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ENCORE 700 PLUNGER PUMP Encore® Plunger Metering Pump IM.ENC.PLUNGER Unit 10 Mill Hall Business Estate Aylesford Kent ME20 7JZ +44 (0) 1622 719945 www.waterprocesssolutions.com enquiries@waterprocesssolutions.com ISSUE 2 - 18/8/2016...
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Unit 10 Mill Hall Business Estate Aylesford Kent ME20 7JZ www.waterprocesssolutions.com Phone: +44 (0) 1622719945 email: enquiries@waterprocesssolutions.com EC-DECLARATION OF CONFORMITY Directives covered by this declaration 89/336/EEC Electromagnetic Compatibility Directive, amended by 92/31/EEC & 93/68/EEC 73/23/EEC Low Voltage Equipment Directive, amended by 93/68/EEC 89/392/EEC Machinery Directive, amended by 91/368/EEC, 93/44/EEC &...
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ENCORE 700 PLUNGER PUMP PLEASE NOTE: THIS EQUIPMENT HAS BEEN DESIGNED TO PROVIDE RELIABLE SERVICE. HOWEVER BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THE EQUIPMENT, THIS INSTRUCTION MANUAL SHOULD BE READ, UNDERSTOOD AND OBSERVED. FAILURE TO D0 SO CAN RESULT IN IMPROPER OPERATION WITH POSSIBLY HAZARDOUS RESULTS.
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ENCORE 700 PLUNGER PUMP GUARANTEE & WARRANTY Water Process Solutions Ltd (WPS) guarantees that equipment manufactured or represented by the Company is free from defect in workmanship and materials under normal use and service. The Company will make good, by repair, or at its option, by...
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ENCORE 700 PLUNGER PUMP TABLE OF CONTENTS Reordering of Preventive Maintenances Kits PM-1 Very Important Safety Precautions SP-1 Protective Equipment and Clothing SP-2 Technical Data Section 1 Installation Section 2 Operation Section 3 Service Section 4 Illustrations Section 5...
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ENCORE 700 PLUNGER PUMP PM -1 : Preventive Maintenance Protect Your Equipment Investment Minimize Downtime Reorder a Preventive Maintenance Kit Now. Keep One On Hand Quality Preventive Dependable Operation Equipment Maintenance Minimum Downtime There's no question about it Equipment that is properly maintained is dependable equipment.
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ENCORE 700 PLUNGER PUMP PREVENTIVE MAINTENANCE SCHEDULE AND RECORD OF PERFORMANCE This equipment should receive scheduled preventive maintenance on a one year cycle*. It is recommended that the following table be used to plan, schedule and record this important work.
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ENCORE 700 PLUNGER PUMP SP-1: VERY IMPORTANT SAFETY PRECAUTIONS This page, titled "Very Important Safety Precautions "provides, in brief, information of urgent importance relative to SAFETY, INSTALLATION, OPERATION, and MAINTENANCE of this equipment. WARNING TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE,...
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ENCORE 700 PLUNGER PUMP SINCE THE STORAGE AND HANDLING OF SODIUM CHLORITE PRESENTS VERY SPECIFIC HAZARDS, THE USER MUST SEEK THE ADVICE Of HIS SUPPLIER WlTH REFERENCE STORAGE FACILITIES, HANDLING PRECAUTIONS AND HEALTH HAZARDS. SODIUM CHLORITE, WHEN FINELY DIVIDED IN THE PRESENCE OF ORGANIC COMPOUNDS, IS A POSSIBLE FIRE HAZARD.
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ENCORE 700 PLUNGER PUMP SAFE OPERATION AND MAINTENANCE. ADDITIONAL OR REPLACEMENT COPIES OF THIS INSTRUCTION BOOK ARE AVAILABLE FROM: Unit 10 Mill Hall Business Estate Aylesford Kent ME20 7JZ NOTE Minor part number changes may be incorporated into WPS products from time to time that are not immediately reflected in the instruction book.
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ENCORE 700 PLUNGER PUMP SP-2: NOTES ON PROTECTIVE EQUIPMENT AND CLOTHING. The following Warning appears in several locations in this book. It is general in nature due to the variety of hazardous liquids this pump is capable of handling. WARNING: WHEN DEALING WITH HAZARDOUS MATERIAL,...
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ENCORE 700 PLUNGER PUMP SECTION 1 - TECHNICAL DATA Pump Type Variable Eccentric, Plunger type metering pump. Simplex, Duplex double Simplex capabilities Plunger / Gland Ceramic Plunger, PTFE / Glass chevron packing. Single or double chevrons Service Metering of mild to very corrosive (water like viscosity) chemicals.
