Ailipu J-X Series User manual

Ailipu J-X Series Plunger Metering Pump

Operating Instructions

ZheJiang AILIPU Technology Co.,Ltd

Head Office：T1-9 Changhe Road, Binjiang District, Hangzhou

Production Base: No.2 Jinyuan Road, Binhai NewCity, Sanmen County, Taizhou, Zhejiang

Website: WWW.AILIPU.COM

Hotline：400-728-1118 Version No.：ALP-190315-01/A

Table of contents

I、

Outline....................................................................................................................................................................... 3

1.1 Product Code

........................................................................................................................................................4

II、Pump Structure and Working Principle

.......................................................................................................................... 4

2.1

Working Principle of Driving End.................................................................................................................... 5

2.2 Hydraulic End

................................................................................................................................................... 7

2.3 Flow Adjustment

.................................................................................................................................................. 8

III、Installation

................................................................................................................................................................. 8

IV、Operating Guide

......................................................................................................................................................... 9

4.1. Preparation Before Operating the Pump

.................................................................................................................9

4.2. Flow Adjustment (See above 2.3 Flow Adjustment)

................................................................................................9

4.3. Operation

..........................................................................................................................................................10

4.4 Flow Calibration

.................................................................................................................................................10

4.5. Shut Down the Pump

......................................................................................................................................... 10

V、Maintenance, Disassembly and Reassembly

.................................................................................................................10

5.1 Maintenance

.......................................................................................................................................................10

5.2 Disassembly and reassembly

................................................................................................................................11

VI、Fault-finding and Troubleshooting Checklist

...............................................................................................................14

VII、After Sales Service

.................................................................................................................................................. 15

Notes:

If you encounter any problems when using the Ailipu metering pump, please first refer to the operation and

maintenance manual for trouble removal.

If the problem can’t be resolved, please contact your local Ailipu sales representative or our Technical Services

Department.

Trained technicians can diagnose your problems and arrange related solutions.

The solution may include buying replacement parts or returning the product to the factory for repair.

Please read the safety instructions carefully before installing and operating the metering pump:

Safety Instructions

When using a metering pump, basic safety warnings must be observed in case of fire, electric shock or personal

injury. Failure to comply with the following requirements may result in death or serious injury.

General Principle for Safety

Wear work clothing including gloves and safety glasses when operating or approaching the metering pump.

Keep potions and pumps away from children and pets.

Check the anti-corrosive property of the materials of the flow end of the pump when measuring the corrosive

liquid. In case of compatibility problems, the user shall be responsible for personal injury and pump damage.

The metering pump with determined working scope shall be used in accordance with the requirements of the

instruction manual, and shall not be used beyond the scope to avoid personal injury or pump damage.

Don’t cut electric wires or ground wires (consult a qualified electrician for proper installation).

Don’t return pumps to Ailipu company once they have been used for radioactive chemicals.

Shut down the pump, cut off the power supply, and hang the warning signs during the installation or maintenance,

so as to avoid mis-operation that may result in casualties and property damage.

Don’t modify the pump or use accessories that are not purchased from Ailipu company. Otherwise, the user shall

be responsible for the related personal injury and pump damage caused thereby.

Safe Operation Rules

Cut off the power and relieve the pressure at the hydraulic end before repairing or moving the pump.

When connecting or disconnecting the metering pump, make sure that the valve between the system pipe and the

pump is closed.

When inspecting the liquid end, if harmful or unknown liquid is measured at the liquid end, please wear

appropriate protective equipment for operation, empty and clean the liquid end at the same time.

All pumps are inspected with water before delivery. If the liquid transported reacts with water, make the pipes of

the pump fully dry before use.

When equipment doesn’t transfer liquid for a long time, please shut down the pump and cut off the power supply.

If the liquid is easy to crystallize and solidify, please promptly clean up the liquid pump end.

Before starting up the metering pump, ensure that the valve between the system pipe and the pump is open and the

whole pipe is in a smooth state.

Install an appropriate number of filters at the end of the inlet pipe of the metering pump to avoid the pipe blockage

or pump valve blockage.

To ensure the accuracy of measurement, calibration must be performed in any service environment.

Manufacturer's Warranty

The manufacturer warrants that the product is free from defects in material and manufacture, that such warranties are

limited in duration and scope, and that the warranty for the pump that is returned for repair or parts that are required

to be replaced (which have been inspected and the defect is confirmed) is limited. The warranty doesn’t cover the

cost of installation and repair. In any event the manufacturer warrants that costs will not exceed the selling price of

the pump parts. The manufacturer will not be responsible for any damage caused by improper installation, use or

unauthorized repair.

These warranties supersede all other warranties, whether formally stated or implied, and the manufacturer makes no

warranties of fitness or specification, nor is any agency authorized to extend warranties beyond the foregoing scope.

I、

Outline

Zhejiang Ailipu Technology Co., Ltd. mainly researches, develops, produces and sells plunger metering pumps,

mechanical diaphragm metering pumps, hydraulic diaphragm metering pumps and other special pumps. The

technical parameters, testing rules, and others of our metering pumps are in strict accordance with GB7782-2008

Metering Pump andAPI std 675-2014 Positive Displacement Pumps-Controlled Volume.

Two flow regulation modes are available for metering pumps: 1. To change the stroke of the plunger (optimal stroke:

30-100%) of the pumps during shutdown or operation, in which the measurement accuracy is controlled within ±1%.

