LIQUI-MOVER PUMP HANDBOOK · 2017-06-15 · Liqui-Mover pump discharges the condensate out of the pump tank.When properly adjusted, the discharge time should not be less than 20 seconds

LIQUI-MOVER® PUMP

HANDBOOK

Kadant Johnson Inc., 805 Wood Street, Three Rivers, MI 49093 USA 269-278-1715 www.kadant.com

LMP Handbook-4003

LIQUI-MOVER® PUMP

HANDBOOK

Kadant Johnson Inc., 805 Wood Street, Three Rivers, MI 49093 USA 269-278-1715 www.kadant.com

LMP Handbook-4003

What is a Liqui-Mover®

Pump?

A Liqui-Mover pump is a positive displacement pressure powered pump with a minimum of moving parts.The pumping action is accomplished using a positive pressure to push the liquid from the pump tank intothe return line. The Liqui-Mover pump can handle high temperature and high pressure condensate withoutdifficulty.

Liqui-Mover pumps are available in nine sizes. They are available in many configurations, from individualcomponents that are field assembled to complete packaged systems ready for connection to field piping. Abasic Liqui-Mover pump consists of a receiver/reservoir, pump tank, 3-way motive valve, inlet and outletcheck valves, level control, and various other fittings.

How a Liqui-Mover Pump Works

In describing “How a Liqui-Mover Pump Works”, it is advantageous to look at the overall operation, and thenbreak it down into smaller operations for a better understanding.

Condensate from the equipment being drained enters the receiver/reservoir tank and flows down the fill lineinto the pump tank. When the predetermined high level is reached in the pump tank, the level control sys-tem sends out a signal, which causes the 3-way motive valve to cycle. When the 3-way valve cycles, theequalizing line between the receiver/reservoir and the pump tank is closed off and a regulated motive pres-sure is admitted into the pump tank. This motive pressure is confined above the condensate in the pumptank and its effect is to move the condensate out of the pump tank and into the return line. When the con-densate reaches a predetermined low level, the level control sends another signal, causing the 3-way valveto revert to its original position. The residual motive pressure remaining in the pump tank will flow throughthe equalizing line, into the receiver/reservoir, enabling the pressures in the two tanks to equalize with eachother. When this is complete, the flow of condensate from the receiver/reservoir to the pump tank will startagain. The cycle will now repeat.

See below for more details of each stage of the cycle:

STAGE ONE:During the fill cycle, fluid flows from thereceiving chamber (A) through the inletcheck valve (B) into the pumpingchamber (C). The 3-way valve (D) isopen between the pumping chamberand the receiving chamber, equalizingthe pressure between them through theequalizing line (E).

STAGE TWO:When the level control (F) senses thatthe pumping chamber is full, the 3-wayvalve energizes to admit the motivepressure into the pumping chamber (C).The inlet check valve (B) preventsbackflow into the fill line.

The discharge cycle begins whenpressure inside the pumping chamber isgreater than in the discharge line. Thedischarge check valve (G) opens andfluid flows into the discharge line. Duringthis cycle, incoming condensate is storedin the receiver.

STAGE THREE:Once the level control (F) senses thepumping chamber has emptied, the 3-way valve (D) de-energizes, shutting offthe motive pressure, and opening thevent port in the valve. This equalizationcycle allows the pumping chamber (C)and the receiving chamber (A) toequalize in pressure, and the fill cyclebegins again.

Installation

Preparation

For ease of future maintenance, the Liqui-Mover pump should be installed with the check valve side of thepump tank most accessible. Normally the motive inlet and the condensate discharge connections are on theleft when facing the check valves. If a Johnson receiver is supplied, the replaceable sacrificial anode is alsoinstalled and removed from this end. On ERC and FAC (pneumatic operated 3-way valve) units, the controlair is located on the right when facing the check valves. Refer to the enclosed assembly drawing for addi-tional information.

Setting the Unit

On LOOO models, the pump tank has (4) holes for mounting to the floor.

On LROO models, you will also need to install a Johnson supplied receiver. The receiver is held in saddleswith ‘U’ bolts supported by (4) pipes on floor flanges. The floor flanges have mounting holes for attachmentto the floor.

On LRFP models, the entire base of the frame should be supported. Mounting holes can be drilled throughthe frame base for attachment to the floor.

All tanks should be installed level.

Piping

On LROO and LRFP models, the Johnson supplied receiver will normally have (3) top connections for: con-densate inlet, atmospheric vent, and pressure gauge. For ‘closed systems’ (no atmospheric vent), an aireliminator and safety relief valve will need to be installed. On LOOO models, the condensate is piped direct-ly to the inlet check valve from an existing receiver or pipe accumulator.

The motive pressure (normally steam or compressed air) is piped to the 3-way valve through a strainer anda pressure reducing valve. The strainer is supplied on LRFP models. Compressed air of at least 55 psigshould be piped to the pilot valve through a filter/regulator/lubricator on ERC and FAC models. The pilotvalve and the filter/regulator/lubricator are supplied with the unit.

For LROO and LOOO models, friction loss through the piping should be kept to a minimum. Therefore, pipereducers should not be used and pipe runs kept to a minimum. All hand valves should be full port if at allpossible.

Electrical

Connect the electrical service to the on/off switch located on the door of the electrical enclosure per theinstruction label located near the switch. The electrical voltage must be the same as the rating of the levelcontrol relay and the valve, unless a step-down transformer has been supplied.

NOTE: An on/off switch is not standard on NEMA 7 units.

