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Summary of Contents for truflo DAP Series
- Page 1 I n s t a l l a t i o n , O p e r a t i o n , & Ma i n t e n a n c e Ma n u a l A N e w V i s i o n F o r Q u a l i t y P u mp s...
- Page 2 This instruction manual was prepared to assist operators in understanding the correct methods of installing, operating, and maintaining these pumps. TRUFLO shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for Installation, Operation, and Maintenance contained in this manual.
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Page 3: Table Of Contents
CONTENTS 1. SAFETY 1-1 Nomenclature ....................................1-2 General Precautions ................................... 5 2. GENERAL INFORMATION 2-1 Pump Description ..................................2-2 Attached Information ................................2-2.1 Pump Nameplate .................................. 7 2-2.2 Included Information ................................7 2-3 Transportation & Storage ................................ 2-3.1 Storage Requirements ................................. 7 2-3.2 Handling / Lifting .................................. - Page 4 6. BREAKDOWN 6-1 Disassembly ....................................21 6-1.1 Pump from Baseplate ................................21 6-1.2 Disassembly of Bearing Housing ............................21 6-2 Reassembly ....................................21 6-2.1 Inspections ....................................21 6-2.2 Seal Assembly ................................... 24 6-2.3 Seal Testing ....................................24 6-2.4 Pump Assembly ..................................24 6-2.5 Motor and Coupling Assembly ............................
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Page 5: Safety
A pump is a pressure-containing device with rotating parts that can be hazardous. Operators and maintenance personnel must realize this and follow safety measures. TRUFLO shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions in this manual. -
Page 6: General Information
2. GENERAL INFORMATION 2-1 PUMP DESCRIPTION The Model DAP is a horizontal overhung, open impeller centrifugal pump that meets requirement of ANSI B73.1. The model is based on 6 power ends and 31 hydraulic pump sizes. Groupings are as followed. Group 1 ------------ 7 Pump sizes Group 2 ------------ 14 Pump sizes... -
Page 7: Attached Information
2-2 ATTACHED INFORMATION 2-2.1 Pump Nameplate Every pump has a TRUFLO nameplate that provides information about the pump. The nameplate is located on the bearing adaptor. The nameplate provides information about the pump’s characteristics. Note the format of the pump size: Suction Diameter x Discharge Diameter - Impeller Diameter (inches). -
Page 8: 2-3.2 Handling / Lifting
2-3.2 Handling / Lifting WARNING CAUTION Pump and components are heavy. Failure to properly lift Use a forklift or an overhead crane with sufficient and support equipment could result in serious physical capacity to move the equipment. Failure to do so injury or damage to the equipment. -
Page 9: Installation
3. INSTALLATION 3-1 SITE / FOUNDATION A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection. Baseplate mounted pumps are normally grouted on a concrete foundation, which has been poured on a solid footing. -
Page 10: 3-4.1 Alignment Check
Accurate alignment of the equipment must be attained. Trouble free operation can be accomplished by following these procedures. 3-4.1 Alignment Check Proper total alignment calls for alignment checks several times during the installation/start-up process. Below are recommended points for which alignment is performed. Before Grouting Baseplate –... -
Page 11: 3-5.2 Suction Piping
3-5.2 Suction Piping WARNING NPSH must always exceed NPSH as shown on TRUFLO performance curves received with order. (Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping. Properly installed suction piping is a necessity for trouble-free pump operation. -
Page 12: 3-5.4 Final Piping Check
