PERPETUAL MOTION PUMPS PMP-04 The Prodigy Recovery Pump Instruction Manual
- October 27, 2023
- PERPETUAL MOTION PUMPS
Table of Contents
Operations Manual
The Prophet (PMP-06) & The Prodigy (PMP-04)
Please read/understand entire manual prior to use.
Safety
Warning: Never modify the pump or any of the safety relief systems.
Warning: Pump should never be operated above 150psi.
Warning: It is strictly forbidden to let the liquid enter the compressor;
otherwise, it will cause serious damage to the compressor and possible safety
issues. Pump-creating knocking noises is an indication that it has sucked
liquid into the system, discontinue use immediately.
Warning: Never operate the pump without a safety belt cover in place.
Even with cover in place there are moving components, never touch moving
components while in motion. Keep hands, feet, appendages, wiring, plumbing,
clothing, pets, small children, large children, and other objects clear of
moving parts at all times.
Warning: Pump should be isolated from gas supply when not in use. Isolate
pump (close valves) and relieve pressure in cylinders. Never leave pump
unattended while pressurized or in use.
Notice: Pump is originally shipped from factory with oil installed. Oil
should be replaced after the first 100hrs of use and again after every 400hrs
of use or every 6 months; failure to do so will damage the pump and void
warranty. Pump oil is synthetic AW-46.
Foreword
This instruction manual provides you with the basic methods for correct
installation, commissioning, use, maintenance, and maintenance of the
compressor. Our company does not assume any responsibility for damage to the
machine due to violation of the provisions of the instruction manual,
incorrect operation, maintenance, or failure to use our accessories.
This compressor is a device used to transport toxic, harmful, and flammable
gases. On-site staff must be trained and abide by the relevant safety
regulations. Must establish sound and effective rules and regulations and
operating procedures. Violation of safety laws, regulations, and rules may
cause serious consequences.
The oil-free lubrication mentioned in this compressor means that the cylinder
does not need to be lubricated with oil, but the crankshaft connecting rod and
other moving mechanisms must be oil-lubricated.
The compressor will be seriously damaged due to lack of oil. When overhauling
the compressor, it must be stopped and carried out under no pressure. When
disassembling, the gas inside the machine should be completely evacuated
before proceeding.
This compressor is dedicated to liquified gas, and cannot be used as other gas
compressors, otherwise, it will cause damage to the seal and cause air
leakage. When the compressor is tested for air tightness, it shall not exceed
the rated discharge pressure of the compressor of 10 Bar.
Installation
Electrical
Pumps should be wired in accordance with local governing jurisdictions and
abide by all laws and safe use practices. Wiring should be done by a trained
certified professional electrician.
A safety cut-off switch must be installed at the location of the pump within
reach to allow the operator to shut down the pump operation immediately should
a problem occur. Safety switch must be of code and approved for use where
needed in C1D1 environments. (Available with an installation package from
PMP). Due to the high capacity of the motor, these pumps are designed to be
used with a contactor relay. The contactor relay must be installed outside of
C1D1 environments. For single-phase, locations phase inverter may be used.
Wire the switch, contactor, and pump motor as shown below:
Check the wiring of the pump by running the pump. If the pump runs in the
reverse direction, switch any two legs of the wiring going to the pump. Pump
must run in a dedicated direction. For proper coil wiring and amperage rating
please see the motor nameplate.
Plumbing
PMP-04 “The Prodigy”
The Prodigy pump has an inlet and outlet on opposing sides of the pump. The
Inlet side is the 1.5” tri-clamp connection closet to the end of the pump
(furthest from the motor). The outlet of the pump is on the opposite side
(closest to the motor).
Make connections using standard 1.5” Tri-clamp style seals and clamps. Make
sure seals and clamps are rated for both pressure and solvents intended for
use with your system. For LPG gas Viton or PTFE gaskets are recommended, and
clamps with a minimum rating of 250psi.
Tighten clamps using proper torque recommendations by the clamp manufacturer.
Be sure not to over torque the clamps as this may cause damage.
PMP-06 “The Prophet”
The Prophet pump has inlets and outlets on the same side of the pump. While
looking at the end of the pump with the open connections, the inlet is on the
left, the outlet is on the right. The outlet will also be noted as the side
which has the pressure relief valve mounted.
