Graymills DDP-1 User Manual

Graymills
ALUMINUM
Air-Operated Double Diaphragm Pumps 1” Model
Operations and
795–90653
GM 2–01
Maintenance Instructions
WARNING/CAUTIONS Read all these SAFETY INSTRUCTIONS BEFORE installing or using this equip– ment. Keep this manual handy for refer– ence/training.
US and Foreign Patents Pending
1” Aluminum Model
Graymills Corporation 3705 N. Lincoln Avenue Chicago, Illinois 60613
773/248–6825 FAX 773/477–8673 www.graymills.com
02632
Table of Contents
Symbols
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawings 23. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 24. . . . . . . . . . .
Graymills Standard Warranty 26. . . . . . . . . . . . . . . . . . . .
Graymills Phone Number 26. . . . . . . . . . . . . . . . . . . . . . .
WARNING
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instruc­tions.
Safety Alert Symbol
SAFETY ALERT
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic vapors can cause extremely serious injury or death from splashing in the eyes, ingestion, or bodily contamination. Observe all the following precautions when you handle hazardous or potentially hazardous fluids.
D Know what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid spill.
D Always wear appropriate clothing and equipment, such as eye protection and breathing apparatus, to
protect yourself.
D Store hazardous fluid in an appropriate, approved container. Dispose of it according to all Local, State,
and Federal guidelines for hazardous fluids.
D Secure the fluid outlet hose tightly into the receiving container to prevent it from coming loose and
improperly draining the fluid.
D Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the
diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 10.
D Use static wire hoses when pumping flammables.
D Keep containers closed when not in use.
2
WARNING
EQUIPMENT MISUSE HAZARD
Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in splashing in the eyes or on the skin, other serious injury, or fire, explosion or property damage.
D This equipment is for professional use only. Observe all warnings. Read and understand all instruction
manuals, warning labels, and tags before you operate this equipment. If you are not sure, or if you have questions about installation or operation, call Graymills Corporation.
D Never alter or modify any part of this equipment; doing so could cause it to malfunction.
D Check all equipment regularly and repair or replace worn or damaged parts immediately.
D Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump
or in the Technical Data on page 24.
D Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa, 8 bar, )
maximum incoming air pressure.
D Be sure that all fluids and solvents used are chemically compatible with the wetted parts shown in the
Technical Data on page 24. Always read the manufacturer’s literature before you use fluid or solvent in the pump.
D Never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
Pressure Relief Procedure on page 11 before you move or lift the pump.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose. If the equipment is not properly grounded, sparking may occur. Sparks can ignite fumes from solvents and the fluid being pumped, dust particles, and other flammable substances, whether you are pumping indoors or outdoors, and can cause a fire or explosion and serious injury and property damage.
D To reduce the risk of static sparking, ground the pump and all other equipment used or located in the
work area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. See Grounding on page 5.
D If you experience any static sparking or even a slight shock while using this equipment, stop pumping
immediately. Check the entire system for proper grounding. Do not use the system again until you have
identified and corrected the problem.
D Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the
fluid is exhausted along with the air. See Air Exhaust Ventilation on page 10.
D Do not smoke in the work area. Do not operate the equipment near a source of ignition or an open flame,
such as a pilot light.
3
SAFETY PRECAUTIONS
CAUTION
D Verify the chemical compatibility of the pump wetted parts and the substance being pumped, flushed or
recirculated. Chemical compatibility may change with temperature and concentration of the chemical(s) within the substance being pumped, flushed or recirculated.
D The pump should not be used for the structural support of the piping system. Be certain system compo-
nents are properly supported to prevent stress on the pump parts.
D Do not allow pump to operate dry for long periods of time; this may cause unnecessary wear or damage
to the pump.
D Maximum temperature limits are based upon mechanical stress only. Certain chemicals will significantly
reduce maximum safe operating temperatures. Consult Graymills for chemical compatibility and temper­ature limits.
United States Government safety standards have been adopted under the Occupational Safety and Health Act. You should consult these standardsparticularly the General Standards, Part 1910, and the Construction Standards, Part 1926.
4
Installation
General Information
D The Typical Installations shown in Figs. 2–4 are only
guides for selecting and installing system components. Contact Graymills for assistance in planning a system to suit your needs.
D Always use Genuine Graymills Parts and Accessories.
D Reference numbers and letters in parentheses refer to
the callouts in the figures and the parts list.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before oper­ating the pump, ground the system as ex­plained below. Also, read the section FIRE AND EXPLOSION HAZARD, on page 3.
To reduce the risk of static sparking, ground the pump and all other equipment used or located in the pumping area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Ground
all of this equipment.