Pressure Reducing Valve Installation

A pressure reducing valve (PRV) should be installed in the motive pressure line to regulate how fast theLiqui-Mover pump discharges the condensate out of the pump tank. When properly adjusted, the dischargetime should not be less than 20 seconds. A longer discharge time is acceptable, so long as the Liqui-Moverpump can keep up with the incoming condensate load. Normally the motive pressure setting will be approx-imately 20 psig higher than the back pressure to achieve a 20 second discharge time.

Here are some guidelines to be followed when installing a PRV in conjunction with a Liqui-Mover pump:

1. Never install a PRV immediately adjacent to the 3-way motive valve. The shock caused by thesudden opening and closing of the motive 3-way valve will ultimately damage the PRV. We rec-ommend a distance of 20-25 feet between the PRV and the 3-way valve, where the pipe sizeis the same as the 3-way valve connection. A larger diameter pipe of a shorter length that hasan equivalent volume is also acceptable. The PRV should be sized by a pressure reducingvalve manufacturer or representative.

2. A safety relief valve should be installed downstream of the PRV to prevent over-pressurizationat the 3-way valve. The safety relief valve should be sized by a safety relief valve manufactur-er or representative.

3. When steam is the motive pressure, a drip trap, dirt leg, and strainer should be installed aheadof the PRV. The drip trap should not be piped to the Liqui-Mover pump, unless the receiver isvented.When compressed air is the motive pressure, a liquid drainer, dirt leg, and strainer shouldbe installed ahead of the PRV. The liquid drainer should not be piped to the Liqui-Mover pump.

4. The piping from the PRV outlet to the 3-way valve inlet should be sized to minimize the pres-sure drop under ‘flow conditions’.

5. A throttling valve should be installed immediately ahead of the 3-way motive valve so it can beused in conjunction with the PRV to adjust the Liqui-Mover pump discharge time. Typically thethrottling valve is a globe valve.

The above sketch is for reference only. Always consult with the PRV and safety relief valve manufacturer orrepresentative for proper sizing and application of their products.

Motive Supply Header - Steam or Compressed Air

Safety Relief Valve(Piped to safe location)

Dirt Leg

Y Strainer

Drip Trap(Steam) or Liquid Drainer(Air Motive)

PRV

Equalization LineTo Receiver /Condensate Header

To Liqui-Mover PumpThrottle Valve(Globe)

3-Way Valve

20´ – 25´

Installation Diagram for Liqui-Mover Pump with Compressed Motive

Safety Relief Valve(When Needed)

This Connection Required ForLiqui-Mover Pumps Having a PneumaticOperated 3-Way Valve (ERC and FAC units)

Regulator w/ Gage

Filter w/ Auto Drain

Motive - Compressed Air Supply

Liqui-Mover Pump

To 1/4" NPT AirInlet Connection ofLiqui-Mover Pump

Throttle Valve(Globe)

To Motive Inletof Liqui-Mover Pump

1. This is the recommended piping for a Liqui-Mover pump with compressed motive.

2. The air should be clean, dry and regulated so that the Liqui-Mover pump discharges in therecommended time.

3. The above parts furnished by customer.

NOTE:1. The above sketch is for reference only.2. Additional isolation hand valves may be added as required for maintenance purposes.3. Globe valves should be used where flow restriction is required.4. Gate valves should be used where minimal flow restriction is required.5. For proper PRV installation, see manufacturers installation instructions.

Start-Up Instructions1. On Liqui-Mover pumps that are not pre-piped, inspect the inlet and outlet check valves for

proper flow direction. Refer to the Liqui-Mover pump assembly drawing and parts list.2. If the receiver and/or pump tank contains sub-cooled condensate, this needs to be drained

prior to start-up.3. On ERC and FAC units, open the compressed air line to the filter/regulator/lubricator and set

the air pressure to 55 psig, minimum.4. On ERC and ERS units, turn on the electrical power.5. Open the motive steam or compressed air supply to the PRV and set the pressure to approx-

imately 20 psig higher than the back pressure. The throttling (globe) valve should be closed.6. Open all remaining isolation (hand) valves, except the isolation valve ahead of the inlet check

valve (fill line).7. Once condensate in seen in the receiver, slowly open the isolation valve in the fill line and

watch for condensate to fill the pump tank.8. When the 3-way motive valve energizes, slowly open the throttling (globe) valve ahead of the

3-way motive valve. This will allow the pump tank to discharge.9. After a few discharge cycles, you will be able to fully open the throttling valve and set the

motive pressure to achieve a 20-25 second discharge time using the PRV.10. The unit is now in service.

DischargedCondensate

Equalize Line

Drip Trap - SteamLiquid Drainer - Air

Strainer

Globe Valve

PRV

Motive Supply

Check Valve

OutletCheckValve

ReceiverMay Be JoCo ASME LabeledReceiver, Existing Receiver,

Oversized Pipe Header, or Etc.

3-Way Motive Valve

Pumping Tank

ControlPanel

Vent Line

Incoming Condensate

InletCheckValve

TYPICAL INSTALLATION SKETCH

CV3S-1000 Series with 4-Way Pilot Valve

Port 3(Motive In)

Port 2 (Equalize)

Port 1 (Common)

A

B

INA

EXB

Filter/Regulator/LubricatorSolenoid Pilot Valve4-Way

Port 2 (Equalize)

Port 3(Motive In)

Port 1 (Common)

B EX

A IN

B

A

Solenoid Pilot Valve4-Way

Filter/Regulator/Lubricator

CV3S-100 Series with 3-Way Pilot Valve

32 1


Motive In

Equalize

Common


31

2

Motive In

Equalize

Common



Pilot De-Energized Pilot Energized

Pilot De-Energized Pilot Energized

Coil Voltage Freq. Coil No. Approx. Current Fuse Service JOCO Fuse No.

