417632) PULLEY DRIVE - PARTS 440.400.001.020A ISSUE 3 2-10 WT.440.400.001.UA.IM.1012...
  • Page 73 W2T11093 Breather Cap  AAA1902 W2T11026 Nameplate, Encore 700 NOTE:  Part of APQ4791.  Part of AOO4859..Part of AOO4751. WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AKG3009 (W2T417632) PULLEY DRIVE - PARTS LIST 440.400.001.020B...
  • Page 74 ® ENCORE 700 METERING PUMP 6, 8 10, 11 12, 14, 15 DIRECT DRIVE PULLEY DRIVE WORM POSIITON WORM POSITION NOTE: FOR PARTS LIST SEE DWG. 440.400.000.010C&D. ANM4784 ENCORE ® 700 METERING PUMP - PARTS Simplex Gearbox Assembly 440.400.000.010A ISSUE 2 2-98 WT.440.400.001.UA.IM.1012...
  • Page 75 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.000.010C&D. ANM4784 ENCORE ® 700 METERING PUMP - PARTS Simplex Gearbox Assembly 440.400.000.010B ISSUE 3 7-01 WT.440.400.001.UA.IM.1012...
  • Page 76  E942 W2T409235 Tape, Thread Sealant  AAA3726 Label, Dataplate, LMAD  AAA1902 W2T11026 Label, Nameplate, Encore 700  NOTE: PART OF AOO4751 • PART OF AJE4758 • PART OF ANM4767 PART OF AAA9593 PART OF AAA9596 PART OF APQ4775...
  • Page 77 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART ALT. PART QTY. DESCRIPTION APP5655 W2T11093 Breather Cap  APS4845 W2T417684 Shaft, Eccentric, 4.8mm Stroke (1-3/8" & 2" Liquid End Only)  ALI4852 W2T11404 Shaft, Eccentric, 9.6mm Stroke  AIA4800 W2T417615 Sheave, 4.8mm Stroke (1-3/8"...
  • Page 78 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.000.020C&D. AAA1445 ENCORE ® 700 METERING PUMP - PARTS Double Simplex Gearbox Assembly 440.400.000.020A ISSUE 3 7-01 WT.440.400.001.UA.IM.1012...
  • Page 79 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.000.020C&D. AAA1445 ENCORE ® 700 METERING PUMP - PARTS Double Simplex Gearbox Assembly 440.400.000.020B ISSUE 4 2-10 WT.440.400.001.UA.IM.1012...
  • Page 80 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION APQ5142 W2T417678 Gearbox, Simplex  AJA5697 W2T417624 Connection, DSplex,  AXS3656 W2T11182 Cap Scr., M8 x 20, Sock. Hd., 316SS  AKG4783 Bushing Drive, DSplex (5" and 6-1/2" Liquid End Only) ...
  • Page 81 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION APS4845 W2T417684 Shaft, Eccentric, 4.8mm Stroke  ALI4852 W2T11404 Shaft, Eccentric, 9.6mm Stroke  AIA4800 W2T417615 Sheave, 4.8mm Stroke  AIA4795 W2T11341 Sheave, 9.6mm Stroke ...

  • Page 82: Aab5792 (W2T9612) Detent Stroke

    ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AKG5547 W2T417641 NUT, PRELOAD ALE4774 W2T11422 O-RING (#152) BUNA-N ARQ3426 W2T11452 BEARING, 17 x 40 x 17.5MM AVM3239 W2T11162 WASHER, OVERSIZED OD, M8 AXS3656 W2T11182 CAP SCR.

  • Page 83: 1-3/8" Cartridge Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.050.010.010C&D. 1-3/8” CARTRIDGE LIQUID END - PARTS 440.050.010.010A ISSUE 2 4-09 WT.440.400.001.UA.IM.1012...
  • Page 84 ® ENCORE 700 METERING PUMP NOTE: ( ) INDICATES REFERENCED PARTS. 1-3/8” CARTRIDGE LIQUID END - PARTS 440.050.010.010B ISSUE 0 6-95 WT.440.400.001.UA.IM.1012...
  • Page 85 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION AKG5103 W2T11402 Disc, Backing, 1.375" Diaphragm ALI5124 W2T11408 Ring, Backup, 1.375" Diaphragm AQA3639 W2T11172 Screw, Cap, M8 x 100, Sock. Hd., 316SS AWO5392 W2T11160 Washer, Flat M8, 316SS AQO4074 W2T11475 Diaphragm, 1.375"...
  • Page 86 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION AMK5913 W2T11344 O-Ring (022) Viton, 25.121 ID x 1.78mm AMK5919 W2T11350 O-Ring (016) Viton, 15.60 ID x 1.78mm AOO4265 W2T11278 Spring, .50" Ball AAB9599 W2T8992 Guide, Polymer, .500"...