3-5.4 Final Piping Check After connecting the piping to the pump Rotate shaft several times by hand to be sure that there is no binding and all parts are free. Check alignment, per the alignment procedure outlined in section 3-5 to determine absence of pipe strain. If pipe strain exists, correct piping. -
Page 13: Operation
The maximum impeller setting should not exceed more than 0.005 inch (0.13mm) above the values in table or significant performance degradation will occur. TRUFLO pumps are designed such that, when new, the additional 0.005 inch clearance maybe set between the pump casing and impeller. -
Page 14: 4-1.3 Couple Pump And Driver
Cartridge seals installed by the user require removal of handling clips prior to operation, allowing the seal to slide into place. If the seal has been installed in the pump at the TRUFLO factory, these clips may have already been removed. For... -
Page 15: Start-Up
Connection of Sealing liquid For satisfactory operation, there must be a liquid film seal between the faces to lubricate them. Refer to seal manufacturer’s drawing for location of taps. Some methods that may be used to flush/cool the seal are: Product Flushing –... -
Page 16: Operation
Slowly open discharge valve until the desired flow is obtained. CAUTION Observe pump for vibration levels, bearing temperature and excessive noise. If normal levels are exceeded, shut down and resolve. 4-3 OPERATION 4-3.1 General Considerations Always vary capacity with regulating valve in the discharge line. Never throttle flow from the suction side. Driver may overload if the pumpage specific gravity (density) is greater than originally assumed, or the rated flow rate is exceeded. -
Page 17: 4-3.4 Operating Under Freezing Conditions
4-3.4 Operating under Freezing Conditions Exposure of freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump. Liquid inside pump should be drained. Liquid inside cooling coil, if used, should also be drained. 4-4 SHUT DOWN Slowly close discharge valve. -
Page 18: Preventive Maintenance
5. PREVENTIVE MAINTENANCE 5-1 GENERAL COMMENTS A routine maintenance program can extend the life of your pump. Well-maintained equipment will last longer and require fewer repairs. You should keep maintenance records; this will help pinpoint potential causes of problems. 5-2 MAINTENANCE SCHEDULE 5-2.1 Break In Period Covered in section 4-3.2. -
Page 19: Maintenance Of Bearings
5-3 MAINTENANCE OF BEARINGS 5-3.1 Oil Lubricated Bearings WARNING TRUFLO® Pumps are shipped without oil. Oil lubricated bearings must be lubricated at the job site. Remove fill plug and add oil until level is at the center of sight glass. Replace fill plug. -
Page 20: Maintenance Of Shaft Seals
5-4 MAINTENANCE OF SHAFT SEALS 5-4.1 Mechanical Seals When mechanical seals are installed, a manufacturer’s reference drawing is supplied with the data package. This drawing should be kept for future use when performing maintenance and adjusting the seal. The seal drawing will also specify required flush liquid and attachment points. -
Page 21: Breakdown
6. BREAKDOWN 6-1 DISASSEMBLY 6-1.1 Pump from Baseplate Lockout motor following all recommended plant procedures. Block out the pump by closing the suction and discharge valves. Open the ports and completely drain the pump including the back cover plate. Disassemble any attached auxiliary seal piping. Drain oil from bearing housing. - Page 22 Examine motor for grease leakage beyond the seals. Examine motor for bearing wear. Clean all mating surfaces of the pump including the seal faces. 10. Examine the impeller vanes for wear. Replace it if there is more than 1/4” of wear. 11.
- Page 23 17. Examine pump for thrust bearing endplay. (Figure 6.3) Figure 6.3: Thrust Play Checking endplay on thrust bearing. Thrust play should not be more then 0.0015” 18. Examine pump for bracket/frame perpendicularity. (Figure 6.4) Figure 6.4: Frame Adaptor/Case Perpendicularity Checking frame adaptor perpendicularity. This value should not be more then 0.005”...