Size (Amps) (Amps)

Inrush Sealed

B4 120 60 31 5.6 0.54 0.8 Cont. CSE175-3025-03

B4 240 60 32 2.8 0.27 0.5 Cont. CSE175-3025-08

B4 240 50 32-50 2.8 0.27 0.5 Cont. CSE175-3025-08

C4 120 60 595 12.7 1.00 1.25 Cont. CSE175-3025-04

C4 240 60 596 6.4 0.50 0.8 Cont. CSE175-3025-03

C4 240 50 596-50 6.4 0.50 0.8 Cont. CSE175-3025-03

D7 120 60 61 12.0 1.04 1.4 Cont. CSE175-3025-05

D7 240 60 62 6.0 0.53 0.8 Cont. CSE175-3025-03

D7 240 50 62-50 6.0 0.53 0.8 Cont. CSE175-3025-03

D3 120 60 71 20.0 1.82 2.50 Cont. CSE175-3025-06

D3 240 60 72 10.0 0.92 1.25 Cont. CSE175-3025-04

D3 240 50 72-50 10.0 0.92 1.25 Cont. CSE175-3025-04

D4 120 60 81 33.5 4.57 6.0 Int. * CSE175-3025-07

D4 240 60 82 16.8 2.35 3.0 Int. * CSE175-3025-09

D4 240 50 82-50 16.8 2.35 3.0 Int. * CSE175-3025-09

Int. * : Intermittent service - solenoid energized not over 45% of the time and not longer than 1/2 hour at one time

Fuses manufactured by: Gould Shawmut TR XX RBussman FRN-R-XX(Replace X's with Fuse Amps)

Reference Johnson Drawing A37786

Johnson Solenoid Coil and Fuse Specification Sheet

Troubleshooting

Contents

General Troubleshooting

General ERC and ERS Troubleshooting

ERC Troubleshooting

ERS Troubleshooting

FAC Troubleshooting

Preventative Maintenance Check List

Preventative Maintenance Check List Additional For FAC

Ceramic Electrode Plugs

Electrode Lengths

8300 Series Relay Installation and Maintenance

Intrinsically Safe Relay Installation and Maintenance

Page 1 - General Troubleshooting LMTSO387-03

OBSERVATION PROBABLE CAUSE REMEDY

1. Liqui-Mover pump fails to fill. 1. Increase in liquid level inreceiver, possible flood inreceiver.

Obstruction in fill line, valve closed,inlet check valve backwards.

Inspect fill line for closed valve, inletcheck valve in reverse, or obstructionin fill line. Refer to Assembly & PartsList Drawing.

2. Increase in liquid level inreceiver, possible flood inreceiver, increase in receiverpressure.

3-Way Valve Assembly out ofadjustment.

Inspect 3-Way Valve Assembly.Refer to Valve Section.

3. Receiver empty.Liqui-Mover pump levelfluctuating.

Receiver pressure greater thanpressure in discharge line.

If unit has been in operation for aperiod of time without problems,check for traps blowing through. Ifnew installation receiver pressure maybe greater than anticipated. Backpressure may be less than anticipated.A 2-Way Controlled Valve may berequired in discharge line.

4. 3-Way Motive Valve will notdeenergize.

See observation under specific ERSor ERC Troubleshooting Section.

See specific remedy.

2. Liqui-Mover pump fills tooslow.

1. No liquid level in receiver. Load to unit not as great asanticipated.

No action required.

2. Receiver flooding. Obstruction or restriction in fill line. Inspect fill line for partially closedvalve or defective check valve.Inspect fill line for proper size fittingsand pipe. Refer to Assembly andParts List Drawing for specific unit.

GENERAL TROUBLESHOOTING OF LIQUI-MOVER PUMPS



3. Receiver flooding. Restriction in vent line, 3-Way Valveassembly out of adjustment.

Inspect vent line for partially closedvalve, proper size fittings and pipe.Refer to Assembly and Parts ListDrawing. Inspect 3-Way ValveAssembly. Refer to Valve Section.

3. Liqui-Mover pump fills veryrapidly.

1. Unit cycling almostnormally, receiver flooding.

Defective check valve in discharge lineand/or fill line. Possible back flow toLiqui-Mover pump.

Inspect discharge line check valve andfill line check valve. Refer toAssembly and Parts List Drawing.

4. Noise in or at fill line checkvalve.

1. Vibration and water hammerat fill line check valve.

Cold condensate. Inspect for cold condensate. Throttleflow control valve, ahead of 3-WayMotive Valve Assembly. Refer toAssembly and Parts List Drawing,and start-up procedure.

5. Liqui-Mover pump dischargesvery rapidly.

1. Water hammer in dischargeline.

Motive pressure too high. Throttle flow control valve or installpressure reducing valve. See start-upprocedure.

2. Receiver flooding, rise inreceiver pressure duringdischarge.

Defective check valve in fill line,discharging condensate back intoreceiver.

Inspect fill line check valve. Refer toAssembly and Parts List Drawing.

6. Liqui-Mover pump dischargecycle too long.

1. Possible receiver flooding,discharge time greater than30 seconds.

Flow control valve throttled too much. No action required, if receiver notflooding. If receiver flooding, adjustflow control valve for discharge of20 - 25 seconds (approx.).



