ProMinent Duodos 10 Assembly And Operating Instructions Manual

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Page 1

Assembly and operating instructions

A1136

Duodos 10 Air-driven double diaphragm pump

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

Original Operating Instructions (2006/42/EC)Part number 985472 BA DUO 011 09/16 EN

Page 2

Supplemental instructions

General non-discriminatory approach

Supplementary information

In order to make it easier to read, this document uses the male form in grammatical structures but with an implied neutral sense. It is aimed equally at both men and women. We kindly ask female readers for their understanding in this simplification of the text.

Please read the supplementary information in its entirety.

Information

This provides important information relating to the cor‐ rect operation of the unit or is intended to make your work easier.

Warning information

Warning information includes detailed descriptions of the haz‐ ardous situation, see

tion’ on page 5

Ä Chapter 2.1 ‘Labelling of Warning Informa‐

The following symbols are used to highlight instructions, links, lists, results and other elements in this document:

More symbols

Symbol Description

Action, step by step.

⇨ Outcome of an action.

Links to elements or sections of these instructions or other applicable documents.

[Button]

List without set order.

Display element (e.g. indicators).

Operating element (e.g. button, switch).

‘Display /GUI’

CODE

Screen elements (e.g. buttons, assignment of function keys).

Presentation of software elements and/or texts.

Page 3

Table of contents

1 Function and identification.................................................... 4

1.1 Function........................................................................ 4

1.2 Identification.................................................................. 4

2 Safety and Responsibility...................................................... 5

2.1 Labelling of Warning Information.................................. 5

2.2 Users' qualifications...................................................... 6

2.3 Intended use................................................................. 7

2.4 Duodos general safety notes........................................ 7

3 Transport and storage......................................................... 10

3.1 Transport.................................................................... 10

3.2 Storage....................................................................... 10

4 Assembly............................................................................ 11

4.1 Installation surroundings............................................. 11

4.1.1 Securing the double diaphragm pump..................... 12

4.2 Ambient conditions..................................................... 13

4.3 Layout of the suction side........................................... 13

4.4 Compressed air supply............................................... 14

5 Operation of the double diaphragm pump.......................... 15

6 Commissioning................................................................... 16

6.1 Checks prior to commissioning................................... 16

6.2 Priming........................................................................ 17

6.3 Interrupting operation.................................................. 17

7 Checking Tightening Torque Prior to Commissioning......... 18

8 Maintenance of the double diaphragm pump...................... 19

8.1 Troubleshooting.......................................................... 19

8.2 Air valve maintenance................................................ 20

8.3 Maintenance of the pilot valve.................................... 23

8.4 Maintenance of the ball valves................................... 24

8.5 Maintenance of the diaphragms................................. 25

9 Disposal of Used Parts....................................................... 27

10 Technical Drawing – Duodos 10......................................... 28

10.1 Exploded drawings and parts lists............................ 29

11 Spare Parts kits................................................................... 33

12 Technical data..................................................................... 34

12.1 Performance curves.................................................. 36

13 Declaration of Conformity................................................... 37

14 Index................................................................................... 38

Page 4

Function and identification

1 Function and identification

1.1 Function

The Duodos is an air-driven double diaphragm pump.

The Duodos is run-dry safe and self-priming.

The pump capacity of the double diaphragm pump can be con‐ trolled by changing the pressure in the air supply. The air control is designed for oil-free operation. The Duodos is optimally suited to the transport of liquid chemicals.

The Duodos double diaphragm pump transports liquids to a dis‐ charge lift of 70 m. As the pump capacity depends greatly on the back pressure, the performance curve must always be observed. At the same time, the differential pressure between the hydraulic and pneumatic sides must not exceed 2 bar. Higher values reduce the service life of the double diaphragm pump.

When selecting the double diaphragm pump you must check its material compatibility. In addition, the density, viscosity, solids con‐ tent and temperature of the liquid being transported must be con‐ sidered.

Permissible values for the medium Temperature of the medium

–

PP version: 5 ... 65 °C

–

PVDF version: -13 ... 93 °C

Viscosity of the medium max. 200 mPas

Solids content: none

1.2 Identification

Type Housing Diaphragm Feed rate l/h Order numbers

Duodos 10 PP

Duodos 10 PVDF

Santoprene

Teflon

0 ... 900 1010793

0 ... 900 1010797

Page 5

2 Safety and Responsibility

2.1 Labelling of Warning Information

Safety and Responsibility

Introduction

These operating instructions provide information on the technical data and functions of the product. These operating instructions pro‐ vide detailed warning information and are provided as clear stepby-step instructions.

The warning information and notes are categorised according to the following scheme. A number of different symbols are used to denote different situations. The symbols shown here serve only as examples.

DANGER! Nature and source of the danger Consequence: Fatal or very serious injuries.

Measure to be taken to avoid this danger.

