OPERATION MANUAL Squire “Plus 2” 2-Head Washer / Filler PROCESS & PACKAGING, INC. 5450 Tech Circle, Moorpark, CA 93021 Tel: (805) 529-9890 Fax: (805) 529-9282 Table of contents TITLE SECTION Table of contents Preface Disclaimer Confidentiality and Copyrights Operational Safety Notes EMERGENCY STOP Training Specifications Start-up and Shut-down Procedure C.I.P. Procedures Plant Layout Electrical Section Mechanical Section Pneumatics Section I/O Listing Oxine Planned Prevenative Maintenance Schedule Quality Control Dimensions Spares Services Cycle Times Flow Diagram Control Philosophy Program Listing Appendix Section PROCESS & PACKAGING, INC. ã1998 A B C D E F G H I J K L M N O P Q R S T V W X Y Z PREFACE B The SYSTEM has been designed as a self contained and reliable automatic keg processing machine. Although kegs are loaded and unloaded manually, all washing, sanitizing, and filling operations are fully automatic for consistent high quality results. The following instructions and information have been prepared to clarify operational and maintenance procedures and should ensure long, reliable service from the machine if followed carefully. Proper maintenance and use of approved spare parts will extend the life of the system and it's reliability. The use of any non approved spare parts may void any warrants or guarantees, actual or implied. DISCLAIMER C The customer assumes all responsibility for the SYSTEM once delivered. The SYSTEM is tried and tested equipment. As such IDD Processing & Packaging will not be held responsible for alterations and modifications carried out by the customer without the written approval of IDD Processing & Packaging. CONFIDENTIALITY & COPYRIGHT All information within is confidential and the copyright of IDD Process & Packaging, Inc. No portion of this data shall be released, disclosed, used or duplicated for use in procurement or manufacturing without the express written permission from IDD Process & Packaging, Inc. PROCESS & PACKAGING, INC. ã1998 D OPERATIONAL SAFETY NOTES WEAR SAFETY GOGGLES Wear Safety Goggles approved for use by your Safety and Operational Procedures Committees when operating or observing this system. WEAR CHEMICAL RESISTANT GLOVES & APRON Wear Chemical Resistant Gloves and Apron approved for use by your Safety and Operational Procedures Committee. WEAR BACK SUPPORT EQUIPMENT Wear Back Support Equipment approved for use by your Safety and Operational Procedures Committees and use proper lifting technique approved for use by your Safety and Operational Procedures Committees. A full keg weighs up to 165 lbs and must be lifted using proper equipment. VENTILATION Area should have adequate ventilation approved for use by your Safety and Operational Procedures Committees. Respirators should be used during cleaning and operations where fumes are present. EMERGENCY STOP MANUAL PROCESS STOPS To STOP the process sequence at any time for each of the process heads, use the Manual Stop Process Buttons, that are located on the Control Panel. PROCESS & PACKAGING, INC. ã1998 E TRAINING F SPECIFICATIONS G . On-site training is available from our technical staff at the customers request. Output subject to keg valve style, keg size and wash sequence used. Note: Insert your specific optimum and acceptable values into this chart for your internal reference. This chart is the be used as a bench mark in the future of your production. Change in operating personnel, valves, wash sequences and mechanical integrity can be tracked with this bench-marking. Date: Keg Size: Valve Style: Kegs/Hour: Keg Size: Valve Style: Kegs/Hour: Keg Size: Valve Style: Kegs/Hour: Keg Size: Valve Style: Kegs/Hour: Keg Size: Valve Style: Kegs/Hour: Special Notes: Date: Special Notes: Date: Special Notes: Date: Special Notes: Date: Special Notes: PROCESS & PACKAGING, INC. ã1998 START UP AND SHUT DOWN PROCEDURES SEE CONTROL PHILOSOPHY SECTION FOR DETAILS PROCESS & PACKAGING, INC. ã1999 H START UP PROCEDURE SQUIRE PLUS 2 H 1 1. Turn on the control power supply. 2. Open fresh water supply to Sterilant Dosing Unit. 3. Fill the Detergent Tank with cold or 120 to 150 degree F fresh water and dose with 2% v/v Caustic or a 50/50 blend of Phosphoric/Nitric cleaning agent at 0.3-0.5% v/v. If using cold water turn on Heater to bring temperature upto required temperature (120 to 150 degree F). 4. Turn on the machine air, air purge, CO2 or Nitrogen and Product supplies. 5. Start the Detergent Pump. 6. Connect the wash coupler to Keg (ensure any Cap is removed first) and place inverted Keg onto the wash platform. 7. Push washer start button. 8. After the first Keg has been processed on the wash and fill heads, reject it and do not allow it to enter the full Keg warehouse. This will ensure that all the Machine systems were properly primed prior to commencing production. NOTE: Follow the SQUIRE control philosophy in section X for full operating instructions. SHUTDOWN PROCEDURE SQUIRE PLUS 2 After the last Keg has been processed: 1. Turn off detergent pump and sterilant supply. 2. Turn off the machine water, CO2 or Nitrogen, Air purge and product supplies. 3. Place the Fill Connection Head into the cleaning cap and tighten clockwise. 4. Empty Detergent Tank. NOTE: The SQUIRE PLUS 2 is now ready for cold water flush out, clean down and C.I.P. PROCESS & PACKAGING, INC. ã2001 H2 C.I.P. PROCEDURES See the 'Control Philosophy' section and the following notes to suit the specific plant requirements PROCESS & PACKAGING, INC. ã1999 I FLUSH OUT AND CLEAN UP PROCEDURE SQUIRE PLUS 2 I1 1. Flush out the detergent supply with clean water to remove any scum, scale or residuals that may have formed in the tank. 2. Flush out of residual product from the Filling Head and adjacent pipework can be achieved as described in the C.I.P. sequence that follows. It is recommended that all product residuals are flushed from the system with cold water prior to introducing the C.I.P. cleaning solution under item 6 of the C.I.P. procedures. 3. Clean up of the SQUIRE can be best achieved with warm soapy water and brush. Rinsing with LOW pressure water hose can be carried out. Care MUST be taken not to wet the areas around electrical equipment such as the pump motors, control panels and electrical terminal boxes. C.I.P. SEQUENCE SQUIRE PLUS 2 1. Connect the filler connection head to the cleaning cap by turning in a clockwise movement. Depress and lock down the coupling head lever by pulling up and pushing down. 2. Turn off CO2 isolating valve, if installed. 3. Connect your C.I.P. return line to the F.O.B. Drain or C.I.P Pipe (If installed) for C.I.P. solution recovery. 4. Move selector switch to C.I.P. This will open Product and Filler Drain/F.O.B. valves. 5. C.I.P. solution will flow through the Product valve across the connection head out through the Racker Drain/F.O.B. valve for as long as desired. 6. Allow C.I.P. to continue for at least 20 minutes with 2 to 3 % caustic at 160 degrees F. 7. Flush out caustic to drain with cold water until caustic residual is clear. 8. Prime system with 50 ppm OXINE in water for 15 minutes prior to commencing keg filling for sanitization purposes. 9. To end the sequence, simply move selector switch back to Rack. 10. Ready for washing and filling Kegs. PROCESS & PACKAGING, INC. ã2001 I2 PLANT LAYOUT SEE SECTION L FOR ADDITIONAL INFORMATION PROCESS & PACKAGING, INC. ã1999 J ELECTRICAL SECTION K PLEASE NOTE: Customer to supply local disconnect and ground fault device PROCESS & PACKAGING, INC. ã1999 MECHANICAL SECTION L SEE SUPPLEMENTAL TECHNICAL DATA MANUAL FOR ADDITIONAL INFORMATION IF PROVIDED PROCESS & PACKAGING, INC. ã2003 Top-Flo Centrifugal Top-Flo CentrifugalPump PumpModel Model“TF-C” “TF-C”Series ® ® Operation Maintenance & Parts List Please read and understand this manual prior to installing, operating or maintaining this pump. www.toplineonline.com Table of contents SAFETY INFORMATION..........................................................2 CLEANING SAFETY PROCEDURES.......................................9 GENERAL INFORMATION Warranty..............................................................................3 Shipping Damage...............................................................3 Hidden Damage..................................................................3 Warranty Claim...................................................................3 Ordering/Returning Parts...............................................24 INTRODUCTION......................................................................4 Description of Components......................................................4 Construction.......................................................................4 Mechanical Specifications..................................................4 Motor Frame Sizes..............................................................4 Performance Characteristics..............................................5 INSTALLATION.........................................................................6 Pump Dimensions...............................................................6 Unpacking...........................................................................7 Pump Location/Leveling.....................................................7 PIPING INFORMATION Suction Piping................................................................. 7-8 Discharge Piping.................................................................7 Locating Valves............................................................... 7-8 Electrical.............................................................................8 Flush Seal Option (Water Cascade)....................................8 OPERATION.............................................................................8 Prior to first operation.........................................................8 Seal Service Type D..........................................................10 Cleaning Safety Procedures...............................................9 Preliminary Test Run..................................................... 9-10 Operation Considerations............................................. 9-10 MIANTENANCE Stub Shaft Seal.................................................................11 Disassembly for “D” Seal........................................... 12 -13 Replacing Motor...............................................................13 Stub Shaft Adjustment......................................................14 Drive Collar Adjustment....................................................15 Disassembly for “DG” Seal...............................................16 Reassembly for “DG” Seal (setting the drive collar) ..... 17-18 Disassembly and Reassembly for “E” Seal................19–21 Maintenance Notes...........................................................22 TROUBLESHOOTING AND CAUSES...................................23 PARTS ORDERING................................................................24 Water Cascade Assembly Parts....................................25 Repair Kits, All Pumps.....................................................25 PARTS LIST TF-C100..... (With Spare Parts).........................................26 TF-C114..... (With Spare Parts).........................................27 TF-C216..... (With Spare Parts).........................................28 TF-C218..... (With Spare Parts).........................................29 TF-C328..... (With Spare Parts).........................................30 1 safety TOP-FLO® “TF-C” Series centrifugal pumps have been designed to be safe and reliable when properly used and maintained. Operators and maintenance personnel must follow safety measures. Failure to observe the instructions in this manual could result in personal injury or machine damage. • Do Not operate pump beyond the rated conditions for which the pump was sold. • Do Not use heat to remove impeller or disassemble pump due to risk of explosion of trapped liquid. Warnings, cautions and notes are contained in this manual. To avoid serious injury and/or possible damage to equipment, pay attention to these messages. WARNING Hazards or unsafe practices which COULD result in severe personal injury or death and how to avoid it. CAUTION Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. NOTE Important information pertaining directly to the subject. (Information to be aware of when completing the task.) WARNING Do not operate pump without CASING/VOLUTE clamped securely in place. WARNING To avoid electrocution, ALL electrical should be done by a registered Electrician, following Industry Safety Standards. All power must be OFF and LOCKED OUT during installation. CAUTION Wear gloves to avoid cutting injuries from sharp pump parts. WARNING ROTATING SHAFT DO NOT OPERATE WITHOUT GUARD IN PLACE WARNING TO AVOID POSSIBLE SERIOUS INJURY, SHUT OFF AND DRAIN PRODUCT FROM PUMP PRIOR TO DISCONNECTING PIPING. WARNING TO AVOID SERIOUS INJURY, DO NOT INSTALL OR SERVICE PUMP UNLESS ALL POWER IS OUT AND LOCKED OUT. Read and understand this manual prior to installing, operating or maintaining this pump. 2 warranty TOP LINE PUMP WARRANTY Seller warrants its products to be free from defects in materials and workmanship for a period of one (1) year from the date of shipment. This warranty shall not apply to products which require repair or replacement due to normal wear and tear or to products which are subjected to accident, misuse or improper maintenance. This warranty extends only to the original Buyer. Products manufactured by others but furnished by Seller are exempted from this warranty and are limited to the original manufacturer’s warranty. Seller’s sole obligation under this warranty shall be to repair or replace any products that Seller determines, in its discretion, to be defective. Seller reserves the right either to inspect the products in the field or to request their prepaid return to Seller. Seller shall not be responsible for any transportation charges, duty, taxes, freight, labor or other costs. The cost of removing and/or installing products which have been repaired or replaced shall be at Buyer’s expense. Seller expressly disclaims all other warranties, express or implied, including without limitation any warranty of merchantability of fitness for a particular purpose. The foregoing sets forth Sellers entire and exclusive liability, and Buyer’s exclusive and sole remedy, for any claim of damages in connection with the sale of products. In no event shall Seller be liable for any special consequential incidental or indirect damages (including without limitation attorney’s fees and expenses), nor shall Seller be liable for any loss of profit or material arising out of or relating to the sale or operation of the products based on contact, tort (including negligence), strict liability or otherwise. GENERAL INFORMATION SHIPPING DAMAGE Inspect your shipment immediately. If shipping damage is found, note it on the drivers copy (packing slip) and request the driver to ask the Inspector to call. You are responsible for initiating shipping damage claims. HIDDEN DAMAGE If during installation, you discover hidden damage caused in shipping, contact the Shipper immediately and ask for an Inspector to call. Notify your Top Line Distributor of the problem. WARRANTY CLAIM Please read the Warranty statement to correctly determine if you have a claim. In warranty claims you must have a “Returned Goods Authorized” (RGA) from Top Line before any returns will be accepted. Your Top Line Distributor will help you with a warranty problem. ORDERING/RETURNING PARTS See page 24 for complete information on ordering parts. Complete the Distributor/Product information immediately and keep for later reference. 