2. Receiver flooding. Dischargetime greater than 30 seconds.

Restriction or increase of backpressure in discharge line.

Inspect discharge line for partiallyclosed valve(s), obstructions orchange in pressure. A pressureincrease may require adjustment offlow control valve to reduce dischargetime. Inspect discharge check valve.

3. No motive pressure flow.Receiver flooding.

Motive supply failure, obstruction inmotive supply line.

Inspect for motive supply pressure,closed valve, or obstruction in motivesupply line. Inspect strainer.

4. 3-Way Motive Valve noisy. Condensate in motive supply line. Inspect motive supply line forcondensate. Check drip trap. Refer toAssembly and Parts List Drawing.

5. Receiver pressure increaseduring discharge.

3-Way Valve out of adjustment,leakage into receiver.

Refer to Valve Section.

6. 3-Way Motive Valve will notdeenergize.

See observation under specific RelaySection.

See specific remedy.

Page 4 - ERC or ERS Troubleshooting LMTSO387-03

GENERAL ERC & ERS TROUBLESHOOTING


1. 3-Way Valve erratic.Operates from one level only.

1. Condensate level inLiqui-Mover pump at onelevel.

Electrode wires reversed. Poorground connection.

Refer to Relay TroubleshootingSection.

2. 3-Way Valve erratic. Operatesfrom low level only.

1. Condensate level in Liqui-Mover pump at low level.

Electrode plugs shorted. Electrodeplug grounded. Holding contact bad.


3. 3-Way Valve erratic. 1. Condensate level can be highor low.

Moisture in electrode holder. Dirtyelectrodes. Cracked or brokenelectrode plug.


Page 5 - ERC Troubleshooting LMTSO387-03

TROUBLESHOOTING – ERC UNITS(w/Electrodes-Relay-Cylinder Operated Valves)


1. 3-Way Cylinder Operated Valvewill not cycle on (closedmotive side – open vent side).

1. Relay pulls in. Air pilotshifts.

Packing nut too tight. Back-off packing nut. Refer to ValveSection.

2. Relay pulls in. Air pilotshifts.

Obstruction in air line to cylinder. Check air lines for obstructions orbreaks.

3. Relay pulls in. Air pilotnot shifting.

Air pilot valve. Check wiring, check for voltage topilot coil. Check air pressure (55 psigminimum).

4. Relay will not pull in. Power failure. Refer to Relay TroubleshootingSection.

5. Relay will not pull in. Electrode circuit or relay malfunction. Refer to Relay TroubleshootingSection.

2. 3-Way Cylinder Operated Valvewill not cycle off (open motiveside – closed vent side).

1. Relay drops out. Airpilot shifts.

Packing nut too tight. Back-off packing nut. Refer to ValveSection.

2. Relay drops out. Airpilot not shifting.

Air supply or air pilot valve. Check for proper air pressure. Inspectrelay contacts for being weldedtogether. If okay, repair or replacepilot valve.

3. Relay drops out. Airpilot shifts. Receiverflooding.

3-Way Cylinder Valve Assemblyjammed.

Inspect 3-Way Cylinder ValveAssembly for obstruction, dirt orforeign debris. Refer to Valve Section.

4. Relay will not drop out.Receiver flooding.

Electrode holder wet or dirty, probe orwire grounded.


3. 3-Way Cylinder Operated Valvecycles On–Off erratically.

1. Relay does not followerratic valve operation.

Air supply fluctuating. Inspect air supply for fluctuations. Airpilot requires 55 psig minimum.

Page 6 - ERS Troubleshooting LMTSO387-03

TROUBLESHOOTING – ERS UNITS(w/Electrodes-Relay-Solenoid Steam Valve)


1. 3-Way Valve will not energize(closed motive side – open ventside).

1. Relay pulls in. Liqui-Moverpump flooded.

Overload tripped or fuse bad. Replace fuse. Refer to Valve Section.

2. Relay pulls in. Solenoidvalve noisy.

Packing nut too tight. Dirty armature. Back-off packing nut. Refer to ValveSection. Check valve adjustment.

3. Relay pulls in. Fuse notblown.

Solenoid valve coil open. Inspect Solenoid Valve for burnt orbroken lead wires or bad coil. InspectSolenoid Valve for mechanical jam.Refer to Valve Section.

4. Relay will not pull in. Power failure. Inspect for supply voltage. Refer toRelay Troubleshooting Section.

5. Relay will not pull in. Electrode circuit or relay malfunction. Refer to Relay TroubleshootingSection.

2. 3-Way Valve will notdeenergize (open motive side –close vent side).

1. Relay drops out. Receiverflooding.

Packing nut too tight. Back off packing nut. Refer to ValveSection.


Electrode holder wet or dirty, probeor wire grounded.



Electrodes shorted. Inspect Liqui-Mover pump chamberfor debris. Refer to RelayTroubleshooting Section

4. Relay drops out. Receiverflooding.

3-Way Steam Valve Assemblyjammed.

Inspect 3-Way Solenoid ValveAssembly for obstruction, dirt, orforeign debris. Refer to Valve Section.

Page 7 - FAC Troubleshooting LMTSO387-03

TROUBLESHOOTING – FAC UNITS(Refer to General Troubleshooting Section, Pages 1 through 3, then the following.)


1. 3-Way Cylinder Operated Valvewill not cycle on (closed motiveside – open vent side).

1. Air pilot shifts. Air pressure too low. Raise air pressure.

2. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to ValveSection.

