Professional Documents
Culture Documents
Excellent
Minerals
Solutions
GEHO
TZPM
Training
Weir Minerals Netherlands b.v. Excellent
Minerals
Solutions
TRAINING TZPM
2
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TRAINING TZPM
INDEX
Total pump system
Frame unit
Lubrication unit
Valve unit
Diaphragm unit
Propelling liquid unit
Piston unit
Vent line unit
Pulsation dampener
Pressure relief unit
Zapex coupling
HMI panel
Maintenance
Priming the slurry section
Priming the propelling liquid section
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Solutions
TRAINING TZPM
Discharge valve
Válvula de descarga
Piston
Suction valve Pistón
Válvula de succión
Propelling liquid
Fluido propulsor Lubrication unit sump
Sistema de lubricacion
4
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Drive end
5
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Solutions
Water end
6
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Piston numbering
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8
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Suction stroke
Discharge stroke
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Frame unit
1. Crankshaft
2. Cross head
4 1 3 2 5
3. Connecting road
4. Oil sump
5. Dust cover
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Frame unit
1. Crankshaft
2. Cross head
3. Connecting road
4 1 3 2 5 4. Oil sump
5. Dust cover
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Lubrication System
Every 2000 running hours / twice a year or due to a earlier defined sampling period:
Take an oil sample, just before the discharge filter, when oil pump is running and the oil is at a normal temperature.
WARNING
The oil is under pressure and can be hot.
Send the oil sample to the laboratory for recommendations and for a time schedule, for replacing the oil.
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Lubrication System
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Lubrication System
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Lubrication System
1. Pressure gauge
1
2. Electric motor
3. Internal suction filter
4. Hydraulic gear pump
5. Flow sensor 2
6. Oil drain plug
7. Discharge pressure filters
3
7 6 5 4
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Lubrication System
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Lubrication System
Valve unit
1.Valve housing
2
2.Valve cover
3.Conical valve 1
4.Valve disc 8
10
5.Valve seat 7
11
6.Lock nut 9
3
7.Compression spring
6
8.Clamping piece
9.Guide bush 4
10.Stud bolt with 5
hydraulic tensioning
11.Hydraulic nipples
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Stud bolt
Nuts
Seals
Hydraulic nipple
Cover Piston
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Diaphragm unit
De-aeration
De-aeration channels
Initiators
Cover
Control rod
Diaphragm
Guide bush
Alumina inlay
Diaphragm
housing
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6. Initiator 4
7. Pressure transmitter
8. Air supply 13
1
9. Flow switch
14
10. Check (non-return) valves
2 3
11. Suction filter
8
12. Gear pump
9
13. Accumulator
14. Gauge 12
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Check
valve
(NRV)
To and from diaphragm housing
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1 7
2 8
3 9
4 10
5
6 11 29
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Hex.socket head
Cover
capscrew
Filter (breather)
Valve spindle
1e Slide bearing
Retaining ring
Orifice
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Piston unit
6
1. Propelling liquid
2. Piston body
3. Cylinder liner
4. Piston rod
5. Drain
6. Flushing nozzle
7. Thrust piece
8. Chevron seals
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Ventline unit
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Connecting
points
for
Cover
auxiliaries
Nitrogen
Diaphragm
Slurry side
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A. Nitrogen bottle
B. Nitrogen bottle valve
R. Safety relieve, to protect the pulsation
dampener against overload.
Relieve pressure depends on the maximum
allowed pressure of the pulsation dampener.
S. Drain valve
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WARNING
The oil in the connecting piece remains under pressure
5 even when the pump is idle.
1. Non-return valve unit 4 Behind the non-return valves and before the pressure
2. Connecting piece relief valve.
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HMI panel
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HMI panel
1 2
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HMI panel
2
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HMI panel
1
2
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HMI panel
1
HMI overview screen
Touch screen on (1)
“SPEED” than (2) pops-up
with new pop-up with speed 2
setting buttons
“UP” Speed-up
“DOWN” Speed-down
“ZERO” Speed set point
goes down to “0”
Only 2 (two) pop-ups can be
available per screen
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HMI panel
1
HMI propelling liquid screen
1. Touch screen buttons
selection
2. Return to last page 3
3. 15 minutes valve button
needed for priming of the
pump
4. Ability to copy screen to
USB stick.
4
The USB connector is on
the backside of the HMI
inside the cabinet
2
5. Manual filling diapragm
housings
4
5 2
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HMI panel
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HMI panel
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Maintenance preparation
DANGER
DANGER
Always first make sure, that there are no additional forces from the pistons or from the drive train, before turning a
crankshaft in its balance position.
