Goldacres ZETA 140, ZETA 70, ZETA 200, ZETA 230, ZETA 170 Operator And Parts Manual

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UDOR Diaphragm
Pumps
Operator’s & Parts Manual
GA8700374 REV 1.0 MAR 16
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General Information and Specs ..........3
Pump Identication ....................3
Before Start Up .......................4
Controls on System ....................5
Installation, Start Up and Switching O ....6
Maintenance .........................7
Lubrication ...........................8
Trouble Shooting ......................9
Oil and Weight .......................10
Torque Specication ..................11
Pump ...............................14
Pump Diaphragms ....................14
To replace a side diaphragm in pump: ...15
Air Damper Chamber .................15
IOTA 20 .............................16
Kappa 40 / Delta 40 ...................18
Zeta 70 .............................20
Zeta 85 .............................22
Zeta 100 ............................24
Zeta 140 ............................26
Zeta 170 ............................28
Zeta 260 ............................30
Zeta 300 ............................32
Pump Kits ...........................33
Zeta pump kit contents ................34
Safety ..............................35
The Operator ........................35
Safety Precautions ...................35
Personal Protective Equipment (PPE) ....36
Warranty ............................36
Goldacres Warranty Statement .........37
Terms and Conditions .................38
2-3-2016
Operator’s Manual Part Number: GA8700374
Contact
Goldacres
1-3 Morang Crescent,
Mitchell Park Vic 3355
P: 03 5342 6399
F: 03 5342 6308
info@goldacres.com.au
Please note: All information in this operator’s manual is based on the latest product information available at the time of printing.
The policy of Goldacres is one of continuous improvement and as such, Goldacres reserve the right to alter any specications and
designs without notice and without incurring any obligation regarding such changes. No part of this manual may be reproduced without written permission from Goldacres. All photographs and technical information remain the property of Goldacres.
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General Information and Specs
General
Diaphragm pumps are constant displacement
pumps providing a consistent ow, largely unaected by changes to operating pressure.
Diaphragm pumps have good suction capacity and can easily self prime, they can also run dry without damage. On Goldacres sprayers we supply the operator with the pump RPM
and therefore the operator can be condent of the ow rate of the pump and condent
the agitation to sprayer tank is consistent, even when quite large changes to operating pressures are made.
Centrifugal pumps - It is not possible to
be certain of the pump ow by monitoring
pump speed and the limited suction capacity of a centrifugal pump adds a further area of uncertainty to pump output. Centrifugal pumps
ow rate varies considerably with pressure
changes.
Maintenance - It is sometimes claimed centrifugal sprayer pumps require less maintenance than diaphragm pumps. At Goldacres we have not found this to be the case. Cast iron pumps are subject to chemical erosion. Centrifugal pumps which are run dry even for short periods can be severely damaged.
Flow Vs Pressure.
The ow output by diaphragm pumps are largely unaected by changes to operating
pressure.
For example:
UDOR 250 l/min pump @ 500rpm
0 Bar = 225.7 l/min output
10 Bar = 223.1 l/min output
Maximum achievable ow to the
boom.
Goldacres design sprayers so that the ow to
the boom should be approximately half the
stated maximum ow of the pump - this is due
to the pump also needing to supply agitation to the main tank. For example a 250 l/min pump should realistically achieve a maximum
ow of approximately 125 l/min to the boom.
Goldacres Crop Cruisers are tted with
hydraulic drive diaphragm pumps.
Trailed Sprayers - Hydraulically driven pumps are becoming more common as tractors come out with more hydraulic outlets. Fitting a hydraulic drive to the pump eliminates any maintenance or safety issues that are often associated with PTO shaft drives.
The UDOR diaphragm pumps tted to
Goldacres sprayers do not require a coupling between the hydraulic motor and pump. The
MI pump is tted with a ange which will
accept this motor shaft. A hydraulic drive is
required for tractors tted with 1000 RPM PTO
drives. Standard diaphragm pump RPM is 540.
To measure pump RPM with a hydraulic drive
tted an RPM sensor is tted on the shaft
of the pump which will provide you with a readout that will be shown on your controller.
There are many factors that can change how often a pump needs to be serviced - however it is common for pumps to be serviced annually as preventative maintenance which will ensure reliability when the sprayer is in operation.