3. Air pilot shifts. Obstruction in air line to cylinder. Check air lines for obstructions orbreaks.

4. Air pilot not shifting. Wisker valve not operating or bad. Break air line between pilot valve andwisker valve.

1. If pilot valve still does not shift,break air line between air filter andchoke. Clean .010˝ hole in choke orreplace choke. Reassemble andretest. If pilot valve still does notshift, replace pilot valve.

2. If pilot valve shifts, shut off allsteam, condensate, and motive linesto and from the unit. Reconnect theair line between the pilot valve andthe wisker valve. Remove the cover(LMH-02032-1 or 6) and manuallyraise the float tube.



a. If the pilot valve shifts,disassemble flanges that mountthe control head and remove,inspect, and repair floatassembly as required. Refer toDwg. A-97-19-4-17, Pg. 5.

b. If the pilot valve does not shift,remove the air switch andinspect for missing or brokenspring pins, magnet, or snaprings. Note: The magnet mustbe able to rotate freely only 30degrees. If all appears proper,replace the wisker valve, Referto Dwg. A-97-19-4-17, Pg. 3.

2. 3-Way Cylinder Operated Valvewill not cycle off (open motiveside – closed vent side).

1. Air pilot shifts. Low air pressure. Raise air pressure.

2. Air pilot shifts. Packing nut too tight. Back-off packing nut. Refer to ValveSection.

3. Air pilot shifts. Obstruction in air line to cylinder. Check air lines for obstructions orbreaks.

4. Air pilot not shifting. Wisker valve not operating or bad. Break the air line between the pilotvalve and the wisker valve. Block offair flow from the fitting on top of thepilot valve.



1. If pilot valve does not shift, replacethe pilot valve.

2. If the pilot valve shifts, shut off allsteam, condensate, and motive linesto and from the unit. Reconnect theair line between the pilot valve andthe wisker valve. Remove the cover(LMH-02032-1 or 6) and manuallylower the float tube.

a. If the pilot valve shifts,disassemble flanges that mountthe control head and remove,inspect, and repair floatassembly as required. Refer toDwg. A-97-19-4-17, Pg. 5.

b. If the pilot valve does not shift,remove the air switch andinspect for missing or brokenspring pins, magnet, or snaprings. Note: The magnet mustbe able to rotate freely only 30degrees. If all appears proper,replace the wisker valve. Referto Dwg. A-97-19-4-17, Pg. 3.

LIQUI-MOVER PUMP

PREVENTATIVE MAINTENANCE CHECK LIST

HOW OFTEN CHECK REFERENCE

6 Months 1. Check electrodes for build up offoreign matter. With build up, poorconductivity may occur creatingerratic pumping behavior.

Remove cap on electrode holder.Remove electrode plugs, this will alsoremove electrodes. Clean electrodeswith steel wool or emery cloth.Replace.

2. Check 3-Way valve adjustment andmake necessary adjustments. Alsocheck valve packing and replace ifrequired.

Refer to specific valve repair andmaintenance guide.

1 Year 1. Check electrical wiring. Inspect wires at electrode plugs andvalve for a deterioration of insulationand frayed wires.

2. Check anode in receiver tank. Drain tank – remove anode byunscrewing anode plug on the receivertank end. If over 60% eaten away,replace.

3. Clean gauge glasses when required. Disassemble and pull clean cloththrough glass with cleaning wire.

4. Drain tanks to remove residue. Remove drain plugs in bottom of bothtanks. Replace.

5. Check relay contacts (points). If dirty, clean. if burnt, replace, (ERSunits only).

6. Check Solenoid Valve current. With Solenoid Valve energized,measure current. Too high a currentcould indicate a dirty armature or wornarmature – clean or replace asnecessary. Refer to A-97-23-1-10 inValve Section.

CAUTION: Before performing any of the above maintenance checks, shut off electricalpower, steam, and condensate ahead of the unit.

Page 2 – Preventative Maintenance

FAC LIQUI-MOVER PUMP

PREVENTATIVE MAINTENANCE CHECK LIST

HOW OFTEN CHECK REFERENCE

1 Month 1. Oiler Level. Should deliver (1) drop per week.Adjustment screw.

2. Air Filter – Main. Blow down or clean as required.

3. Air Filter – Secondary.(Located on Control Head)

Blow down or clean as required.

6 Months 1. Flush External Float Housing. Remove 1-1/2˝ drain plug and flush.

CAUTION:These items in addition to standard Liqui-Mover pump maintenance check items.

Before performing any of the above maintenance checks, shut off all steam,condensate and air lines.

CAUTION: Since Line Voltage is often present during electrical tests, only qualified electricians should per-form electrical tests.

A. OPERATION – This description applies to a pump down or direct type of level control. The sequence isas follows:

1. The relay is deenergized as shown in the diagram and the valve is deenergized and closed while theliquid in the tank is rising.

2. When the liquid reaches the high level electrode, it completes the circuit from terminal 5 to 3, ener-gizing the relay. This can be heard as a click as the load contact is reversed.

3. The load contact closes and the valve opens admitting pressurized steam or air into the tank whichcauses the liquid level to lower.

4. When the relay energized, an internal “holding” circuit closed from terminal 4 to 3. When the liquidleaves the high level electrode this “holding” circuit through the ground, the liquid, and the low levelelectrode keeps the relay energized.

5. When the liquid drops below the low level electrode this holding circuit is broken and the relay isdeenergized, opening the load contact.

6. The valve closes, shutting off the pressurized gas line and allowing the liquid to rise again.

B. RELAY DOES NOT PULL IN

1. POWER FAILURE – Check for voltage at the two (2) terminals located on the lower left hand cornerof the level control relay. This voltage should be either 120 or 240 volts A.C. as determined by thevoltage of the relay(s) and solenoid operated valve(s).