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ENCORE 700 PLUNGER PUMP Material Identification / Composition The chemical composition of materials (these include optional variable materials) used in the manufacture of the Metering Pump are listed in Table 1.2 below. Common Term Composition Ceramic 99% Aluminium Oxide Hypalon...
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ENCORE 700 PLUNGER PUMP 440.050.190.010A-F 440.050.190.010A-F...
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ENCORE 700 PLUNGER 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. SS TO 70°F, 5%, PVC 125°F SAT HYPALON TO 180°F...
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ENCORE 700 PLUNGER PUMP 440.050.190.010A-F SECTION 2 - INSTALLATION LIST OF CONTENTS General Information Unpacking Mounting the Pump Pipe Line Diameter Plunger Size Pressure Rating Installation Illustrations Typical Installation - Simplex Manual Arrangement 440.400.1-PLUNGER Typical Installation - Double Simplex Manual Arrangement 440.400.2-PLUNGER...
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ENCORE 700 PLUNGER PUMP c. Connect to a power supply matching the characteristics specified on the motor nameplate in accordance with local code requirements. Sufficient flexibility must be provided in the connection to permit adjustments. Be sure to provide a shut-off switch in the power supply.
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ENCORE 700 PLUNGER PUMP Select pipe diameter so that the velocity in the suction line does not exceed 0.2 metres / sec. 2.5 PRESSURE RATINGS Pressure Ratings Plunger Size Maximum working Pressure (Bar) 6p & 12p (3/8” &3/4” dia) 10 & 20 mm 200 bar 24p ( 1 ½”...
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ENCORE 700 PLUNGER PUMP Recommended minimum height from floor to valve connections should be 12 inches (305 mm) Dimensions are feet and inches (indicates mm) Simplex and Duplex manual arrangement space recommendations Drawing 440.400.1-Plunger...
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ENCORE 700 PLUNGER PUMP Recommended minimum height from floor to valve connections should be 12 inches (305 mm) Dimensions are feet and inches (indicates mm) Double Simplex manual arrangement space recommendations Drawing 440.400.2-Plunger...
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ENCORE 700 PLUNGER PUMP WARNING: TO AVOID POSSIBLE SEVER PERSONAL INJURY WHEN HAZARDOUS CHEMICALS ARE PUMPED AND/OR ELEVATED TEMPERATURE/PRESSURES ARE ENCOUNTERED, USE RIGID PIPE. METERING PUMPS - TYPICAL INSTALLATION SUCTION LIFT DWG NO. 440.400.3 - PLUNGER...
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ENCORE 700 PLUNGER PUMP WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY WHEN HAZARDOUS CHEMICALS ARE PUMPED AND / OR ELEVATED PRESSURE / TEMPERATURES ARE ENCOUNTERED, USE RIGID PIPE Metering pumps typical installation – Flooded suction. Drawing 440.400.4-Plunger...
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ENCORE 700 PLUNGER PUMP Note: Field wiring (NOT BY WPS) must conform to local codes. Metering pumps – Installation wiring for intermittent start / stop operation. Drawing 440.400.5-Plunger...
ENCORE 700 PLUNGER PUMP SECTION 3 - OPERATION LIST OF CONTENTS Para / Dwg No Preparation for Operation Starting and Stopping the Pump Intermittent Start-Stop Operation Adjustment of Feed Rate Frequency of the Pump Stroke 3.4.1 Length of the Pump Stroke 3.4.2...
ENCORE 700 PLUNGER PUMP d. Start the motor and run the pump at a stroke setting of 100% on the scale until it is primed and ready for operation. The pump is designed to self-prime under a no back pressure condition;...
ENCORE 700 PLUNGER PUMP a. Manual positioning: Pump stroke length is adjusted by turning the stroke control knob (33). Percent stroke length is shown on the micrometer scale which consists of a linear scale and a circular scale. Ten turns of the knob covers 0 to 1 00% of the stroke length. Numbers on the scale represent percent stroke.
ENCORE 700 PLUNGER PUMP 3.6 THEORY OF OPERATION The theory of operation for the Encore Plunger Pump is addressed by discussing the operation and interrelationship of the following assemblies: • Pump Drive Mechanism • Speed Reducer • Stroke Control Mechanism •...
ENCORE 700 PLUNGER PUMP 3.6.4 Liquid Ends (Refer to List of Contents in Section 5 to identify applicable Dwgs. For liquid ends) The Encore metering pump offers four different sizes of liquid ends to provide a wide capacity and pressure range. The Simplex arrangement has a capacity up to 145 l/hr and pressure up to 200 Bar.