Make connections using standard 1.5” Tri-clamp style seals and clamps. Make
sure seals and clamps are rated for both pressure and solvents intended for
use with your system. For LPG gas Viton or PTFE gaskets are recommended, and
clamps with a minimum rating of 250psi.
Tighten clamps using proper torque recommendation by clamp manufacture. Be
sure not to over torque the clamps as this may cause damage.
Disconnect
It is important to have service disconnects (valves) on either side of the pump allowing isolation of the pump in the event of a problem, and for isolation when not in use (overnight). When the pump is not to be used for a period of time, close the valves on both sides of the pump, and relieve the pressure in the cylinders. This helps prevent unnecessary loading on piston seals as well as prevents a continuous leak in the event of an unnoticed seal. If piston seals should start to leak, the pump will vent gas through the crankcase vent port. Any indication of gas leaking through the crank vent port; discontinue use immediately and have the pump serviced by certified repair personnel.
Location
Pump should be installed in a well-ventilated room with adequate fire protection in accordance with all local jurisdictions and laws regarding the storage/use of LPG gases.
Usage
To begin pumping LPG gasses open the valves on the inlet side the pump, then
the valve on the outlet side of the pump. Activate the switch to start the
motor. When the motor activates it should reach operational speed (1800RPM)
relatively quickly. If motor/pump seems to be operating slowly or struggling
to achieve speed in a timely manner, stop the pump and check outlet
pressures/outlet blockages preventing the pump from starting.
Once the pump is running it is important to monitor the pump to ensure it
stays within operational boundaries regarding temperature, pressure, and
pressure differential.
Temperature:
Inlet temperature should not exceed 104°F
Outlet temperature should not exceed 266°F
Pressure:
Outlet pressure should not exceed 150psi
Outlet pressure is limited by a recirculating pressure safety valve. If
pressures are continuously at or near 150psi the pump will not operate with
any efficiency. In normal operation pump should not be continuously run above
100psi for a long period of time.
Pressure Differential (PMP-04 The Prodigy Only)
Because the Prodigy pump is only single-stage compression, it should not be
continuously run above 4x pressure differential for a period greater than 60
minutes or run above 8x pressure differential ever. For example, if the inlet
pressure on the pump is 20psi, the outlet should be limited to 80psi for
continuous use or a maximum of 150psi for no more than 60 minutes. If the
inlet pressure is vacuum (-14.5psi) outlet of the pump should be limited to
43.5psi for continuous use or a maximum of 101.5 psi.
In the event differential pressure is exceeding limitations, stop the pump and
remedy the pressure differential. This can be done by either increasing the
pressure at the inlet (heating/evaporating gasses more quickly), or by
decreasing the pressure at the outlet (bleeding pressure or cooling the outlet
vessel to a lower temperature).
Failure to comply with pressure differential limitations will cause premature
damage to the pump and motor.
Completion
When finished with the pumping process shut off the pump using the power
switch. Close both valves (inlet/outlet) isolating the pump and if possible,
release the pressure on the unit, discharging in a safe manner in accordance
with all local governing regulations.
Maintenance/Care
Pump crankcase contains oil that must be routinely changed out every 200hrs. Because there is no runtime indicator, it is imperative that operators keep detailed documentation regarding usage/time. To change the oil open the ball valve on the lower section of the crankcase and drain oil into an approved container. Dispose of according to local governing regulations. Refill the crankcase by removing the fill plug on the side of the crankcase and filling it with synthetic AW-46 oil. Fill with oil until the oil level is ½ the distance on the sight glass.
PMPumps feature dry-seal cylinders which require no oil lubrication. Because of this there will be noticeable wear over time. If pumping becomes substantially less efficient (taking longer to run a process) it is most likely time for a rebuild. Additionally, if gasses are ever-present seeping from the crankcase vent a rebuild is necessary. The crankcase vent helps ventilate pressures inside the crankcase. If piston rings/seals become worn over time they may allow for gasses to seep into the crankcase where they will be vented through the port into the environment. This can provide cause an unsafe working environment, so care must be taken to check this port for signs of gasses daily. Furthermore, the vent fitting in this port can be removed and replaced with an external ventilation routing directing leaking gasses to a safer location outside the building if desired or required by local governing regulations.
Rebuilding of pumps should only be performed by a qualified trained professional. Failure to do so could result in damage to pump or hazardous working conditions.