3 INTRODUCTION DESCRIPTION This manual contains installation, operation, cleaning, repair instructions and parts lists for the “TF-C” Series Centrifugal Pumps. It also provides a Troubleshooting Causes chart to help in determining and correcting possible pump problems. The “TF-C” Series Centrifugal Pumps consist of two sections, the motor assembly, and the pump components. (Figure 1) The pump is mounted on the drive motor with an adapter, and is coupled to the motor with a stainless steel stub shaft. The pump impeller mounts on the stub shaft and is secured with a fl oating impeller retainer pin. floating The casing is joined to the adapter by a clamp, greatly simplifying removal and also permitting the casing outlet to be rotated to various positions. (The TF-C 100 is secured with two wing nuts and may only be mounted with the outlet facing straight up.) The mechanical external balanced seal assures a long wear life. The drive motor is mounted on a frame with adjustable legs in accordance with sanitary design requirements providing simple installation and easy leveling of the pump. 40 TF-C100 6D *80CA *80A *80B *80 6A *24 71 71B 11 CLAMP 4 *90 1 75K 2 introduction performance characteristics: Nominal Capacity: To 780 GPM Viscosity: To 1500 CPS Temperatures: To 212°F (100°C) Nominal Speeds: To 2900 RPM - 50HZ; To 3500 RPM - 60HZ STANDARD CONSTRUCTION: • Casting, backplate, and impeller are 316L stainless steel with a 32Ra grit polished sanitary finish. • Port Connection: Clamp fittings are standard. • Power: Supplied by a standard foot-mounted C-face motors through 60 horsepower. • Seal: “Type D” Seal material is carbon rotating on stationary stainless steel backplate. Water cascading attachment is available option (“F” Seal.) Dual seal is available option (“E” Seal.) • Elastomers: Buna, FKM and EPDM. MECHANICAL SPECIFICATIONS PORT SIZE Inches IMPELLER DIA. Inches (mm) MODEL Inlet Discharge Minimum Maximum TF-C100 1-1/2 - 1 - 3.0 (76) 3.68 (93) TF-C114 1-1/2 2 1-1/2 1-1/2 2.5 (63) 4.0 (101) TF-C216 2 2-1/2 1-1/2 1-1/2 4.0 (101) 6.0 (152) TF-C218 2 3 1-1/2 1-1/2 6.0 (152) 8.0 (203) TF-C328 3 4 2 2 5.5 (139) 8.0 (203) AVAILABLE MOTOR FRAME SIZES FOR PUMP MODELS TF-C10056C 143TC-145TC TF-C11456C 143TC-145TC 182TC-184TC TF-C21656C 143TC-145TC 182TC-184TC 213TC-215TC 254TC-256TC TF-C218143TC-145TC 182TC-184TC 213TC-215TC 254TC-256TC 284TC-286TC TF-C328182TC-184TC 213TC-215TC 254TC-256TC 284TC-286TC 324TC-326TC 5 INSTALLATION TOP-FLO®® CENTRIFUGAL PUMP DIMENSIONS PUMP DIMENSIONS PUMP MODEL PUMP MODEL C100 C114 C216 C218 C328 SUCTION 1.500 1.500 2.000 2.000 3.000 DISCHARGE 1.000 1.500 1.500 1.500 2.000 *X 3.500 3.625 4.500 5.500 5.500 *Y 1.554 1.594 1.906 1.719 2.219 **X ----3.875 4.750 5.750 5.750 **Y ----- 1.844 2.156 1.969 2.719 Z 1.453 2.625 3.688 4.750 4.750 PUMP AND MOTOR DIMENSIONS WITH “WASHDOWN” TOTALLY ENCLOSED BALDOR MOTORS PUMP PUMP FRAME A *C **C HD AB *J E MODEL C100 56C 8.313 13.312 ------7.500 5.000 6.875 3.000 C114 56C 8.313 16.821 17.071 7.500 5.000 10.375 3.000 56C 8.313 16.821 17.071 7.500 5.000 10.375 3.000 143 TC 8.563 17.813 18.063 5.250 10.844 4.000 143 8.563 17.813 18.063 7.500 5.250 10.844 4.000 145 TC 19.848 10.688 5.000 C114 145 8.563 19.848 18.063 7.500 5.250 10.688 5.000 182 TC 9.813 20.938 21.180 8.500 5.875 12.219 4.500 9.813 20.938 182 21.180 8.500 5.875 12.219 4.500 184 TC 23.790 24.915 12.000 5.500 184 TC 9.813 23.790 24.915 8.500 5.875 12.000 5.500 C216 56C 8.313 16.976 17.226 7.500 5.000 10.531 3.000 56C 8.313 16.976 17.226 7.500 5.000 10.531 3.000 143 TC 8.563 17.968 18.223 5.250 10.844 4.000 143 8.563 17.968 18.223 7.500 5.250 10.844 4.000 145 TC 20.003 20.253 5.000 145 8.563 20.003 20.253 7.500 5.250 10.844 5.000 9.813 21.157 21.399 8.500 5.875 12.219 4.500 182 TC 182 9.813 21.157 21.399 8.500 5.875 12.219 4.500 184 TC 24.009 24.259 5.500 C216 184 9.813 24.009 24.259 8.500 5.875 12.219 5.500 213 TC 12.156 26.487 26.624 9.250 7.375 13.969 12.156 26.487 213 26.624 9.250 7.375 13.969 5.500 215 TC 27.864 28.114 7.000 12.156 215 27.864 28.114 9.250 7.375 13.969 7.000 254 TC 16.094 28.533 28.783 10.250 9.625 14.594 8.250 16.094 254 28.533 28.783 10.250 9.625 14.594 8.250 256 TC 30.163 30.413 10.000 256 16.094 30.163 30.413 10.250 9.625 14.594 10.000 C218 143 TC 8.563 18.036 18.281 7.500 5.250 10.281 4.000 143 8.563 18.036 18.281 7.500 5.250 10.281 4.000 145 TC 20.066 18.286 5.000 145 8.563 20.066 18.286 7.500 5.250 10.281 5.000 182 TC 9.813 21.211 20.941 8.500 5.875 12.281 4.500 182 9.813 21.211 20.941 8.500 5.875 12.281 4.500 184 TC 24.071 24.321 5.500 184 9.813 24.071 24.321 8.500 5.875 12.281 5.500 213 TC 12.156 25.686 25.936 9.250 7.375 13.281 C218 213 12.156 25.686 25.936 9.250 7.375 13.281 5.500 215 TC 27.176 27.426 7.000 215 12.156 27.176 27.426 9.250 7.375 13.281 7.000 254 TC 16.094 28.096 28.346 10.250 9.625 14.157 8.250 254 16.094 28.096 28.346 10.250 9.625 14.157 8.250 256 TC 29.726 29.977 10.000 256 16.094 29.726 29.977 10.250 9.625 14.157 10.000 284 TC 20.438 33.916 34.166 11.000 13.125 15.281 9.500 284 20.438 33.916 34.166 11.000 13.125 15.281 9.500 286 TC 11.000 286 33.916 34.166 11.000 13.125 15.281 11.000 C328 182 TC 9.813 22.024 22.524 8.500 5.875 13.094 4.500 20.438 182 9.813 22.024 22.524 8.500 5.875 13.094 4.500 184 TC 24.884 25.384 5.500 184 9.813 24.884 25.384 8.500 5.875 13.094 5.500 213 TC 26.999 9.250 7.375 14.094 12.156 26.499 213 26.499 26.999 9.250 7.375 14.094 5.500 215 TC 29.664 28.489 7.000 12.156 215 29.664 28.489 9.250 7.375 14.094 7.000 254 TC 16.094 28.909 29.409 10.250 9.625 15.000 8.250 12.156 254 28.909 29.409 10.250 9.625 15.000 8.250 256 TC 30.539 31.039 10.000 16.094 C328 256 30.539 31.039 10.250 9.625 15.000 10.000 284 TC 20.438 34.729 35.229 11.000 13.125 16.094 9.500 16.094 284 34.729 35.229 11.000 13.125 16.094 9.500 286 TC 11.000 20.438 286 34.729 35.229 11.000 13.125 16.094 11.000 324 TC 22.375 37.311 37.811 12.000 14.125 17.156 10.500 20.438 324 37.311 37.811 12.000 14.125 17.156 10.500 326 TC 12.000 22.375 326 TC 37.311 37.811 12.000 14.125 17.156 12.000 22.375 * WITH CLAMP CONNECTIONS (STANDARD) CONNECTIONS (STANDARD) ** WITH THREADED BEVEL BEVEL-SEAT SEAT CONNECTIONS CONNECTIONS *** DIMENSIONS ARE FOR BALDOR DIMENSIONS ARE WASHDOWN MOTORS MOTORS OTHER MOTOR MANUFACTURERS DIMENSIONS MAY VARY 6 F L 4.875 4.875 4.875 5.500 5.500 5.500 7.500 7.500 7.500 4.875 4.875 5.500 5.500 5.500 7.500 7.500 7.500 8.500 8.500 8.500 10.000 10.000 10.000 5.500 5.500 5.500 7.500 7.500 7.500 8.500 8.500 8.500 10.000 10.000 10.000 11.000 11.000 11.000 7.500 7.500 7.500 8.500 8.500 8.500 10.000 10.000 10.000 11.000 11.000 11.000 12.500 12.500 12.500 2.750 6.219 6.219 6.219 6.219 6.781 6.781 6.781 6.062 6.062 6.062 6.062 6.688 6.688 6.688 7.813 7.813 7.813 8.437 8.437 8.437 6.312 6.312 6.312 6.938 6.938 6.938 7.312 7.312 7.312 8.188 8.188 8.188 8.812 8.812 8.812 7.250 7.250 7.250 7.625 7.625 7.625 8.500 8.500 8.500 9.125 9.125 9.125 9.812 9.812 9.812 ALL DIMENSIONS IN INCHES. INCHES. DIMENSIONS ARE APROXIMATE AND FOR GUIDANCE ONLY. NOTES: 1. THESE DIMENSION ARE FOR PUMPS USING NEMA STANDARD “C” FLANGE MOTORS INSTALLATION INSTALLATION UNPACKING UNPACKING EQUIPMENT EQUIPMENT Check Check all all parts parts received received and and inspect inspect for for damages damages that that may may have have occurred occurred during during shipping. shipping. Report any damage to the carrier. Report any damage to the carrier. PUMP PUMP LOCATION LOCATION •• Place Place as as close close as as practical practical to to the the liquid liquid supply and keep supply piping short supply. Keep supply piping short andand straight. straight. Keeping Keeping the the pump pump supplied supplied with with liquid liquid will will prevent prevent damaging damaging from from cavitation. cavitation. •• The The pump pump must must be be accessible accessible for for service service and and inspection inspection during during operation. operation. •• The ooding. The motor motor must must be be protected protected from from flflooding. ADJUSTABLE LEGS ADJUSTABLE LEGS Adjustable legs PUMP PUMP LEVELING LEVELING •• Level Level the the pump pump by by rotating rotating the the adjustable adjustable legs. (Figure 3) legs. (Figure 3) SUPPLY SUPPLY AND AND DISCHARGE DISCHARGE PIPING/VALVES PIPING/VALVES •• Use Use line line size size equal equal to, to, or or larger larger than than connection size on pump, especially connection sizes on pump, especiallythe the inlet inlet supply supply line. line. •• Keep line short and and straight and use Keep supply the supply line short straight. Use as few elbows, valves, or other types of as few elbows, valves, or other types of restriction restrictionsasaspossible. possible.Avoid Avoidupupand anddown down rises rises which which will will trap trap air. air. •• Be lineslines are well Be certain certain all all joints joints in in suction the suction are sealed to prevent air leaks. well sealed to prevent air leaks. •• Maintain Maintain aa straight straight length length of of pipe pipe at at least least 44 diameters diameters long long at at the the pump pump inlet. inlet. (Figure (Figure 4) 4) •• The pump casing may be rotated with The pump casing may be rotated with the the discharge discharge connection connection pointing pointing in in any any direction. direction. The The best best pump pump performance performance will will be with the outlet up, to the left, or positions be with the outlet up, to the left, or positions in in between. between. These These positions positions insure insure the the casing ooded and casing is is flflooded and prevents prevents problems problems due due to to air air in in the the system. system. (Figure (Figure 6) 6) •• Support the supply and discharge piping Support the supply and discharge piping near near the the pump pump so so no no strain strain is is put put on on the the pump pump casing. casing. •• IfIf an an expansion expansion joint joint is is used, used, install install aa pipe pipe anchor anchor between between itit and and the the pump. pump. •• •• IfIf aa reducer reducer is is connected connected to to the the inlet, inlet, use use an an eccentric eccentric type type (Figure (Figure 5) 5) to to prevent prevent problems problems due due to to trapped trapped air. air. CAUTION CAUTION Wear Wear gloves gloves to to avoid avoid cutting cutting injuries injuries from from sharp sharp pump pump and and piping parts. piping parts. Line Line slope slope will will depend depend on on application application requirements. The best pump requirements. The best pump operation operation is is with with supply supply line line sloped sloped slightly slightly upward upward toward toward pump pump to to prevent prevent trapped trapped air. air. IfIf the the system must drain into the pump casing, system must drain into the pump casing, keep keep downward downward slope slope to to aa minimum minimum or or priming priming problems problems may may occur. occur. •• Install Install shutoff shutoff valves valves to to isolate isolate pump pump from from supply and discharge lines to allow pump supply and discharge lines to allow pump service service without without draining draining the the system. system. 77 INSTALLATION • This pump is not self-priming. The pump is • installed above the supply liquid level. Install a foot valve or other system check valve to keep casing flooded flooded for priming. (Figure 7) • • A throttling valve may be required to control the pump flow flow rate to prevent motor overload. Always install the throttling valve in the discharge piping, never in the supply piping, and at least 10 diameters from the pump outlet (Figure 7) ELECTRICAL CONNECTIONS WARNING To avoid electrocution, ALL electrical installation should be done by a registered electrician, following Industry Safety Standards. All power must be OFF and LOCKED OUT during installation. • Read the manufacturer’s motor instructions • before making installation. Follow the manufacturer’s lubrication schedules. •• Check the motor nameplate to be sure the motor is compatible with the electrical supply and all wiring, switches, starters, and overload protection are correctly sized. •• Check pump rotation following electrical installation. Correct rotation is counter clockwise when facing pump inlet connection. (Figure 5) FLUSH SEAL OPTION When this option is ordered, a fitting fitting assembly is supplied for directing a flow flow of water onto the backplate/seal area. The water supply should be cool and filtered. filtered. If the product solidifi solidifies es at cool temperatures, use warm or hot water. The connection size is 1/4 inch O.D. tubing and the required flow flow is approximately 5 U.S. gallons per hour. (Figure 8) WARNING TO AVOID SERIOUS INJURY, DO NOT INSTALL OR SERVICE PUMP UNLESS ALL POWER IS OFF AND LOCKED OUT. 8 PRIOR TO FIRST OPERATION CLEAN PUMP AND PIPING Disassemble pump and clean all product contact parts and seals prior to first first operation. Follow instructions in the “Cleaning Safety Procedures” and “Disassembly for Cleaning and Repair” section (pages 9 and 12). The pump should be thoroughly cleaned of any materials which may have accumulated during installation. OPERATION CLEANING SAFETY AND TEST RUN CLEANING SAFETY PROCEDURES AMMETER TEST Manual Cleaning: 1. Do not use toxic and/or flammable solvents. 2. Lock out electrical power and shut off all air prior to cleaning equipment. 3. Keep electrical panel covers closed and power off when washing equipment. WARNING To prevent an accidental start-up the power source should be locked out using your lock and key. 4. Clean up spills as soon as possible. 5. Never attempt to clean the equipment while it is operating. 6. Wear proper protective apparel. Operate pump under process conditions and check motor amp draw versus nameplate full load rating. If amp draw exceeds motor rating, a system change or pump change is required. If process conditions and/or liquid changes, (higher viscosity, higher specific gravity) recheck motor amp draw. Contact your authorized TOP LINE distributor for assistance. WARNING TO AVOID ELECTROCUTION, ONLY A QUALIFIED ELECTRICIAN SHOULD INSTALL THE AMMETER. OPERATION CONSIDERATIONS • Cleaning-In-Place 1. Make certain that all connections in the cleaning circuit are properly applied and tight to avoid contact with hot water or cleaning solutions. • 2. When the cleaning cycle is controlled from a remote or automated cleaning center, follow all established safety procedures for servicing the system. PRELIMINARY TEST RUN See OPERATION on page 10 to set pump up for a test run. CHECK FOR POSSIBLE MOTOR OVERLOAD CONDITION Certain combinations will overload the motor when operated with open, unrestricted discharge, which results in a high flow rate. Additional discharge restriction may be required to lower the flow rate and lower the horsepower requirements. DO NOT add restrictions to the supply line. If the pump was incorrectly sized, a smaller impeller or a higher horsepower motor may be required. Any system throttling valves, or similar devices used to control flow rate must be installed in the discharge line, not the supply line. Restriction in the supply line may cause cavitation and pump damage. “Water hammer” in the system can damage the pump and other system components. Water hammer often occurs when valves in the system are suddenly closed causing lines to move violently and with a loud noise. When this condition is present, find and eliminate the source of the water hammer. One way to eliminate water hammer is to slow down the actuation speed of the valve. • Do not expose the pump to freezing temperatures with liquid in the casing. Frozen liquid in the casing will damage the pump. Drain casing before exposing to freezing temperatures. DISASSEMBLY, CLEANING/REPAIR It is not necessary to disassemble the pump for cleaning if used in a CIP Installation (Clean-In-Place). However, periodically take pump apart, thoroughly inspect, clean and reassemble. (See MAINTENANCE - DISASSEMBLY) If uncertain about pump selection and application, temporarily install an ammeter in the electrical service to check the amp draw. 9 OPERATION OPERATION WARNING WARNING Skinand andeye eyeprotection protectionare arerequired required Skin whenhandling handlinghazardous hazardousor ortoxic toxicflfluids. when uids. CAUTION CAUTION IfIfpump pumpisisbeing beingdrained, drained,take takenecessary necessary precautionsto precautions toavoid avoidpersonal personalinjury. injury. NOTE: NOTE:Disposal Disposalofofdrainage drainagemust mustbe beinin conformance conformancewith withenvironmental environmentalregulation. regulation. Pumps Pumpsmust must have have been been correctly correctlyinstalled installed as as described described in the in “INSTALLATION” “INSTALLATION” section. section. SEAL SEALFLUSH FLUSH 1.1.IfIfthe thepump pumphas hasthe theflflush ush seal sealoption, option,start start the theflflow ow ofofflflush ush water water(approximately (approximately55US US gallons gallonsper perhour hourrecommended recommendedrate). rate). PRIME PRIMEPUMP PUMP 2.2.Flood Floodthe thepump pumpcasing casingwith withliquid liquidBEFORE BEFORE starting startingpump pumptotoavoid avoiddamage damagetotothe thepump pump parts. parts.Fill Fillthe thesupply supplytank tankwith withliquid liquidand and open opensupply supplyline linevalve valve(suction). (suction).Any Anyair air trapped trappedininthe thesupply supplyline lineororcasing casingshould should be bevented. vented.(Figure (Figure9)9) PRIMING PRIMINGWITH WITHOUTSIDE OUTSIDESOURCE SOURCE The Thepump pumpwill willnot notself selfprime primeififthe theliquid liquid supply supplyisisbelow belowthe thepump pumplevel. level.(Figure (Figure10) 10) 3.3.Close Closethe thedischarge dischargevalve valveand andopen openthe theair air vents. vents. 4.4.Open Openthe thevalve valveininthe theoutside outsidesupply supplyline line until untilthe theliquid liquidflflows ows from fromthe thevent ventvalves. valves. Slowlyopen opendischarge the discharge until 8.8.Slowly valvevalve until desired flow is obtained. fldesired ow is obtained. Observe Observe pressure pressure gauges gauges and if pressure is not quickly, attainedstop and if pressure is not attained quickly, stop pump and prime again. pump and prime again. 