Piusi VISCOMAT 90 T User Manual

ENGLISH
A INDEX
A Index H2 Preliminary Inspection
B Machine and Manufacturer Identification H3 Mechanical Installation
C Declaration of Conformity H4 Hydraulic Connection
D

Machine Description

H5 Considerations Regarding Delivery
E

Technical Specifications

and Suction Lines
E1 Performance Specifications H6 Maximum pressure decrease
E2 Electrical Specifications H7 Electrical Connections
F

Operating Conditions

I

Initial Start-Up

F1 Environmental Conditions L Daily Use
F2 Electrical Power Supply M

Problems and Solutions

F3 Working Cycle N

Maintenance

F4 Fluids Permitted / Fluids Not Permitted O Noise Level
G Moving and Transport P Disposal of Contaminated Materials
H

Installation

Q Disposal
H1 Disposing of the packing material R Exploded Diagrams
S Dimensions
B MACHINE AND MANUFACTURER IDENTIFICATION
MODEL: VISCOMAT
MANUFACTURER: PIUSI SPA
46029 SUZZARA (MN)
IDENTIFICATION PLATE (EXAMPLE WITH THE FIELDS IDENTIFIED):
PRODUCT
CODE
PRODUCTION
YEAR
MODEL
TECHNICAL
SPECIFICATIONS
MANUAL
ATTENTION
Always check that the revision level of this manual coincides with what is shown on the identification plate.
C DECLARATION OF CONFORMITY
DECLARATION OF INCORPORATION
The undersigned PIUSI S.p.A.
Via Pacinotti, Z.I. Rangavino
46029 Suzzara (Mantova) – Italy
Declares under its own responsibility that the machine:
VISCOMAT
described below:
Machine for transferring lubricant oil
is manufactured to be incorporated into a machine or to be assembled with other machinery to
build a machine according to the Machine Directive 98/37/CE.
Moreover, we declare that the machinery cannot be put into operation until the machine in
which it will be incorporated and of which it will become a component, has been identified and
its compliance with the Machine Directive 98/37/CE has been declared.
Suzzara 01.09.2005
________________________
OTTO VARINI, Chairman
D MACHINE DESCRIPTION
PUMP: Self-Priming, volumetric, rotating electric vane pump equipped with by-pass valve.
MOTOR: Asynchronous motor, single-phase or three-phase, 2 or 4 pole, closed type
(Protection class IP55 according to regulation EN 60034-5-86), self-ventilating,
flange-mounted directly to the pump body.
E TECHNICAL SPECIFICATIONS
E1 PERFORMANCE SPECIFICATIONS
The performance data provided for the various pressure that the pump must overcome.
pump models of the VISCOMAT family can be Diagram "A" illustrates a flow rate/back
illustrated with curves that show the relationship pressure curve typical of all of the pumps in the
between the flow rate supplied and the back VISCOMAT family.
Diagram "A" Diagram "B"
Back pressure [P] bar Back pressure [P] bar
Point "1" is the point at which the pump is At flow rate zero (point "3") the entire flow rate
functioning with practically no back pressure, supplied by the pump is recirculated in the
in which case the pump supplies the maxi- by-pass, and the pressure in the delivery line
mum flow rate (Q max). reaches the value of P By-pass.
Point "2" is the functioning point characteri-
zed by the maximum back pressure (P max) VISCOMAT pumps can, therefore, function in
at which the pump supplies the minimum the face of any back pressure between zero
flow rate (Q min). and P max, supplying a flow rate varying little
When the back pressure exceeds the value P as a function of the back pressure between
max, thanks to the special design of the by- the values of Q max and Q min.
pass, there is a sudden opening of the by- The values for Q min, Q max, P max and P by-
pass, with a consequent sudden reduction of pass are provided for each model of pump in
the flow rate supplied. the Table below:
BY PASS Max. back Max. flow rate
Condition pressure condition condition
PUMP MODEL
D (l/min) P (bar) D (l/min) P (bar) D (l/min) P (bar)
VISCOMAT 70 M 0 7,5 26 6 30 1
VISCOMAT 90 T 0 6 50 5 55 1
VISCOMAT 70 100/50 0 6,5 26 4,5 30 1
VISCOMAT 70 100/60 0 5 26 3,5 36 1
VISCOMAT 70 110/50 0 7,5 26 6 30 1
VISCOMAT 70 110/60 0 5 26 3,5 36 1
VISCOMAT 90 230/50 0 6,5 35 2,5 40 1
VISCOMAT 90 230/60 0 7,5 40 3 47 1