  • Page 87: 1-3/8" Threaded Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWG. 440.050.010.020B. 1-3/8” THREADED LIQUID END - PARTS 440.050.010.020A ISSUE 1 2-98 WT.440.400.001.UA.IM.1012...
  • Page 88 WASHER, FLAT M8 • ARE3624 W2T367157 SCREW, M8 x 60 SOCK. HD. CAP. (ENCORE 100) • AQA3639 W2T11172 SCREW, M8 x 60 SOCK. HD. CAP. (ENCORE 700)  AKG3575 W2T11198 O-RING, VITON, 11.3 x 2.4MM • RP684464 W2T16217 TUBING, .37" OD x .25" ID, POLYETHYLENE * AVAILABLE AS AN ACCESSORY.
  • Page 89 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION ALE4874 W2T367046 ADAPTER, 1.375" DIAPHRAGM *• AAB7205 W2T9156 SEAL, BELLOW, CROSSHEAD *• AJA5915 W2T11357 CLAMP, DIAPHRAGM, BELLOW • AMK4863 W2T11047 NUT, M14x 1 • AIA5111 W2T11335 SPACER, 1.375"...

  • Page 90: 2" Cartridge Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.050.010.030C&D. 2” CARTRIDGE LIQUID END - PARTS 440.050.010.030A ISSUE 2 4-09 WT.440.400.001.UA.IM.1012...
  • Page 91 ® ENCORE 700 METERING PUMP NOTE: ( ) INDICATES REFERENCED PARTS. 2” CARTRIDGE LIQUID END - PARTS 440.050.010.030B ISSUE 0 6-95 WT.440.400.001.UA.IM.1012...
  • Page 92 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AAA3323 W2T10795 Disc, Backing, 2" Diaphragm AJE4030 W2T11086 Ring, Backup, 2" Diaphragm AIC5296 W2T11339 Spacer, 2" Diaphragm AVM3618 W2T11163 Screw, Cap, M8 x 60, Sock. Hd., 316SS AWO5392 W2T11160 Washer, Flat M8, 316SS...
  • Page 93 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AMK5913 W2T11344 O-Ring (022) Viton, 25.121 ID x 1.78mm AMK5919 W2T11350 O-Ring (016) Viton, 15.60 x 1.78mm AOO4265 W2T11278 Spring, .50" Ball AAB9599 W2T8992 Guide, Polymer, .500" Ball, PVC AAA5905 W2T11300 Ball, .500"...

  • Page 94: 2" Threaded Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWG. 440.050.010.040B. 2” THREADED LIQUID END - PARTS 440.050.010.040A ISSUE 1 2-98 WT.440.400.001.UA.IM.1012...
  • Page 95 W2T11476 DIAPHRAGM, 2" TEFLON FACED AAA1044 W2T11100 SCREW, CAP, M8 x 65 SOCK. HD., 316SS (ENCORE 100) • AVM3618 W2T11163 SCREW, CAP, M8 x 60 SOCK. HD., 316SS (ENCORE 700)  AWO5392 W2T11160 WASHER, FLAT M8, 316SS • AMK3460 W2T367068 SEAT •...
  • Page 96 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AQO5451 W2T367150 ADAPTER, 2" DIAPHRAGM *• AAB7205 W2T9156 SEAL, BELLOW, CROSSHEAD *• AXS3583 W2T11181 SCREW, CAP, M8 x 25, SOCK. HD., 316SS • AJA5915 W2T11357 CLAMP, DIAPHRAGM, BELLOW •...

  • Page 97: 3" Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.010C&D. 3” LIQUID END - PARTS 440.400.010.010A ISSUE 3 4-09 WT.440.400.001.UA.IM.1012...
  • Page 98 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.010C&D. 3” LIQUID END - PARTS 440.400.010.010B ISSUE 2 4-09 WT.440.400.001.UA.IM.1012...
  • Page 99 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AAA3320 W2T10794 Disc, Backing APP4035 W2T11080 Ring, Backup AVM3599 W2T367176 Cap Screw, M8 x 55, Sock. Hd., 316SS AWO5392 W2T11160 Washer, Flat, M8, 316SS AQO5748 W2T11474 3"...
  • Page 100 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AOO5871 W2T11372 O-Ring (024) Viton, 28.3 ID x 1.78mm APQ5924 W2T11447 O-Ring (115) Viton, 17.12 x 2.62mm ANM4215 W2T10728 Spring, .625" Ball AAB9602 W2T416755 Guide, Polymer, .625" Ball, PVC AEK5860 W2T11298 Ball, .625"...