5.5.Close Closethe thevent ventvalves valvesand andthe thesupply supplyline. line. Use Useaatype typeofofcheck checkvalve valvesystem systemtotokeep keep the thesupply supplyline lineand andpump pumpcasing casingflflooded ooded STOP STOPPUMP PUMP with withliquid. liquid.Otherwise, Otherwise,the thepump pumpmust mustbe be primed primedbefore beforeeach eachoperation. operation.(See (SeeFigure Figure7)7) 9.9.To Tostop stopthe thepump, pump,shut shutoff offthe thepower powerto to the thepump pumpmotor. motor.Liquid Liquidininthe thesystem systemcan can 6.6.Start Startthe thepump pumpmotor. motor. flflow ow freely freelythrough throughthe thepump. pump.The Thepump pump PUMP PUMPCHECK CHECK does doesnot notact actas asaashut shutoff offvalve. valve.Shut Shutoff off 7.7.Check Checktotosee seethat thatliquid liquidisisflflowing owing and andall all supply and discharge lines. supply and discharge lines. piping pipingconnections connectionsand andseals sealsare areleak leakfree. free. The Thepump pumpmust mustbe beoperated operatedagainst againstaa closed closeddischarge dischargefor foraashort shorttime. time.However, However, continued continuedoperation operationwill willheat heatliquid liquidinincasing casing totoboiling boilingand andlead leadtotopump pumpdamage. damage. 10 10 MAINTENANCE maintenance SEAL Service SERVICE STUB SHAFT SEAL NOTES The shaft design utilizes a drive collar as shown in Figure 11 to assure proper location of the seal assembly. The TF-C100 does not require a drive collar. The drive collar is incorporated in the design of the stub shaft. The drive collar must be properly located on the shaft, following procedures outlined on page 15. This type of seal should be replaced when the face is worn away, or when when leakage leakage is is away or noted (Figure 12) To remove the seal, disconnect the suction and discharge piping. Then, remove the casing, impeller, and backplate. Protect the sealing face of the backplate from nicks and scratches. NOTE: When the carbon seal is replaced, the position of the drive collar should be checked and reset if necessary, per the dimensions given on page 15. Inspection during cleaning will determine if the carbon seal needs replaced. No additional drive collar adjustment is necessary unless the seal is replaced. (Figure 12) SERVICE/REPAIR Periodically inspect all parts of the pump to prevent malfunctions caused by worn or broken parts. 11 MAINTENANCE DISASSEMBLY for FOR cleaning CLEANING and AND repair REPAIR disassembly CAUTION Wear gloves to avoid cutting injuries from sharp pump parts. 1. Shut off product flow flow to the pump and relieve any product pressure. 2. Shut off and lock out power to the pump. 3. Disconnect the suction and discharge pipe fittings. fittings. 4. Remove the seal guard assembly with a wrench. (Figure 13) 5. Loosen clamp wing nut and swing clamp open. On the TF-C100, remove casing wing nuts. 6. Inspect clamp saddles and the casing for damage or wear and replace if necessary. (Figure 13) 7. Push back on the impeller and position the retaining pin in the center of the stub shaft. This will allow the impeller to pull off the stub shaft. (Figure 14) 8. Rotate the backplate to disengage the backplate pins from the adapter pins. Remove the backplate with gasket attached, by pulling straight off the adapter. (Figure 15) 9. Remove the backplate gasket and inspect it for wear and sealing failure. NOTE: NOTE: Care must be taken to protect the sealing face and edges of the backplate from nicks and scratches. 10. Remove Remove the carbon seal, o-ring, seal cup, and spring from the stub shaft by pulling them straight off the shaft. (Figure 16) 11. Carefully Carefully inspect the o-ring and the carbon seal for signs of abrasions, cuts, or other wear that could cause leakage. (Figure 16) NOTE: NOTE: Replace the carbon seal when the extension end of the seal is less than 1/32”. (Figure 12) 12. After cleaning, inspect the seal, o-ring, and gasket and replace if necessary. 12 MAINTENANCE mainTenance WATER cascade CASCADE - replacing REPLACING motors MOTORS water 13. Remove the water cascade attachment 13. from the adapter, if included. Remove the rubber shaft deflector deflector by pulling it straight off the stub shaft. Examine it for tearing, loose fit, fit, or other defects that would allow liquid leakage into the motor along the shaft. (Figure 17) WARNING TO AVOID SERIOUS INJURY, DO NOT INSTALL OR SERVICE PUMP UNLESS ALL POWER IS OFF AND LOCKED OUT. REPLACING MOTOR To replace or service the motor, disassemble the pump as outlined in DISASSEMBLY steps 1 through 11. 1. Remove the bolts that secure the adapter to the motor frame and remove the adapter. (Figure 18) CAUTION The stub shaft has four sharp diagonal grooves in the end. Wear gloves to prevent injuries to hands. 2. Loosen the two (2) set screws securing the stub-shaft to the motor shaft. Carefully remove the stub-shaft. The stub-shaft is a tight fit, fit, but can be removed by applying pressure around the periphery of the shaft with a pry-bar. (Figure 19) NOTE: Examine the shaft sealing surfaces for nicks or scratches which can cause excessive o-ring wear or leaking. 3. Remove the bolts securing the motor to the mounting brackets. Bolt the new motor to the mounting brackets. (Figure 20) NOTE: Motor maintenance, repair, and wiring specific are not covered in this manual. For specific information contact the motor manufacturer. If required, level the motor by rotating adjustingthe the legs individually and secure them in 3place adjustable legs individually. (Figure & 20) with the set screws. (Figure 20) 13 MAINTENANCE MAINTENANCE INSTALL INSTALL ADAPTER-STUB ADAPTER-STUB SHAFT SHAFT ADJUSTMENT ADJUSTMENT 1. 1. Mount Mount the the adapter adapter to to the the motor motor with with the the drain drain cavity cavity at at the the bottom. bottom. Insert Insert the the four four bolts bolts to to secure secure the the adapter adapter to to the the motor. motor. (Figure (Figure 21) 21) 2. 2. Install Install the the key key in in the the motor motor shaft. shaft. 3. 3. Place Place the the stub-shaft stub-shaft assembly assembly onto onto the the motor motor shaft. shaft. Do Do not not tighten tighten the the shaft shaft set set screws. screws. 4. 4. Install Install the the backplate backplate on on the the adapter adapter and and rotate rotate until until the the backplate backplate pins pins engage engage the the adapter adapter pins, pins, assuring assuring solid solid contact contact of of the the backplate backplate to to the the adapter. adapter. (Figure (Figure 21) 21) 5. 5. Rotate Rotate the the stub stub shaft shaft until until the the impeller impeller retaining retaining hole hole is is in in aa horizontal horizontal position. position. Insert Insert the the impeller impeller retainer retainer pin, pin, and and center center itit in in the the stub-shaft. stub-shaft. Slide Slide the the impeller impeller on on the the shaft. shaft. Hold Hold the the impeller impeller tight tight against against the the shoulder shoulder in in the the shaft shaft and and rotate rotate the the shaft shaft one-quarter one-quarter turn turn until until the the impeller impeller pin pin engages engages with with the the impeller. impeller. (Figure (Figure 22) 22) STUB STUB SHAFT SHAFT ADJUSTMENT ADJUSTMENT 1. 1. Push Push the the stub-shaft/impeller stub-shaft/impeller assembly assembly toward toward the the motor motor until until the the impeller impeller strikes strikes the the front front face face of of the the backplate. backplate. 2. 2. Move Move the the stub-shaft stub-shaft away away from from the the motor motor shaft shaft to to allow allow 1/16-inch 1/16-inch maximum maximum clearance clearance between between the the rear rear face face of of the the impeller impeller and and the the front front (inside) (inside) face face of of the the backplate. backplate. (See (See Figure Figure 22) 22) 3. 3. Tighten Tighten the the two two set set screws screws on on the the stubstubshaft. shaft. 4. 4. Remove Remove the the impeller impeller retainer retainer pin, pin, impeller, impeller, and and the the backplate. backplate. 5. ector (large 5. Slide Slide the the defl deflector (large diameter diameter end end fifirst) rst) onto onto the the shaft shaft until until itit seats seats in in the the shaft shaft groove. groove. (Figure (Figure 23) 23) NOTE: ector cannot NOTE: IfIf the the defl deflector cannot be be forced forced on on with ngers, use with the the fifingers, use aa blunt blunt tool tool to to tap tap itit evenly evenly into into place. place. 14 14 MAINTENANCE MAINTENANCE DRIVE COLLAR ADJUSTMENT (Models TF-C114 through TF-C328) 1. Slide the seal drive collar onto the stub shaft as shown in Figure 24. Use the “A” dimension in the SEAL CHART to properly locate the drive collar on the stub shaft. Tighten the set screws to secure in place. NOTE: TF-C100 pump does not require drive collar. 2. Assemble the spring, seal cup, o-ring, and carbon seal, and install as a unit. Make sure the slot in the seal cup aligns with the pin on the shaft. (Figure 25) Gentle pressure on the o-ring will overcome resistance on the shaft. NOTE: Do not lubricate seals with any type of oil or grease, the seal faces will be lubricated by the product being pumped. SEAL CHART for fifigure gure 24 MODEL A TF-C114 9/16” TF-C216 9/16” TF-C218 9/16” TF-C328 9/16” 3. Assemble the gasket to the backplate. Install the backplate on the adapter. Make sure the seal cup slot is engaged with the pin on the drive collar. (Figure 25) 4. Rotate the backplate until the backplate pins engage the adapter pins. (Figure 25) 5. Rotate the shaft until the pin hole in the end is in a horizontal position. Insert the impeller pin, center it in the shaft end, and slide the impeller on the shaft. Hold the impeller tight against the stub shaft and rotate the shaft one-fourth turn until the impeller pin drops and secures the impeller. (Figure 26) 6. Place the casing over the impeller/ backplate, close and tighten the clamp. (Figure 27) 7. Assemble the cascade water fitting, fitting, if included. Install the seal guard and tighten in place. Assemble the suction line and the discharge line to the casing. NOTE: Check for strain or misalignment of piping to the casing. Re-adjust the casing ports and/or entire motor leveling as necessary. 15 MAINTENANCE “DG” SealS SEALS FIGURE 28 DG-SEAL KEY C114 C216 C218 * 328 QTY. DESCRIPTION MATERIAL 11H 564911H 566911H 568911H 1 BACKPLATE 316L SS *80R 564980R 566980R 568980R 1 INBOARD GASKET INBOARD GASKET 1/8” FDA PTFE 1/8” PTFE *80NSC 564980N-SC 566980N-SC 588980N-SC 1 STATIONARY SEAT SILICONE CARBIDE *80P 564980P 566980P 568980P 1 OUTBOARD GASKET OUTBOARD GASKET 1/16” FDA PTFE 1/16” PTFE 17J 564917J 566917J 568917J 1 GLAND RING 304 SS 17K 564917K 566917K 568917K 4 BOLT/SCREW SS *80 564980 566980 568980 1 ROTATING CARBON SEAL ® CARBON *80V 564980V 566980V 568980V 1 O-RING SEAL VITON® FKM 80A 564980A 566980A 568980A 1 CUP 304 SS *80CA 564980CA 566980CA 568980CA 1 SPRING SS 80L 564980L 566980L 568980L 1 DRIVE COLLAR ® 304 SS 17M 564917M 566917M 568917M 4 LOCK WASHER SS *90V 564990V 566990V 568990V 1 CASING GASKET CASING GASKET VITON® FKM *24 564924 566924 568924 1 IMPELLER RETAINER PIN 316L SS * Recommended spare parts see kits page 25 RECOMMENDED SPARE PARTS SEE KITS PAGE 25 Disassembly At each step in the disassembly, process parts should be inspected for nicks, cuts, abrasions, and other wear. Replace parts if necessary. Care should be taken to protect all sealing surfaces from being damaged during disassembly. • Disconnect suction and discharge piping from pump casing. • Remove seal guard and casing. • Remove the impeller. • Remove the backplate. • Remove casing gasket from the backplate. • Remove the carbon seal, seal cup, and spring from the stub shaft. • Remove the gland ring, seal seat, and PTFE gaskets by removing the four cap screws. Viton® is a registered trademark of DuPont Dow Elastomers 16 MAINTENANCE “DG” SealS SEALS Reassembly Setting the Drive Collar - Measuring Method 1. 1. Assemble the PTFE gaskets, seal seat, gland ring, and secure to the back plate by uniformly tightening the capscrews. Note: The PTFE Teflon®inboard inboard(80R) (80R)and andoutboard outboard(80P) (80P) gaskets are different thicknesses. The thicker gasket (80R) must always be installed on the impeller side to prevent contact between the impeller hub and the stationary seal. 2. 2. Slide the drive collar onto the stub shaft. 3. 3. Install the backplate and the casing gasket. 4. 4. Install the casing and tighten the casing clamp. 5. 5. Scribe a mark on the stub shaft behind the backplate. FIGURE 29 6. 6. Set the drive collar to “A” dimension in the seal chart and tighten the drive collar setscrew. (Figure 30) 7. 7. Remove the casing and backplate. 8. 8. Assemble the spring, seal cup, o-ring, and carbon seal onto the drive collar. The pin on the drive collar must align with the slot in the cup. 9. 9. Slide the backplate onto the stub shaft. Position the impeller retaining pin in the center of the stub shaft hole and install the impeller. Push the impeller against the stub shaft and rotate the stub shaft until the impeller retaining pin falls and secure the impeller. Check the impeller hub and seal face to ensure 10. 10. Check there is a clearance between them before installing the casing. Reset the seal drive collar if required. When the 11. 11. Reset drive collar is positioned correctly and the seal components are properly installed, the shaft should rotate freely by hand. Assemble the casing gasket, casing, and casing 12. 12. Assemble clamp. Use a soft rubber mallet to line up the casing. Tighten the casing clamp and install the seal guard. FIGURE 30 SEAL CHART MODEL A TF-C114 5/16” TF-C216 5/16” TF-C218 5/16” TF-C328 5/16” 17 MAINTENANCE “DG” SealS Setting the Drive Collar – By Position for both “D” Seal & “DG” Seal 1. Assemble the spring, seal cup, o-ring seal, and carbon seal onto the drive collar. Care must be taken so that the spring does not rest on the tab that is bent back. A portion of the spring is offset to provide clearance for this tab. Care must be taken to ensure the pin on drive drive collar is in line with slot on cup. 2. Install as a unit on the shaft. 3. Install the backplate and casing. 6. Slide the drive collar away from the backplace 1/32” (.79mm) and secure the drive collar in this location with the set screws. 7. When the drive collar is properly positioned and the seal components are properly installed, the pump shaft should rotate freely by hand. If excessive effort is required to rotate the shaft, check to be sure that all components are properly installed and the drive collar is properly positioned. 4. Install and tighten the casing clamp. 5. Slide the drive collar and seal assembly toward the backplate until the nose of the drive collar pushes the o-ring and carbon seal tight against the backplate. Note: Extra care should be taken when assembling “TF-C” series pumps with type “DG” or “F” seals. Incorrect stub shaft settings will allow the impeller hub to contact the inboard face of the stationary seal seat. Interference of impeller hub and seal seat face will cause wear of impeller hub and damage the inboard or secondary seal face of the clamped-in-seat. Visual inspection is recommended after installation of the impeller and before installation of casing to ensure clearance between the impeller hub and seal face. If no clearance is visible, the pump should be disassembled and stub shaft moved forward to provide at least 1/32” (.79mm) clearance between the impeller hub and seal seat face. Reset seal drive collar if necessary. 18 MAINTENANCE “E” SealS SEALS “E” water-cooled balanced double seal consists of two carbon seals inside a stuffi stuffing ng box attached to the backplate. It is designed for applications where a vacuum-tight, cool operating seal is required. FIGURE Figure 31 E-SEAL KEY C114 C216 C21B & 328 QTY. DESCRIPTION MATERIAL 17A 564917A 566917A 568917A 4 BOLT/SCREW SS 17C 564917C 566917C 568917C 4 LOCKWASHER SS 17 564911B 566911B 568911B 1 FOLLOWER 316L SS 17B 564917B 566917B 568917B 1 O-RING VITON® FKM 83C 564983C 566983C 568983C 1 STUFFING BOX 316L SS 83E 564983E 566983E 568983E 1 O-RING VITON® FKM 80H 564980H 566980H 568980H 1 SPRING SS 80J 564980J 566980J 568980J 1 DRIVE COLLAR 304 SS 80G 564980G 566980G 568980G 2 CUP 304 SS *80V 564980V 566980V 568980V 2 O-RING VITON® FKM *80 564980 566980 568980 2 CARBON SEAL CARBON 83D 564983D 566983D 568983D 4 BOLT/SCREW 316L SS 11B 564911B 566911B 568911B 1 BACKPLATE 316L SS 90V 564990V 566990V 568990V 1 CASING GASKET CASING GASKET VITON® FKM * RECOMMENDED SPARE PARTS SEE KITS PAGE 25 Recommended spare parts see kits page 25 Disassembly At each step in the disassembly, process parts should be inspected for nicks, cuts, abrasions, and other wear. Replace parts if necessary. Care should be taken to protect all sealing surfaces from being damaged during disassembly. • Disconnect suction and discharge piping from pump casing. • Remove seal guard, casing, and impeller. • Remove the 4 screws (17A) that retain the follower to the stuffi stuffing ng box. • Remove the backplate and stuffing stuffing box. • Remove the inboard carbon seal, seal cup, and seal spring. • Remove the drive collar. • Remove the carbon seal, seal o-ring, cup, and follower. Viton® is a registered trademark of DuPont Dow Elastomers 19 assembling the pump. (Figure 34) Flush water must enter 45° (except for the TCF-C114) to vertical when spaced 90° from each other and should be positioned stuffing two (2) 1/8” NPT water connections which are 9. Attach the water inlet and outlet to the stuffing box. The MAINTENANCE 8. Mount the seal guard on the adapter. Reassembly screws. (Figure 33) 7. Assemble the follower to the stuffing box with the four 1. Scribe a mark on the shaft at location “A”. (Figure 32) 1. 