VISCOMAT pumps can pump oils of very dif- noticeable the greater the back pressure
ferent viscosities, within the limits indicated in against which the pump is working.
the TECHNICAL SPECIFICATIONS, without Diagram "B" illustrates how the characteristic
requiring any adjustment of the by-pass. curve changes in the case of the maximum
The characteristic flow rate/back pressure and minimum viscosities (respectively equal
curve illustrated in diagram "A" relates to to 50 cSt and 500 cSt), showing that, at the
functioning with oil of a viscosity equal to maximum working back pressure (Pmax),
approximately 110cSt (comparable, for exam- the flow rate Q min suffers a variation of
ple, to oil SAE W80 at a temperature of 22°C). between 10% and 15% with respect to the
As the viscosity of the oil varies, the variation value relative to a viscosity of 110 cSt.
in the pump's performance will be more
ELECTRICAL POWER POWER CURRENT SPEED
PUMP MODEL Voltage Frequency Rated Maximum Rated
Current
(V) (Hz) (Watt) (Amp) (rpm)
VISCOMAT 70 M AC 230 50 750 4,6 1400
VISCOMAT 70 T AC 400 50 750 2,2 1450
VISCOMAT 90 T AC 400 50 2000 5 1450
VISCOMAT 70 100/50 AC 100 50 900 10,5 1450
VISCOMAT 70 100/60 AC 100 50 1100 13 1700
VISCOMAT 70 110/50 AC 110 50 1200 12,7 1450
VISCOMAT 70 110/60 AC 110 50 1200 12,6 1700
VISCOMAT 90 230/50 AC 230 50 1200 6 1400
VISCOMAT 90 230/60 AC 230 60 1550 7,7 1650
ATTENTION
The power absorbed by the pump depends on the functioning point and the viscosity of the
oil being pumped.
The data for MAXIMUM CURRENT provided in the Table refer to pumps functioning at the point
of maximum compression P max, with oils of a viscosity equal to approximately 500 cSt.
ENGLISH
F OPERATING CONDITIONS
F1 ENVIRONMENTAL CONDITIONS
TEMPERATURE: RELATIVE HUMIDITY:
min. -10 o C / max +60 o C max. 90%
ATTENTION
The temperature limits shown apply to the pump components and must be respected to
avoid possible damage or malfunction.
It is understood, nevertheless, that for a given oil, the real functioning temperature range also
depends on the variability of the viscosity of the oil itself with the temperature. Specifically:
• The minimum temperature allowed (-10°C) could cause the viscosity of some oils to
greatly exceed the maximum allowed, with the consequence that the static torque
required during the starting of the pump would be excessive, risking overload and
damage to the pump.
• The maximum temperature allowed (+60°C) could, on the other hand, cause the viscosity
of some oils to drop well below the minimum allowed, causing a degradation in
performance with obvious reductions in flow rate as the back pressure increases.
F2 ELECTRICAL POWER SUPPLY
Depending on the model, the pump must be fed by The maximum acceptable variations from the
three-phase or single-phase alternating current whose electrical parameters are:
nominal values are those indicated in the Table of Voltage: +/-5% of the nominal value
paragraph E2 - ELECTRICAL SPECIFICATIONS. Frequency: +/- 2% of the nominal value
ATTENTION
Power from lines with values outside the indicated limits can damage the electrical
components.
F3 WORKING CYCLE
The motors are intended for continuous use.
Under normal operating conditions they can function continuously with no limitations.
ATTENTION
Functioning under by-pass conditions is only allowed for brief periods of time (2-3
minutes maximum).
Whenever a particular installation carries the risk of functioning in by-pass mode for longer
periods of time, it is necessary that the by-passed flow not be recirculated inside the
pump, but be returned to the suction tank.
F4 FLUIDS PERMITTED / FLUIDS NOT PERMITTED
PERMITTED:
• OIL with a VISCOSITY from 50 to 500 cSt (at working temperature)
NOT PERMITTED: RELATED DANGERS:
• GASOLINE • FIRE - EXPLOSION
• INFLAMMABLE LIQUIDS with PM < 55°C • FIRE - EXPLOSION
• WATER • PUMP OXIDATION
• FOOD LIQUIDS • CONTAMINATION OF THE SAME
• CORROSIVE CHEMICAL PRODUCTS • PUMP CORROSION
INJURY TO PERSONS
• SOLVENTS • FIRE - EXPLOSION
DAMAGE TO GASKET SEALS
G MOVING AND TRANSPORT
Given the limited weight and size of the The pumps were carefully packed before