A quality multigrade engine oil should be used in the pump.
Pump Identication
The label on the pump bears the model, the code, the serial number and the main technical
specications with the maximum operational
values of the product. The specimen at the side is an example of a label and its position on the Pump.
IC - 1⅜” 6 Spline PTO
TS2C - Through Shaft,
1⅜” 6 Spline PTO
both sides
MI - 25.4mm Internal hole for a Hydraulic motor.
VA - Mounting surface for gear box drive, (engine Drive).
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Safety Symbols
The “WARNING” symbol here at the side
draws the operator’s attention to situations and/or problems related to the correct operation of the Pump.
The “DANGER” symbol here at the side
draws the operator’s attention to situations and/or problems that could compromise the safety of people.
Introduction
The Diaphragm Pumps of UDOR, with radial piston kinematic drive, are designed and manufactured to pump or transfer water or pesticides and herbicides in water solution to be used according to the instructions of the actual producers.
They are generally driven by: electric motors, endothermic petrol or diesel engines and hydraulic motors, tractor P.T.O.. Couplings
may be fullled by means of transmission shaft, direct anging, reduction unit or
multiplier, joints, pulleys and belts.
The Pump is supplied to be installed on
a more complex machine or plant; the manufacturer of such machine or plant shall add all the information related to safety of the assembled machine/plant
fullled.
Intended Use
The Diaphragm Pumps of UDOR are designed for use in machines or systems that transfer water or pesticides or herbicides, under pressure, such as the following for example: Sprayers, Mist Sprayers, Herbicide Spray Booms, Gardening, Civil and Industrial Washing Systems, Drain and Pipe Cleaning,
Fire-ghting, Antifreeze Systems.
The temperature of the workplace shall be between: Min. 0°C (32°F) - Max.45°C (113°F)
The Pump cannot be used submerged under any type of liquid.
Operational Restriction
The specications of the liquid to be used
are described in detail herewith: do not use
for dierent liquids; in particular, it is NOT
possible to use UDOR Pumps in the following conditions:
- In the presence of water with high salt
content, such as seawater for example.
- In workplaces where there is a corrosive or explosive atmosphere.
- In the presence of any liquid that is not compatible with the constructional material of the Pump.
- To pump paint, solvents, fuel and any
ammable liquid (not suitable for ATEX
workplaces).
- For foodstus.
- To wash people, animals, live electrical or electronic equipment.
- To wash the Pump itself.
General Warnings
- Never start the Pump under pressure.
- Constantly check the state of wear of
the pipes and relevant ttings, especially
those under pressure. Pipes with signs of abrasion or that do not guarantee a perfect seal shall be replaced.
- Protect rotating parts with a cover to prevent contact.
- The Pump is designed to be integrated in a machine or system, with various supply systems, which may make the noise level vary, even quite substantially. The manufacturer of such machine or system shall assess the level of noise emitted by the assembled machine or system and inform the user appropriately, also in relation to the use of suitable personal protection equipment.
Before Start Up
Liquids To Be Pumped
The Pump is designed and manufactured to transfer water or pesticides and herbicides in water solution to be used according to the instructions of the actual producers.
The liquid intake must be free from sand or other solid particles in suspension.
The liquid intake shall have viscosity and density similar to water.
The temperature of the liquid to be pumped must be between 5°C (41°F) and 38°C (100°F).
Any other use is not admitted unless
authorised in writing by the Engineering
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Department of UDOR.
Inlet And Outlet Of The Pump
The Inlet of the liquid to be pumped, also called intake or supply, is generally of larger diameter than the Outlet, also called delivery.
The Inlet and Outlet CANNOT be inverted.
Inlet Conditions (Suction)
Make sure the supply line is connected correctly and that it complies with the following requisites:
- Any point of the inlet pipeline cannot be smaller than the diameter of the Pump inlet.
- Be absolutely leak-proof to avoid any air
inltration.
- Not have 90° bends near the Pump inlet.
- Not have contractions or restrictions.
- Avoid any turbulence near the Pump inlet and in the supply tank.