2. 2. 6. 3. 3. 5. TF-C328 TF-C218 TF-C216 9/16” 9/16” “E” SealS SEALS 9/16” TF-C114 9/16” MODEL A SEAL CHART FIGURE 32 the shaft and seal parts. (Figure 33) Assemble the defl deflector, ector, follower, one carbon seal, one Assemble the stuffing box and backplate assembly on seal o-ring, one seal cup, and the drive collar onto the shaft. pins on the drive collar. collar ear on each cup is not in alignment with the drive Position the drive collar in relation to the scribe mark “A” Ensure the spring is seated in each cup and the drive and tighten the setscrews. (Figure 32) A onto the shaft. 4. Assemble the seal spring, seal cup, seal o-ring, and seal 4. 4. Assemble the seal spring, seal cup, seal o-ring, and seal onto the shaft. A and tighten the setscrews. (Figure 32) 5. Ensure the spring is seated in each cup and the drive 5. 3. Position the drive collar in relation to the scribe mark “A” collar ear on each cup is not in alignment with the drive pins on the drive collar. shaft. seal o-ring, one seal cup, and the drive collar onto the 6. ng box and backplate assembly on 6. Assemble the stuffi stuffing 2. Assemble the deflector, follower, one carbon seal, one the shaft and seal parts. (Figure 33) 1. Scribe a mark on the shaft at location “A”. (Figure 32) 7. ng box with the four 7. Assemble the follower to the stuffi stuffing screws. (Figure 33) Reassembly 8. 8. Mount the seal guard on the adapter. MAINTENANCE 9. ng box. The 9. Attach the water inlet and outlet to the stuffi stuffing stuffi ng two (2) 1/8” NPT water connections which are stuffing spaced 90° from each other and should be positioned 45° (except for the TCF-C114) TF-C114) totovertical verticalwhen whenassembling the pump. (Figure assembling the pump. 34) Flush (Figure water 34) Flush must enter waterone must enter connection one connection and and exit through exit through the other. the other. A FIGURE 32 SEAL CHART MODEL A TF-C114 9/16” TF-C216 TF-C218 TF-C328 9/16” “E” SEALS 9/16” 9/16” FIGURE Figure 33 20 MAINTENANCE “E” SealS SEALS Reassembly (cont’d) 10.The 10. The amount of water needed will vary depending on the operating temperature of the pump. For vacuum applications, 10 drops per minute discharge is recommended. NOTE: Approximately 3 gallons per hour is required to Note: maintain the seal temperature at 100°F when the product temperature is 175°F. A A FIGURE 34 ANGLE CHART MODEL A TF-C114 31° TF-C216 45° TF-C218 45° TF-C328 45° 21 MAINTENANCE NOTES A routine maintenance program can extend the life of your pump. Keep maintenance records. These will help pinpoint potential problems and causes. Routine Maintenance • Check for unusual noise, vibration and bearing temperatures • Bearing lubrication (See Motor Manufacturer) • Inspect pump and piping for leaks • Seal monitoring • Check Mechanical Seal area for leakage Should be no leakage • Vibration analysis • Discharge pressure • Check backplate gasket for wear/damage • Temperature monitoring 22 TROUBLESHOOTING AND CAUSES NOT ENOUGH LIQUID DELIVERED VIBRATION/NOISE • Impeller diameter too small for duty • Starved suction • Discharge head too high • Suction lift too high • Insufficient NPSH (Net Positive Suction Head) available • Air leak in supply or at seal area • Supply line too long; too small; blocked • Wrong direction of rotation • Air entrained in liquid • Pump not primed • Liquid too hot, too viscous • Speed too slow (low voltage, wrong frequency, wrong motor) • Impeller shaft loose or bent • Impeller out of balance • Suction or discharge plugged or closed • Impeller hub/impeller shaft wear • Air entrained in liquid • Motor bearings worn • Insufficient NPSH (Net Positive Suction Head) available • Pump not level; legs not touching floor • Foreign material in pump • Piping not supported NOT ENOUGH PRESSURE RAPID SEAL WEAR • Impeller diameter too small for duty • Excessive spring loading • Air leak in supply or at seal area • Abrasive product • Wrong direction of rotation • Loose impeller shaft • Speed too slow (low voltage, wrong frequency, wrong motor) • Water hammer • Air entrained in liquid MOTOR OVERLOAD • Discharge head too low allowing pump to deliver too much liquid • Impeller diameter too large for duty • Liquid heavier or more viscous than rating • Electrical supply, voltage or frequency incorrect • Prolonged “dry” running • Abrasive solids (unfiltered) in water flushed seal supply SEAL LEAKS • Gasket damaged or worn • Seal not installed correctly • Carbon seal worn or damaged • Inlet/Outlet connection loose or no gasket • Casing clamp loose • Mechanical abnormality in pump • Impeller interference • Seal binding • Defective motor • Faulty electrical connections • Overload heaters too small for motor 23 PARTS ORDERING HOW TO ORDER PARTS By Phone Telephone your repair parts or fittings order to your Distributor. To speed your order and avoid delays, please have your equipment model and serial number and the part numbers from the parts list before you call your Distributor. If you do not know your Distributors number, call Top Line Process Equipment Company at: Phone: 800-458-6095 Fax: 814-362-4453 Your call will be directed to a specialist who can provide you with Distributor information for your area. HOW TO RETURN PARTS Parts may be returned for a credit, subject to the conditions of our return goods policy. To obtain authorization to return a part, contact your Distributor. Please give the following information: • Invoice number and date • Quantity • Part Number (from parts list) • Exact reason for return Your Distributor will provide a Return Goods Authorization. (Returns will not be accepted without advance authorization.) EQUIPMENT INFORMATION Any correspondence concerning pump will require the following information be documented: PRODUCT NAME/MODEL____________________________________________________________ SERIAL NUMBER____________________________________________________________________ DATE OF PURCHASE________________________________________________________________ INVOICE NUMBER__________________________________________________________________ INVOICE DATE______________________________________________________________________ DISTRIBUTOR______________________________________________________________________ ADDRESS__________________________________________________________________________ CITY_______________________________________________STATE__________ZIP_____________ CONTACT__________________________________________________________________________ PHONE_____________________________________________________________________________ FAX________________________________________________________________________________ 24 SPARE PARTS WATER CASCADE ASSEMBLY (#5649127) (Consists of threaded attaching ferrule, compression fitting fitting with nut, and 1/4” diameter stainless water pipe.) Repair KITS REPAIR Kits To maintain continuous uninterrupted operation of your pump, the following kits are recommended. “D” SEAL Seal KITS Kits TF-C100 TF-C100 BUNA TF-C114 TF-C114 VITON FKM ® BUNA TF-C216 TF-C216 VITON FKM ® BUNA TF-C328 TF-C218/C328 VITON FKM ® BUNA VITON FKM ® Kit #1 5629K-1 5629V-1 Kit #1 5649K-1 5649V-1 Kit #1 5669K-1 5669V-1 Kit #1 5689K-1 5689V-1 Kit #2 5629K-2 5629V-2 Kit #2 5649K-2 5649V-2 Kit #2 5669K-2 5669V-2 Kit #2 5689K-2 5689V-2 Kit #3 5629K-3 5629V-3 Kit #3 5649K-3 5649V-3 Kit #3 5669K-3 5669V-3 Kit #3 5689K-3 5689V-3 Kit #1 (Consists of 1 - Carbon Seal, 1 - Casing Gasket, 1 - O-Ring, and 1 - Retaining Pin) Kit #2 (Consists of 3 - Carbon Seals, 3 - Casing Gaskets, and 3 - O-Rings) Kit #3 (Consists of 1 - Carbon Seal, 1 - Spring, 1 - Cup, and 1 - O-Ring) “DG” SEAL KITS “E” SEAL KITS TF-C114 KIT 5649K-1DG CONSISTS CONSISTS OF: OF: 564980 564924 564980N-SC 564980P 564980R 564980V 564990V 5669K-1DG CONSISTS OF: CONSISTS OF: 566980 566924 566980N-SC 566980P 566980R 566980V 566990V 5989K-1DG CONSISTS OF: CONSISTS OF: 568980 568924 568980N-SC 568980P 568980R 568980V 568990V KEY # 80 24 80NSC 80P 80R 80V 90V QTY. 1 1 1 1 1 1 1 DESCRIPTION Carbon Seal, Rotating Impeller Retainer Pin Stationary Seat, Silicone Carbide PTFE Ptfe Gasket, Outboard PTFE Ptfe Gasket, Inboard Seal, O-Ring Viton Seal, O-Ring FKM ® Casing Gasket, Viton Casing Gasket, FKM ® TF-C216 KIT KEY # 80 24 80NSC 80P 80R 80V 90V QTY. 1 1 1 1 1 1 1 DESCRIPTION Carbon Seal, Rotating Impeller Retainer Pin Stationary Seat, Silicone Carbide PTFE Ptfe Gasket, Outboard PTFE Ptfe Gasket, Inboard Seal, O-Ring Viton Seal, O-Ring FKM ® Casing Gasket, Viton FKM ® Casing Gasket, TF-C218/328 KIT KEY # 80 24 80NSC 80P 80R 80V 90V QTY. 1 1 1 1 1 1 1 DESCRIPTION Carbon Seal, Rotating Impeller Retainer Pin Stationary Seat, Silicone Carbide PTFE Ptfe Gasket, Outboard PTFE Ptfe Gasket, Inboard ® Seal, O-Ring Viton Seal, O-Ring FKM ® Casing Gasket, Viton Casing Gasket, FKM Viton® is a registered trademark of DuPont Dow Elastomers TF-C114 KIT 5649EK-1 CONSISTS CONSISTS OF: OF: 564980 564980V 564980G 564917B 564983E 564980H 564990V 5669EK-1 CONSISTS OF: CONSISTS OF: 566980 566980V 566980G 566917B 566983E 566983E 566980H 566980H 566990V 566990V 5989EK-1 5989EK-1 CONSISTS OF: CONSISTS OF: 568980 568980 568980V 568980V 568980G 568980G 568917B 568917B 568983E 568983E 568980H 568980H 568990V 568990V KEY # 80 80V 80G 17B 83E 80H 90V QTY. 2 2 2 1 1 1 1 DESCRIPTION Carbon Seal Seal O-Ring Viton® Seal O-Ring FKM Cup (E Seal) O-Ring Viton® O-Ring FKM O-Ring Viton® O-Ring FKM Spring (E Seal) Casing Gasket Viton® Casing Gasket FKM TF-C216 KIT KEY # 80 80V 80G 17B 83E 83E 80H 80H 90V 90V QTY. 2 2 2 1 1 1 1 1 1 1 DESCRIPTION Carbon Seal Seal O-Ring Viton® Seal O-Ring FKM Cup (E Seal) O-Ring Viton® O-Ring FKM O-Ring Viton® O-Ring FKM Spring Spring (E (E Seal) Seal) Casing Gasket Viton® Casing Gasket FKM TF-C218/328 TF-C218/328 KIT KIT KEY KEY # # 80 80 80V 80V 80G 80G 17B 17B 83E 83E 80H 80H 90V 90V QTY. QTY. 2 2 2 2 2 2 1 1 1 1 1 1 1 1 DESCRIPTION DESCRIPTION Carbon Carbon Seal Seal Seal O-Ring Viton® Seal O-Ring FKM Cup Cup (E (E Seal) Seal) O-Ring Viton® O-Ring FKM ® O-Ring Viton O-Ring FKM Spring (E Seal) Spring (E Seal) Casing Gasket Viton® Casing Gasket FKM 25 PARTS LIST LIST TF-C100 40 40 40 6D 4D *80CA *80CA *80A *80A *80B *80B *80 *80 4A 6A 22 *24 *24 71 71 71B 71B 11 11 *90 *90 11 75K 75K TOP-FLO MODEL TF-C100 ® KEY PART NO. QTY. DESCRIPTION 1 563911510 1 Casing 1.5” x 1” KEypart no.qty.description 2 56392 1 Impeller 3.68” 1 563911510 1 Casing 1.5” x 1” 6A 56396A 2 Shaft Set Screw 2 56392 1 Impeller 3.68” 6D 5639605 1 Stub Shaft-56C Frame 6A 56396A 2 Shaft Set Screw 11 562911 1 Backplate 6D 5639605 1 Stub Shaft-56C Frame *24 564924 1 Impeller Retainer Pin 11 562911 1 Backplate 40 564940 1 Deflector *24 564924 1 Impeller Retainer Pin 71 56397156 1 Adapter 40 564940 1 Deflector 71B 563971B 4 Adapter Mounting Bolt 71 56397156 1 Adapter 75K 563971K 2 Wing Nut 71B 563971B 4 Adapter Mounting Bolt 75K 563971K 2 Wing Nut Viton® is a registered trademark of DuPont Dow Elastomers 26 KEY PART NO. QTY. DESCRIPTION *80 563980 1 Carbon Steel KEypart no.qty.description *80A 564980A 1 Cup *80 563980 1 Carbon Steel *80B 563980B 1 Seal O-Ring, Buna *80A 564980A 1 Cup *80CA 563980CA 1 Spring *80B 563980B 1 Seal O-Ring, Buna *90 562990 1 Casing Gasket, Buna * 80CA 563980CA 1 Spring *90 562990 1 Casing Gasket, Buna *Spare parts recommended See page 25 for spare part kits *Spare parts recommended ® EPDM and Viton elastomers available upon request See page 25 for spare part kits EPDM and FKM elastomers available upon request PARTS LIST LIST KEY KEY NO. KEY PART PART NO. NO. 11 564911515 1 564911515 564911515 11 564912015 1 564912015 564912015 22 56492 2 56492 56492 6A 6A 56496A 56496A 6A 56496A 6E 6E 56496E56 6E 56496E56 56496E56 6E 6E 56496E14 6E 56496E14 56496E14 6E 6E 56496E18 6E 56496E18 56496E18 11564911 11 564911 11 564911 11F 11F 564911F 11F 564911F 564911F *24 *24 564925 *24 564925 564925 40 40 564940 40 564940 564940 40 40 566940 566940 40 566940 71 71 56497156S 71 56497156S 56497156S 71 71 56497118S 71 56497118S 56497118S 71A 71A 564971A 71A 564971A 564971A 71B 564971B56 71B 564971B56 71B 564971B56 QTY. QTY. QTY. 1 11 1 11 1 11 2 22 1 11 1 11 1 11 1 11 2 22 1 11 1 11 1 11 1 11 1 11 2 22 4 44 71B 71B 71B 564971B14 564971B14 564971B14 4 44 71B 71B 71B 564971B18 564971B18 564971B18 4 44 TF-C114 DESCRIPTION DESCRIPTION Casing Casing 1.5”x1.5” 1.5”x1.5” Casing Casing 2”x1.5” 2”x1.5” Impeller Impeller 4” 4” Shaft Set Shaft Set Screw, Screw, 56C 56C Stub Stub Shaft-56C Shaft-56C Frame Frame Stub Stub Shaft Shaft 14T 14T Stub Stub Shaft Shaft 18T 18T Backplate Backplate Backplate Backplate Pin Pin Impeller Impeller Retainer Retainer Pin Pin Deflector, Defl Deflector, ector, 56C-14T 56C-14T Frame Frame Deflector, Defl ector, 18T Frame Frame Deflector, 18T Frame Adapter, Adapter, 56C-14T 56C-14T Frame Frame Adapter Adapter 18T 18T Frame Frame Adapter Adapter Pin Pin Adapter Mounting Adapter Mounting Screw, Screw, 56C 56C Adapter Adapter Mounting Mounting Screw, Screw, 14T 14T Adapter Adapter Mounting Mounting Screw, Screw, 18T 18T *Spare *Spare parts parts recommended recommended See page 25 for See page 25 for spare spare part part kits kits ® ® EPDM EPDMand andViton FKM elastomers elastomers available upon request EPDM and Viton elastomersavailable availableupon uponrequest request KEY KEY KEY 75 75 75 75K 75K 75K *80 *80 *80 *80A *80A *80A *80B *80B *80B *80CA **80CA 80CA 80L 80L 80L 80M 80M 80M *90 *90 *90 131 131 131 PART NO. PART NO. NO. 564975 564975 564975 329901 329901 329901 564980 564980 564980 564980A 564980A 564980A 564980B 564980B 564980B 564980CA 564980CA 564980CA 564980L 564980L 564980L 564980M 564980M 564980M 564990 564990 564990 5649131 5649131 5649131 QTY. QTY. QTY. 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 131 131 131 564913118 564913118 564913118 1 11 DESCRIPTION DESCRIPTION Clamp Clamp Assembly Assembly Wing Wing Nut Nut Carbon Carbon Seal Seal Cup Cup Seal Seal O-Ring, O-Ring, Buna Buna Spring Spring Drive Drive Collar Collar Drive Collar Drive Collar Set Set Screw Screw Casing Casing Gasket, Gasket, Buna Buna Seal Seal Guard Guard Assembly Assembly –– 56C 56C && 14T 14T Frame Frame Seal Guard Assembly Seal Guard Assembly –– 18T 18T Frame Frame Adjustable ADJUSTABLE LEG KITS ADJUSTABLE Leg LEG KitS KITS (304 Stainless Steel) (304 STAINLESS STAINLESS STEEL) STEEL) Part PART NUMBER PART Number NUMBER 56S56C 56S56C 56S140TC 56S140TC 56S180TC 56S180TC 56S210TC 56S210TC 56S250TC 56S250TC 56S280TC 56S280TC 56S320TC 56S320TC Frame FRAME SIZE FRAME Size SIZE 56C 56C 143/145 143/145 182/184 182/184 213/215 213/215 254/256 254/256 284/286 284/286 324/326 324/326 Viton Viton®® is is aa registered registered trademark trademark of of DuPont DuPont Dow Dow Elastomers Elastomers 27 27 PARTSLIST LIST LIST PARTS KEY KEY PART NO. NO. KEY PART NO. 1 566912015 1 566912015 1 564911515 1 566912515 1 566912515 1 564912015 2 56692 2 56692 2 56492 6A 6A 56696A 56696A 6A 56496A 6E 56496E56 6A 6A 56696A56 56696A56 6E 56496E14 6A 6A 56496A 56496A 6E 56496E18 6E 6E 56696E56 56696E56 11 564911 6E 6E 56696E14 56696E14 11F 564911F 6E 56696E18 6E 56696E18 *24 564925 6E 56696E21 6E 56696E21 40 564940 6E 56696E25 6E 56696E25 40 566940 11566911 11 566911 71 56497156S 11F 564911F 11F 564911F 71 56497118S *24 *24 566924 566924 71A 564971A 40 566940 40 566940 71B 564971B56 28 QTY. QTY. QTY. 1 1 1 1 1 1 1 1 1 2 2 2 1 11 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 22 1 11 2 11 4 DESCRIPTION DESCRIPTION Casing 2”x1.5” 2”x1.5” Casing 1.5”x1.5” Casing 2.5”x1.5” Casing 2”x1.5” Impeller 6” Impeller 4” Shaft Set Screw – Shaft Set Screw, 56C 14T, 21T, 25T Stub Shaft-56C Frame Shaft Set Screw – 56C Stub Shaft 14T Shaft Set Screw – 18T Stub Shaft 18T Stub Shaft – 56C Frame Backplate Stub Shaft - 14T Frame Backplate Pin Stub Shaft – 18T Frame Impeller Retainer Pin Stub Shaft – 21T Frame Deflector, 56C-14T Frame Stub Shaft – 25T Frame Deflector, 18T Frame Backplate Adapter, 56C-14T Frame Backplate Pin Adapter 18T Frame Impeller Retainer Pin Adapter Pin Deflector, Defl ector, 56C, 14T, Adapter Mounting 18T Frame Screw, 56C 40 56694021 Deflector, 40 56694021 11 Defl ector, 21T Frame 71B 564971B14 4 Adapter Mounting 40 56694025 Deflector, 40 56694025 11 Defl ector, 25T Frame Screw, 14T 71 566971S 1 Adapter, 56C & 14T Frame 71 566971S 1 71B 564971B18 4 Adapter Mounting 71 56697118S 71 56697118S 11 Adapter 18T Frame Screw, 18T 71 56697121S 71 56697121S 11 Adapter 21T Frame 71 56697125S 71 56697125S 11 recommended Adapter 25 T Frame *Spare parts 71A 564971A 71A 564971A Adapter Pin See page 2522for spare part