pumps (see paragraph R - DIMENSIONS shipment.
AND WEIGHTS), moving the pumps does Check the packing material on delivery and
not require the use of lifting devices. store in a dry place.
PACKING SIZE TOTAL WEIGHT
VISCOMAT MODEL
A (mm) B (mm) H (mm) (Kg)
SINGLE-PHASE 70 180 350 240 14.3
THREE-PHASE 70 180 350 240 12.8
THREE-PHASE 90 180 350 240 15
H INSTALLATION
H1 DISPOSING OF THE PACKING MATERIAL
The packing material does not require Refer to local regulations for its disposal.
special precautions for its disposal, not being
in any way dangerous or polluting.
H2 PRELIMINARY INSPECTION
• Check that the machine has not suffered • Make sure that the motor shaft turns
any damage during transport or storage. freely.
• Clean the inlet and outlet openings, • Check that the electrical specifications
removing any dust or residual packing correspond to those shown on the
material. identification plate.
H4 HYDRAULIC CONNECTION
• Make sure that the hoses and the suction avoid the pump running dry during the
tank are free of dirt and filing residue that priming phase.
might damage the pump and • When connecting pump models
accessories. furnished with BSP threading (cylindrical
• Always install a metal mesh filter in the gas) do not use joints with a conical
suction hose. thread.
• Before connecting the delivery hose, • Excessive tightening of these could cause
partially fill the pump body with oil to damage to the pump openings.
The MINIMUM recommended characteristics for hoses are as follows:
SUCTION HOSE
- Minimum nominal diameter: 1"
- Nominal recommended pressure: 10 bar
- Use tubing suitable for functioning under suction pressure.
DELIVERY HOSE
- Minimum nominal diameter: 3/4"
- Nominal recommended pressure: 30 bar
ATTENTION
The use of hoses and/or line components that are inappropriate for use with oil or have
inadequate nominal pressures can cause damage to objects or people as well as pollution.
The loosening of connections (threaded connections, flanges, gasket seals) can likewise
cause damage to objects or people as well as pollution.
Check all of the connections after installation and on a regular on-going basis with
adequate frequency.
H5 CONSIDERATIONS REGARDING DELIVERY AND SUCTION LINES
DELIVERY by-pass with a consequent noticeable
reduction of the flow rate supplied.
The choice of pump model to use should be In such a case, in order to permit the correct
made keeping in mind the viscosity of the oil to functioning of the pump equal to the
be pumped and the characteristics of the viscosity of the oil being pumped, it will be
system attached to the delivery of the pump. necessary to reduce resistance in the
The combination of the oil viscosity and the system by employing shorter hoses
characteristics of the system could, in fact, and/or of larger diameter.
create back pressure greater than the On the other hand, if the system cannot be
anticipated maximums (equal to P max), so modified it will be necessary to select a
as to cause the (partial) opening of the pump pump model with a higher P max.
ENGLISH
SUCTION at which cavitation phenomena begin
decreases.
VISCOMAT series pumps are characterized In the case of oils with viscosities equal to
by excellent suction capacity. approximately 500 cSt, the suction pressure
must not exceed values of the order of
In fact, the characteristic flow rate/back 0,3 -0,5 bar to avoid triggering cavitation
pressure curve remains unchanged even at phenomena.
high pump suction pressure values. The values indicated above refer to the
In the case of oils with viscosity not greater suction of oil that is substantially free of air.
than 100 cSt the suction pressure can reach
values on the order of 0.7 - 0.8 bar without If the oil being pumped is mixed with air,
compromising the proper functioning of the the cavitation phenomena can begin at
pump. lower suction pressures.
Beyond these suction pressure values, In any case, for as much as was said above,
cavitation phenomena begin as evidenced it is important to guarantee low suction