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ENCORE 700 PLUNGER PUMP Section 4 - SERVICE LIST OF CONTENTS Para/Dwg No General Periodic Cleaning Cleaning Pumping Head Parts 4.2.1 Clogging of Solution Tube 4.2.2 Periodic Preventive Maintenance Gearbox Lubrication 4.3.1 Priming Troubles or Loss of Suction 4.3.2 Hazardous Properties of Sodium Chlorite 4.3.3...
ENCORE 700 PLUNGER PUMP 4.2 PERIODIC CLEANING 4.2.1 Cleaning Pumping Head Parts WARNING: Use extreme care to avoid contact with material and possible severe personal injury. When using hazardous material observe all safety precautions recommended by the material manufacturer / supplier.
ENCORE 700 PLUNGER PUMP TABLE 4-1 SCHEDULED MAINTENANCE INDEX Interval MAINTENANCE PREVENTIVE OPERATION MAINTENANCE KIT Annually Replace PTFE chevrons and Packing - see liquid end neck rings. drawing. Every six months Valve sets, which include the See liquid end drawing.
ENCORE 700 PLUNGER PUMP b) Where liquid is withdrawn from containers which are replaced when they are empty or if the level in a fixed tank occasionally falls below the suction line inlet, air will be inducted into the pump. If the pump is discharging against atmospheric pressure (or only slightly above), the pump may be expected to reprime itself if the liquid supply is replenished and it is operated briefly at full stroke.
ENCORE 700 PLUNGER PUMP eyes, skin, mucous membranes and clothing. Wash contaminated clothing quickly and thoroughly with water to avoid fire. d) The danger lies in the fact that sodium chlorite in contact with or mixed with organic substances, such as clothing, cloth gloves, cotton waste, sawdust, mops, brooms, etc., become extremely sensitive to any agent, such as heat, friction or impact, and these exposed organic substances will ignite readily when any of these are applied accidentally or otherwise.
ENCORE 700 PLUNGER PUMP 4.3.5 Inspection After the disassembled parts are cleaned and prior to reassembly perform the following: a) Check for physical damage of removed parts (chipped, cracked. Damaged threads. etc.). Replace damaged parts. b) Discard and replace all removed 0-rings, seals, gaskets, packing or neck rings.
ENCORE 700 PLUNGER PUMP 4.4.2 Draining System of Hazardous Material WARNING: To avoid possible severe personal injury by being sprayed by liquid under pressure, allow system to drain fully before attempting to disassemble piping and removing valves and / or head.
ENCORE 700 PLUNGER PUMP 4.4.5 Valve & Plunger Replacement All 0-rings must be lightly lubricated with silicone grease before assembly. a) Reverse assembly procedures for replacement of cartridge. b) Refer to Table 4-2 for head size and corresponding torque values for head screws and cartridge valve clamping.
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ENCORE 700 PLUNGER PUMP WARNING: To avoid possible severe personal injury by being sprayed by liquid under pressure, allow system to drain fully before attempting to disassemble piping and removing valves or heads. (1) Remove the liquid end, which includes the valves, head and plunger as described in paragraph 4.4.2.
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ENCORE 700 PLUNGER PUMP (6) Slide out the worm wheel (3), and drive bushing (22) assembly, through the flange opening. (7) On a bench, remove taper roller bearing (24), from the drive bushing (22). (8) Unscrew the five M6 screws (4) and remove the worm wheel (3).
ENCORE 700 PLUNGER PUMP f. Eccentric Assembly, Taper Roller Bearings, Connecting Rod, Stroke Control Housing and Knob Replacement (see Dwg. 440.400.000.01 0) (1) Coat set screws (9) with Nylok (TM) before replacing stroke control knob. (2) Reverse remaining removal procedures for replacement of items. During replacement procedure, also adhere to the following: a.
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ENCORE 700 PLUNGER PUMP TABLE 4-3 ENCORE PLUNGER METERING PUMP TROUBLESHOOTING GUIDE Fault Condition Possible Cause Corrective Action Zero or insufficient stroke length Adjust to proper stroke length No feed rate or insufficient feed rate Ball valves on suction or discharge Replace balls in valves.
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ENCORE 700 PLUNGER PUMP WARNING LABELS AND TAGS The following warning labels and tags have been attached listed below: 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.
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ENCORE 700 PLUNGER PUMP SECTION 5 - ILLUSTRATIONS LIST OF CONTENTS Dwg No Direct Drive Assembly, Simplex 440.400.00 1.01 0 A&B Pulley Drive Assembly, Simplex 440.400.00 1.020 A&B Gearbox Assembly, Simplex 440.400.000.010 A, B, & C Gearbox Assembly, Double Simplex 40.400.000.020 A-D...
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ENCORE 700 PLUNGER PUMP AIC3021 DIRECT DRIVE 440.400.001.010B...