2. DEFECTIVE LEVEL CONTROL – Disconnect the electrodes and jumper the terminal marked “C” tothe terminal marked “H”. The 3-way steam valve should turn on when the jumper is connected andshut off when the jumper is removed. To check the holding circuit proceed as above but do notremove the jumper wire; instead add another jumper wire from the terminal marked “C” to the termi-nal marked “L”. Remove the first jumper wire connected to “H” and the relay should remain energized.If the relay does not remain energized, it is bad and will have to be replaced.

BLACK WHITE

A.C. Line

1LCR

2LCR

AUX PWR RELAY

SOV1

LCR

OPT. COUNTER

3

4

5

to SHORT ELECT.

to LONG ELECT.

GND. & ELECT.

APR

APRFU

OPT. CYCLE COUNTER

109

8300 Series Relay Installation and Maintenance

Black White

A.C. Line

1LCR

2LCR

SOV1

OPT. CYCLE COUNTER

LCR

OPT. COUNTER

9 10

3

4

5

to SHORT ELECT.

to LONG ELECT.

GND. & ELECT.

ERC ERS

3. POOR GROUND CONNECTION – The control will not function unless a good dependable groundconnection is made to the terminal marked “C”. When installed in non-conductive tanks a third elec-trode (the longest) is required for a ground connection.

4. BROKEN WIRES – Check for broken wires by grounding the spark plug holding the short electrode.If the relay fails to energize, one or both of the electrode leads are open, or there is a bad groundconnection. Run temporary wires from the control panel to the electrode holder and retest.

5. BUZZ OR CHATTER – If the resistance or conductivity of the liquid is too low, the relay may buzz,chatter, or fail to operate at all. Consult area representative for selecting a relay with proper sensi-tivity.

6. FOULED ELECTRODES – Accumulated dirt, oil, and other deposits may insulate the electrodes andprevent operation. Electrodes should be inspected and cleaned at regular intervals.

C. VALVE DOES NOT ENERGIZE WHEN THE RELAY DOES

1. FUSE – ERS – ERS units are equipped with a fuse for solenoid valve coil protection. Check thefuse for continuity and replace if bad. One spare is included with each Liqui-Mover pump. Referto Drawing A-27541, Symbol No. A-97-23-1-15 for solenoid coil protection.

2. SOLENOID COIL – Remove the wires going to the solenoid coil from the terminal strip and checkfor continuity. If an open circuit is found, there is a broken wire, a bad connection, or the coil itselfis bad. Repair or replace as necessary.

3. AUXILIARY RELAY – ERS – ERS units are equipped with an auxiliary relay because the levelcontrol relay contacts are not heavy enough to handle the inrush current of a direct operatedsolenoid valve. Inspect this relay for burnt contacts. Clean or replace contacts/relay as required.

D. VALVE ENERGIZED WHEN RELAY IS NOT ENERGIZED

1. RELAY CONTACTS – The relay contacts may have failed to open. On ERS units inspect the aux-iliary relay visually for stuck contacts. On ERC and ERS units check the contacts on the level con-trol relay with a V.O.M.

E. RELAY WILL NOT DEENERGIZE

1. GROUND WIRE – A wire from the relay to an electrode may be grounded to the conduit or enclo-sure.

2. WET PLUG – Dirt or moisture on an electrode plug can ground the electrode to the holder.Cleaning the electrode plugs periodically and using a proper holder will help keep the plugsclean.

3. CRACKED PLUG – The electrode plug may be cracked, allowing moisture to ground the elec-trode to the enclosure.

F. RELAY FLUCTUATES AT HIGH LEVEL

1. ELECTRODE WIRING – Wire to low level electrode may be broken.

2. ELECTRODE – Low level electrode may have broken off or become insulated due to grease ordirt.

3. RELAY HOLDING CIRCUIT – If the internal holding circuit of the relay fails to close, the relaywould fluctuate at the high level. To test relay see Section B-2.

G. RELAY FLUCTUATES AT LOW LEVEL

1. WIRES REVERSED – Wires to electrodes may be reversed.

2. RELAY HOLDING CIRCUIT – If the internal holding circuit of the relay is shorted, it would causethe relay to fluctuate at the low level. To test the relay see Section B-2.

H. RELAY CHATTERS AFTER DISCHARGING

1. WET PLUG – The underside of the electrode plug may be coated with dirt or moisture causingcontinuity across the insulator. If steam is used as the motive substance to lower the liquid level,when the tank is vented at the start of the fill period the steam expands. This may leave a film ofmoisture on the underside of the plug which can cause relay fluctuation a few times before the mois-ture evaporates and lets the relay drop out. This can be avoided by using a relay with lower sensi-tivity if the liquid is sufficiently conductive, or by insulating the electrodes, leaving 1/4˝ bare at thelower end.

INSTALLATION – The electrode circuit of this relay is intrinsically safe and can be located in a hazardousarea with an electrode holder and tank which are not explosion-proof. However, the rest of the circuits mustbe protected by explosion-proof enclosures and rigid conduit with conduit seals.

OPERATION – This description applies to a “pump down” type of level control and the sequence is as fol-lows:

1. The relay is deenergized as shown in the diagram and the valve is deenergized and closed while theliquid in the tank is rising.

2. When the liquid reaches the high level electrode, it completes the circuit from terminal 14 to 15, ener-gizing the relay. This can be heard as a click and all the load contacts are reversed.