- If an inlet lter is used, it must allow 200% more ow than the ow required by the
Pump. It must not cause any contraction
or any pressure drop. The lter should grant a ltration degree between 32 and 50
Mesh and should be cleaned on a regular basis to ensure its proper functionality.
- Maximum inlet pressure admitted: 0.5 bar (7 PSI).
- Maximum negative inlet pressure admitted:-0.2 bar (-3 PSI) [-6 inch.Hg].
- Maximum oset admitted between pump
and supply source underneath: 2m. (6.5ft.).
Outlet Conditions
Make sure the delivery line and all the accessories are connected correctly, secured
rmly, hermetically sealed and that the pipes are sized appropriately. All pressurised pipes
must be marked durably with the maximum admitted pressure, which must never be less than the maximum working pressure of the Pump, written on the Label.
Speed and Rotation Direction
The rotation speed of the shaft of the
Pump must never exceed the RPM written on the Label of the actual Pump.
The minimum RPM admitted is: maximum RPM x 0.6.
The rotation direction of the shaft of UDOR Pumps may be clockwise or anticlockwise.
Controls on System
Unloader Valve
A pressure regulator valve must be installed to avoid the pressure exceeding the maximum limit indicated on the Label of the Pump.
Use of the Pump, even for a short period,
with a pressure higher than such limit would damage the Pump itself.
The regulator valve shall be compatible
with the maximum pressure, ow rate and
temperature values written on the Label and in
the “INLET CONDITIONS”.
Incorrect installation of the pressure
regulator valve could cause serious personal injuries and damage to property as well as seriously damaging the actual Pump.
The circuit must be equipped with another safety valve to prevent the maximum pressure from being exceeded in the case of anomalies in the pressure regulator valve.
Nozzle
A deteriorated nozzle could cause a drop in pressure; in this case, do not adjust the
pressure regulator valve in the attempt to increase the pressure of the system because when the delivery line closes, this would cause a boost in pressure, which could damage the Pump.
If the pressure drops, it is advisable to replace
the nozzle and adjust the system’s pressure
again.
The ow rate of the Pump must be at least 10% higher than the ow rate that the utilities demand; the excess ow rate must be
discharged.
Pulsation Dampener (Accumulator)
Before starting the Pump, verify the air pressure in the accumulator, if present.
This operation may be carried out, with the
Pump o, connecting an air source to the ination valve.
The air pressure should be checked periodically.
Using the Pump without air in the
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accumulator may cause system malfunctioning, damage the accumulator diaphragm or the whole Pump.
The accumulator’s air pressure varies according to the Pump’s operating pressure:
Pump Working Pressure
bar
2 5 10 20 30 40 50
PSI
29 72 145 290 435 580 725
Accum­ulator
bar 1 2 4 5 6 7 8 PSI 15 29 58 72 87 102 116
UDOR normally inates the Pumps pulsation
dampener at a pressure of 5 bar (72 PSI) approx.
Pressure Gauge
Install a gauge as near as possible to the outlet of the Pump because the maximum pressure written on the Pump’s Label refers to the pressure detected in that point and not on
the nozzle or on other accessories.
All the components of the machine
or of the circuit must have technical
specications compatible with the data
written on the Pump’s Label.
Installation, Start Up
and Switching O
Positioning
Smaller and lighter pumps can be handled by hand in compliance with current standards. Heavier pumps must be handled using a suitable lifting device. If you need to use a lifting device, use appropriate strap/s, being careful not to damage the product. The weight of the pumps is written in the table on page
10.
To safeguard the lifetime of the components subject to wear and tear such as valves and diaphragms, the pump should be installed below or at water level.
UDOR Diaphragm Pumps are, in any case,
self-priming; they may be installed above
the water source. In this case, the maximum
allowed dierence in height is 2 mt. (6.5 ft.).
If the Pump is used in a particularly dirty workplaces or is exposed to atmospheric agents, you are recommended to protect it, respecting the ventilation conditions.
Assembly
Fit the Pump on a rigid surface keeping the
power take-o and support feet horizontal to
ensure correct drainage in the case of leakage of water or oil. The Pump must be secured
rmly on a base, which must be perfectly
aligned with the transmission components. In the case of belt transmission, make sure the pulleys are aligned and check the tension of the belts.
Use appropriately sized hoses, both on the
inlet and outlet of the Pump, according to the
technical specications written on the Label.
