286EP-40-PR & 281-300-PR Pump & Rinse Manual

Page 2 Installation GuidelinesPage 3 ElectricalPage 5 TestingInstallation and OperationPump & RinseThe Motor and Control Panel Was Wired For Electrical Power Specified At The Time Of PurchaseSee Wiring Diagram Inside The Door of The Control PanelAny Changes Should Be Done By A Licenced ElectricianIndex: Page 6 How to Pump OutPage 7 Parts ListPage 10 Pump Tube InstallationIMPORTANT286EP-40-PR & 281-300-PR PUMP & RINSE WARNINGCheck All Factory Wiring To Motor and Control PanelIt is the responsibility of the purchaser to have the electrical service installed by a licensed electrician inaccordance with the power requirements of the motor, the electrical service available and local electrical codes.Failure to have the electricity installed correctly will result in damage to the pump and potentialbodily injury, loss of life and property damage from electrical shock and fire.CAUTIONPump and Plumbing Must Be SecurePeristaltic pumps will cause significant vibrations. The pump must be firmly bolted into position.Surface conditions may requireIsolation pads on the frame and pulsation dampeners on thesuction and/or discharge ports. Plumbing joints and hangers must be secure. Plumbing hangersmay have to be closer than usual.The degree of pulsation will vary based on head conditions at the installation sight. The higherthe head conditions the greater severity of the vibration.CAUTIONDo Not Distort The Mounting Frame When Bolting Pump Unit In Place.If the surface on which the pump unit is located is not smooth and level, bolting down the pump unit withoutshimming will distort the pump mounting frame. This may cause unnecessary vibration between the pumpand the motor drive resulting in undue wear on the shaft bearings of both pump and motor drive.Installation Guidelines:OverviewPump Out Hose&Hose Stand Pump CoverPump UnitHose Suction PortControl PanelMotorStart/ StopDischarge PortRinse Station Suction Port3 Way Ball ValveInstalling the Edson Pump and Rinse requires a little planning. The Hose Stand and/or Rinse Station can be located somedistance from the pump unit. Whatever the distance, planning the electrical connections and plumbing are necessary.Following is a list of things that need to be done.Portable Toilet Rinse Station2 “FNPT DrainConnetionRinse HoseFlush PortFresh WaterSolenoidWire HarnessBall ValveStart/ StopElectrical:1. Wire Appropriate Electrical Power To The Control Panel. Make sure motor rotation give suction on 3 way ball valve port.2. Connect The Rinse Station Start/ Stop to The Pump Unit Control Panel - The rinse station stop/start has a 10 ft wireharness installed with wires numbered. These need to be connected to the terminal strip in the pump unit control panel.If the distance between the rinse station and the pump unit requires longer wires then the electrician should provideappropriate wiring.3. Connect Hose Stand Start/Stop to The Pump Unit Control Panel - The stop and start button contact blocks on the hosestand have numbered pig tail wires installed that correspond to connections on the pump unit control panel terminalstrip. Electrician must install appropriate wires between the two.Plumbing:1. Connect The Pump Out Hose ToThe Hose Suction Port Of The Pump Unit - If hose stand is next to the pump unit thehose can be screwed directly into pump by installing the 1/1/2” reducer bushing of the port. If the hose stand is somedistance from the pump unit, run 2” pipe or full vacuum suction hose to the hose stand.2. Connect The 2” Drain From The Rinse Station to The Rinse Station Suction Port Of The Pump Unit - Use 2” pipe orhose rated for full vacuum of 29 inches of mercury.3. Connect A Water Line to The Fresh Water Solenoid Inside The Rinse Station. Adjust flow with the ball valve.4. Connect 2” Discharge Port To Sewer.5. All Plumbing Fittings Must Be Air Tight.If possible all connections should be made by bringing wires and plumbing from under the coverand rinse station. If this is not possible cutting holes to allow connections through the fiberglasscover and rinse station should be oriented so they do not interfere with access and use