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ENCORE 700 PLUNGER PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION ARQ5712 W2T367161 Cover, Simplex, Direct Drive AXS3656 W2T11182 Scr., Cap, M8 x 20, Sock. Hd., 316SS AXQ3743 W2T417691 Adhesive, GE Silicone RTV AAA9542 W2T365047 Coupling, Sure-Flex, .625"/.625", 56C...
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ENCORE 700 PLUNGER PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION AJA5596 W2T367023 Slide Plate, Motor 56C APS3182 W2T367122 Pulley, Motor 56C, Double Groove AXS3532 W2T367184 Screw, 3/8-16 x 3/4", Flat Head Cap AAB2979 W2T9572 Screw, Set M6 x 12, Sock.
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ENCORE 700 PLUNGER PUMP 6, 8 10, 11 12, 14, 15 DIRECT DRIVE PULLEY DRIVE WORM POSIITON WORM POSITION Simplex Gearbox Assembly 440.400.000.010C...
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ENCORE 700 PLUNGER PUMP Simplex Gearbox Assembly 440.400.000.010C...
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ENCORE 700 PLUNGER PUMP KEY NO. LEGACY PART NO. ALT. PART NO. QTY. DESCRIPTION APQ5142 W2T417678 Gearbox, Simplex AKC5702 W2T417631 Flange, Gear Access, Simplex AXS3656 W2T11182 Cap Scr., M8 x 20, Sock. Hd., 316SS ANM4788 W2T417655 Bushing Drive, Simplex, LMAD ...
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ENCORE 700 PLUNGER 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" & 2" Liquid End Only) ...
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ENCORE 700 PLUNGER 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. M8 x 20, SOC. HD.
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ENCORE 700 PLUNGER PUMP PLUNGER LIQUID END SUPPLEMENT PLUNGER-TYPE LIQUID END The plunger-type liquid end is shown as a sectioned view at Fig.1, 2, 3, or 4. As full details of construction are shown, a written procedure for dismantling and assembling is not necessary.
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ENCORE 700 PLUNGER PUMP (2) Lantern rings. If grease is being used, take care only to use a type which is compatible with the liquid being pumped; a fraction of a turn of the greaser every month should be sufficient.
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ENCORE 700 PLUNGER PUMP 2.3 Stroke Control Mechanism Locked CAUSE REMEDY Insufficient lubrication Check oil level in crankcase. If dry, it may be necessary to dismantle the pump movement - Refer to text. 2.4 Crankcase Noisy and / or Hot Whilst Running...
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SEE SECTION BELOW [STANDARD] SINGLE VALVE [OPTIONAL] DOUBLE VALVE ARRANGEMENT GLAND ARRANGEMENT GLAND FOLLOWER R1/8 TAPER PLUG 2 x NECK RING LANTERN RING 2 x CHEVRON PACKING PART NO. TITLE: 6P PLUNGER HEAD ASSY RD91- 6PAS DOUBLE CHEVRON WITH LANTERN RING PROJECT NO.
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11 12 [STANDARD] SINGLE VALVE [OPTIONAL] DOUBLE VALVE ARRANGEMENT GLAND ARRANGEMENT GLAND FOLLOWER 2 X R1/8 TAPER PLUG 2 X NECK RING 2 x CHEVRON PACKING LANTERN RING PART NO. TITLE: 12P PLUNGER HEAD ASSY DOUBLE CHEVRON WITH LANTERN RING RD91-12PAS FOR FLUID FLUSH [NEW STANDARD ARRANGEMENT] PROJECT NO.
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APPLY LOCTITE 277 SEE SECTION BELOW GLAND ARRANGEMENT [STANDARD] SINGLE VALVE ARRANGEMENT [OPTIONAL] DOUBLE VALVE GLAND FOLLOWER R1/8 TAPERED PLUG ARRANGEMENT 2 x NECK RING LANTERN RING 2 x CHEVRON PACKING PART NO. TITLE: 24P PLUNGER HEAD ASSY DOUBLE CHEVRON WITH LANTERN RING RD91-24PAS FOR FLUID FLUSH [NEW STANDARD ARRANGEMENT] PROJECT NO.
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APPLY LOCTITE 277 SEE SECTION BELOW [STANDARD] SINGLE VALVE GLAND ARRANGEMENT [OPTIONAL] DOUBLE VALVE GLAND FOLLOWER R1/8 TAPERED PLUG ARRANGEMENT 2 x NECK RING 2 x CHEVRON PACKING LANTERN RING PART NO. TITLE: 32P PLUNGER HEAD ASSY DOUBLE CHEVRON WITH LANTERN RING RD91-32PAS FOR FLUID FLUSH [NEW STANDARD ARRANGEMENT] PROJECT NO.
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