Description of hazard

– Denotes an immediate threatening danger. If the

situation is disregarded, it will result in fatal or very serious injuries.

WARNING! Nature and source of the danger Possible consequence: Fatal or very serious injuries.

Measure to be taken to avoid this danger.

– Denotes a possibly hazardous situation. If the sit‐

uation is disregarded, it could result in fatal or very serious injuries.

CAUTION! Nature and source of the danger Possible consequence: Slight or minor injuries. Mate‐

rial damage.

Measure to be taken to avoid this danger.

– Denotes a possibly hazardous situation. If the sit‐

uation is disregarded, it could result in slight or minor injuries. May also be used as a warning about material damage.

NOTICE! Nature and source of the danger Damage to the product or its surroundings.

Measure to be taken to avoid this danger.

– Denotes a possibly damaging situation. If the situa‐

tion is disregarded, the product or an object in its vicinity could be damaged.

Page 6

Safety and Responsibility

2.2 Users' qualifications

Type of information Hints on use and additional information.

Source of the information. Additional measures.

–

Denotes hints on use and other useful information. It does not indicate a hazardous or damaging sit‐ uation.

WARNING! Danger of injury with inadequately qualified personnel! The operator of the plant / device is responsible for

ensuring that the qualifications are fulfilled.

If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this could result in dangers that could cause serious injuries and material damage.

– All work on the unit should therefore only be con‐

ducted by qualified personnel.

– Unqualified personnel should be kept away from

the hazard zone

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,

if required, trained in the tasks assigned to him/her and possible dangers that could result from improper behaviour, as well as having been instructed in the required protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructed

person and who has also received additional training specific to the system from ProMinent or another authorised distribution partner.

Trained qualified per‐ sonnel

Electrician Electricians are deemed to be people, who are able to complete work on elec‐

Customer Service depart‐ ment

A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based on his/her training, knowledge and experience, as well as knowledge of pertinent regula‐ tions. The assessment of a person's technical training can also be based on several years of work in the relevant field.

trical systems and recognize and avoid possible hazards independently based on his/her technical training and experience, as well as knowledge of pertinent standards and regulations.

Electricians should be specifically trained for the working environment in which the are employed and know the relevant standards and regulations.

Electricians must comply with the provisions of the applicable statutory direc‐ tives on accident prevention.

Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system.

Page 7

2.3 Intended use

Safety and Responsibility

Note for the system operator The pertinent accident prevention regulations, as well

as all other generally acknowledged safety regulations, must be adhered to!

CAUTION! Intended use Possible consequences if the instructions are not

observed: Minor injuries and material damage

– The pump is intended for liquids transport – The pump is not intended for the transport of gas‐

eous or solid media

– Only use the pump in accordance with the tech‐

nical data and specifications outlined in the oper‐ ating instructions.

– The pump is not designed for use in areas at risk

from explosion

– Only switch the device on if it has been properly

fastened to the ground or its holding fixture.

2.4 Duodos general safety notes

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

Please ensure when handling hazardous substances that you have read the latest safety data sheets pro‐ vided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a sub‐ stance can be re-evaluated at any time based on new findings.

The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associ‐ ated hazard assessment for the workstations affected.

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Safety and Responsibility

WARNING! Hazardous media / contamination of persons and

equipment Possible consequence: Fatal or very serious injuries.

material damage

– Ensure the device is resistant to the media being

conveyed

– Always observe the safety data sheets for the

media to be conveyed. The system operator must ensure that these safety data sheets are available and that they are kept up-to-date

– The safety data sheets for the media being con‐

veyed are always decisive for initiating counter measures in the event of leakage to the media being conveyed

– Observe the general restrictions in relation to vis‐

cosity limits, chemical resistance and density

WARNING! Service life of the diaphragm Possible consequence: Fatal or very serious injuries

The service life of the diaphragm cannot be precisely specified. For this reason, the possibility of fracture and subsequent leakage of liquids must be taken into account.

In addition, you must prevent particles from the defec‐ tive diaphragm reaching the media being conveyed. This can be achieved e.g. by filtration, a hose rupture alarm or other means suitable for the respective process.

CAUTION! Compressed air Before working on the double diaphragm pump, close

the compressed air lines and vent the double dia‐ phragm pump.

Before undertaking any maintenance and repair work, close off the compressed air supply, discharge the compressed air and detach the air supply line from the double diaphragm pump. The line to the discharge side of the double diaphragm pump may be under pressure and must likewise be vented.

CAUTION! Hot surface When conveying hot liquids, the pump can likewise

become hot. Hot surfaces may then be present on the pump. Bear this in mind and take suitable measures to reduce any hazards.