3. Load contact 10 – 7 closes and the valve opens admitting pressurized steam or air which causes theliquid level to lower.

4. When the relay was energized, an internal “holding” circuit closed from terminal 16 to 15. Hencewhen the liquid leaves the high level electrode this “holding” circuit through the ground, the liquid,and the low level electrode keeps the relay energized.

5. When the liquid drops below the low level electrode this holding circuit is broken and the relay is deen-ergized, opening the internal holding connection from 14 to 16 and opening load contact 10 – 7.

6. The valve closes, shutting the pressurized gas line and allowing the liquid to rise again. When theliquid reaches the low level electrode the relay remains deenergized since the internal connectionfrom 16 to 15 is now open, so the cycle will be repeated.

INTRINSICALLY SAFE RELAY FOR LEVEL CONTROL

120 VAC

11 12 13

14 15 16

6

5

4

3

9

Sol.Valve

Electrode Holder

High Level Electrode

Low Level Electrode

10

8

7

BFuse

240 VAC

11 12 13

14 15 16

6

5

4

3

9

B

Sol.Valve

10

8

7

Fuse

* Note: For ERC type units no overload is used.The air pilot valve is connected to relay termi-nals 11 and 7 or as shown on wiring assembly.

Older models use a thermal element in place ofthe fuse shown.

A

B

SERVICE INSTRUCTIONS For 120V Control. (For 240V see diagram)

A. RELAY DOES NOT PULL IN

1. POWER FAILURE – Check for voltage at terminals 11 and 12. Should be within 10% of rated value.

2. RELAY FAILURE – Remove leads from terminals 14, 15, and 16. With power on, touch a jumper from14 to 15 and you should hear the relay click on. If not, the relay should be replaced. To test seeSection 1.

3. POOR GROUND CONNECTION – There must be a low resistance “ground” connection from termi-nal 14 to the liquid either through the tank or through a “ground” electrode which contacts the liquid.

4. BROKEN WIRES – An open connection in the line from 15 to the short electrode will prevent therelay from energizing. To check, run a temporary wire from terminal 15 to the short electrode.

5. FOULED ELECTRODES – Deposits of dirt or grease on the upper electrode can insulate it and pre-vent relay from pulling in. If this occurs, electrodes should be cleaned regularly as required. If largequantities of oil, grease, or sludge are encountered, the electrodes can be mounted inside a pipewith the bottom below the lowest water level and a vent hole above high water level. A small flow ofwater into the top of the pipe will keep the electrodes operating in clean water.

6. ELECTRODES TOO SHORT – If the liquid can not reach the high level electrode, the relay will notpull in.

7. LOW CONDUCTIVITY – If the conductivity of the liquid is below 17 micromhos it may not allow con-duction of enough current to operate the relay. Specify conductivity data to the factory and a moresensitive relay can be supplied.

B. VALVE DOES NOT ENERGIZE WHEN RELAY DOES

1. OVERLOAD TRIPPED – If the overload has tripped, reset it. If it continues to trip, see Drawing A-97-23-1-9.

2. RELAY CONTACT – With relay energized (water at high level or a jumper on terminals 14-15) checkfor voltage on terminals 11-7. If not voltage, and connection from 12-10 is okay, relay contact 10-7may be defective. Transfer its connections to spare contact 6-3.

3. SOLENOID COIL OR AIR PILOT VALVE COIL – Check wires to coil. If coil is mechanically free,apply voltage to coil. If coil does not pull and wiring is proper, replace coil.

C. VALVE ENERGIZED WHEN RELAY IS NOT

1. RELAY CONTACT – Relay contact 10-7 may fail to open. Transfer its connections to spare contact6-3.

D. RELAY FLUCTUATES AT HIGH LEVEL

1. ELECTRODE WIRING – Wire from 16 to low level electrode may be broken.

2. ELECTRODE – Low level electrode may have broken off or become insulated due to grease or dirt.

3. RELAY HOLDING CIRCUIT – If the internal holding circuit of the relay fails to close, the relay wouldfluctuate at the high level. To test relay see Section 1.

E. RELAY FLUCTUATES AT LOW LEVEL AFTER ONE CYCLE

1. ELECTRODE GROUND – Turbulance may cause long electrode to contact stilling well or tank.

2. WET PLUG – The underside of the electrode plug may be coated with dirt or moisture causing ashort across the insulator. If steam is used as the motive substance to lower the liquid level, whenthe tank is vented at the start of the fill period the steam expands. This may leave a film of moistureon the underside of the plug which can cause relay fluctuation a few times before it evaporates andlets the relay drop out. This can be avoided by using a relay with lower sensitivity if the liquid is suf-ficiently conductive, or by insulating the electrodes, leaving 1/4˝ bare at the lower end.

F. RELAY FLUCTUATES AT LOW LEVEL

1. WIRES REVERSED – Wires to electrodes may be reversed.Terminal 15 should connect to high level(short) electrode and terminal 16 to low level (long) electrode.

2. RELAY HOLDING CIRCUIT – If the internal holding circuit of the relay is shorted, it would cause therelay to fluctuate at the low level. To test the relay see Section 1.

G. RELAY CONTINUOUSLY ENERGIZED AFTER ONE CYCLE

1. GROUNDED WIRE – Wire from terminal 16 to the low level electrode may be shorted to the conduitor enclosure.

2. CRACKED PLUG – The insulating plug on the low level (long) electrode may be cracked, allowingmoisture to short the electrode to the enclosure.