D Pump: Connect a ground wire and clamp as shown in
Fig. 1. Loosen the grounding lug locknut (W) and washer (X). Insert one end of a 12 ga (1.5 mm@) mini­mum ground wire (Y) into the slot in the lug (Z) and tighten the locknut securely. Connect the clamp end of the ground wire to a true earth ground.
Figure 1
1. Read HAZARDOUS FLUIDS on page 2.
2. Use fluids and solvents which are compatible with
the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturers warnings.
Tightening Screws Before First Use
After you unpack the pump, and before you use it for the first time, check and retorque external fasteners. Retorque the fluid cover screws first, then the manifold screws. This keeps the manifolds from interfering with tightening the fluid covers. See the Service section for torque specifica­tions.
After the first day of operation, check and retorque the fasteners again. Although the recommended frequency for retorquing fasteners varies with pump usage, a general guideline is to retorque fasteners every two months.
Y
Z
X
W
02646
D Air and fluid hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to ensure grounding continuity.
D Air compressor: Follow the manufacturer’s recommen-
dations.
D All solvent pails used when flushing: Follow the local
code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.
D Fluid supply container: Follow the local code.
5
Installation
Mountings
CAUTION
The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust Ventilation on page 10.
D Be sure the mounting surface can support the weight of
the pump, hoses, and accessories, as well as the stress caused during operation.
D For all mountings, be sure the pump is bolted directly to
the mounting surface.
D For ease of operation and service, mount the pump so
the air valve cover (2), air inlet, and fluid inlet and outlet ports are easily accessible.
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them during cleaning and repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install a grounded, flexible air hose (A) between the accessories and the 1/2 npt(f) pump air inlet (N). See Fig. 5. Use a minimum 3/8 (9.5 mm) ID air hose. Screw an air line quick disconnect coupler (D) onto the end of the air hose (A), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting until you are ready to operate the pump.
Installation of Remote Pilot Air Lines
1. Connect air line to pump as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors (14) on air motor of pump.
Air Line
WARNING
A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump. Trapped air can cause the pump to cycle unex­pectedly, which could result in serious injury, including splashing in the eyes or on the skin, injury from mov­ing parts, or contamination from hazardous fluids. See Fig. 3.
1. Install the air line accessories as shown in Figs. 2–4 on pages 8 and 9. Mount these accessories on the wall or on a bracket. Be sure the air line supplying the accessories is grounded.
a. Install an air regulator (C) and gauge to control the
fluid pressure. The fluid outlet pressure will be the same as the setting of the air regulator.
NOTE: by replacing the push type connectors, other sizes or types of fittings may be used. The new fittings will require 1/8 in. npt threads.
NOTE: the air pressure at the connectors must be at least 30% of the air pressure to the air motor for the pump to operate.
Fluid Suction Line
1. Use grounded fluid hoses. The pump fluid inlet (R) is 1 npt(f). See Fig. 5. Screw the fluid fitting into the pump inlet securely.
2. If the fluid inlet pressure to the pump is more than 25% of the outlet working pressure, the ball check valves will not close fast enough, resulting in inefficient pump operation.
3. At inlet fluid pressures greater than 15 psi (0.1 MPa, 1 bar), diaphragm life will be shortened.
4. See the Technical Data on page 24 for maximum suction lift (wet and dry).
6
Installation
Fluid Outlet Line
WARNING
A fluid drain valve (J) is required to relieve pressure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure. Install the valve close to the pump fluid outlet. See Fig. 3.
1. Use grounded fluid hoses (L). The pump fluid outlet (S) is 1 npt(f). See Fig. 5. Screw the fluid fitting into the pump outlet securely.
2. Install a fluid drain valve (J) near the fluid outlet. See the WARNING at left, and Figs. 2–4 on pages 8 and 9.
3. Install a shutoff valve (K) in the fluid outlet line.
7
Installation
Figure 2
KEY FOR FIG. 2
A Air supply line B Bleed-type master air valve
(required for pump) C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter G Fluid suction line H Bung adapter J Fluid drain valve (required) K Fluid shutoff valve L Fluid line Y Ground wire (required; see page 5
for installation instructions)
TYPICAL BUNG-MOUNT INSTALLATION
FBE C
A
KL
D
J
Y
H
Figure 3
KEY FOR FIG. 3
A Air supply line B Bleed-type master air valve
(required for pump) C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter G Fluid suction line J Fluid drain valve (required) K Fluid shutoff valve L Fluid line Y Ground wire (required; see page 5
for installation instructions)
G
02648
TYPICAL FLOOR-MOUNT INSTALLATION
FBE C
A
KL
D
J
G
Y
02651
8
Loading...
+ 18 hidden pages