1. Switch of the power from the main motor and lock the switch.
2. Drain the slurry section. Refer to the related chapter.
3. Drain the propelling liquid section. Refer to the related chapter.
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Maintenance preparation
A. Crankshaft of the TZPM pump, the viewpoint is from the driven shaft side
B. Gravity centre of the crankshaft
C. Threaded hole points downwards, indicating the gravity centre of the crankshaft (the holes are made for handling the
crankshaft during assembly)
D+E. Threaded holes
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Maintenance preparation
Procedure
1. Remove the cover of the crankshaft compartment of the frame.
2. Find the threaded hole (C) at the crankshaft in the ring. Refer to the figure above for the viewpoint.
3. Turn the crankshaft, until the threaded hole (C) points downwards, as shown in the figure above.
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Maintenance preparation
Legend
A. Hydraulic connector
B. High pressure hose
C. Operating handles
D. Air pressure supply connector
E. Hydraulic pressure gauge
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Maintenance preparation
Operating instructions
1. Connect the hydraulic connector (A) to the according quick release
connector (“nipple”).
2. Pressurize the hydraulic pump.
3. Turn the operating handle (C) to pressurize the tool to be operated.
4. Check the pressure gauge (E).
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Maintenance preparation
CAUTION
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Legend
A. Diaphragm housing cover
B. Hydraulic tension ring unit
C. Diaphragm housing cover stud bolt
D. Diaphragm housing cover nut
E. Pin (to turn the cover nut)
F. Tension-ring-nut
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Disassembly
Drain the propelling liquid.
Diaphragm housing cover
1. Use the special tool "DIAPHRAGM COVER LIFTING
DEVICE".
2. Remove the two topmost cover nuts.
3. Remove the two lowest cover nuts.
4. Put the "DIAPHRAGM COVER LIFTING DEVICE" to the
diaphragm cover. Make sure that the threaded bolts fit in
the holes.
5. Tighten the "DIAPHRAGM COVER LIFTING DEVICE"
with two screws.
6. Remove the remaining cover nuts.
7. Remove the diaphragm housing cover. Use the push-off
bolts.
8. Remove the diaphragm housing cover seal ring.
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Diaphragm
1. Mark (clearly, with a permanent white marker)
at the diaphragm (B) its top-side position
(=12:00 o-clock) (to enable diagnosis after
removing).
2. Remove the diaphragm (B) from the
diaphragm lousing (A).
3. Loosen and remove the monitoring rod (C)
from the diaphragm (B).
4. Check the monitoring rod (C) for ab-normal
wear or damage.
5. If necessary, then replace the monitoring rod
(C).
6. Check the diaphragm (B).
7. Mark any indicator of ab-normal wear or failure
or damage.
8. Replace the diaphragm (B), according to the
regular maintenance schedule, or if necessary.
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Disassembly
Overview
A. Filling ring
B. Covering ring at the filling ring
C. Diaphragm housing
D. Screw at the filling ring (standard = 6x)
E. Diaphragm
F. Guide bush for the monitoring rod
G. Initiator housing
H. Screw at the covering ring (standard = 3x)
I. Screw for the guide bush (standard = 2x, the
position is 90°turned)
R. De-aeration holes in the housing and in the
filling ring
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Diaphragm
1. Mark (clearly, with a permanent white marker)
at the diaphragm (B) its top-side position
(=12:00 o-clock) (to enable diagnosis after
removing).
2. Remove the diaphragm from the diaphragm
housing (A).
3. Loosen and remove the monitoring rod (C)
from the diaphragm .
4. Check the monitoring rod (C) for ab-normal
wear or damage.
5. If necessary, then replace the monitoring rod
(C).
6. Check the diaphragm (B).
7. Mark any indicator of ab-normal wear or failure
or damage.
8. Replace the diaphragm (B), according to the
regular maintenance schedule, or if necessary.
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Diaphragm-rod unit
1. Loosen the monitoring rod from the diaphragm.
2. Remove the monitoring rod.
3. Check the monitoring rod for ab-normal wear or
damage.
4. Replace the monitoring rod, if necessary.
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Diaphragm-rod unit
1. Clean the thread of monitoring rod (C).
2. Clean the threaded pin (B) of the diaphragm (A).
3. Apply to the threaded pin (B) a nut-lock (like
"LOCTITE NUTLOCK 243").
4. Screw the monitoring rod (C) to the pump
diaphragm (A).
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Diagnosis recommendation:
1 Remove the diaphragm and keep it available for
inspection and diagnosis.
2 Drain the oil of the propelling liquid system of
the involved diaphragm.
3 Do the oil quality laboratory check. Decide how
to proceed, depending on the level of the
contamination of this oil.
Draining and inspection and cleaning of the
"Propelling liquid chamber":
1 Inspect the propelling liquid chamber behind the
diaphragm. Search for any kind of slurry
contamination. Slurry can settle in lower places
and get trapped in clearances between parts and
in de-aeration holes.
