1、 Daily maintenance standards
Lubricating oil management
After the initial 250 hours of operation, the lubricating oil in the drive box needs to be replaced, and it should be replaced every 2500 hours or 6 months thereafter. Recommend using Mobilgear630 or XP220 lubricating oil, and switch to XP68 when the ambient temperature is below -5 ℃. When replacing, it is necessary to drain the old oil through the oil drain hole and filter the new oil with an 80 mesh filter.
Inspection of overcurrent components
Check the condition of the one-way valve and diaphragm every 6 months, with a focus on observing the sealing of the valve ball and the integrity of the diaphragm surface. If the one-way valve is found to be stuck or the diaphragm has cracks or bulges, it should be replaced immediately. For mRoy series hydraulic diaphragm pumps, it is necessary to check the oil level in the drive box and the emulsification of lubricating oil, as emulsified oil may indicate diaphragm rupture.
Pipeline system optimization
It is recommended to use self filling installation, with the suction end lower than the liquid level of the storage tank, and the maximum suction stroke not exceeding 4 meters of water column. If suction lifting installation is necessary, a foot valve should be installed at the suction pipe mouth, and filters, shut-off valves, and flexible joints should be installed in the pipeline for regular cleaning and maintenance.
2、 Diaphragm replacement steps
preprocessing
Adjust the stroke to 0%, cut off the power and hang a "under repair" warning sign. Before disassembling the pump head, mark the inlet and outlet positions with a marker pen to prevent misalignment during reassembly.
Dismantling and installation
Remove the fixing screw of the pump head and rotate the hydraulic end counterclockwise to disengage from the drive shaft. Check if the old diaphragm is damaged, and if there is any material leakage during the testing process, confirm that the diaphragm has ruptured. When installing a new diaphragm, rotate the back plate clockwise to the mechanical stop position to ensure that the leakage discharge hole is located at the bottom of the pump body. After reinstalling the pump head, adjust the stroke to 100%, rotate the motor fan blades to extend the diaphragm, and finally tighten the pump head screws to a torque of 45 in-lb.
Verification Test
After starting the pump, observe whether it runs smoothly, check that there is no lubricating oil leakage from the pump head detection port (the oil seal is normal), and that there is no process material leakage (the diaphragm seal is intact). Measure the actual flow rate through the calibration column and confirm that the deviation from the set value is ≤± 2%.
3、 Fault diagnosis and handling
The pump is not running
Check the power supply, fuse, and thermal overload device. If the motor malfunctions, replace it. For pneumatic pumps, it is necessary to confirm whether the air pressure has reached 0.3-0.7MPa.
Insufficient/unstable traffic
Clean the filter and feed line, and check if the one-way valve is stuck. If the valve ball wears out and causes seal failure, the valve component and O-ring need to be replaced. For high viscosity media, the pulse width can be extended to 300ms to improve measurement accuracy.
abnormal pressure
Insufficient pressure may be caused by a malfunction of the oil replenishment valve or leakage of the feed valve, and the sealing surface of the valve body needs to be inspected. If the pressure fluctuation is severe, a pulse damper should be installed in the outlet pipeline, and a back pressure valve should be installed to prevent siphoning when the pressure is below 3 bar.
Abnormal noise or leakage
The noise may be caused by incorrect installation of the one-way valve or worn bearings, and the valve body needs to be reassembled and coated with thread glue. If the detection port leaks lubricating oil, the oil seal needs to be replaced; If there is a material leakage during the process, the diaphragm needs to be replaced and the oil level in the drive box checked.