Graymills DDP-5 User Manual
®
Graymills Corporation 3705 N. Lincoln Avenue Chicago, Illinois 60613
773-248-6825 FAX 773-477-8673 www.graymills.com
Air Operated
Double Diaphragm Pumps
Operations and
Maintenance
Instructions
795–08691
GM 12–07
www.graymills.com
WARNING/CAUTIONS
Read all these SAFETY INSTRUCTIONS
BEFORE installing or using this equipment.
Keep this manual handy for reference/training.
DACT50 Acetal NPT Pumps*
PLHG50 Polypropylene Pumps
PQHG50
PLTG50
PQTG50
* These models are certified.
2
Table of Contents
Symbols
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Charts 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graymills Warranty 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graymills Phone Number 21. . . . . . . . . . . . . . . . . . . . . . . .
EC–Declaration of Conformity 22. . . . . . . . . . . . . . . . . . . .
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.
Know what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid spill.
Always wear appropriate clothing and equipment, such as eye protection and breathing apparatus, to
protect yourself.
Store hazardous fluid in an appropriate, approved container. Dispose of it according to all Local, State,
and Federal guidelines for hazardous fluids.
Secure the fluid outlet hose tightly into the receiving container to prevent it from coming loose and
improperly draining the fluid.
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 7.
Use static wire hoses when pumping flammables.
Keep containers closed when not in use.
3
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.
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.
Never alter or modify any part of this equipment; doing so could cause it to malfunction.
Check all equipment regularly and repair or replace worn or damaged parts immediately.
Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump
or in the Technical Data on page 4.
Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7 MPa, 7 bar, )
maximum incoming air pressure.
Be sure that all fluids and solvents used are chemically compatible with the wetted parts shown in the
Technical Data on page 4. Always read the manufacturer’s literature before you use fluid or solvent in
the pump.
Never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
Pressure Relief Procedure on page 10 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.
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 6.
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.
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 7.
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.
4
SAFETY PRECAUTIONS
CAUTION
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.
The pump should not be used for the structural support of the piping system. Be certain system components are properly supported to prevent stress on the pump parts.
Do not allow pump to operate dry for long periods of time; this may cause unnecessary wear or damage
to the pump.
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 standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926.
Technical Data
Maximum fluid working pressure 100 psi (0.7 MPa, 7 bar). . . . . .
Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 to 100 psi (0.18 to 0.7 MPa, 1.8 to 7 bar )
Maximum air consumption 28 scfm (0.672 cubic meters/min.). .
Maximum free flow delivery (1/2 in. ports) 15 gpm (57 l/min). . .
Maximum pump speed 400 cpm. . . . . . . . . . . . . . . . . . . . . . . . . .
Gallons (Liters) per cycle 0.04 (0.15). . . . . . . . . . . . . . . . . . . . . .
Maximum suction lift (water w/buna balls) . . . . . . . . . . . . . . . . . .
15 ft (4.5 m) dry, 25 ft (7.6 m) wet
Maximum size pumpable solids 3/32 in. (2.5 mm). . . . . . . . . . . .
Sound power level (measured per ISO standard 9614–2)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute 77 dBa. . .
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute 95 dBa
Sound pressure level (measured 1 meter from pump)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute 67 dBa. . .
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute 85 dBa
Air inlet size 1/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air exhaust port size 3/8 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid inlet size. 1/2 and 3/4 in. npt(f) or bspt(f). . . . . . . . . . . . . . .
Fluid outlet size. 1/2 and 3/4 in. npt(f) or bspt(f). . . . . . . . . . . . . .
Wetted parts (in addition to ball, seat, duckbill, and diaphragm
materials, which vary by pump)
Polypropylene pumps polypropylene, PTFE. . . . . . . . . . . . . . . . .
Non-wetted external parts polypropylene, stainless steel, polyester
and aluminum (labels), nickel-plated brass
Weight (approximate) 6.5 lb (2.9 kg). . . . . . . . . . . . . . . . . . . . . . .