2 Clean and dry and inspect all surfaces.
3 Clean and dry and inspect all de-aeration holes.
4 Clean and dry and inspect all plugs and
connections and joints.
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Assembly
ATTENTION
After a diaphragm leakage or damage or
contamination, before starting the assembly, it is
essential to clean and dry all parts.
Cleaning
1. Check that all cleaning preparations are done
properly.
2. Clean and dry the diaphragm housing.
3. Clean and dry all parts.
4. Clean and dry (with high pressure air) the de-
aeration holes at the diaphragm housing (1x), and
(if applicable) the filling ring (2x).
CAUTION
Cleaning all de-aeration holes is essential for
proper de-aeration.
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Mounting
5. Use the "DIAPHRAGM COVER LIFTING DEVICE".
6. Screw the push-off bolts back in 0-position.
7. Check that the cover is hoisted perfectly vertical.
8. Put the diaphragm housing cover to the diaphragm
housing. Make sure that the threaded bolts fit in the
holes.
9. Tighten the most left en right diaphragm cover nut.
10. Screw evenly, until the cover sits flat on the housing via
its raised face (check for even clearance all around).
11. Un-tighten the two hoisting bracket screws.
12. Remove the "DIAPHRAGM COVER LIFTING DEVICE".
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Maintenance Initiator
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Maintenance gearbox
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Disassembly
1. Flush and drain the slurry section.
2. Close and secure the isolation valves in the
slurry suction line and discharge line, to
isolate the working area.
3. Drain the valve.
4. Remove the protection guard from the
connecting nipple (E) at the valve housing
cover (A).
5. Connect the high pressure hose to the
connecting nipple (E) and to the hydraulic
pump unit.
6. Pressurize the hydraulic pump unit.
7. Loosen all the outside lock-nuts (D).
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Preparation
1. Clean and grease all the sealing surfaces and threat
surfaces with suitable grease.
2. ATTENTION!
Make sure that all the push-off bolts (G) at the valve
cover (A) are unscrewed and free from any contact
with the top of the valve housing. Ensure a metal to
metal fit between the valve housing cover and valve
housing.
Place the valve cover
3. Insert a new square gasket into the valve housing
cover (A).
4. Fit the valve housing cover (A) to the valve housing
(H). Use a lifting device. Use the lifting eye (F). Make
sure that the gasket stays well in place.
5. Screw by hand all the outside lock-nuts (D) against the
hexagon surface of the strain-nuts (B).
6. Screw by hand all the inside strain-nuts (B) (including
the lock-nut (D)) on the valve studs (C) against the
pistons.
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Disassembly
1 Release the pressure from the slurry section.
2 Remove the valve housing cover.
3 Remove the square gasket.
4 Remove the compression spring.
5 Remove the conical valve.
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Assembly
1 Insert the conical valve.
2 Insert the compression spring
3 Install a new square gasket.
4 Install the valve housing cover.
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Valve seat
Disassembly
Remove the valve seat, using the hydraulic seat connector
1. Remove the valve housing cover.
2. Remove the conical valve.
WARNING
• Re-install the valve housing cover, to prevent getting hit
by a valve seat.
3. Install the valve housing cover.
4. Remove the protection guard from the hydraulic
connector.
5. Connect the hydraulic pump unit to the connector at the
valve housing.
6. Pressurize the hydraulic pump unit until the valve seat is
loose.
7. Release the pressure from the hydraulic pump unit.
8. Disconnect the hydraulic pump unit.
9. Remove the valve housing cover.
10. Remove the valve seat from the valve housing.
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Assembly
Install the valve seat, using a mechanical tool
1. Clean the valve seat.
2. Clean the bore in the valve housing.
3. Make sure that they are free of dust, paint, or oil.
4. Insert new O-rings into the grooves at the valve seat.
5. Insert valve seat (D) into the bore in the valve housing.
6. Put valve seat tool (C) to the valve seat.
7. Tap valve seat tool (B+C) until the valve seat (D) fits. Use
a hammer (A).
8. Remove the valve seat tool.
9. Make sure that the valve seat is mounted correctly and
tight.
If you can pull out the valve seat by hand, then inspect
the surfaces of the housing and the valve, and repeat
this procedure.
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Overview
A. Valve seat
B. Valve disc
C. Conical valve
D. Compression spring
E. Clamping piece locking screw
F. Guide groove for special tool
G. Clamping piece
H. Valve guide bush
I. Valve cover
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Disassembly
Use the procedure below, to remove the valve guide
bush from the clamping piece.
Check the guide bush:
1. Remove the valve housing cover.
2. Turn the valve housing cover until the clamping
piece (A) is visible.
3. Check the inner surface of the guide bush (D).
4. If the guide bush (A) is worn-out or damaged, then
replace the guide bush (D).