of thecomponents.Test The Pump Out Unit.z Insure all ball valves on suction and discharge are open.z Clamp one of the adapter fittings into the end of the hose.z Push the green start button on the pump unit cover orthe hose stand depending on equipment.z Put you palm over the end of the hose. You should feel animmediate strong suction. If you use a vacuum gauge,vacuum pressure should build to 25”hg to 27”hg.z Hold the hose end into the water. Water should flowimmediately into the hose. Let it run till timer runs out andcheck for leaks.Start273-150273-125274-150 Deck Adapters272QC-150Test The Rinse Station.z Insure all ball valves on suction and discharge are open.z Open lid and push the green start button on the front of thestation.z The pump unit should start and the 3-way ball valve on thepump inlet should change position. If you are near the pumpunit, you should hear the pump running and a noise of themotorized ball valve changing position.z Simultaneously with the pump starting the solenoid on thewash-down station, fresh waterline should open and watershould start to flow from the spigot inside the sink.z The pump should be able to pump the water flowing into thesink. If water splashes out of the sink or the pump is unableto keep up with the flow close down the flow from the waterline.z Check the rinse hose. If necessary adjust small ball valve onthe solenoid assembly to balance pressure for rinse hose.z Let unit run till it times out. There may be a small amountof water remaining in the sink and the sink drain.3-WayMotorizedBall Valve276-150Electrical24VAC OutputTransformer12VDC Power Supplyfor 3-Way ValveRun TimerMotor ContractR1 R2Relay Relay11G L1 L2 19 18 17 16 15 14 13 12Terminal StripThe Motor and Control Panel Was Wired For Electrical Power Specified At The Time Of PurchaseSee Wiring Diagram Inside The Door of The Control PanelAny Changes Should Be Done By A Licenced ElectricianIMPORTANTPanel Locator:Pumping Out3. Turn On The Pump Out System.z Push the green start button on the pump unit cover orthe hose stand depending on equipment.5. Open The Hose Ball Valve Slowly & Pump Out.z When the holding tank is empty, close the ball valve.z Pump water through your toilet into the holding tank.z Pump out again. This procedure rinses the entiresystem and helps to prevent odor.z Close The Ball Valve & Disconnect The Hose4. Connecting The Hose To The Boatz Unwind the hose all the way from the hosestand.z Clamp the hose to the deck adapter or hold theuniversal nozzle in the deck fitting.6. Flush the Hose.z Put the hose into water & open the ball valve long enough toflush the hose and plumbing.z Lift the hose and close the ball valve.z Push the Red Stop Button.7. Clean Up.z Curl the hose onto the hose stand.z Secure the boat deck fitting.z Rinse the deck and pump out with water.z Wash your hands.fig. 22fig. 25fig. 231111234567890123456789012345678901212345123456789012345678901234567890121234512345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678901234567890121212345678901234567890123456789012121234567890123456789012345678901212123456789012345678901234567890121212345678901234567890123456789012121234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345612345678901234567890123456789012123456789012345678901234567890121234567890123456789012345611111234567890123456789012345678901212345123456789012345678901234567890121234512345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678901234567890121212345678901234567890123456789012121234567890123456789012345678901212123456789012345678901234567890121212345678901234567890123456789012121234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678912345678901234567891234567890123456789123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456123456789012345678901234567890121234567890123456789012345678901212345678901234567890123456fig. 26Ball Valve2. Prepare The Waste Deck Fitting On the Boat.z Remove the cap from the boat deck fitting.z Screw in a deck adapter, 273-150 (1 1/2") or 273-125 (1 1/4").z If neither fit, clamp the universal nozzle 272QC-150 to the hose.z If pumping out a portable holding tank or bucket,clamp the potty wand 274-150 to the hose.1. All Ball Valves Except Ball Valve On The End Of The Hose Must Be Opened.273-150273-125274-150272QC-150fig. 24Startfig. 