kits ® 71BEPDM 566971B56 4 71B 566971B56 4 Adapter Screw, and Viton elastomers available Mounting upon request 56C, 14T Frame 71B 71B 566971B 566971B 44 Adapter Mounting Screw, 18T, 21T, 25T Frame 75 75 566975 566975 1 1 Clamp Assembly Viton® is a registered trademark of DuPont Dow Elastomers Viton® is a registered trademark of DuPont Dow Elastomers TF-C216 TF-C114 KEY KEY KEY 75K 75K 75 *80 *80 75K *80A *80A *80 *80B *80B *80A **80CA 80CA *80B 80L 80L *80CA 80M 80M 80L *90 *90 80M 131 131 *90 131 131 131 NO. PART NO. PART NO. 329901 329901 564975 566980 566980 329901 566980A 566980A 564980 566980B 566980B 564980A 566980CA 566980CA 564980B 566980L 566980L 564980CA 566980M 566980M 564980L 566990 566990 564980M 5669131 5669131 564990 5649131 566913118 566913118 QTY. QTY. QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 131 131 131 564913118 566913121 566913121 1 1 1 DESCRIPTION DESCRIPTION DESCRIPTION Wing Nut Clamp Assembly Carbon Seal Wing Nut Cup Carbon Seal Seal O-Ring, Buna Cup Spring Seal O-Ring, Buna Drive Collar Spring Drive Collar Set Screw Drive Collar Casing Gasket, Buna Drive Collar Set Screw Seal Guard Assembly Casing Gasket, Buna 56C-14T Frame Seal Guard Assembly Seal Guard – 56C & 14T Frame Assembly – 18T Seal Guard Assembly Seal Guard Assembly – 18T Frame – 21T & 25T ADJUSTABLE LEG KITS Adjustable ADJUSTABLE Leg LEG KitS KITS Stainless Steel) (304 (304STAINLESS STAINLESSSTEEL) STEEL) Part PART NUMBER PARTNumber NUMBER 56S56C 56S56C 56S140TC 56S140TC 56S180TC 56S180TC 56S210TC 56S210TC 56S250TC 56S250TC 56S280TC 56S280TC 56S320TC 56S320TC Frame FRAME SIZE FRAMESize SIZE 56C 56C 143/145 143/145 182/184 182/184 213/215 213/215 254/256 254/256 284/286 284/286 324/326 324/326 *Spare parts recommended See page 25 for spare part kits EPDM EPDMand andViton FKM®elastomers elastomersavailable availableupon uponrequest request 27 PARTS LIST LIST TF-C218 PARTS LIST TF-C114 KEY KEY PART NO. NO. 1 1 568912015 568912015 1 1 568913015 568913015 PART NO. 2 2KEY 56892 56892 1 564911515 6A 6A 56896A 56896A 564912015 6E 6E 1 56896E14 56896E14 56492 6E 6E 2 56896E18 56896E18 56496A 6E 6E 6A 56896E21 56896E21 6E 56496E56 6E 6E 56896E25 56896E25 56496E14 6E 6E 6E 56896E28 56896E28 56496E18 11568911 11 6E 568911 564911 11F 11F 11 564911F 564911F 11F 564911F *24 *24 568924 568924 564925 40 40*24 56894014 56894014 564940 40 40 40 56894021 56894021 566940 40 40 40 56894028 56894028 71 56497156S 71 71 56897114S 56897114S 56497118S 71 71 71 56897118S 56897118S 564971A 71 7171A 56897121S 56897121S 564971B56 71 7171B 56897125S 56897125S 71 71 56897128S 56897128S 564971B14 71A 71A71B 564971A 564971A 71B 71B 568971B14 568971B14 71B 564971B18 QTY. QTY. 1 1 1 1 1 1 QTY. 2 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 1 2 2 4 4 4 4 DESCRIPTION Casing, C218, 2”x1.5” Casing, C218, 3”x1.5” DESCRIPTION Impeller 8” Casing 1.5”x1.5” Shaft Set Screw StubCasing Shaft 2”x1.5” – 14T Frame StubImpeller Shaft –4” 18T Frame Screw, 56C StubShaft ShaftSet – 21T Frame Stub Shaft-56C Frame Stub Shaft – 25T Frame Shaft 14TFrame StubStub Shaft – 28T Stub Shaft 18T Backplate Backplate Backplate Pin Backplate Pin Pin Impeller Retainer Retainer Pin Deflector, DeflImpeller ector, 14T & 18T Frame ector, Frame Deflector, DeflDefl ector, 21T56C-14T & 25T Frame ector, Frame Deflector, DeflDefl ector, 28T18T Frame Adapter, Adapter, 14T56C-14T Frame Frame Adapter Frame Adapter, 18T18T Frame Adapter Adapter, 21TPin Frame Adapter Adapter, 25TMounting Frame Screw, 56C Adapter, 28T Frame Adapter Adapter Pin Mounting Screw, 14T Adapter Mounting Adapter Screw, 14T Mounting Frame Screw, 18T *Spare parts recommended *Spare parts recommended See page 25 for spare part kits See page®25 for spare part kits EPDM and Viton elastomers available upon request EPDMand andViton FKM®elastomers EPDM elastomersavailable availableupon uponrequest request Viton® is a registered trademark of DuPont Dow Elastomers Viton® is a registered trademark of DuPont Dow Elastomers KEY KEY 71B 71B PART NO. NO. 568971B 568971B QTY. QTY. 4 4 KEY 75 75 75K 75K75 75K *80 *80 *80 *80A *80A *80A *80B *80B *80B **80CA 80CA *80CA 80L 80L 80L 80M 80M 80M *90 *90 *90 131 131 131 131 131 131 131 131 131 131 131 131 PART NO. 568975 568975 564975 329901 329901 329901 568980 568980 564980 568980A 568980A 564980A 568980B 568980B 564980B 568980CA 568980CA 564980CA 568980L 568980L 564980L 566980M 566980M 564980M 568990 568990 564990 568913114 568913114 5649131 568913118 568913118 568913121 568913121 564913118 568913125 568913125 568913128 568913128 QTY. 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 11 1 1 1 11 1 1 DESCRIPTION Adapter Mounting Screw, 18T, 21T, 25T & 28T Frame DESCRIPTION Clamp Assembly Clamp Wing NutAssembly Wing Nut Carbon Seal Carbon Seal Cup CupO-Ring, Buna Seal Seal Spring O-Ring, Buna Spring Drive Collar Drive Collar Drive Collar Set Screw Drive Gasket, Collar Set Screw Buna Casing Casing Gasket, Buna Seal Guard Assembly – 14T Seal Guard Assembly Seal Guard Assembly – 18T – 56C & 14T Frame– 21T Seal Guard Assembly Seal Guard Assembly Seal Guard Assembly – 25T – 18T Frame Seal Guard Assembly – 28T ADJUSTABLE LEG KITS Adjustable ADJUSTABLE Leg LEG KitS KITS Stainless Steel) (304 (304STAINLESS STAINLESSSTEEL) STEEL) Part PART NUMBER PARTNumber NUMBER 56S56C 56S56C 56S140TC 56S140TC 56S180TC 56S180TC 56S210TC 56S210TC 56S250TC 56S250TC 56S280TC 56S280TC 56S320TC 56S320TC Frame FRAME SIZE FRAMESize SIZE 56C 56C 143/145 143/145 182/184 182/184 213/215 213/215 254/256 254/256 284/286 284/286 324/326 324/326 29 PARTS LIST PARTS LIST LIST KEY PART NO. KEY KEY PART NO. NO. 1 1 1 564911515 568913020 568913020 1 564912015 568914020 568914020 1 1 2 56492 568923 568923 2 2 6A 6A 56896A 56896A 6A6E 6E 56496A 56896E14S 56896E14S 6E6E 6E 56496E56 56896E18S 56896E18S 6E6E 6E 56496E14 56896E21S 56896E21S 6E 6E 56896E25S 56896E25S 6E6E 56496E18 6E 56896E28S 56896E28S 116E 6E 564911 56896E32 56896E32 11 564911F 568911 11F11568911 11F 11F 564911F 564911F *24 564925 *24 *24 568924 568924 4040 40 564940 568940 568940 4040 40 566940 56894021 56894021 7140 40 56497156S 56894028 56894028 40 40 56894032 56894032 7171 71 56497118S 56897114 56897114 71A71 71 564971A 56897118 56897118 71B71 71 564971B56 56897121 56897121 71 71 56897125 56897125 71 71 56897128 56897128 71B71 71 564971B14 56897132 56897132 71A 71A 564971A 564971A 71B 71B 568971B14 568971B14 71B 71B 71B 564971B18 568971B 568971B QTY. QTY. QTY. 11 1 1 11 1 11 2 2 21 1 11 1 1 11 1 1 11 1 11 1 1 21 1 11 1 1 11 1 1 11 1 11 1 1 11 1 21 1 1 41 1 1 1 1 41 1 2 2 4 4 4 4 4 TF-C114 TF-C328 DESCRIPTION DESCRIPTION Casing Casing, 1.5”x1.5” C328, 3”x2” Casing, 2”x1.5” C328, 4”x2” Casing Impeller 8” Impeller 4” Shaft Set Screw Shaft Set 56C Stub Shaft Screw, 14T Frame Stub Frame Stub Shaft-56C Shaft 18T Frame Stub Shaft Shaft 21T Stub 14TFrame Stub Shaft 25T Frame Stub Shaft 18T Stub Shaft 28T Frame Backplate Stub Shaft 32T Frame Backplate Pin Backplate Backplate Pin Impeller Retainer Pin Impeller Retainer Pin Defl ector, 56C-14T Frame Deflector, 14T Deflector, & 18T Frame Deflector, Deflector, ector, 21T 25T Frame Defl 18T& Frame Deflector,56C-14T Deflector, 28T Frame Frame Adapter, Deflector, 32T Frame Deflector, Adapter 18TFrame Frame Adapter, 14T Adapter Pin Frame Adapter, 18T Adapter, 21T Frame Adapter Mounting Adapter, 25T Frame Screw, 56C Adapter, 28T Frame Adapter Mounting Adapter, 32T Frame Adapter 14T Pin Screw, Adapter Mounting Adapter Mounting Bolt, 14T Frame Screw, Adapter 18T Mounting Bolt, 18T 21T, 25T, 28T Frame *Spare parts recommended See page 25 for spare part kits *Spare parts recommended EPDM and Viton® elastomers available upon request See page 25 for spare part kits EPDM EPDMand andViton FKM®elastomers elastomersavailable availableupon uponrequest request KEY KEY KEY 75 75 75 75K 75K 75K *80 80 80 *80A *80A *80A *80B *80B *80B *80CA *80CA 80L 80L *80CA 80M 80M 80L *90 *90 80M 131 131 *90 131 131 131 131 131 131 131 131 131 131 PART NO. PART NO. NO. 564975 568975 568975 329901 329901 329901 568980 568980 564980 568980A 568980A 564980A 568980B 568980B 564980B 568980CA 568980CA 568980L 568980L 564980CA 566980M 566980M 564980L 568990 568990 564980M 568913114 568913114 568913118 568913118 564990 568913121 568913121 5649131 QTY. QTY. QTY. 11 1 1 11 1 11 1 111 111 111 11 11 1 111 111 111 564913118 1 568913125 568913125 568913128 568913128 11 11 DESCRIPTION DESCRIPTION Clamp Assembly Clamp Assembly Wing Nut Wing Nut Carbon Seal Carbon Seal Cup Cup Seal O-Ring, Buna Seal O-Ring, Buna Spring Drive Collar Spring Drive Collar Set Screw Drive Collar Casing Gasket, Buna Drive Collar Set Screw Seal Guard Assembly – 14T Seal Guard Assembly – 18T Casing Gasket, Buna Seal Guard Assembly – 21T Seal Guard Assembly Seal Guard Assembly – 25T –Seal 56C & 14T Frame Guard Assembly – 28T & 32TAssembly Seal Guard – 18T Frame Adjustable ADJUSTABLELEG Leg LEGKITS KitS KITS ADJUSTABLE (304STAINLESS STAINLESS StainlessSTEEL) STEEL) Steel) (304 PART NUMBER FRAME SIZE PartNUMBER Number FRAME FrameSIZE Size PART 56S56C 56C 56S56C 56C 56S140TC 143/145 56S140TC 143/145 56S180TC 182/184 56S180TC 182/184 56S210TC 213/215 56S210TC 213/215 56S250TC 254/256 56S250TC 254/256 56S280TC 284/286 56S280TC 284/286 56S320TC 324/326 56S320TC 324/326 Viton® is a registered trademark of DuPont Dow Elastomers Viton® is a registered trademark of DuPont Dow Elastomers 30 27 NOTES 31 . . . the source for all your product needs in the process industries Contact your Top Line Representative for Assistance Office: Office: P.O. Box 264 · Bradford, PA 16701 Plant: 21 Valley Hunt Drive · Lewis Run, PA 16738 800-458-6095 814-362-4626 Fax: 814-362-4453 Pumps PUMPS & STRAINERS- Centrifugal, Rotary Lobe, Filters and Strainers VALVES - Manual, Actuated, Diaphragm VALVEs FITTINGS - Clamp, Sanitary Butt-Weld, Bevel Seat, Tube OD Butt-Weld, Custom, Biopharm Fittings TUBING, Gauges, GAUGES, Sight SIGHT Glasses, GLASSES, Braided BRAIDED Hose HOSE www.toplineonline.com CAT-PM CAT-PM10/11 1/12 PROCESS VALVE N/O Part # : VA0166 N/C Part # : VA0165 Repair Kit Part # : VA0167 Process & Packaging, Inc. PN1159 IDD Process & Packaging, Inc. 5450 Tech Circle, Moorpark, CA 93021 Tel: 805-529-9890, Fax: 805-529-9282, Toll Free: 800-621-4144 Email: [email protected], Web Site: www.iddeas.com Part #: VA1701 Pinch Valve Operation Operation Pressures Operating pressures for controlled material vary depending on sleeve elastomer and valve size, and can range from a moderate vacuum (up to 26" Hg) to a maximum of 90 psi when controlling with air. Required control pressure is normally 20 to 40 psi greater than the material pressure. Use of excessive actuation pressure (air or liquid) than that which results in complete valve closure will impact sleeve life. Use of actuation pressure above 90 psi is not recommended. Recommended Configuration Regulate control air to pinch valve at 25 to 35 PSIG subject to product CO2 levels and temperature Airpinch valves are normally open and require constant pressure for complete closure. Therefore, a loss of control pressure will allow the valve to open. In the event of sleeve failure, controlled material can enter the actuation system. Process & Packaging, Inc. ADJUSTABLE SINGLE STAGE INJECTORS MODEL TF0402S IDD Process & Packaging, Inc. 5450 Tech Circle, Moorpark, CA 93021 Tel: 805-529-9890, Fax: 805-529-9282, Toll Free: 800-621-4144 Email: [email protected], Web Site: www.iddeas.com Detergent Dosing Unit FLOAT VALVE WITH PROPORTIONER PART #: TF0400 INSTALLATION INSTRUCTIONS 1. PARTS: ITEM A. B. C. D. E. F. G. H. I. J. K. DESCRIPTION Valve Assembly Proportioner with Backflow Preventer ¼” ID X 8’ Long Vinyl Supply Tubing & Foot Valve Assembly Float and Chain Mounting Bracket Ceramic Weight ½” ID X 3’ Long Vinyl Discharge Tubing Model 903 Foot Valve (Model 440-24 Only) Metering Tip Kit (61-9k for 440-23T) (100-15K for 440-23BT) Large Lt. Blue & Tan Metering Tips (For 440-24) Bracket Mounting Screws QTY. 1 1 1 1 1 1 1 1 1 1 2 2. INSTALLATION: A. Valve Bracket and Proportioner Assembly: Attach mounting bracket to valve assembly with two (2) screws provided. Screw siphon breaker and proportioner to valve outlet, then mount bracket to tank as shown in figure #1. Either attach a garden hose to the valve assembly or mount the valve assembly directly to a 1/4 NPT pipe line by removing the inlet garden hose adapter. Apply pipe dope, hand tighten, and then turn with a wrench until tight. DO NOT OVER TIGHTEN. The plastic discharge tubing is supplied and must be used. The pipe or hose outlet should be below the bottom of the float. WARNING: Do not use Teflon® tape to seal internal plastic threads as the extra thickness of the tape may cause the plastic to crack. Use a non-welding liquid sealant instead. B. Float: Run chain through the clip on the pull wire until the top of the float is about 1 or 2 inches above the desired maximum water level (with pull wire in "up" position). Snap the bead into the clip to hold the chain in place. Excess chain may be cut off if so desired (see Figure #1). C. Chemical Supply: Place the chemical container in a convenient location not more than 6 feet below the valve, (greater lifts will reduce injection capacities). Insert the end with the foot valve of the 8 foot vinyl tubing into the chemical container. Slip the ceramic weight over the chemical intake tubing and then cut the tubing to any convenient length that will allow it to extend from the bottom of the chemical container to the proportioner inlet barb (See Figure #1). 3. OPERATION: Turn on the main water valve. At least 15 PSI pressure must be available to operate the proportioner. As the tank fills, chemical concentrate will be drawn up thought the plastic tubing and mixed with the incoming water. When the fluid level in the tank reaches 1 to 2 inches below the top of the float the valve will close. When the tank levels drops about 4 inches the valve will open again. 4. CHEMICAL INJECTION ADJUSTMENTS: WARNING: USE CARE WHEN HANDLING HAZARDOUS CHEMICALS. Metering tips are used to control chemical feed rates. Tables 1, 2, & 3 show the dilution ratios for various chemical viscosities. For very viscous products the induction rate can be increased by substituting 1/2" ID inlet tubing. (Leave a short piece of 3/8" ID tubing on proportioner and foot valve barbs as bushings.) 1 cps (centipoise) is equal to the viscosity of water 75 cps is approximately equal to the viscosity of 10 weight motor oil 200 cps is approximately equal to the viscosity of most dishwashing detergents I-461 Rev. E29345 8/03 Pg. 1 of 3 FLOAT VALVE WITH PROPORTIONER PART #: TF0400 INSTALLATION INSTRUCTIONS 5. SERVICING: CAUTION: TURN OFF WATER SUPPLY BEFORE SERVICING. A. Proportioner fails to draw chemical: 1. Proportioner outlet tubing cut too short for priming or not attached. Pinch outlet tube to create back pressure, which will cause unit to prime. The foot valve will keep the inlet tube primed thereafter. 2. Insufficient water supply pressure. 15 psi is the minimum allowable B. Proportioner stops drawing chemical: 1. Inspect foot valve for dried chemical or dirt. Soak in hot water to clean. 2. Proportioner metering tip clogged with dried chemical. Remove tip and try injecting in hot water. If there is no suction, remove proportioner and soak in hot water to clear interior passages. 3. If there is a buildup of calcium carbonate (lime) inside the proportioner then soaking it in a delimeing solution or vinegar will restore it to working order. C. Proportioner continues to draw chemical after water valve closes: Chemical supply is higher than bottom of discharge tube creating a natural siphon. Lower the supply container or hang up outlet tube after use. D. Valve malfunction: 1. Check that the wire moves freely up & down and that a “click” can be heard when the wire is pulled and released, indicating that the magnet is activating the plunger properly. To inspect internal parts, remove magnet housing and carefully pull off the enclosing tube so as not to drop the plunger, kick-off spring and spacer. Check for dirt or damage impeding plunger and kickoff spring movement. Inspect the diaphragm, making sure the two small pin holes (bleed holes) in the diaphragm convolution are clear to allow the valve to close. 