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Page 24: 6-2.2 Seal Assembly
6-2.2 Seal assembly Generic Cartridge Seal Tighten the impeller to the end of the shaft. This will allow the proper final weight adjustment required to evenly secure the seal in the back cover plate. After the pump has been checked with the above steps proceed with the following assembly steps. -
Page 25: 6-2.5 Motor And Coupling Assembly
The most concise method to perform in the field is the use of dial indicators to measure the bearing rotor movement and location inside the bearing assembly. A second method requires a feeler gauge to measure the gap between case and impeller. -
Page 26: Troubleshooting
7. TROUBLESHOOTING 7-1 PUMP TROUBLESHOOTING GUIDE Problem Cause Remedy Pump not primed. Re-prime pump, check that pump and suction line are full of liquid. Suction line clogged. Remove obstructions. Impeller clogged with foreign material. Back flush pump to clean impeller. No Liquid Delivered. -
Page 27: Mechanical Seal Troubleshooting Guide
7-2 MECHANICAL SEAL TROUBLESHOOTING GUIDE Problem Cause Remedy Running too close to vapor point Chemical attack Broken metal bellows Identify cause and correct Over pressurized back cover plate High/low viscosity pumpage Ceramics are exposed to different temperatures, thermal Broken ceramic Reduce differential temperatures shock Broken metal bellows primary... -
Page 28: Parts Breakdown
8. PARTS BREAKDOWN SECTIONAL VIEW - GROUP 1 230A 240 211 GRP 1 230B 103 205 203 ITEM PART NAME / DESCRIPTION ITEM PART NAME / DESCRIPTION Casing Back Cover (End-Cover) Flush & Drain Plug 230A Discharge Tap Plug Pump Case Drain Case Gasket 230B Suction Tap Plug... -
Page 29: Sectional View Of A Group 2 Pump
SECTIONAL VIEW - GROUP 2 230A 241 251 231 GRP 2 230B 209 208 203 104 202 219 218 ITEM PART NAME / DESCRIPTION ITEM PART NAME / DESCRIPTION Casing Bearing Carrier Impeller Thrust Bearing Snap Ring 230A Discharge Tap Plug Oil Sight Glass Impeller gasket Oil Drain Plug... -
Page 30: Sectional View Of A Group 3 Pump
Sectional View of GROUP 3 230A 241 251 231 GRP 3 230B 209 208 203 104 202 219 218 ITEM PART NAME / DESCRIPTION ITEM PART NAME / DESCRIPTION Casing Bearing Carrier Impeller Thrust Bearing Snap Ring 230A Discharge Tap Plug Oil Sight Glass Impeller gasket Oil Drain Plug... -
Page 31: Set-Up
APPENDIX General Alignment Criteria Good alignment is achieved when the dial indicator readings are 0.002 inch (0.05mm) as specified in the alignment procedure. During the installation phase, however, it is necessary to set the parallel alignment in the vertical direction to different criteria due to difference in expansion rates of the pump and driver. -
Page 32: Parallel Alignment
Positive Reading – The coupling halves are closer at the bottom than at the top. Correct by either lowering the driver feet at the shaft end (remove shims) or raising the driver feet at the other end (add shims) Repeat steps 1-3 until the indicator reads 0.002 inch (0.05 mm) or less. Horizontal Correction (Side-to-Side) Zero the indicator on left side of coupling half, 90... -
Page 33: Complete Alignment
DSP SERIES (Self-Priming ANSI Pump) Note: The only difference in the DSP and the DAP series and procedures are outlined below. The DSP assembly has a different casing only; the remaining parts are identical to DAP parts. Discharge Tap/Air bleed valve It is recommended that a tap with a tap (1/4”... -
Page 34: Common Conversions
COMMON CONVERSIONS Flow (capacity) GPM (US) l/min GPM (UK) 0.2271 3.785 0.8327 4.403 16.6 3.666 0.2642 0.06 0.2200 1.201 0.2727 4.5458 GPM (US) x 0.2271 = m l/min x 0.2642 = GPM (US) /h x 4.403 = GPM (US) GPM (US) x 3.785 = l/min /h x 16.6 = l/min l/min x 0.06 = m Head (pressure / vacuum) - Page 35 Truflo Pumps, Inc. 7105 Cessna Drive Greensboro, NC 27409 Ph.: (336) 664-9225 Fax: (336) 664-1353 www.truflo.com...
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