3. SHORTED ELECTRODE – The low level (long) electrode may be touching the stilling well or tank.

H. RELAY CONTINUOUSLY ENERGIZED

1. GROUNDED WIRE – Wire from terminal 15 to the high level (short) electrode may be shorted to theconduit or enclosure.

2. WET PLUG – Dirt or moisture on the electrode plug for the high level electrode can short the elec-trode to the holder. Cleaning periodically or using a stilling well may help keep the plugs clean. If theproblem persists it may be solved by using a relay with lower sensitivity if the liquid is sufficiently con-ductive, or by insulating the electrodes, leaving 1/4˝ bare at the lower end.

3. CRACKED PLUG – The insulating plug on the high level relay may be cracked, allowing moisture toshort the electrode to the enclosure.

I. RELAY TEST – To test the relay, disconnect leads from terminals 14, 15, 16, 7 and the solenoid wire toterminal 11. Connect a 120V lamp to 11 and 7. Connect one end of a 47,000 ohm resistor to 14. With120V supplied to 11 and 12, placing jumpers as shown should give the indicated response:

Jumper Response

Resistor to 16 Lamp Off

Leave Resistor to 16, Add 15-16 Lamp On

Leave Resistor to 16, Remove 15-16 Lamp On

Remove Resistor to 16 Lamp Off

THE KADANTJOHNSON LIQUI-MOVER® PUMP

CERAMIC ELECTRODE PLUGS PREVENTIVE MAINTENANCE

SUBJECT: ELECTRODE PLUGS

The Ceramic Electrode Plugs supplied with Kadant Johnson Liqui-Mover pumps, are by the nature of their material, fragile. While it is true that they can operate at high temperatures and pressures with no adverse affect, any rough handling will be a source of future problems. To avoid operating difficulties always follow these

tips to prevent damage to the Electrode Plugs.

1. Do not tap Upper Ceramic Insulator with

any tool.

2. Do not use excessive force when

tightening The Knurled Nut at the top of

the Electrode Plug – finger tight only. Use

di-electric grease on threads.

3. When tightening the Probe Rod to the

Electrode Plug, do not apply torque to the

Middle Collar on the plug, instead hold by

coupling on bottom of Electrode Plug.

4. Do not bend Probe Rod after it is installed

in Electrode Plug.

5. Use high temperature #18 gauge Teflon

insulated wire rated for 200° C (392° F) 600

volt between the electrode plugs and

control box. Beldon #83009 or equal is

suggested.

6. Replace copper gasket each time

Electrode Plug is removed. Tighten

Electrode Plug to 40 to 60 ft-lbs.

Ceramic Electrode Plugs PM Effective: December 1, 2015

Assembly Instructions for Valve Packing

Instructions

1. Remove worn packing.

2. Disconnect stem. Check surface for scratches and wear.

3. Install one bull ring, two piece packing (stagger ends),then one bull ring.

4. Reinstall packing gland. Tighten snug only. Do not over-tighten.

5. Readjust valve seat with stem coupling. See instructionssent with valve.

Note: During operation of valve, packing will require adjust-ment periodically. Tighten only enough to preventleakage in 1/8˝ turn increments.

PackingGland

Bull Ring

Packing Stagger Ends

Bull Ring

Bushing

Stem

Packing Computer Bull Ring PackingAssembly No. No. Two Required Two Required

V11026 23S10000 CSS-836-025-012-TE CSS-835-012-025-TK

V11026-1 23S10025 CSS-836-031-009-TE CSS-835-009-031-TK

V13026 23S10050 CSS-836-031-012-TE CSS-835-012-031-TK

* V16026 23S10075 CSS-836-044-025-TE CSS-835-025-044-TK

MATERIAL: Packing – Crane Style K17-60 Teflon Filled Kevlar with Break-in Lube

Bull Ring – 1/16˝ Thick Virgin Teflon

TEMPERATURE: -100°F to 600°F

* For all 600 Series Solenoid Valves which use bracket SV-603-1, new packing nut SV-613-2 (23062944)must be furnished with new packing.

FAC ERC-ERS NEW STYLE

LMH GAUGE GLASS LEVELS ELECTRODES GAUGE GLASS LEVELS

SIZE TOP BOTTOM ∆ SHORT LONG TOP BOTTOM ∆5 N/A N/A N/A 1.50 6.50 1.00 0.00 5.0

10 3.0 3.4 3.25 4.00 8.00 .75 1.75 4.0

20 2.8 1.3 7.50 4.00 12.00 .75 1.75 8.0

40 2.8 1.3 7.50 4.00 12.00 .75 1.75 8.0

50 1.4 3.3 11.75 5.00 17.00 .75 1.75 12.0

65 1.4 3.3 11.75 5.00 17.00 .75 1.75 12.0

110 1.4 3.3 11.75 5.00 16.00 .75 2.75 11.0

150 .8 3.1 15.50 5.00 20.00 .75 4.75 15.0

200 7.00 27.00 2.25 9.75 20.0

NOTES:

1. All levels shown are nominal dimensions.

2. All high level alarm electrodes 1˝ shorter than short electrode.

3. All low level alarm electrodes 1˝ longer than long electrode.

4. Holder meets NEMA 1 and NEMA 4 requirements – for NEMA 7 applications

An intrinsically safe relay must be used with this holder.

5. All ground electrodes are 2˝ longer than long electrode.

ELECTRODE LENGTHS

Documents

LIQUI-MOVER PUMP HANDBOOK · 2017-06-15 · Liqui-Mover pump discharges the condensate out of the pump tank.When properly adjusted, the discharge time should not be less than 20 seconds