2. Valve will not operate if pressure exceeds 150 psi. CAUTION: When servicing unit, be sure that replacement parts have been installed according to drawing * Note: All induction rates are based on a water pressure of 40 psi. Table 1 440-23BT Metering Tip Color Tan Orange Turquoise Pink Clear Brown Red White Green Blue Yellow Black Purple Gray No Tip I-461 Rev. E29345 8/03 1 cps Oz/Gal 0.33 0.42 0.51 0.78 0.87 0.99 1.37 1.52 1.72 2.13 3.05 4.50 7.75 9.86 19.63 Ratio 387-1 307-1 251-1 165-1 147-1 129-1 93-1 84-1 74-1 60-1 42-1 28-1 17-1 13-1 7-1 Injection Rates For Viscosities Shown 75 cps Oz/Gal Ratio 0.26 500-1 0.32 430-1 0.34 382-1 0.56 230-1 0.67 192-1 0.74 174-1 0.91 141-1 1.04 123-1 1.22 105-1 1.27 101-1 1.71 75-1 1.96 65-1 2.4 53-1 2.54 50-1 3.16 40-1 200 cps Oz/Gal 0.12 0.17 0.19 0.3 0.33 0.37 0.44 0.48 0.52 0.54 0.56 0.57 0.59 0.63 0.67 Ratio 1090-1 735-1 676-1 422-1 391-1 345-1 289-1 264-1 244-1 239-1 229-1 224-1 217-1 204-1 190-1 Pg. 2 of 3 FLOAT VALVE WITH PROPORTIONER PART #: TF0400 INSTALLATION INSTRUCTIONS Table 2 440-23T Metering Tip Color Clear Purple Yellow Green Pink Turquoise Black Gray Red Blue Brown White Orange Light Blue* Tan* No Tip 1 cps Oz/Gal 0.30 0.48 1.28 1.67 2.36 3.76 4.47 5.53 7.00 8.78 10.95 14.19 17.58 21.75 27.98 33.15 Ratio 430-1 265-1 100-1 77-1 54-1 34-1 29-1 23-1 18-1 15-1 12-1 9-1 7-1 6-1 5-1 4-1 Injection Rates For Viscosities Shown 75 cps Oz/Gal Ratio 0.22 592-1 0.32 406-1 0.82 157-1 1.29 99-1 1.65 77-1 2.55 50-1 3.03 42-1 3.67 35-1 4.79 27-1 5.39 24-1 6.49 20-1 7.08 18-1 7.91 16-1 8.66 15-1 9.15 14-1 10.54 12-1 200 cps Oz/Gal 0.13 0.24 0.6 1 1.25 1.85 2.12 2.58 2.79 3.06 3.35 3.46 3.71 3.9 4.11 4.52 Ratio 864-1 524-1 212-1 128-1 103-1 69-1 60-1 50-1 46-1 42-1 38-1 37-1 35-1 33-1 31-1 28-1 Table 3 440-24 Metering Tip Color Clear Purple Yellow Green Pink Turquoise Black Gray Red Blue Brown White Orange Light Blue* Tan* No Tip 1 cps Oz/Gal 0.66 1.01 1.53 2.52 3.53 5.73 6.72 8.95 12.34 14.00 18.68 24.45 30.97 38.26 53.96 66.07 Ratio 195-1 127-1 83-1 51-1 36-1 22-1 19-1 14-1 10-1 9-1 7-1 5-1 4-1 3-1 2.5-1 2-1 Injection Rates For Viscosities Shown 75 cps Oz/Gal Ratio .027 470-1 .041 315-1 1.03 124-1 1.64 78-1 2.04 63-1 3.24 40-1 3.88 33-1 4.98 26-1 6.22 21-1 7.28 18-1 9.02 14-1 10.35 12-1 11.86 11-1 13.31 10-1 15.21 8-1 18.61 7-1 200 cps Oz/Gal .14 .33 .86 1.44 2.09 2.92 3.34 4.04 4.67 4.99 5.35 5.53 5.88 6.22 6.49 7.07 Ratio 903-1 393-1 148-1 89-1 61-1 44-1 38-1 32-1 27-1 26-1 24-1 23-1 22-1 21-1 20-1 18-1 * These tips are not included in the standard tip pack. I-461 Rev. E29345 8/03 Pg. 3 of 3 G&L PUMPS BEER BOOST PUMP PART #: PU0100 WASH PUMPS PART #: PU0222 PNEUMATICS M PROCESS & PACKAGING, INC. ã2003 I/O LIST PROCESS & PACKAGING, INC. ã1999 N OXINE PROCESS & PACKAGING, INC. ã1999 O Manual Oxine Dilution & Use Useful figures to have available if you are diluting Oxine manually without a titration kit. These figures are applicable with Oxine that has been activated within 48 hours of dilution with a food grade acid at 2.5 to 3 pH . For keg sanitizing and use with the Super King, Mini King or Squire series machines: It is recommended that you start by using approximately 100 ppm of activated Oxine for keg sanitizing until you can determine through your own QC procedures whether you need to increase or decrease the amount based upon microbial results obtained. Experience indicates that normal usage will be in the range of 20 to 100 ppm. 1. Take a one gallon container with a screw lid and drill a hole in the cap to suit the dosing unit siphon tube. 2. Take 0.6 liter (20 ounces) of Oxine, add food grade acid to lower the pH to approximately 2.5 to 3.0 pH to activate the Oxine and stir. This will give you approximately 20,000 ppm of activated Oxine. CAUTION – Do so in a well ventilated area and do NOT breathe the fumes given off during activation. See the MSDS in this section for more details. 3. When activated (after 5 to 10 minutes) add 3 liters (101 ounces) of water to the activated Oxine (5:1 ratio). This will give you approximately 4,000 ppm of activated Oxine. Stir and replace cap with siphon tube into Oxine. 4. Using the chart supplied with the Oxine doser venturi kit select the colored venturi that will then give you a 40:1 reduction ratio. This will give you approximately 100 ppm of activated Oxine being supplied as your rinse and sanitizing water to the keg for pre and post rinse. 5. This can be verified with the Oxine test kit or Oxystix attainable from IDD Process & Packaging, Inc. Other ratios of Oxine for general sanitizing purposes One unit of manually activated Oxine at 20,000ppm and you: Add 1 unit of water, the concentration reduces to 10000ppm – Ratio of water to Oxine 1:1. Add a further 2 units of water, the concentration reduces to 5000ppm – Ratio of water to Oxine 3:1. Add a further 4 units of water, the concentration reduces to 2500ppm – Ratio of water to Oxine7:1. Add a further 8 units of water, of the concentration reduces to 1250ppm – Ratio of water to Oxine 15:1. Add a further 16 units of water, the concentration reduces to 625ppm – Ratio of water to Oxine 31:1. Add a further 32 units of water, the concentration reduces to 312.5ppm – Ratio of water to Oxine 63:1. Add a further 64 units of water, the concentration reduces to 156.5ppm – Ratio of water to Oxine 127:1. Add a further 128 units of water, the concentration reduces to 78ppm – Ratio of water to Oxine 255:1. Add a further 256 units of water, the concentration reduces to 39ppm – Ratio of water to Oxine 511:1. Add a further 512 units of water, the concentration reduces to 19.5ppm – Ratio of water to Oxine 1023:1. Add a further 1024 units of water, the concentration reduces to 9.5ppm – Ratio of water to Oxine 2047:1. Add a further 2048 units of water, the concentration reduces to 5ppm – Ratio of water to Oxine 4095:1. Add a further 4096 units of water, the concentration reduces to 2.5ppm – Ratio of water to Oxine 8191:1. Add a further 8192 units of water, the concentration reduces to 1.25ppm – Ratio of water to Oxine 16382:1. OXINE & PUROGENE SANITIZER The following information is offered as suggested uses of Oxine and Purogene and is not intended to be definitive or accurate for all applications. IDD Process & Packaging, Inc. do not accept any liability for the use or application of Oxine or Purogene. OXINE AND PUROGENE...THE SANITIZERS FOR ALL REASONS. For years it has been known that chlorine dioxide gas is a powerful anti-microbial agent. However, this gas is toxic and unstable in an aqueous solution. Modern technology has overcome these problems with Oxine and Purogene. Today, stabilized chlorine dioxide (ClO2) is available in a concentrated stable form with very low toxicity. As a powerful oxidant, stabilized ClO2 is virtually unaffected by organic load and hard water. These technical advances have resulted in the FDA, EPA and USDA approving stabilized ClO2 as an acceptable sterilant for numerous applications within the brewery, dairy and food processing plants. Properties which make stabilized ClO2 most attractive to the brewer, maltster and other beverage plant operators are: LOW ODOR - Unlike typical sanitizers such a hypochlorites, quaternary ammonium, or even peroxy-acetic acid, stabilized ClO2 has an almost undetectable odor while surpassing the bacteriocidal efficacy of these other compounds. Hypochlorites can form chlorophenols (a medicinal flavor compound) when combined with organic material in beer: Quaternary ammonia compounds have well known negative effects on flavor; the end product of the reduction of peroxy-acetic acid is acetic acid, with its typically "vinegar-like" character. Even small amounts remaining in a tank and having the opportunity of coming in contact with beer, can have a deleterious effect on beer flavor. LOW CORROSIVITY - Stabilized ClO2 is not harmful to vessels or piping systems when used at the recommended dosages. Typically, brewers like the effectiveness of hypochlorites but a major drawback is hypochlorites role in causing stress corrosion fatigue in stainless steel, particularly at weld joints. Stabilized ClO2 while actually being 4 to 7 times more effective as a sanitizer than hypochlorite, does not enhance or contribute to “stress corrosion fatigue” in the metal. Stabilized ClO2 is only slightly more corrosive than tap water at and much of this is due to the acid used in the activation of the product. When it is used as a final rinse in vessels, or piping systems, it is perfectly safe to leave a 10 ppm solution un-rinsed in a tank, pipe network or piece of process equipment, (i.e. bottle fillers, keg racking machines, sheet or pressure leaf filters, etc.). EASE OF HANDLING - While idophors, peroxy-acetic acid and hypochlorites are popular sanitizers for tanks, fillers and other equipment, they have some handling drawbacks. Iodophors are really only effective at low pH, thus they are typically carried as a concentrate in a solution of phosphoric or nitric acid. This makes them hazardous to handle. Iodophors also have a tendency to stain equipment (and people). Pereoxy- PROCESS & PACKAGING, INC. ©2003 OXINE & PUROGENE SANITIZER acetic acid is actually quite volatile at moderately elevated temperatures (120_F/50_C) and can cause spontaneous explosions. It is also corrosive in its concentrated form. Hypochlorites as chlorine gas have a short-term exposure limit slightly higher than that of stabilized ClO2 (1.0 ppm versus 0.3 ppm respectively). However, since stabilized ClO2 is 4 to 7 times more effective than hypochlorites at normal use levels, it is less hazardous. NO ENVIRONMENTAL IMPACT - Stabilized ClO2 does not form the highly carcinogenic trihalomethanes as do hypochlorites in the presence of organic materials. Oxine is environmentally and user friendly and has been accepted by the EPA has having no environmental impact upon disposal. It is not corrosive nor is it volatile in its concentrated (2%) form. EFFICACY - Stabilized ClO2 does not act by chlorination but by oxidation and has proven effective against all common brewery, winery and beverage plant microorganisms. It is an effective bacteriostat at use rates as low as 5 to 20 ppm against such common pests as Lactobacillus and Pediococcus sp. and at 50 ppm against Wild Yeasts and Mold strains. As with all gaseous products such as stabilized ClO2, Oxine can be monitored by using a standard gas monitoring system such as those supplied by LAB SAFETY SUPPLIES COMPANY. Toll free telephone number 800-356-0722. It is necessary to take extra care with good ventilation during the "activation" process of Oxine. If it is considered necessary to monitor gas levels at this time for your safety records, we recommend that the chlorine "low range" (0.05 to 16ppm) tube be used to monitor gas levels. These tubes readily detect and measure all types of inorganic chlorine. MALTHOUSE: Stabilized ClO2 is an effective wash down sanitizer for walls and floors, germination areas and steep tanks. At 100 to 500 ppm it will kill and bleach out mold and mildew common to these high-humidity areas. Stabilized ClO2 is successfully used in barley steep waters to inhibit microbial growth of all types. Typically at 10 to 50 ppm depending on the microbial load, one can assure a safe re-cyling of the steep water into subsequent batches. Stabilized ClO2's strong oxidizing capability actually reduces B.O.D. loads for disposal. BREWHOUSE: Safe for all vessels and piping systems, whether copper or stainless steel, stabilized ClO2 can ensure a microbially free environment in coppers/kettles, mash filters or lauter tuns, swirl tanks, settlers and wort cooling systems when used at 50 to 100 ppm. The related piping systems for wort transfer to fermentation areas can be sanitized at 100 ppm. A 50 ppm solution is also safe to leave in the pipelines during periods of nonuse, to keep them sanitized. PROCESS & PACKAGING, INC. ©2003 OXINE & PUROGENE SANITIZER FERMENTATION/STORAGE AREAS: A 50 ppm solution is adequate to sanitize tank walls and related piping systems. Since low levels of contact with finished product do not effect final beer flavor, one can safely use stabilized ClO2 in a final rinse and be able to obtain some residual bacteriostatic value. It is recommended that boots, gloves, yeast-handling tools and the like be sanitized at 100 ppm. Stabilized ClO2 at 100 ppm is ideal for foot baths at or near tank entry areas. FILTRATION: Stabilized ClO2 is particularly useful for stabilizing and sanitizing filter systems. It can be used to shock sanitize activated carbon and sand/gravel filters in the water treatment facility. Typically, a 50 to 100 ppm solution is run slowly through these type filters. Stabilized ClO2 will not be absorbed significantly by the active carbon. Once the bed is sanitized it is then possible to dose Oxine into the water stream prior to the filter bed at a concentration of 1 to 5 ppm in order to prevent future contamination. Plate-and-frame filters can be sanitized with a 10 to 50 ppm solution without the typical water flush/rinse required by acid-sanitizers and the like. A standing solution of up to 10 ppm can be left in a filter during periods of non-use with no harm to the filter frame or the sheets. It is recommended that this procedure be carried out after any normal beer filter use to inhibit the growth of yeasts and bacteria, since residual beer on the sheets makes for an ideal growth media. A solution of the same strength sprayed over the outer exposed edges of the filter sheets will prevent mold growth when standing. PACKAGING: Stabilized ClO2 provides a safe sanitization and soaking solution for keg washer rackers, bottle and can fillers. Sanitize at 50 ppm and soak or stand filler bowls in cold water at 10 ppm. Aseptic keg, bottle and can rinsing immediately prior to filling with beer is enhanced when 20 to 50 ppm of stabilized ClO2 is used as a final cold rinse. The use of stabilized ClO2 as an aseptic "fog" spray around aseptic bottle and can fillers is highly effective as a sanitizer and microbial preventative at 10 to 20 ppm. The non-corrosive nature of stabilized ClO2 makes it an ideal growth inhibitor in tunnel pasteurizers. Stabilized ClO2 is most effective in the moderate temperature zones (warm-up and cool-down fresh water zones) of the pasteurizer. A 20 to 30 ppm solution is normally adequate and quite safe to the equipment. PROCESS & PACKAGING, INC. ©2003 OXINE & PUROGENE SANITIZER TANK-TRUCK WASHING: As in the typical use for tank washing and sanitizing, stabilized ClO2 can be used for the sanitization and cleanup of bulk tankers and their related piping and hoses. Wash down tank internals, pumps and hoses at 100 ppm, externals at 250 to 500 ppm. This will prevent transfer of micro-organisms to or from the connecting systems. MOLD AND MILDEW CLEANUP AND CONTROL: Clean off walls and floors as well as air handling units and machinery using a 200 to 500 ppm solution of stabilized ClO2. This effectively kills mold and mildew spores while still retaining some bleaching ability to remove tough black stains. This is good procedure prior to painting, or prior to the application of a mold and slime growth inhibitor such as Alltech's Mold-Zap. PROCESS WATER TREATMENT: The FDA has approved stabilized ClO2 for process water sanitization at between 100 to 200 ppm available ClO2. Potable water treatment is approved for human consumption at 4 ppm available ClO2. ACTIVE CARBON BED (ACB): Infected ACB's can be back flushed and soaked in a 100 ppm solution of ClO2 for 15 to 60 minutes, after which time a forward flush-out of 15 to 30 minutes with the process water can take place. It is then advisable to inject 1 to 3 ppm of activated ClO2 into the process water stream thereafter prior to the ACB to prevent future infections. GLASS WASHING/RINSING: Even at the final stage of the brewer's trade, where bars and pubs have a need for an effective and safe drinking-glass sanitizer, stabilized ClO2 can fill the need. Since stabilized ClO2 can be safely consumed at 4 ppm, it makes an ideal glass rinse. Unlike typical quaternary ammonium rinses, it will not have any deleterious effect on beer flavor, nor on beer foam quality. Use at 20 to 50 ppm in final rinse water. WASHING OF YEAST SLURRY WITH STABILIZED ClO2 (OXINE): Stabilized ClO2 (Oxine) will effectively kill unwanted bacteria in yeast at 20 to 40 ppm, while leaving the culture yeast unharmed. Because of stabilized ClO2's unique action, it does not have the drawbacks of phosphoric acid. It does not form chlorophenols (which contribute to a much feared medicinal character in beers) in the presence of organic materials. METHOD: Normally, an initial washing at 20 to 40 ppm (20 ppm for homogenous yeast, 40 ppm for "clumpy" or highly flocculant strains) is effective against most Lactobacilli and Pediococci species. This "wash" is done by adding stabilized ClO2 directly to yeast slurry on a volume/ppm basis. It does not need to be activated as the pH of the yeast slurry is low enough to convert to ClO2. PROCESS & PACKAGING, INC. ©2003 OXINE & PUROGENE SANITIZER Stabilized ClO2 is supplied at a concentration of 20,000 ppm or 2% Chlorine Dioxide when activated. Therefore, on a volume basis, one could essentially make up with one gallon of stabilized ClO2 concentrate, one thousand gallons of solution at 20 ppm. By this method, we can also assume with one gallon of concentrate to make up one thousand gallons of yeast slurry at 20 ppm. It is impractical to measure the concentration of ClO2 in the presence of yeast, so the dilution must be made based on the strength of the concentrate (20,000 ppm). Yeast slurry should be thin enough to allow for homogeneous mixing, usually 20 to 40% solids. The killing action of stabilized ClO2 is very fast compared to the traditional phosphoric acid wash. Only 15 to 30 minutes need be allowed for effective bactericidal effect of stabilized ClO2, with no resultant stress on yeast cells. DOSING RATE: NORMAL WASH: For regular washing of homogenous recycled brewers yeast, a 20 to 40 ppm wash for a minimum 30 minutes to 5 hours prior to pitching. Mix 1 to 2 ml of stabilized ClO2 concentrate with each liter of yeast slurry. Agitate thoroughly during the process. ACTIVATION OF CONCENTRATE: Since the ClO2 is in a stabilized form in concentrate, it must be "activated" before using. To activate Oxine add acid to lower the pH in a well ventilated area to below 5 pH. Activation can be verified by a corresponding color change of the concentrate from clear to yellow/green. Any number of acids will activate the stabilized ClO2, however, food grade Citric or Phosphoric acid is recommended for this application. Normally it requires up to 200 grams of Citric Acid to activate one gallon of stabilized ClO2 concentrate (up to 50 grams per liter of stabilized ClO2 concentrate). Following are the details for replacement chemicals for your Oxine Test Kits. 10% Potassium Iodide - 100 g diluted to 1,000 ml with distilled water. 