Start Up
Before starting, check the following:
- Check the oil level through the dedicated
oil reservoir or inspection cap; top-up if
necessary.
- Check the pressure value on the
accumulator, if installed; inate or deate if
necessary.
- The pressure regulator valve must be set
at “0” pressure to favour intake.
Start and run the Pump for approximately 10 seconds until all the liquid has discharged from the delivery line. Once the intake cycle is complete, you can set the Pump at the required pressure, by adjusting the pressure regulator valve, without ever exceeding the maximum pressure written on the Pump’s Label.
Switching O and Storage
After use or if the Pump is to be put away in storage, wash it internally. You can do this by running the Pump for several minutes with clean water, then disconnect the supply line and leave the Pump to run for approximately 15 seconds so that all the water inside the pump is drained.
A few minutes devoted to the internal washing
of the pump brings considerable benets in
terms of the pump’s lifetime.
Never leave liquid inside the pump.
Damage to the diaphragms or to other components is often caused by liquid that is left inside the pump for a long time.
Do not wash the Pump externally: water
could get into the Pump crankcase, for
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example through the seal rings of the crankshaft.
Do not throw the liquid used to wash
the Pump outdoors but observe current standards.
Precautions Against Freezing
If shutdown during winter or in the case of places and seasons subject to frost, once the
Pump has nished working, run it for the time required to Pump an emulsion of 50% of clean water and 50% of antifreeze uid through it in order to prevent freezing and damage to the
Pump.
The Pump must not be used to Pump
antifreeze uid that is not mixed with
water. In the presence of ice or very cold temperatures at the workplace, the Pump must never be started, otherwise
the Pump could be seriously damaged. To start the system, the whole circuit must be completely defrosted.
Maintenance
Routine Maintenance
If the Pump is used for light-duty purposes, the following routine maintenance jobs are advised:
- After the rst 50 hours: Oil change (see
section 9.2 - Lubrication)
- Every 500 hours: Oil change - Replace the
diaphragms (see instructions below)
- Every 1000 hours: Replace the valves
For heavy-duty purposes, carry out the maintenance jobs more often.
1. DRAIN CRANKCASE OIL: Drain Pump
crankcase by removing the oil drain plug (T) located at the bottom of the Pump, also
remove the oil ll cap (F) or plug (R).
2. EXTERNAL MANIFOLD REMOVAL: If your
Pump has external manifolds ( I ), these must be removed prior to heads (B) removal.
3. HEAD REMOVAL: Do repairs one head (B)
at a time. Remove the head bolts (A), then remove the Pump head (B) which may require
some “light” prying.
4. DIAPHRAGM REMOVAL: Turn crankshaft
(N) to bring piston (Q) up to the top of its stroke, remove the diaphragm bolt (L) and washer (M), then remove the diaphragm (O).
If necessary, take o one sleeve (P) and wash
well the internal components using diesel fuel. The sleeve (P) must be re-mounted in the same position as before.
5. INSTALLING NEW DIAPHRAGMS: Clean
well the threaded hole of the piston (Q). Install the diaphragm bolt (L) and washer (M) into the new diaphragm (O). Install this assembly to the piston (Q). Use Loctite 243 thread locker or equivalent on the diaphragm bolt (L). Then
torque to the recommended specications
(see page 12). Now rotate crankshaft (N) to bring the piston (Q) and diaphragm (O) to the bottom of its stroke. Then seat the outside edge of the diaphragm (O) into the Pump body.
6. HEAD INSTALL: When reinstalling the Pump
head (B) it is very important to make sure that the check valves are installed correctly. For each cylinder there are two valves, one valve
lets the uid ow into the head, the other valve lets the uid ow out of the head. PAY VERY CLOSE ATTENTION TO THIS. After
having correctly positioned the Pump head (B), tighten the screws (A) with the proper torque (see page 12).
7. INSTALLING PULSATION DAMPENER DIAPHRAGM: Bleed o the air in the chamber
using the air-valve (G) on the dampener,
then remove the cover bolts (E), cover (D)
and diaphragm (C), install correctly the new diaphragm (C). Reinstall cover (D) and tighten the screws (A) with the proper torque (see page 12). Recharge dampener with air
according to UDOR specications at page 6.