Replace the guide bush:
5. Remove the clamping piece locking screw.
6. Remove the clamping piece (A) from the valve
housing cover.
7. Put the clamping piece (B) into a vice.
8. Put the valve guide bush removal tool (B) into the
grooves (C) of the clamping piece (A).
9. Remove the valve guide bush (D) from the
clamping piece (A). Use a hammer.
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Assembly
1 Heat up the clamping piece to 220°C
2 Put the clamping piece into a vice or press.
3 Put the valve guide bush into the clamping piece.
4 Put the clamping piece to the valve cover.
5 Tighten the clamping piece locking screw.
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5. Put the valve nut wrench (A) to the assembled valve (B).
6. Tighten the valve disc lock nut.
7. Make sure that the valve disc does not turn with the
valve disc lock nut.
8. Make sure that valve disc lock nut and the valve disc are
in full contact.
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Piston unit
A. "PISTON ROD"
B. "THRUST PIECE"
C. Threaded bolts
D. Piston "GUIDE RING"
E. 2x chevron piston seals
"SET OF ROOF SHAPED RINGS"
F. Piston "NUT"
G. "RETAINING PLATE"
H. "CYLINDER LINER"
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DANGER
• Before going on, make sure, that the crankshaft is
blocked against rotating, to avoid risks during working.
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Assembly
Preparation
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Final works
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Priming
Priming
Priming
De-aerating the propelling liquid chambers and positioning the diaphragms in starting position:
6. Partly open drain valve (B) in the discharge line, to maintain in the slurry section a pressure, as specified in the
document "UTILITY CONSUMPTION LIST".
• The pressure of the flush water must be high enough to force the propelling liquid to escape through non-return-valve (F).
7. Open the vent valves (E) of all propelling liquid chambers (located on the rear side top of the diaphragm housing).
The flush water pressure moves all diaphragms in the priming start position (ZSL).
Position marker (M) of each diaphragm rod meets switch (ZSL) and at the GEHO touch panel its light will light on.
8. Check at the GEHO touch panel, that the lights of switch (ZSL) of all pistons light on.
9. Continue with the next chapter, to prime the propelling liquid section. 134
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Priming
1. Refer to the previous chapter to fill the slurry section with flush water and to move each diaphragm with rod indicator (M)
in its priming start position (ZSL).
2. Open the flush water connection (D) in the suction line.
3. Partly open the drain valve (B) in the discharge line, to maintain in the slurry section a pressure, as specified in the
document "UTILITY CONSUMPTION LIST".
• A diaphragm needs pressure at both sides, to move properly.
• The pressure of the flush water must be high enough to force the propelling liquid to escape through non-return-valve 135 (F).
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Priming
5. Open the vent valves (E) in the propelling liquid section of all diaphragms.
6. Open the vent valve (G) to de-aerate the common line at safety relief valve (H) of the propelling liquid system.
7. Push at the GEHO touch panel the button "MAIN SUPPLY VALVE", to open the main supply filling valve (K) for 15
minutes.
8. Close the vent valves (E) and (G), if the propelling liquid, that discharges through valve (F), contains no air bubbles.
9. If necessary, then repeat the steps 7 and 8 until all vent valves (E) of the diaphragms are closed.
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ATTENTION
Avoid that the pump rotates without lubrication.
12. Start the lubrication pump.
13. Check that the lubrication system delivers the oil quantity.
14. Rotate the pump crankshaft manually.
DANGER
• Make sure that the power of the drive motor is switched off. 138
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15. If at the GEHO touch panel one of the lights of switch (ZSH) or (ZSL) of the diaphragm position is lit, then stop rotation
of the pump.
• If indicator (M) meets switch (ZSL), so related switch light is lit, then the propelling liquid system will fill propelling
liquid, until the indicator light is off.
• If indicator (M) meets switch (ZSH), so related switch light is lit, then the propelling liquid automatic control system
will drain propelling liquid, until the switch light is off.
16. Wait until this switch light is off.
17. Repeat steps 10 to 12 until no switch lights light up during rotation of the pump.
18. Turn the pump crankshaft another 2 turns, to check that no switch lights light up. So all chambers are filled properly
with propelling liquid and piston rod indicator (M) of the diaphragm moves properly between switch (ZSL) and switch
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(ZSH).
Weir Minerals Netherlands b.v. Excellent
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Priming
NOTE!
Make sure that the air pressure remains above 450kPa (4,5bar) at all times.
When it goes below the 400kPa or there has been an air pressure trip alarm, than steps
12 to 23 have to be repeated again.
This is because the 2/2-way valves are in a failsafe position, when there is still pressure
left in the slurry side, the diaphragms will go back to their start positions.
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TRAINING TZPM
Questions?
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