  • Page 101: Issue

    ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION APM5645 W2T367112 ADAPTER, 3" DIAPHRAGM *• AAB7205 W2T9156 SEAL, BELLOW, CROSSHEAD *• AXS3583 W2T11181 SCREW, CAP, M8 x 25, SOCK. HD., 316SS • AJA5915 W2T11357 CLAMP, DIAPHRAGM, BELLOW •...

  • Page 102: 4" Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.020C&D. 4” LIQUID END - PARTS 440.400.010.020A ISSUE 3 4-09 WT.440.400.001.UA.IM.1012...
  • Page 103 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.020C&D. 4” LIQUID END - PARTS 440.400.010.020B ISSUE 2 4-09 WT.440.400.001.UA.IM.1012...
  • Page 104 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AJE4048 W2T11087 Disc, Backing ALJ4039 W2T99904 Ring, Backup ARE3624 W2T367157 Cap Screw, M8 x 70, Sock. Hd., 316SS AWO5392 W2T11160 Washer, Flat, M8, 316SS ARQ5736 W2T11454 4"...
  • Page 105 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AMK5934 W2T367078 O-Ring (126) Viton, 34.59 ID x 2.62mm AMK5929 W2T367077 O-Ring (119) Viton, 23.47 x 2.62mm AAB9218 W2T365136 Spring, .75" Ball AAB9221 W2T8563 Guide, Polymer, .75" Ball, PVC ACG3819 W2T11262 Ball, .75"...
  • Page 106 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AKC5653 W2T367040 ADAPTER, 4" DIAPHRAGM *• AAB7205 W2T9156 SEAL, BELLOW, CROSSHEAD *• AXS3583 W2T11181 SCREW, CAP, M8 x 25, SOCK. HD., 316SS • AJA5915 W2T11357 CLAMP, DIAPHRAGM, BELLOW •...