by accentuated running noise that over pressures (short hoses and possibly of larger
time can cause pump damage, not to diameter than the inlet opening of the pump,
mention a degradation of pump performance. fewer curves, filters of wide cross-section and
As viscosity increases, the suction pressure kept clean).
ATTENTION
It is a good system practice to immediately install vacuum and air pressure gauges at
the inlets and outlets of the pump which allow verification that operating conditions are
within anticipated limits.
To avoid emptying the suction hose when the pump is turned off, the installation of a
foot valve is recommended.
H6 MAXIMUM PRESSURE DECREASE
VISCOMAT series pumps are equipped with an in the table under paragraph E1 - Performance
adjusting screw to adjust the by-pass valve specifications.
pressure (pos. 10 in the exploded view). Should it be necessary to decrease the
The screw is pre-set in the factory for operating at maximum pressure, unscrew the adjusting screw
a maximum pressure that is equal to the until you reach the desired value.
maximum counter-pressure conditions indicated The flow rate curve will be modified as follows:
Adjusting
screw
unscrewed
Adjusting
screw
screwed
1-2 6 (bar)
As a result, plant specifications being equal, due to the earlier opening of the by-pass
the flow rate of the pump will be decreased valve.
H7 ELECTRICAL CONNECTIONS
All motors come with a short cable used for terminal strip cover, remove the above
production testing. mentioned cable and connect the line accor-
To connect the motor to the line, open the ding to the following chart.
THREE-PHASE SINGLE-PHASE
AC LINE
TO MOTOR
TO
MOTOR
Single-phase motors are supplied with a chart).
bipolar switch and capacitors wired and The capacitor characteristics are those
installed inside the terminal strip box (see indicated on the pump label.
The switch has the function of any way replace the main power switch
starting/stopping the pump and cannot in required by the applicable regulations.
ATTENTION
Pumps are supplied without electrical safety devices such as fuses, motor protectors, and
systems to prevent accidental restarting after periods of power failure or any other kind.
It is the installer's responsibility to carry out the electrical connection with respect to the
applicable regulations.
Comply with the following (not exhaustive) instructions to ensure a proper electrical connection:
• During installation and maintenance correct rotation direction by referring to
make sure that power to the electric lines paragraph R - DIMENSIONS AND WEIGHTS.
has been turned off. • All motors are equipped with a ground
• Employ cables characterized by terminal to connect to the ground line of
minimum cross-sections, rated voltages the electrical network.
and installation type adequate to the • Always close the cover of the terminal
characteristics indicated in paragraph strip box before turning on the electric
E2 - ELECTRICAL SPECIFICATIONS and power, after checking the integrity of the
the installation environment. gasket seals that ensure protection grade
• For three-phase motors, ascertain the IP55.
I INITIAL START-UP
VISCOMAT series pumps are self-priming and, therefore, able to draw oil from the tank even
when the suction hose is empty on start-up. The priming height (distance between the surface
of the oil and the inlet opening) must not exceed 2,5 meters.
ATTENTION
Wetting the Pump. Before starting the pump, wet the inside of the pump body with oil throu-
gh the inlet and outlet openings.
The priming phase may last from several seconds to a few minutes, depending on the
characteristics of the system.
If this phase is excessively prolonged, 1) that under conditions of maximum back
stop the pump and verify: pressure, the power absorption of the
• that the pump is not running completely motor stays within the values shown on
"dry" the identification plate
• that the suction hose guarantees against 2) that the suction pressure does not exceed
air infiltration and is correctly immersed in the limits indicated in paragraph
the fluid to be drawn H5 - CONSIDERATIONS REGARDING