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8. REFILL PUMP CRANKCASE: Re-mount
the oil drain plug (T). Fill Pump with SAE
15W-40 OIL to recommended mark on the oil reservoir (H) or on the sight glass (S). Rotate
the crankshaft (N) while lling to eliminate air pockets. Re-mount the oil ll cap (F) or the oil ll plug (R).
9. INITIAL START UP: Start the Pump with
the outlet line at “0” pressure; after about 5 minutes at “0” pressure you may increase
the outlet pressure and make a few cycles
of pressure on/o. This will evacuate any
remaining air pockets in the crankcase. Turn
Pump o and re-check oil level. Rell as
necessary to proper oil level.
IMPORTANT: During initial start up, monitor the oil color. If it turns milky white, the diaphragms were not seated correctly.
Lubrication
The Pump is supplied with the correct amount of lubrication oil (see table on page 10).
Periodically check the oil level in the Pump through the oil level indicator.
Use OIL type SAE 15W-40 or equivalent. Here are some recommended types of oil:
Brand Type
AGIP F.1 Supermotoroil 15W-40
BP Vanellus C 15W-40 CASTROL GTX 15W-40
ESSO Unio 15W-40
MOBIL Super M 15W-40 SHELL Rimula R4 15W-40 / Helix
Super 15W40
TOTAL Rubia 15W-40 / Quartz 5000
15W-40
The oil is to be changed by draining it through the dedicated bottom discharge cap and strictly with the Pump stopped.
The oil level could vary during priming ; then it will stabilize when the system is pressurized. If the oil level gets lower during the rst few
hours of the pump’s operation , it could be
normal. Simply rell. If instead , the oil level
changes considerably after several hours of operation, the pump’s diaphragms might be damaged or there might be restrictions along the suction line.
Do Not Start The Pump If There Is No
Oil In The Pump!
During maintenance, you are
recommended to:
- Use and wear suitable personal protection equipment (i.e. gloves).
- Wait for the machine to cool down and to have stopped completely.
During maintenance, do not throw
residues outdoors but observe current standards.
If the Pump is to be scrapped:
1. Separate the various parts depending on
their type (i.e. plastic, harmful uids, metal
etc.).
2. Use public or private waste disposal systems envisaged by local law to dispose of waste.
3 This device could contain harmful
substances: improper use or incorrect
disposal could have negative eects on
human health and on the environment.
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Problems Probable Causes Solutions
No pressure.
Very little pressure.
Pressure drops below working range when relief valve is open to boom or gun.
Insucient strainer capacity,
or dirty or plugged strainer.
Use larger capacity strainer or clean strainer.
Suction hose restriction. Eliminate restriction. Collapsed suction hose inside
or outside tank restricting
ow.
Replace collapsed hose.
Air leak in inlet line. Examine hoses and ttings, ensure
air tight t and no leaks.
Pressure relief valve stuck or worn.
Repair or replace relief valve (§).
Excessive tank foam due to
low tank volume.
Rell tank.
Nozzle volume is greater than
Pump capacity.
a. Check relief valve adjustment.
b. Reduce nozzle orice size or number of nozzles used.
One or more check valves seating improperly.
Clean or replace check valves(§).
Excessive gauge vibration.
Excessive pulsation.
Pulsation dampener pressure too low or too high.
Adjust pulsation dampener pressure. (see page 6) – (§).
Air leak in inlet line. Examine hoses and ttings, ensure
air tight t and no leaks.
Insucient strainer capacity,
or dirty or plugged strainer.
Use larger capacity strainer or
clean strainer. Air not entirely evacuated from Pump cavity.
Run Pump with an open discharge
to totally evacuate air.
Pump does not suck
water.
Air leak in inlet line. Examine hoses and ttings, ensure
air tight t and no leaks. Insucient strainer capacity,
or dirty or plugged strainer.
Use larger capacity strainer or
clean strainer. One or more check valves seating improperly.
Clean or replace check valves(§).
Pump oil has milky color.
The Pump oil comes out of
discharge line; the oil level
drops markedly.
Oil plug pops out.
One or more diaphragm failures.
STOP THE PUMP IMMEDIATELY!
Replace the diaphragms (§).