  • Page 107: 5" Liquid End

    ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.030C&D. 5” LIQUID END - PARTS 440.400.010.030A ISSUE 3 4-09 WT.440.400.001.UA.IM.1012...
  • Page 108 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.030C&D. 5” LIQUID END - PARTS 440.400.010.030B ISSUE 2 4-09 WT.440.400.001.UA.IM.1012...
  • Page 109 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION ASG3633 W2T367165 Cap Screw, M8 x 80, Sock. Hd., 316SS AWO5392 W2T11160 Washer, Flat, M8, 316SS APM5758 W2T11477 5" Diaphragm ALI5285 W2T417651 Head, PVC AMK5290 W2T417657 Head, Kynar AAB2537...
  • Page 110 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AJE3882 W2T367029 O-Ring (134) Viton, 47.29 ID x 2.62mm AMK5934 W2T367078 O-Ring (126) Viton, 34.59 x 2.62mm ALI4222 W2T11325 Spring, 1.125" Ball AAB5987 W2T9476 Guide, Polymer, 1.125" Ball, PVC ABE3796 W2T11256 Ball, 1.125"...
  • Page 111 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AJA5631 W2T367024 ADAPTER, 5" DIAPHRAGM *• AAB7205 W2T9156 SEAL, BELLOW, CROSSHEAD *• AXS3583 W2T11181 SCREW, CAP, M8 x 25, SOCK. HD., 316SS • AJA5915 W2T11357 CLAMP, DIAPHRAGM, BELLOW •...
  • Page 112 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.040C&D. 6-1/2” LIQUID END - PARTS 440.400.010.040A ISSUE 1 2-06 WT.440.400.001.UA.IM.1012...
  • Page 113 ® ENCORE 700 METERING PUMP NOTE: FOR PARTS LIST SEE DWGS. 440.400.010.040C&D. 6-1/2” LIQUID END - PARTS 440.400.010.040B ISSUE 1 4-09 WT.440.400.001.UA.IM.1012...
  • Page 114 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AAA9089 W2T10042 Head, PVC AAA9116 W2T416687 Head, Kynar AAA9137 W2T416688 Head, 316SS AAA5283 W2T10474 Screw, Cap M8 x 120, Sock. Head, 316SS AWO5392 W2T11160 Flat Washer, M8, 316SS ...
  • Page 115 ® ENCORE 700 METERING PUMP KEY NO. LEGACY PART NO. ALT PART NO. QTY. DESCRIPTION AAC6437 W2T8384 Retainer/Guide, PVC, For Solution Only AAC6440 W2T8385 Retainer/Guide, Kynar, For Solution Only AAC5390 W2T416792 Retainer/Guide, SS, For Solution Only AJE3930 W2T417629 Retainer/Guide, PVC, For Slurry & Polymer ALI3938 Retainer/Guide, Kynar, For Slurry &...
  • Page 116 ® ENCORE 700 METERING PUMP KEY NO. PART NO. QTY. DESCRIPTION AAA9098 ADAPTER, 6.5" DIAPHRAGM AAB7205 SEAL, BELLOW, CROSSHEAD AXS3583 SCREW, CAP, M8 x 25, SOCK. HD., 316SS AJA5915 CLAMP, DIPHRAGM, BELLOW WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. 6-1/2”...
  • Page 117 SECTION 6 - PREVENTIVE MAINTENANCE KITS AND SPARE PARTS LIST List of Contents TABLE NO. Spares for Encore 700 ............6.1 1-3/8" Maintenance Kit, Cartridge Valves ......6.1.1 1-3/8" Maintenance Kit, Threaded Valves ......6.1.2 2" Maintenance Kit, Cartridge Valves ....... 6.1.3 2"...
  • Page 118 ® ENCORE 700 METERING PUMP Table 6.1 - Spares For Encore 700 Description Used On LEGACY Part Number ALT PART NO. 1-3/8" Head AAA1136 W2T110105 2" Head AAA1118 W3T108069 3" Head AAA1121 W3T108070 Diaphragm Maintenance Kit 4" Head AAA1124 W3T108071 5"...
  • Page 119 ® ENCORE 700 METERING PUMP Table 6.1.1 - 1-3/8" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 1-3/8" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon APS4297 W3T110398 316SS 316SS Viton...
  • Page 120 ® ENCORE 700 METERING PUMP WT.440.400.001.UA.IM.1012...
  • Page 121 ® ENCORE 700 METERING PUMP Table 6.1.3 - 2" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 2" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon AJE4773 W3T110389 316SS 316SS Viton...
  • Page 122 ® ENCORE 700 METERING PUMP Table 6.1.5 - 3" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 3" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon AOO4862 W3T110395 316SS 316SS Viton...
  • Page 123 ® ENCORE 700 METERING PUMP Table 6.1.6 - 4" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 4" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon AJE5023 W3T108932 316SS 316SS Viton...
  • Page 124 ® ENCORE 700 METERING PUMP Table 6.1.7 - 5" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 5" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon ANM5211 W3T108951 316SS 316SS Viton...
  • Page 125 ® ENCORE 700 METERING PUMP Table 6.1.8 - 6-1/2" Maintenance Kit, Cartridge Valves Guide LEGACY Guide Seat Ball Spring O-Ring ALT PART 6-1/2" Retainer Qty.  PART Material Material Material Material Material NUMBER Material NUMBER 316SS 316SS Hypalon AAA4982 316SS 316SS Viton AAA4985...
  • Page 126 ® ENCORE 700 METERING PUMP Table 6.2 - Adapter and Bellow Seal Kit Adapter With Pre-Installed Bellow Seal Pump Size LEGACY PART NUMBER ALT PART NUMBER 1-3/8" AAB9305 W3T108212 2" AAB9302 W3T108211 3" AAB9299 W3T108210 4" AAB9308 W3T110146 5" AAB9311 W3T108213 6-1/2"...
  • Page 127 ® ENCORE 700 METERING PUMP WT.440.400.001.UA.IM.1012...
  • Page 128 ® ENCORE 700 METERING PUMP SECTION 7 - CAPACITY TEST DATA CONFIGURATION: SERIAL #: PISTON SIZE: GPH: SPM: GEAR RATIO: BACK PRESSURE (PSI): MOTOR TYPE: CAPACITY IN GPH AT FULL RATED PRESSURE STROKE LENGTH PUMP 1 CHECK LIST PASSED (Y/N) VALVE SEALING (NO EXTERNAL LEAKS): DIAPHRAGM SEALING (NO EXTERNAL LEAKS): GREASE SEAL (NO EXTERNAL LEAKS):...

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