Hytrel
is a registered trademark of the DuPont Company.
Loctite is a registered trademark of the Loctite Corporation.
5
Installation
The typical Installations in Figure 1 are only guides for selecting and installing system components. Contact Graymills or
your distributor for assistance in planning a system to suit your needs.
Figure 1
ABOVE-GROUND TRANSFER INSTALLATION
A
D
H
N
L
KEY
A Pump
C Electrically conductive air supply line
D Air line quick disconnect
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
L Fluid suction line
Y Ground wire (required; see page 6
P
KEY
A Pump
C Electrically conductive air line to pump
T
E Gun air line shutoff valve
F Air line filter
K
H
U
G Gun air regulator
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
P Circulating valve
R Electrically conductive air line to gun
S Air spray gun
T Electrically conductive fluid return line
U 5-gallon pail
V Agitator
Y Ground wire (required; see page 6
for installation instructions)
E
F
B
G
Y
AIR SPRAY INSTALLATION
E
F
D
G
C
V
Y
A
C
S
R
J
K
9074A
M
55-GALLON BUNG PUMP INSTALLATION
for installation instructions)
KEY
APump
B Bleed-type master air valve
(required for pump)
C Electrically conductive
air supply line
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Pump air regulator
H Fluid drain valve (required)
J Fluid regulator (optional)
K Electrically conductive
fluid supply hose
L Fluid suction line
M Underground storage tank
N Wall mounting bracket
Y Ground wire (required; see page 6
for installation instructions)
A
C
D
Y
K
H
L
9075A
KEY
W Muffler
X Electrically Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust
All wetted and non-wetted pump parts must be
compatible with the fluid being pumped.
VENTING EXHAUST AIR
Z
W
X
6
Installation
Tightening Threaded Fasteners Before
First Use
After unpacking the pump, and before using it for the first
time, check and retorque all external fasteners. See the
Service section for torque specifications. After the first day
of operation, retorque the fasteners again. Although pump
use varies, a general guideline is to retorque fasteners every
two months.
Use a compatible thread sealant on all male threads.
Tighten all connections firmly to avoid air or fluid leaks.
CAUTION
To avoid pump damage, do not overtighten the fittings
to the pump.
Grounding
Figure 2
KEY
APump
H Fluid drain valve (required)
S Dispense valve
T Fluid drain line
Y Fluid section grounding via grounding strip or grounding
screw (required for metal and acetal pumps)
Z Container ground wire (required)
Hose must be conductive.
Dispense valve nozzle must be in contact with container.
Y
Z
GROUNDING A PUMP
Y
A
H
T
S
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded when using
flammables. Before operating the pump,
ground the system as explained below. Also
read the section Fire and Explosion
Hazard on page 3.
When pumping conductive flammable fluids, always
ground the entire fluid system by making sure the fluid
system has an electrical path to a true earth ground (see
Fig. 2). Never use a polypropylene pump with non-conductive flammable fluids as specified by your local fire
protection code.
US Code (NFPA 77 Static Electricity) recommends a
conductivity greater than 50 x 10
(mhos/meter) over your operating temperature range to
reduce the hazard of fire. Consult your fluid supplier to
determine the conductivity or resistivity of your fluid.
The resistivity must be less than 2 x 1012 ohm-centimeters.
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.
–12
Siemans/meter
Attaching the ground wire to the grounding screw (106)
grounds the wetted parts. See grounding screw on page 16.
Fig. 2 shows a recommended method of grounding flammable fluid containers during filling. Ground all of this
equipment:
Pump: Connect the non–clamp end of the ground wire
to the grounding strip or grounding screw, and connect
the clamp end of the ground wire to a true earth ground.
To order a ground wire and clamp, order Part No.
790–100835.
Air and fluid hoses: Use only electrically conductive
hoses.
Air compressor: Follow manufacturer’s recommendations.
Solvent pails used when flushing: Follow the local
code. Use only grounded 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.
Fluid supply container: Follow the local code. Dispense valve nozzle must be in contact with container.
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