27Stop273-150273-125274-150 Deck Adapters272QC-150 5 4 3 Parts List1698171813202123 210 111214161519 722Qty286EP-40-PR - Pump Out - 2 Hp Peristaltic Station With Pump And Rinse OptionsKey # Order No. Description1 286EP-PUMP Pump Out - 2 Hp Peristaltic Pump Assembly - PUMP ONLY 12 161-A-1910 Peristaultic Pump ONLY 13 161-A-2441 Motorized Ball Valve 14 161-A-1912 Motor, 2HP Single Phase 120/240 volt, 3450RPM, 56C, TEFC 15 161-A-1977 Helical Worm Gear Unit 16 161-A-1997 Coupling Cover for 286EP, 16 Gauge Stainless Electropolished 17 161-A-1913 Shaft Coupling Body, 1" Bore 18 161-A-1975 Shaft Coupling Body, 7/8" Bore 19 161-A-1914 Shaft Coupling Insert 110 160-A-2008 Elbow, 2" 90 Degree, Brass 111 161-D-180 Pump Frame, Peristaultic - Painted 112 161-A-2294 Electrical Box Mounting Plate 113 161-A-2599 Electrical Control Panel 1161-A-2369-A Relay Socket, 24 Volt (115867) 2161-A-2369-B Relay, 24 Volt (105704) 2161-A-2442 Relay, 4 Pole, 24 Volt 1161-A-2443 Relay Socket, 4 Pole, 24 Volt 1161-A-2445 Power Supply, 12 Volt 120 Watt 1161-A-1861 Timer, Multi Functional, Timer ONLY 114 161-B-808 Pump Enclosure with signs 115 260-284 Hose Stand 116 161-A-2043 Button - Green Start Button - 2 NO 117 161-A-1705-FL Button, Momentary, Red Flush Mount 118 261-25-150 Hose - Pump Out Hose Assembly - 25 Feet Long 1262-25-150 Hose - Pump Out Hose ONLY - 25 Feet Long 1159MA-150NY Hose Coupling - Threaded Male 1-1/2" Nylon 2160-A-2424 Hose Clamp, Single Ear Oetiker, Stainless 2269CL-150V Check Valve/Sight Glass - 1 1/2" - Viton Gasket 1264-90-150 Ball Valve - 1-1/2" 90 Degree 1152FM-150NY Quick Clamp Adapter FE QC x MNPT 1-1/2" Polypropylene 1273-125 Deck Fill Adapter - 1-1/4" 1273-150 Deck Fill Adapter - 1-1/2" 1272QC-150 Pump Out Nozzle - Quick Clamp 1274-150 Potty Wand 1281-300-PR Wash-Down Station With Pump & Rinse OptionsKey # Order No. Description19 160-A-1418 Gas Hinges W/ 2 Flat Mounting Pads 220 Flush Hose 121 161-A-2043 Button - Green Start Button - 2 NO 122 161-A-1705-FL Button, Momentary, Red Flush Mount 123 161-A-2444 Solenoid Valve, 1/2" 110 Volt 1 Parts List1. Greasing The Hose• Turn off and lock out all electrical power to the peristaltic pump.• Remove the main fiberglass cover from over the pump unit.• Remove the clear plastic cover from the face of the pump.• Using the grease gun and the long nozzle, apply a bead of greasealong the surface of the hose where the rollers make contact. Apply grease to the exposed surface of the rollers.MaintenanceWARNINGTurn Off & Lock Out Electrical Service To The Pump Motor Before PerformingAny Pump Maintenance.Failure To Do This Could Result in Bodily InjuryPut Grease On the Rollers.Put Grease On The HoseWhere The Rollers Roll. ?: 508 995 9711 1. SPECIFICATIONS AND INSTALLATION 1.1 Operating principle The principle of peristaltic pumping is based on the ability of the pipe made of a flexible material (elastomer type) to deform and then return to its initial shape. A drive causes the rotor equipped with a roller to rotate. The pipe is compressed by the roller, and closes occlusively. Behind the roller, the return of the pipe to its initial shape creates a vacuum, which exerts suction on the product. The volume of product between two rollers is transferred inside the pipe from the suction part of the pump to the discharge part. Under the pressure of the second roller, the product is discharged in the pipework. The capacity obtained varies according to pipe diameter, and the rotational speed of the rotor. Direction of Rotation The pump's symmetric construction makes it fully reversible by simply changing the direction of rotation. Maximum pump performance characteristics and specifications are obtained in both directions. Transition sleeve Roller Flange Pump body pipe Stator Rotor ?: 508 995 9711 MAINTENANCE 3.1 List of spare parts A list of spare parts for your pump is available from our Customer Service Department. Please give the Serial Number of your equipment Pump diagram 406A 407A416407C433436405434424412409406407427401438437418404405B435417405A406B407B425422423428402438412409404401420 ?: (33) 01 41 08 15 15 Internal cleaning Cleaning procedures and frequency depend on the specific application of the pump, and the product being pumped. In any case, the minimum procedure is described below. With the pump running, feed in the cleaning product that is compatible with the pumped product and pump materials at the suction end. Cleaning time is defined according to the process using the pump. When this time has expired, shut down the pump according to paragraph 2.2.3. 