• that any filters installed are not blocked SUCTION & DELIVERY LINES
• that the delivery hose allows for the easy 3) that the back pressure in the delivery line does
evacuation of the air. not exceed the values indicated in paragraph
• that the priming height is not greater than H5 - CONSIDERATIONS REGARDING SUC-
2,5 meters
TION & DELIVERY LINES.
When priming has occurred, after For a complete and proper verification of points
reattaching the delivery gun, verify that the 2) and 3), the installation of vacuum and air
pump is functioning within the anticipated pressure gauges at the inlet and outlet of the
ranges, possibly checking: pump is recommended.
L DAILY USE
No particular preliminary operation is required for every day use of VISCOMAT pumps.
MANUAL OPERATION • turn the on-switch present on some pump
• Before starting the pump, make sure that models (single-phase) or the start/stop
the ultimate shut-off device (delivery switch installed on the electrical power
nozzle or line valve) is closed. line.
If the delivery has no shut-off device (free • make sure that the tank is filled with a
delivery) make sure that it is correctly quantity of oil greater than the quantity to
positioned and appropriately attached to be supplied (running dry could damage
the delivery tank. the pump).
ATTENTION
Never start the pump by simply inserting the plug in the outlet
• Open the delivery valve or activate the delivery gun, gripping it securely.
ATTENTION
Fluid exits at high pressure from a delivery gun fed by a VISCOMAT pump.
Never point the outlet of the gun towards any part of the body.
• Close the delivery gun or the line valve to stop delivery. The pump will immediately enter
by-pass mode.
ENGLISH
ATTENTION
Running in by-pass mode with the delivery closed is only allowed for brief periods (2 to 3 minutes
maximum).
When the thermo-protector trips, turn-off the electric power and wait for the motor to cool.
• Stop the pump.
AUTOMATIC OPERATION • the pressure switch, at the moment that
In certain applications it can be advanta- the pressure drops below the value "Pm"
geous to provide for the automatic automatically starts the pump allowing
starting/stopping of the pump by means of delivery.
a pressure switch that monitors the • during delivery the pump delivers against
pressure of the delivery line. a back pressure that, depending on the
The functional logic of this type of installation conditions of the delivery line, could turn
is as follows: out to be higher or lower than the
• the pump is stopped, the delivery gun is pressure "Pm".
closed and the delivery line is under • at the moment the delivery gun is closed,
pressure. the pressure will increase rapidly and the
• the delivery gun is then opened, with the pressure switch, at the moment in which
consequent sudden lowering of pressure the pressure exceeds the value "Pa" will
in the delivery line. automatically stop the pump.
The values of "Pa" and "Pm" are characteristics of the pressure switch used and are often
adjustable within a certain range.
For the safe and proper functioning of the pump in these types of applications it is
absolutely indispensable to make sure that:
• "Pa" is sufficiently lower than the seal, to avoid frequent unwanted cycling
by-pas pressure, to assure that the pump on and off caused by its leakage.
will stop as soon as the gun is closed and • whenever the system is entirely
that the pump will not run a long time in composed of metal tubing, or, at any rate,
by-pass mode. of highly rigid tubing, one should
• "Pm" is several bar lower than "Pa" to consider installing an accumulator
avoid the pump starting when not wanted capable of preventing small leaks (from
due to small pressure drops not caused the foot valve, for example) from causing
by opening the gun. a pressure drop sufficient to automatically
• the foot valve guarantees an effective start the pump.
ATTENTION
Failure to comply with the above can damage the pump.
M PROBLEMS AND SOLUTIONS
Problems Possible cause Corrective action
Check the electrical connections