Diaphragm replacement
instructions:
see pages 7-8.
(§)These operations must be carried out by qualied personnel.
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Trouble Shooting
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Series Recommended Oil Quantity Pump Weight
Kg. Lbs. Lt. Gal. Kg. Lbs.
ZETA 70 0,5. 1.10 0,56 0.15 9 20
ZETA 85 1,02 2.25 1,14 0.30 12 26 ZETA 100 1,02 2.25 1,14 0.30 13 29 ZETA 120
ZETA 140
1,04 2.29 1,16 0.31 18 40
ZETA 170 1,15 2.54 1,28 0.34 24 53 ZETA 200 1,15 2.54 1,28 0.34 26 57 ZETA 230
ZETA 260
2,40 5.29 2,68 0.71 36 79
ZETA 300 2,50 5.51 2,79 0.74 38 84 RO 320
RO 400
4,10 9.04 4,58 1.21 63 139
IOTA 20 IOTA 25
0,18 0.40 0,20 0.05 4 9
KAPPA 15 0,10 0.22 0,11 0.03 2,5 5.5 KAPPA 25
KAPPA 32
0,26 0.57 0,29 0.08 8 18
KAPPA 40 / DELTA 40 KAPPA 50
0,49 1.08 0,55 0.15 11 24
KAPPA 33 KAPPA 43 KAPPA 53
0,56 1.23 0,63 0.17 11 24
KAPPA 55 KAPPA 65
0,62 1.37 0,69 0.18 13 29
KAPPA 75 1,04 2.29 1,16 0.31 18 40 KAPPA 100 1,02 2.25 1,14 0.30 20 44 KAPPA 125 1,82 4.01 2,03 0.54 28 62 KAPPA 120
KAPPA 150
1,76 3.88 1,97 0.52 42 93
OMEGA 135 1.45 3.20 1.62 0.42 28 62 OMEGA 140 2,14 4.72 2,39 0.63 40 88 OMEGA 170 2,42 5.33 2,70 0.71 45 99 BETA 110 2,14 4.72 2,39 0.63 45 99 BETA 150 2,42 5.33 2,70 0.71 52 115 BETA 200
BETA 240
4,50 9.92 5,03 1.33 75 165
Oil and Weight
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Torque Specication
PTO for details on
Torque Specication
12
1 2 3 4
Diaphragm Bolt (use Loctite
®
243)
Head Bolts Pulsation
Dampener Bolts
Inlet Flange Bolts
MOD. N•m lbf•ft N•m lbf•ft N•m lbf•ft N•m lbf•ft
ZETA 70 25 18 25 18 --- --- --- ---
ZETA 85 25 18 40 30 --- --- --- --- ZETA 100 25 18 40 30 25 18 --- --- ZETA 120
ZETA 140
30 22 40 30 25 18 --- ---
ZETA 170 ZETA 200
30 22 40 30 25 18 --- ---
ZETA 230 ZETA 260 ZETA 300
30 22 40 30 --- --- --- ---
RO 320 RO 400
30 22 50 37 --- --- --- ---
IOTA 20 IOTA 25
14 10 25 18 25 18 --- ---
KAPPA 15 14 10 14 10 14 10 --- --­KAPPA 25
KAPPA 32
25 18 40 30 40 30 --- ---
KAPPA 40 / DELTA 40 KAPPA 50
25 18 40 30 40 30 --- ---
KAPPA 33 KAPPA 43 KAPPA 53
25 18 40 30 --- --- 10 7
KAPPA 55 KAPPA 65
25 18 40 30 40 30 10 7
KAPPA 75 25 18 40 30 40 30 10 7 KAPPA 100 25 18 40 30 28 20 10 7 KAPPA 125 25 18 40 30 28 20 10 7 KAPPA 120
KAPPA 150
30 22 45 33 28 20 10 7
OMEGA 135 30 22 40 30 --- --- --- --- OMEGA 140 30 22 50 37 28 20 --- --- OMEGA 170 30 22 50 37 28 20 --- --- BETA 110 30 22 50 37 28 20 --- --- BETA 150 30 22 50 37 28 20 --- --- BETA 200
BETA 240
30 22 50 37 --- --- --- ---
Torque Specication
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