3.4.3 Lubrication The pipe must be coated with Delasco grease to aid insertion (see paragraph 3.5.2.1). The reference numbers of the compound grease, packaged in pots of 250g, 500g, 1kg and 10kg, suitable for this procedure are: PCM 096200.000, 096201.000, 096202.000 and 096203.000. It is essential to ensure there is grease in the stator and to add more if necessary (the maximum quantity is 25g of grease). 3.4.4 Torque Overall torque for the mounting hardware is defined in the following table: Hardware diameter Torque in Newton metres M3 0.7 M6 5.6 M8 13.3 3.5 Corrective maintenance 3.5.1 Troubleshooting See troubleshooting table below. Warning The pump body pipe is a wearing part. Its life-span varies according to the frequency of use, nature of the product being pumped, temperature, speed and discharge pressure. Since the pipe's qualities are adapted to the product being pumped, it is essential to ensure compatibility, otherwise rapid destruction of the pipe, swelling or chemical corrosion etc. may occur. ?:508 995 9711 Symptom Cause Solution a) Air intake at suction a) Check for watertight connection between pump and connection piece. Pump does not prime itself, or does so with difficulty b) Poor condition of suction pipework b) Particularly concerns flexible pipes (hoses) subject to pinching or internal separation. Provide reinforced hoses, resistant to pressure loss. c) Blockage c) Clean suction connection piece, possibly by simply reversing the direction of pump rotation. Ensure filter or strainer is not clogged. d) Inadequate pump rating d) Viscosity and/or concentration of dry matter require a higher passage diameter and reduced pump rotation speed. e) Head loss at suction e) Reduce suction height, or modify pipework routing. f) Pump was out of service and immobile for a long period f) Remove pipe from pump during long shutdown periods. g) Excessive suction height (5 m max.) g) Move the pump nearer. Pump drainage a) Faulty seal a) Proceed as described above. Suction is operative, but pump does not discharge the product. a) Blocked pipework a) Apply a cleaning cycle, possibly by reversing direction of rotation. b) Pressure too high: inappropriate discharge connection piece b) Diameter at least equal to the pump outlet opening (refer to paragraph 1.3). c) Discharge circuit creates too much head loss c) Rearrange the installation to eliminate elbows and T-joints. d) Viscosity and/or concentration too high d) Pump is undersized, and/or pump rotational speed is too high. Leakage at pump outlet opening a) Faulty seal a) Check the pump/connection piece connection. Avoid having an elbow at 90o in immediate proximity to pump outlet. b) Undersized discharge connection piece b) Refer to, and strictly observe, our installation recommendations concerning minimum diameter for each pump type. Vibration in discharge connection piece a) Pumping circuit creating hammer blows a) Provide a flexible pipe connecting the pump to the connection piece. Possibly use a pulsation damper. 3.5.2 Disassembly (see diagram paragraph 3.1) Before carrying out any servicing on the pump, check that all necessary precautions have been taken: suction and discharge valves closed, pipework cleaned and purged, electrical power supply disconnected, and all usual measures concerning safety of personnel to be implemented in accordance with the texts in force. 