Lack of electric power
and the safety systems.
Check for possible damage or
Rotor jammed obstruction of the rotating
THE MOTOR IS NOT
components.
TURNING
Wait until the motor cools,
The motor protecting thermal
verify that it starts again, look
switch has tripped
for the cause of overheating
Motor problems Contact the Service Department
Bring the voltage back within the
Low voltage in the electric power line
THE MOTOR TURNS
anticipated limits
SLOWLY WHEN
Verify the oil temperature and warm
STARTING Excessive oil viscosity
it to reduce the excessive viscosity
Low level in the suction tank Refill the tank
Foot valve blocked Clean and/or replace the valve
Filter clogged Clean the filter
Lower the pump with respect to
Excessive suction pressure the level of the tank or increase
the cross-section of the tubing
Use shorter tubing or of greater
High loss of head in the delivery cir-
diameter
cuit (working with the by-pass open)
Dismantle the valve, clean
By-pass valve blocked
and/or replace it
LOW OR NO FLOW
Air entering the pump or the Check the seals of the
RATE
suction tubing connections
Use tubing suitable for working
A narrowing in the suction tubing
under suction pressure
Check the voltage at the pump.
Low rotation speed Adjust the voltage and/or use
cables of greater cross-section
The suction tubing is resting
Raise the tubing
on the bottom of the tank
Verify the oil temperature and
Excessive oil viscosity
warm it to reduce the
excessive viscosity
Reduce the suction pressure
Cavitation occurring
(see paragraph H5)
Dispense fuel until the air is
INCREASED PUMP Irregular functioning of the
by-pass purged from the by-pass system
NOISE
Wait for the oil in the tank to
Presence of air in the oil
settle
LEAKAGE FROM THE Damage to the mechanical Check and replace the
PUMP BODY seal mechanical seal
N MAINTENANCE
VISCOMAT series pumps are designed and constructed to require a minimal amount of
maintenance.
• On a weekly basis, check that the tubing • On a monthly basis check and clean the
joints have not loosened, to avoid any filters placed at the pump inlet.
leakage. • On a monthly basis, check that the
• On a monthly basis, check the pump electric power supply cables are in good
body and keep it clean of any impurities. condition.
O NOISE LEVEL
Under normal operating conditions noise value of 70 dB "A" at a distance of 1 Meter
emission for all models does not exceed the from the electric pump.
P DISPOSING OF CONTAMINATED MATERIALS
In the case of maintenance or destruction of
parts into the environment.
the machine, do not disperse contaminated
Refer to local regulations for their proper disposal.
Q DISPOSAL
The components must be given to companies that specialise in the disposal and recycling of
industrial waste and, in particular, the DISPOSAL OF PACKAGING.
The packaging consists of biodegradable cardboard which can be delivered to companies for
normal recycling of cellulose.
DISPOSAL OF METAL COMPONENTS
The metal components, both painted and stainless steel, are usually recycled by companies
that are specialised in the metal-scrapping industry.
DISPOSAL OF ELECTRIC AND ELECTRONIC COMPONENTS:
these have to be disposed by companies that are specialised in the disposal of electronic com-
ponents, in accordance with the instructions of 2002/96/EC (see text of Directive below).
ENVIRONMENTAL INFORMATION FOR CUSTOMERS IN THE EUROPEAN UNION
European Directive 2002/96/EC requires that the equipement bearing this sym-
bol on the product and/or its packaging must not be disposed of with unsorted
municipal waste. The symbol indicates that this product should be disposed of
separately from regular household waste streams.It is your responsibility to
dispose of this and other electric and electronic equipment via designated col-
lection facilities appointed by the government or local authorities.
DISPOSAL OF OTHER PARTS:
The disposal of other parts such as pipes, rubber seals, plastic components and cables should
be entrusted to companies that special in the disposal of industrial wate.
R EXPLODED DIAGRAMS
S DIMENSIONS
direction of rotation