0.2N Hydrochloric Acid - Add 16.6 ml Concentrated HCL (39%) to 800 ml water. Bring to 1,000 ml with water. 0.00564N PAO (Phenylarsine Oxide). Oxine is available from IDD in 1, 5, 30, 55 gallon and tote containers. Test kits and replacement materials can also be purchased from IDD. PROCESS & PACKAGING, INC. ©2003 OXINE & PUROGENE SANITIZER STORAGE: Concentrated ClO2 can be stored in a dry area away from acids for up to 3 years under standard conditions. Activated ClO2 has a half-life of approximately 48 hours under standard conditions. Activated ClO2 can be added to cold water at 4,000 ppm. Under such conditions a half-life of up to 2 weeks is possible under standard conditions. AUTOMATIC ACTIVATION SYSTEMS: A series of low cost, hands free, automated activation systems are available to provide a continuous volume of activated ClO2 into a storage reservoir as needed. These systems eliminate the need for manual mixing, measuring and dispensing. PROCESS & PACKAGING, INC. ©2003 INTERNATIONAL, INC. MATERIAL SAFETY DATA SHEET I SECTION 1: CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME Oxine® CHEMICAL FAMILY Mixture of Oxychlorine Compounds MANUFACTURER Bio-Cide International, Inc., 2845 Broce Drive, Norman, OK 73072 U.S.A. (800.323.1398) EPA REGISTRATION NUMBER: 9804-1 EFFECTIVE DATE: June 2004 SUPERSEDES: April 2002 SECTION 2: COMPOSITIONIINFORMATION ON INGREDIENTS Chemical Name C.A.S. No. % by Wt. Sodium Chlorite 7758-19-2 3.35% SECTION 3: HAZARDS IDENTIFICATION EMERGENCY OVERVIEW Clear liquid with very faint chlorinous odor May cause skin reaction. May cause eye irritation. POTENTIAL HEALTH EFFECTS INHALATION: Prolonged inhalation of fog or mist may be irritating to nose and throat. SKIN: Based on rabbit studies, product is listed as "practically not an irritant". Prolonged exposure may produce localized irritation, contact dermatitis, mild erythema and edema. EYE: Based on rabbit studies, product has been given an EPA Category III rating as a mild irritant. Exposure can produce slight irritation of conjunctiva, cornea and eyelid. INGESTION: Ingestion may produce gastric discomfort, nausea, vomiting and diarrhea. Intake of large quantities may produce methemoglobinemia. SYSTEMS OF OVER EXPOSURE Skin and eye irritation. Exposures to chlorine dioxide from activation can produce coughing. MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE Skin disorders, such as dermal allergies and dermatitis. Exposure to chlorine dioxide produced by activation can aggravate pulmonary disorders, such as emphysema. - 1- CHRONIC EXPOSURE EFFECTS May cause localized irritation to areas exposed to product. , SECTION 4: FIRST AID MEASURES The following procedures are recommended as emergency first aid only. They are not intended to replace or supplant the treatment advice of a physician or other authorized health care specialist. Inhalation: Move person to fresh air. If person is not breathing, call 911 or an ambulance, and then give artificial respiration, preferably mouth-to-mouth if possible. Call a poison control center or doctor for further treatment advice. Skin Contact: Take off contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. Call a poison control center or doctor for further treatment advice. Eye Contact: Hold eye open and rinse slowly and gently with water for 15-20 minutes. Remove contact lenses, if present, after the first 5 minutes, then continue rinsing eye. Call a poison control center or doctor for further treatment advice. If Swallowed: Call a poison control center or doctor immediately for treatment advice. Have person sip a glass of water if able to swallow. Do not induce vomiting unless told to do so by a poison control center of doctor. Do not give anything by mouth to an unconscious person. NOTES TO PHYSICIAN Chlorine dioxide vapors are emitted when this product contacts acids or chlorine. If these vapors are inhaled, monitor patient closely for delayed development of pulmonary edema which may occur up to 48-72 hours post inhalation. SECTION 5: FIRE FIGHTING MEASURES FLAMMABLE PROPERTIES Autoignition temperature Flash Point Flammable Limits - LEL Flammable Limits - UEL Not Not Not Not Applicable Applicable Applicable Applicable EXTINGUISHING MEDIA Water unless contraindicated by other materials involved in the fire. FIRE-FIGHTING EQUIPMENT Standard protective gear with self-contained breathing apparatus. SPECIAL FIRE-FIGHTING PROCEDURES Do not allow product to evaporate to dryness. atmosphere. Open or vent any large containers. If chlorine dioxide gas is produced, vent to UNUSUAL FIRE OR EXPLOSIVE HAZARDS The sodium chlorite in dried Oxine~ is a strong oxidizer, which supports combustion. Chlorine dioxide, which may evolve from Oxine'" solutions, is explosive in the gaseous phase at concentrations greater than 10% by volume. Do not allow chlorine dioxide gas to accumulate within a confined space. Note: See STABILITY AND REACTIVITY (SECTION 10) for hazardous combustion and thermal decomposition information. -2 - SECTION 6: ACCIDENTAL RELEASE MEASURES ENVIRONMENTAL NOTIFICATION All spills and leaks involving more than 10 gallons should be reported to the nearest regional EPA office or designated state emergency response office with 24 hours. Spills from ocean vessels or which may contaminate U.S. costal waterways should be reported to the nearest Coast Guard office within 24 hours. SPILL OR LEAK PROCEDURE Small spills, involving less than 10 gallons, may be flushed to a designated and permitted sewer system with the amount of water that is about 10 times the amount of the spill. Large spills, involving more than 10 gallons, should be contained and neutralized using anyone of the three neutralizers: i) sodium sulfite, ii) sodium bisulfite, or iii) sodium thiosulfate. The neutralization reaction can be extremely exothermic, and therefore, care should be taken to add the neutralizer in small increments. Sodium sulfite is the most preferred (least exothermic) neutralizer that can be used in the ratio of 1 Ib per gallon of spilled material. Sodium thiosulfate can be used in the ratio of 2 Ibs of anhydrous salt or 3 Ibs of pentahydrate salt per estimated gallon of the spilled material. The neutralized solution can then be flushed to a designated and permitted sewer system with double the amount of water. The product that is not neutralized may be disposed of as chemical waste in the manner indicated below. The vicinity of the spill should be thoroughly flushed with water after clean-up. At no time should the spilled material be allowed to dry to a crystalline salt. Do not discharge this product to storm drains or to any surface or groundwater source unless specifically allowed under a valid NPDES permit. If the neutralizer is not available, volumes larger than 10 gallons should be carefully transferred into a container and taken to an authorized chemical disposal site (Class I or landfill) in accordance with all federal, state, and local regulations. Consult with selected facility regarding the need for prior neutralization of waste. SECTION 7: HANDLING AND STORAGE HANDLING Use product only as directed by the label. Avoid contact with skin and eyes; avoid breathing any vapors or fumes resulting from product activation. Wash thoroughly after handling. Thoroughly rinse all protective gear and handling equipment, such as transfer pumps and lines, with water prior to reuse or storage. Keep away from children, animals, and unauthorized personnel. PRODUCT STORAGE Store in a cool, dry, well-ventilated location away from acids, chlorine and chlorine compounds, hypochlorites (bleach), organic solvents, sulfur and sulfite compounds, phosphorus, combustiblelflammable materials, and direct sunlight. Keep containers tightly closed when not in use and open carefully to prevent spillage. Storage on wooden floors and pallets is not recommended. Do not contaminate water, food or feed by storage or disposal. SECTION 8: EXPOSURE CONTROLS/PERSONAL PROTECTION ENGINEERING CONTROLS VENTILATION Open air or good room ventilation is normally adequate for safe use of this product. Avoid breathing any vapors or fumes resulting from acid activation. -3 - PERSONAL PROTECTIVE EQUIPMENT (PPE) Eye/Face Protection Good manufacturing practice recommends use of chemical safety goggles for all applications involving chemical handling. Skin Protection Good manufacturing practice recommends that, at a rmrumurn, rubber, neoprene, or other chemically impervious gloves be worn for all applications involving chemical handling. Respiratory Protection In accordance with OSHA regulations (29 CFR 1910.134 and 29 CFR 1910.1000), fogging or spraying applications may require worker respiratory protection, such as: (1) NIOSH/MSHA approved air-purifying respirators, or (2) NIOSH/MSHA approved canister/cartridge facial respirators rated for chlorine/acid vapors or specified for chlorine dioxide. General Product should be stored and applied in close proximity to a safety shower, chemical eyewash station or other fresh water source. SECTION 9: PHYSICAL Odor, Color, Grade General Physical Form Volatile Organic Compounds Flash Point Evaporation Rate Solubility in Water Boiling Point Vapor Density Vapor Pressure Specific Gravity pH Melting point: SECTION AND CHEMICAL PROPERTIES Clear liquid with very faint chlorinous odor Liquid <0.1% by weight Not applicable Comparable to water Complete 213°F (100.5°C) 0.02 kglm3 23.7 mm Hg (25°C) 1.03 glml (200C) 8.0 - 8.5 Not determined. 10: STABILITY AND REACTIVITY CHEMICAL STABILITY Stable Materials and Conditions to Avoid: Avoid storing product under conditions in which it could evaporate to crystalline salt. Avoid accidental contact of concentrate with acids, chlorine compounds, hypochlorites (bleach), sulfur and sulfite compounds, phosphorous, organic solvents and combustiblelflammable material Hazardous Reaction and Decomposition Products: Exposure to acids or chlorine compounds can produce uncontrolled generation of chlorine dioxide gas. Hazardous Polymerization: Hazardous polymerization will not occur -4- SECTION 11: TOXICOLOGICAL INFORMATION ANIMAL TOXICOLOGY Inhalation LC50: Dermal LD50: Oral LD50: >5.61 mg/I >2,020 mg/kg (rabbit) 4,360 mg/kg (rat) CARCINOGENICITY Active ingredients are not listed by ROTECS, OSHA, IARC, NTP or EPA. No evidence to date implicating product as a carcinogen or tumor promoter. MUTAGENICITY Though product active ingredient is a chemical oxidant, no evidence to date for mutagenicity from whole animal or in vitro studies. REPRODUCTIVE/DEVELOPMENTAL TOXICITY No known effects to date. SECTION 12: ECOLOGICAL INFORMATION ECOTOXICOLOGICAL INFORMATION This product is toxic to fish and aquatic organisms. Do not discharge effluent containing this product into lakes, streams, ponds, estuaries, oceans or other waters unless in accordance with the requirements of a National Pollutant Discharge Elimination System (NPDES) permit and the permitting authority has been notified in writing prior to discharge. Do not discharge effluent containing this product to sewer systems without previously notifying the sewage treatment plant authority. For guidance, contact your State Water Board or Regional office of the EPA. SECTION 13: DISPOSAL CONSIDERATIONS CONTAINER DISPOSAL Triple rinse. Then offer for recycling or reconditioning; or puncture and dispose of in a sanitary landfill; or by incineration; or, if allowed by state and local authorities, by burning. If burned, stay out of smoke. PESTICIDE DISPOSAL Wastes resulting from the use of this product may be disposed of on site or at an approved waste disposal facility. DISPOSAL PROCEDURE Small quantities, less than 10 gallons, may be flushed to an authorized and permitted sewer with copious amounts of water. Larger volumes should be taken to an authorized chemical disposal site (Class I or landfill) in accordance with all federal, state and local regulations. Consult with selected facility regarding the need for prior neutralization of waste. SECTION 14: TRANSPORT Not DOT Regulated -5 - INFORMATION SECTION 15: REGULATORY INFORMATION US FEDERAL REGULATIONS TSCA All product ingredients are in inventory SARA TITLE 312/313 Neither the product nor its constituent ingredients are listed under SARA reporting requirements. Chlorine dioxide produced from activation is listed under SARA 313. RCRA Not considered a hazardous waste either categorically or by chemical listing. FIFRA Oxine" is an EPA registered sanitizer (EPA No. 9804-1) FEDERAL OSHA REGULATIONS Neither product nor constituent ingredients is classified as an acute or chronic health hazard by OSHA. Chlorine dioxide produced by activation is regulated with an air exposure limit of 0.1 ppm TL V and 0.3 ppm STEL. STATE LAWS CALIFORNIA: Not regulated under the provisions of Proposition 65 (Safe Drinking Water and Toxic Enforcement Act of 1986) NEW JERSEY: Sodium Chlorite is listed under New Jersey's Chemical Inventory Notification Requirement (NJAC 7:1Z). Estimated release notification, however, is not required. NOTE: Regulatory requirements are subject to change and may vary from one location to another. It is the user's responsibility to ensure compliance with all applicable federal, state and local regulations pertaining to the purchase, transport, storage, use and disposal of this product. CHEMICAL INVENTORIES This material contains one or more substances listed on the TSCA Inventory. Commercial use of this material is regulated by the EPA. This MSDS has been prepared to meet the U.S. OSHA Hazard Communication Standard, 29 CFR 1910.1200 SECTION 16: OTHER INFORMATON NFPA Hazard Classification Health: 1 Flammability: 0 Reactivity: 1 Special Hazards: None National Fire Protection Association (NFPA) hazard ratings are designed for use by emergency response personnel to address the hazards that are presented by short-term, acute exposure to a material under conditions of fire, spill, or similar emergencies. Hazard rating primarily based on the inherent physical and toxic properties of the material but also include the toxic properties of combustion or decomposition products that are known to be generated in significant quantities. NOTICE: Manufacturer believes the information contained herein is accurate; however we make no guarantees with respect to such accuracy and assume no liability in connection with the use of the information contained herein by any party. Any party using this product should review all such laws, rules or regulations prior to use. Product may bleach clothing and fabric materials, such as draperies and carpets. NO WARRANTY IS MADE, EXPRESS OR IMPLIED FOR A PARTICULAR PURPOSE OR OTHERWISE -6 - PLANNED PREVENTATIVE MAINTENANCE PROCESS & PACKAGING, INC. ã1999 P PLANNED PREVENTATIVE MAINTENANCE FOR SQUIRE, MINI KING, SUPER KING & EMPEROR SERIES KEGGING & FLASH PASTEURIZATION SYSTEMS DAILY: 1. Clean machine after use, with low pressure hose and warm soapy water. DO NOT HOSE DOWN THE ELECTRICAL PANELS 2. Check and monitor service pressures and temperatures prior to and during operation in line with operations manual recommendations. 3. Change caustic and/or acid detergents hourly and monitor pH levels as necessary. 4. Check the connection head spear adapters for damage. Change if necessary. Any damage may be transferred to the keg valve seal. WEEKLY: 1. 2. 3. 4. Check connection head seals and “O” rings for wear and damage. Replace if necessary. Check for leaks on all service lines and unions. Replace seals and/or tighten as necessary. Check for loose nuts and bolts. Tighten as necessary. Check for loose wire terminations. Tighten as necessary. MONTHLY: 1. Check dosing units for accuracy and operation in line with operations manual recommendations. Adjust if necessary. 2. Check fiber optic, I.R. and/or fiber optic probes for cleanliness and operation. Clean and/or replace if necessary. 3. Clean out all airline filters and drain out condensate. 4. Check all push button switches and indicator lamps for damage. Replace is necessary. 5. Clean out all steam strainers. 