Therefore, the measuring pump can be used as a measuring instrument (for manual regulation, the relative stroke of

the pumps is indicated by a stroke scale and micrometer; for automatic control, remote control and computer based

flow control, see also the regulation instructions); 2. To regulate the pump speed by changing the power frequency

through frequency conversion for remote control and computer-based management on flow regulation.

Our metering pumps are used to pump liquids with a temperature of -30~250

℃

, a viscosity of 0.3~2,000mm2/s and

solid particle size not more than 0.1

㎜

. Regular plunger metering pump are used in the temperature of -30~200

℃

and a viscosity of 0.3~800mm2/s. (if exceed this range, please advice AILIPU company). Plunger metering pump has

the characteristics of simple structure, convenient maintenance, and high cost-effectiveness, which can transport high

viscosity medium. The range of its working pressure is wide, and the highest pressure is up to 80 MPa, so it can be

widely used in chemical, petrochemical, metallurgy, electric power, medicine, food, plastic foam, mining machinery

and other fields, which has become an indispensable modern industrial dosing pump.

The Instructions are only applicable to J-X Plunger metering pumps.

1.1 Product Code

II、

Pump Structure and Working Principle

The metering pump generally consists of a pump motor, a driving end, and a hydraulic end (see Figure 1).

Fig.1 Metering Pump Outside Drawing

2.1

Working Principle of Driving End

The transmission box is composed of an arch cam mechanism, a stroke adjustment mechanism and a worm gear

reduction mechanism.

Working Principle

A high-speed rotating motor shaft, which transmits torque through an elastic worm coupling (20), slows down by a

worm (22) and a worm gear (8), and rotates the cam (6) on the worm gear bearing through the rotation motion of the

worm wheel. Cam contacts and pushes the front and rear prop blockers to realize the forward-and-back linear motion

of the arch prop (27), thus turning the rotation motion into a straight-line reciprocating motion of the cross head.

Structure diagram of the driving end (see Fig. 2).

Table 2 Driving end parts list of the J-X plunger metering pump

Fig.2 Structure diagram of the driving end of the J-X plunger metering pump

2.2 Hydraulic End

The structures of hydraulic ends for the plunger metering pump (shown in Figure 3) mainly consists of the

plunger, the pump head, the inlet and outlet valves and the seal packing.

Working Principal：

The plunger is mechanically connected with the cross head (arch prop head) and simultaneously makes the straight

reciprocating motion together with the cross head. When the plunger moves leftward (namely, suction stroke), The

volume cavity gradually increases to form a certain vacuum and the pressure inside the pump head is reduced.

When the pump head pressure is lower than the suction line pressure, the inlet check valve will be “pushed”

upwards, allowing the medium contained in the inlet line to enter the pump head cavity. At the end of the suction

stroke, the plunger motion stops instantly. When the pump head pressure is equal to the inlet line pressure, the inlet

check valve ball will be reset. In discharge stroke, the plunger starts to move forward (rightward), and the pump

head pressure rises instantly. When the pump head pressure is higher than the outlet line pressure, the outlet check

valve ball will be “pushed” upwards, allowing the medium contained in the pump head to enter the discharge line.

At the end of the discharge stroke, the plunger motion stops instantly again. When the pump head pressure is equal

to the outlet line pressure, the outlet check valve ball will be reset. Then, the next cycle begins.

Fig.3 Structure diagram of the liquid end

2.3

Flow Adjustment

Rotate the adjusting handwheel (30) and with the help of the stroke adjusting rod (34) and the adjusting rod sleeve

(37) to change the distance between the front and rear prop blockers (2) and the center of the cam, thereby changing

the stroke length of the cross head (plunger).

The stroke adjustment of the pump can be carried out when stopping or running. Adjust the handwheel for axial

movement, the position indicated by the handwheel on the scale is the relative stroke length value (%). After the

stroke adjustment is completed, the pump flow needs about 1~2min to be stable. The greater the change of stroke

length, the longer it takes to stabilize the flow.

Before the delivery, each metering pump is tested by the normal temperature clean water, and a complete test report

is formed. The user must re-test the pump and re-calibrate the flow curve according to the actual working conditions,

so as to adjust the flow according to the re-calibrated flow curve in operation.

III、Installation

3.1 The pump shall be installed on a special spare concrete foundation or cast iron platform and fixed with

foundation bolts after re-calibration, and the concrete foundation shall be 50~100mm above the ground to prevent

being washed by water. At the same time, it needs to reserve enough space around the pump to facilitate the

maintenance and adjustment of the pump.

3.2 The diameters of the suction and discharge pipe should not be less than the diameter of the inlet and outlet pipe of

the pump, and the suction pipe should be as short as possible. If the inlet pipe of the metering pump is too long or the

viscosity of the medium is larger, the diameter of the inlet pipe should be increased, otherwise it will affect the

normal operation of the pump.

3.3 The connecting pipe shall be equipped with measuring instruments, such as pressure gauges.

3.4 Filter devices shall be installed at the end of the suction pipe.

3.5 The discharge pipe shall be fitted with a safety valve or a safety-relief valve (provided by the user). If you need to

reduce the pressure fluctuation at the outlet, please install a pressure stabilizer (such as a buffer) near the discharge

pipe.

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