3.5.2.1 Disassembly of pipe Ref. .427 and transition sleeves Ref. 434 – Unscrew the mounting hardware of the transition sleeves Ref. 434 at the suction and discharge ends by pulling out the flanges Ref. 433. ?: (33) 01 41 08 15 15 – Remove the transition sleeves Ref. 434 and the removable flange Ref.428 from the pipe Ref. 427. – Pull the pipe Ref.427 while running the pump. 3.5.2.2 Disassembly of cover Ref. 422 – Unscrew and remove the cover mounting hardware Ref. 423. – Remove the cover Ref. 422. 3.5.2.3 Disassembly of stator Ref. 417 – Remove the transition sleeves Ref. 434 and the pipe Ref. 427 . – Disassemble the cover Ref. 422 – Unscrew and remove the stator mounting hardware Ref. 417 on the pump support or base. – Unscrew and remove the mounting hardware of stator Ref. 417 and stator Ref. 416. – Withdraw stator Ref. 417 and remove it. – Unscrew the seal mounting hardware Ref. 418 and remove both the hardware and the seal. – Remove the bearing Ref. 435 of the stator Ref. 417. Note – After removing the rotor, follow the same procedure for stator Ref. 416. 3.5.2.4 Disassembly of the assembled rotor – Remove the transition sleeves Ref. 434 and the pipe Ref. 427 . – Disassemble the cover Ref. 422 . – Disassemble the stator Ref. 417. – Pull the rotor pin Ref. 401 assembly of the remaining flange Ref. 404 by extracting it from the bearing Ref. 435 assembled on the stator Ref. 416. ?: (33) 01 41 08 15 15 3.5.2.5 Disassembly of drive – Unscrew the mounting hardware of the drive on the pump base. – Uncouple the drive from the pump by pulling it. – Unscrew the motor mounting hardware on the reducing gear and disassemble the motor. 3.5.3 Reassembly (see diagram paragraph 3.1) 3.5.3.1 Reassembly of Stator Ref. 416 – Place the bearings Ref. 435 in their housing in the stators Ref. 416 and 417 and press them home. – Place the seals Ref. 418 on the stators Ref. 416 and 417 using their mounting hardware and screw down with torque – Mount the brake tube support Ref. 432 fitted with the brake tube Ref. 430. – Place the stator Ref. 416, fitted as above, on the pump support and fix the assembly with the corresponding hardware. 3.5.3.2 Reassembly of assembled rotor – First, reassemble the stator assembly Ref. 416 .– Place the equipped rotor assembly Ref. 401 on the stator assembly Ref. 416, in the bearing Ref. 435. 3.5.3.3 Reassembly of cover Ref. 422 – Grease the stator assembly Ref. 416 and the stator Ref. 417. – Assemble stator Ref. 416 and stator Ref. 417 using centring pins. – Fix the assembly using the corresponding hardware . – Put the cover Ref. 422 in place and fix it using its hardware Ref. 423. ?: (33) 01 41 08 15 15 3.5.3.4 Reassembly of drive – Assemble the motor on the reducing gear and fix it using the corresponding hardware. – Connect the resulting drive to the pump. Check that the drive shaft and the pump shaft are correctly aligned. If they are not, shim the pump support or the drive, if necessary. – Fix the drive on the pump base using its mounting hardware 3.4.4). 3.5.3.5 Reassembly of pipe Ref. 427 and transition sleeves Ref. 434 – Introduce the pipe Ref. 427, previously greased through the opening on the discharge side (at the top), while running the pump in the reverse direction of rotation that allows disassembly. – When the pipe is in place, stop the pump. – Place the securing flange Ref. 428 on the suction side. – Put the transition sleeves Ref. 434 in place at the discharge and suction ends. – Fix the transition sleeves Ref. 434 with its hardware and flange Ref. 433 (see torque paragraph 3.4.4). If only a pipe is being replaced, when reassembling, place grease into the pump through the openings at the suction and discharge ends on the pipe and put in place in this order (see paragraph 3.4.3). ?: (33) 01 41 08 15 15 3.6 Equipment storage when not in use Apply the following procedure: - Release pressure at the suction and discharge ends. - Drain the pipework and the pump. - Clean the pipework and the pump using a cleaning product that is compatible with the pumped product and pump materials. - Run the pump for more effective cleaning. - Switch off the pump. - Isolate the pump from the rest of the circuit. RECOMMENDATIONS: If the pump is not going to be used for a period of more than eight days, it is beneficial to remove the pipe from the pump. 3.7 Accessories See specific information in Section 4 - Appendices.