6. Check all spare parts inventory levels in line with operations manual. Order if necessary. THREE MONTHLY: 1. Check pressure gauges for accuracy. Adjust and/or replace if necessary. 2. Check the transfer system alignment and keg placement over the connection heads. Adjust and/or replace worn parts and lubricate if necessary. 3. Check all hoses for leaks and/or wear. Replace if necessary. 4. Check tri-clover seals for wear and/or damage. Replace if necessary. 5. Check pressure switch calibrations and adjust according to the manual if necessary. 6. Check all reject functions are operational on all process heads. 7. Check all electrical power connections and motor overload settings. Reset if necessary. YEARLY: 1. 2. 3. 4. 5. 6. 7. Inspect all wearing strips. Replace if necessary. Check process valve, seats, “O” rings and seals for wear. Replace if necessary. Inspect pump seals for wear or damage. Replace if necessary. Inspect all air cylinder seals for wear and/or damage. Replace if necessary. Check nylon air lines for leaks and flexibility. Replace if necessary. Check all solenoid valves for proper operation. Replace if necessary. Replace seals on all process valves. PROCESS & PACKAGING, INC. ã1996 QUALITY CONTROL PROCESS & PACKAGING, INC. ã1999 Q QC CHECKS Q KEG & KEG PLANT QUALITY CONTROL CHECKS A. DETERGENT TANK TITRATION The detergent set, detergent tank(s), Q.C. checks should be made before starting and at least twice during each 8 hour operating shift. Adjust frequency to meet the Q.C. department “comfort level”. The acid titration level (phosphoric) should be in the range 0.25% to maximum of 0.4% v/v. The alkali titration level (caustic) in the range of 1.5 to 2.5% v/v. B. KEG WATER CARRY-OVER AND TITRATION CHECKS 1. After the keg has completed the wash head(s) sequence(s), the keg must be allowed to continue through the sterilizing sequence and then rejected (stopped) immediately prior to commencing the racking head(s) sequence(s). When the keg is retrieved at the discharge end of the machine, the keg can be cooled down by placing a cold water hose over the outer surfaces (if steam is used). A Q.C. sample or funnel coupler is then used to tap the keg. The keg must be inverted to remove the contents via the CO2 port of the coupler by allowing the keg to drain or forcing the contents out with air or CO2. The condensate or rinse residuals in a 50 liter or ½ barrel keg normally measures between 40 to 80 ml. A limit of 100 ml. should be set as a maximum allowable limit. If the operation must be checked together with that of the steam quality and relevant steam main condensate traps. 2. The condensate obtained from the keg can be titrated to ensure that there is no acid and/or alkali carry-over from the wash head(s). NOTE 1: For this check, the pH. of the steam condensate should be a known factor if steam is used for purging. NOTE 2: This check should be carried out once a day for each machine lane and then reduced to the Q.C. department “comfort level”. 3. Another keg is used to do a similar check after it has been allowed to complete the sequences through the racker head(s) up to the point of immediately prior to starting the beer filling sequence. Reject the keg prior to starting the beer filling sequence and remove from the conveyor after discharging from the machine. When checking for the quantity of condensate present in the keg, it should be less than 15ml. NOTE: This check should be carried out once a day for each machine lane and then reduced to the suit the Q.C. departments “comfort level”. C. MICROBIOLOGICAL CHECKS TO THE KEG Introduce a liter of sterile liquid, (preferably beer), into a keg having completed the sequence as described in item 3, via a sterilized keg valve and “funnel” coupler. This allows the keg to be checked for microbial integrity by removing 250 ml. of the PROCESS & PACKAGING, INC. ©1999 KEG PLANT QUALITY CONTROL CHECKS (CONT.) Page 2 sterile liquid into a sterile flask. Split the sample into two, 100 ml. samples via Millipore type membranes, plate and incubate the membranes on agar suitable for aerobic and anaerobic organisms. Methods of doing this vary slightly. The main objective, however, is to ensure that consistency in sampling is maintained, i.e. having introduced the sterile liquid into the keg, each keg should be rotated a set number of times to ensure all surfaces have been covered equally before it is extracted. A known quantity should always go into the keg and a known quantity should always be extracted, filtered and plated. NOTE: This procedure should be carried out at least once every two weeks. D. AFTER A C.I.P. SEQUENCE After the C.I.P. sequence, the process mains, bright beer tank and racker connection head(s), can be swabbed and checked for visual cleanliness to ensure that the cleaning operation frequencies are effective and adequate. NOTE: This should be carried out at least once a week. E. BEER STABILITY SAMPLING Samples are taken from the B.B.T. and keg at a frequency laid down by the brewery Q.C. department. A suitable stability test is to set aside a keg of beer from the keg line after filling and “forcing” the contents by leaving the keg in an environment of 70°F (21°C). Taste, odor and clarity tests can then be taken after 72 hours and at regular duration’s thereafter as desired to suit the Q.C. departments standards. A keg filled with beer should be removed from the keg line and allowed to stand for 5 to 10 minutes. The Pressure Test coupler is connected to the keg after being sterilized along with the keg neck. Pressure in the keg should be approximately 75% of the counter pressure used during the latter part of the filling sequence. F. SUMMARY It is possible to determine the following about the keg machine function and cleaning procedures from the aforementioned. 1. The wash water and detergent is being cleared from the keg by the final CO2 or steam purge sequence on the final wash head. 2. The final rinse on the final wash head is removing the detergent residual from the keg. KEG PLANT QUALITY CONTROL CHECKS (CONT.) PROCESS & PACKAGING, INC. ©1999 Page 3 3. The CO2 purge is removing the condensate trace from the keg on the racker head prior to filling with beer. 4. The microbial integrity, via steam sterilizing or Oxine (Cl02) sanitizing of the keg is being achieved. 5. The separate plant C.I.P. sequence is effective in removing all traces of beer protein and other residual from the keg plant connection head(s) and piping system(s). 6. The cleanliness and microbial integrity is being maintained by the separate plant C.I.P. regime. 7. The residual pressure in the keg after filling will indicate that the keg CO2 in solution is going to be maintained. If the pressure in the keg is above that of the filling counter pressure, then it is highly probable that the keg was overfilled and creating a hydraulic pressure. When filling against a “backup” probe, this hydraulic pressure condition will be normal. NOTE: Sample, Funnel and Pressure Test couplers can be purchased from IDD to suit your keg valve type. If you have any questions, please contact Jeff Gunn at IDD Process & Packaging, Inc. Toll free: 800-621-4144, Tel: 805-529-9890, Email: [email protected] PROCESS & PACKAGING, INC. ©1999 Process & Packaging, Inc. Keg Line Quality Assurance QC/Sampling Coupler - Used for removing samples from the keg under aseptic conditions American Sankey QC/Sampling Coupler: SA 35336 European Sankey QC/Sampling Coupler: SA 35266 Funnel Coupler - Used for inserting samples into the keg under aseptic conditions American Sankey Funnel Coupler: SA 35338 European Sankey Funnel Coupler: SA 35265 Pressure Test Coupler - Used for pressure testing the keg after filling American Sankey Pressure Test Coupler: SA 35337 European Sankey Pressure Test Coupler: SA 35267 See the keg QC Procedures for application DIMENSIONS PROCESS & PACKAGING, INC. ã2003 R SQUIRE “PLUS 2” & “SQE” – SINGLE VALVE KEG WASHING, SANITIZING & FILLING SYSTEMS DIMENSIONS: DIMENSION Length Depth Height Estimated shipping weight (crated) SQP2 60 inches 54 inches 68 inches 750 pounds SQE 60 inches 30 inches 50 inches 450 pounds OUTPUT: 5 gallon and 20 liter kegs ¼ barrel and 30 liter kegs ½ barrel and 50 liter kegs Up to 30 per hour Up to 28 per hour Up to 25 per hour NOTE: Output subject to keg and keg valve style and wash sequence used. RECOMMENDED SPARES PARTS PROCESS & PACKAGING, INC. ã1999 S Process & Packaging, Inc. Recommended Spares List for SQUIRES Qty IDD Part# Description 1 EL0400 2 POSITION SWITCH ELEC SWITCH 1 EL0402 PUSH BUTTON RED 22MM ELEC SWITCH 1 EL0403 PUSH BUTTON BLACK 22MM ELEC SWITCH 1 EL0411 PUSH BUTTON GREEN 22MM ELEC SWITCH 1 EL0437 BLOCK, N/C CONTACT ELEC SWITCH 2 EL0438 BLOCK, N/O CONTACT ELEC SWITCH 2 EL0521 6MM BLUE TERMINAL ELEC TERMINALS 2 EL0623 24VDC FUSE HOLDER,GMA ELEC FUSE/HLDR 1 EL0624 115-220vFUSE HLDR,GMA ELEC FUSE/HLDR 5 EL0626 GMA 1 AMP FUSE ELEC FUSE/HLDR 5 EL0627 GMA 5 AMP FUSE ELEC FUSE/HLDR 5 EL0628 GMA 3.15 AMP FUSE ELEC FUSE/HLDR 1 EL0801 LAMP 220V WHITE ELEC LAMP LIGHT 1 EL0808 LAMP 24VDC RED ELEC LAMP LIGHT 1 EL1200 PROBE IR POLY. PNP ELEC SENSOR 5 MD 3137 AMER. SANKEY REBUILD COUP COUPLER 2 MD 35417 WASH COUPLER A.SANKEY 2 PF1600 1/2" & 3/4" TC CLAMP FTNG TC CLAMP 10 PN1601 MALE ELBOW 1/8 X 5/32 PNEU FITIINGS 1 PN1158 BLANKING PLATE PNEU MANIFOLD 2 PN1159 VALVE 3 WAY 24V PNEU MANIFOLD 1 PN1160 DIN PLUG W/LED PNEU MANIFOLD 10 PN1203 1/8" FILTER/BREATHER PNEU SILNCR/FLW 1 PU0100 PUMP-BOOST 110/220V PUMP PRODUCT 1 PU0100TL PUMP PRODUCT 1 PU0100TLRK REPAIR KIT TOPLINE PUMP KIT, PUMP REPAIR 1 PU0222 WASH 110/220-1-60 PUMP LIQUOR 2 PU0300 PUMP KIT, PUMP REPAIR 5 SL0200 SEAL TC PUMP-BOOST 110/220V TOPLINE (NEW STYLE) WASH/BEER PUMP H.TEMP SEAL KIT FOR G&L PUMPS 3/4 EPDM TC SEAL Category General/Specific STANDARDS IDD Process & Packaging, Inc. 5450 Tech Circle, Moorpark, CA 93021 Tel: 805-529-9890, Fax: 805-529-9282, Toll Free: 800-621-4144 Email: [email protected], Web Site: www.iddeas.com COUPLER Process & Packaging, Inc. 1 SL0201 1"EPDM TC SEAL SEAL TC 2 SL0601 CPLER NUT TEFLON SEAL SEAL WASHER 1 SL0602 3/8 NPT TEFLON SEAL WASHER 120 SS0201 BREW HOSE 1/2 (PER INCH) SPEC HOSE 2 SS0401 5/8 TO 1 SPEC HOSE CLAMP 1 TF0309 220-1-3KW 2"NPT INCLY TANK HEATER 1 TF0400 COMPLETE UNIT H/TEMP TANK DOSERS 1 TF0402S INJECTOR SQUIRE ST/ST TANK DOSERS 2 VA0123 V/V SEAT FOR VA0165 VALV PROCESS 2 VA0167 REPAIR KIT FOR VA0165/66 VALV PROCESS 1 VA1701 5/8 POLY/EPDM 3/4 NPT VALV PINCH 1 VA1704 5/8" BLADDER EPDM VALV PINCH IDD Process & Packaging, Inc. 5450 Tech Circle, Moorpark, CA 93021 Tel: 805-529-9890, Fax: 805-529-9282, Toll Free: 800-621-4144 Email: [email protected], Web Site: www.iddeas.com MD 35417 – IDD MODIFIED WASH/FILL COUPLER MODIFIED IDD AMERICAN SANKEY “D” SERIES WASH / FILL COUPLER FOR SQUIRE WASHER / RACKERS & ACCESSORIES SS0400 – HOSE CLAMP MD 35417RK2 HANDLE KIT COMPRISING MD 35417RK1 SEAL KIT COMPRISING COUPLER HANDLE SS0201 – ½” ID BREWERY HOSE TEFLON SEAL, COUPLER NUT COUPLER PIN BOTTOM SEAL MD 35417RK3 HOSE BARB COMPRISING PROBE O-RING EXTENDED HOSE BARB PROBE SEAL COUPLER NUT SS0202 – ½”ID FOOD GRADE CLEAR HOSE SERVICES PROCESS & PACKAGING, INC. ã2003 T SERVICE SUPPLIES T CO2 and Low Pressure (Purge) Air It is recommended that 1" regulators are fitted within 10 feet of the machine and a 3/4" or 1” I/D line is run between the regulator and machine A minimum 3/4" supply line set at 100 psig should be run to the 1” regulators stated above. Controls Air 3/8” minimum supply line at 100 psig and regulated to 80 PSIG at the machine. NOTE: You MUST use an air dryer on your air supplies to the machine to prevent prelubricated pneumatic equipment from seizing up due to condensation moisture in the air supply. In all instances a water separator is NOT sufficient to ensure dry oil free air. Steam Supply Please ensure steam supplies (where appropriate) are run to ASME and local codes in the following manner to ensure a safe, clean supply free of dirt and condensate. PROCESS & PACKAGING, INC. 1996 An Air Dryer will remove moisture from compressed air to a certain degree of dryness and this is referred to as pressure dew point. Different types of dryers can achieve different dew points and, for the most part, the drier the air needs to be, the more expensive it is to dry • Refrigerated Dryers condense the moisture out of the air and drain it away as liquid. They are limited to about 35° F because the water would freeze if it got any colder. • Desiccant Dryers adsorb the moisture in the compressed air and remove it while still suspended as vapor. They are typically applied at about -40° F, but can get to -100 and below. • Membrane Dryers use permeability to separate the moisture from the air and can also achieve low dew points. The selection is made on personal preference, the dryness required, and cost, which should include operating and electrical or utility costs. Reproduced in part from the web site of: Gulf Atlantic Equipment, Co., Jacksonville, Florida. 904-636-8555 Fax: 904-636-8554 © 2006 CYCLE TIMES PROCESS & PACKAGING, INC. ã2003 V 08/31/08 Rev2 SQUIRE “PLUS 2” & “EXTRA” SEQUENCE TIMES OXINE MACHINE WITH ALLEN BRADLEY PLC WASH HEAD Wash Water Pre-soak Air Purge Pre-soak Wash 1 Water (pulse on long seq) Low Flow Wash 1 (pulse on long seq) Air Purge Wash 2 Detergent (Pulsed Wash) Low Flow Wash 2 Air Purge Wash 3 Water (Pulsed Wash) Low Flow Wash 3 Wash 3 fill Sterilize Hold CO2 purge CO2 pressurize REGULAR SEQUENCE LONG SEQUENCE 3 sec. Event 7.5 sec. 7.5 sec. Event 15 sec. 15 sec. Event 7.5 sec. 10 sec. 3 sec. 12 sec. Event 2.5 sec. 3 sec. Event 15 sec. 15 sec. Event 30 sec. 30 sec. Event 7.5 sec. 10 sec. 3 sec. 12 sec. Event 2.5 sec. Event 4 sec. 2 sec. Event 4 sec. 2 sec. FILL HEAD Product Gas Scavenge De-pressurize time FLOW DIAGRAM W PROCESS & PACKAGING, INC. ã2003 FLOW DIAGRAM W DETERGENT RECOVERY SQP2 ONLY DETERGENT TANK WITH SQP2 ONLY . SQE FITTED WITH IN LINE INJECTOR DETERGENT PUMP OPTIONAL WITH SQE PROCESS & PACKAGING, INC. ã2000 CONTROL PHILOSOPHY X PROCESS & PACKAGING, INC. ã2003 SQUIRE “PLUS 2” & “EXTRA” CONTROL PHILOSOPHY 12/13/04 Rev2 WASH SEQUENCE NOTE: The cycle lengths are selected by the operator from the selector switch on the side of the control panel, long or short cycle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Attach the wash coupler to the keg. Depress the blue handle down into the lock position Place keg inverted on the wash platform Press start button. Wash sequence lamp on. Wash water pre-soak time. Wash water off. Air purge on. Purge until keg is clear, checked by liquid sensor. Wash 1 on, enable probe guard Low Flow on when Wash 1 high flow times out. Low flow off. (Repeat high and low flow for Long cycle) Air purge on. Purge until keg is clear, checked by liquid sensor. Reject keg if insufficient liquid was detected during purge of keg, if ok then, Wash drain off. Wash 2 detergent and detergent recovery on for SQP2 only and wash 2 detergent and wash drain on for SQE. Low Flow on when Wash 2 high flow times out. Low Flow off (Repeat high and low flow for Long cycle) Wash 2 detergent and low flow off. Air purge on. Purge until keg is clear, checked by liquid sensor. Reject keg if insufficient liquid is detected during purge, if ok then, Detergent return off for SQP2 only. Wash 3 water and wash drain on. Low Flow on when Wash 3 high flow times out. Low Flow off. (Repeat high and low flow for Long cycle) Wash drain off Water fill keg time. Wash 3 off Sterilize hold time. CO2 purge & wash drain on Purge until keg is clear, checked by liquid sensor. Wash drain off SQUIRE “ PLUS 2” CONTROL PHILOSOPHY CONT.) Page 2 WASH SEQUENCE (CONT.) · · · CO2 pressurize keg CO2 and wash drain off. Wash sequence lamp off. END OF CYCLE WASH REJECTED KEG SEQUENCE · · Flash sequence lamp to indicate rejected keg. Operator presses stop button to release keg and reset cycle. FILLING SEQUENCE · · · · · · · · Place keg upright on the floor and connect the filling coupler to the keg. Depress the handle until in the locked down position. Press start button. Product pump on Product valve on Racker drain off (normally on) & F.O.B. on after delay, 5 seconds. When product sensor detects product. Product valve & product pump off, Racker drain on, F.O.B off. END OF CYCLE SCAVENGE SEQUENCE · · · · · · · · Place filling coupler handle to the upright position. Do not remove the coupler. Press the Scavenge start button Filler Gas on. Racker drain off (normally on) Gas scavenge time on. Gas off. Depressurize head. Racker drain on END OF CYCLE SQUIRE “PLUS 2” CONTROL PHILOSOPHY CONT.) Page 3 CIP SEQUENCE · · · · · · · · Place the filling coupler in the CIP cup on the machine and twist to lock in place. Turn CIP/Rack switch to CIP. Product valve & product pump on. Racker drain off (normally on) When CIP is complete. (determined by customer) Return CIP/Racking switch to “Rack” Product valve & product pump off Racker drain on. END OF CYCLE. JRG/Squire “Plus 2” control philosophy - Oxine PROGRAM LISTING Y Program Loaded into PLC & Fully Tested Program Listing Copy is on File PROCESS & PACKAGING, INC. ã1999 APPENDIX Z PROCESS & PACKAGING, INC. ã2003
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