Page 9

Safety and Responsibility

Maximum pump sound pressure level 91 dB Depending on the operating conditions, the maximum

sound pressure level of the device can reach 88 dB ± 3 dB. Bear this in mind and take suitable measures to reduce any impact caused by this sound pressure level. The type and implementation of suitable meas‐ ures depends on the local circumstances and is the responsibility of the system operator.

Check the fastening elements are correctly seated. Before commissioning the double diaphragm pump,

you must check that all fastening elements with sealing rings are correctly seated. The seals may ‘creep’ , so that the fastening elements come loose over time.

In the event of a diaphragm rupture In the event of a diaphragm rupture, the pumped

medium can enter the air system of the double dia‐ phragm pump and from there into the atmosphere. If the pumped medium is a dangerous, harmful or toxic substance, the air outlet must be routed to a suitable area where safe disposal is possible.

Operation in the open air and outdoors

–

Take suitable measures to protect the device from environmental influences when operating outside such as:

–

UV rays

–

Humidity

–

Frost, etc.

Page 10

Transport and storage

3 Transport and storage

n User qualification, transport and storage: trained user, see

Ä Chapter 2.2 ‘Users' qualifications’ on page 6

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

3.1 Transport

Transport

n The pump is protected by means of cardboard packaging n The packaging materials can be recycled n Consider the ambient conditions

3.2 Storage

The device must be completely drained before storage.

Permissible storage conditions:

All versions: + 5 °C ... 60 °C

All versions: < 95% relative air humidity (non-condensing)

Permissible operating conditions:

All versions: - 10 °C ... 40 °C

All versions: < 95% relative air humidity (non-condensing)

Page 11

4 Assembly

4.1 Installation surroundings

Assembly

n User qualification, installation: trained qualified personnel, see

Ä Chapter 2.2 ‘Users' qualifications’ on page 6

CAUTION! Possible consequence: Slight or minor injuries. Mate‐

rial damage.

Observe the permissible ambient conditions.

Upright installation Install the double diaphragm pump upright and plumb.

The valves of the double diaphragm pump operate when loaded by gravity. The valve balls are pressed by gravity into the valve seat and seal it off. Installation outside the vertical axis impairs the function of the valves.

Nominal width of the pipework The threaded connectors must not reduce the nominal

width of the pipework or the double diaphragm pump. The hydraulic connectors have internal and external threads. Do not screw threaded fittings on to the internal thread as this would lead to a reduction of the nominal width.

Keep the suction line short and the number of pipe valves small. Do not reduce the diameter of the suction line. If a rigid pipework system is used, short flexible hose pieces should be inserted between the double diaphragm pump and pipework to protect the double diaphragm pump against vibration and tensile and com‐ pressive forces. The installation of a pulsation damper is recom‐ mended to reduce pulsations in the pumped medium.

Page 12

A1142

2. 3. 4. 5. 6.

10.

11. 12.

13.

14. 16. 17. 18.

19.

15.

Assembly

Fig. 1: Installation surroundings

1. Pulsation damper

2. Flexible connection

3. Pipe connection

4. Manometer

5. Shut-off valve

6. Discharge side

7. Outlet valve

8. Flexible connection

9. Filter/controller module

10. Air dryer (option)

4.1.1 Securing the double diaphragm pump

11. Shut-off valve

12. Compressed air connection

13. Outlet valve

14. Suction side

15. Shut-off valve

16. Manometer

17. Pipe connection

18. Flexible connection

19. Air outlet

Correct securing of the device Only switch the device on if it has been properly fas‐

tened to the ground or its holding fixture. The system operator is responsible for ensuring that the ground and the fittings can hold the device safely and under all operating conditions.

Page 13

4.2 Ambient conditions

4.3 Layout of the suction side

Assembly

NOTICE! Ambient conditions Possible consequence: Property damage and

increased wear and tear

Assembly is to be carried out in the following order. If the pump has to be installed outdoors, then it is to be equipped with protection against sunlight and weather influences.

When positioning the pump, ensure that sufficient room for access is provided for all types of mainte‐ nance work.

Nominal width of the pipework The threaded connectors must not reduce the nominal

Dimensioning of the suction side Layout the suction side with generous dimensions. The

supply of the double diaphragm pump with the liquid to be pumped must be ensured under all load and oper‐ ating statutes. Ensure that the inside diameters of the suction lines are generously sized.

To ensure a maximum service life of the diaphragm, the double diaphragm pump should be installed as close as possible to the pumped medium. If there is a positive priming pressure on the suc‐ tion side of more than 3.0 m water column, the fitting of a back pressure valve in the air outlet of the double diaphragm pump is recommended in order to protect the diaphragm. The minimum air pressure to operate the double diaphragm pump is approximately 1 bar.

Page 14

Assembly

4.4 Compressed air supply

Compressed air supply The double diaphragm pump must be connected to a

compressed air supply in accordance with the current state of the art (ISO 8573-1). We require unoiled, residual oil-free (residual oil from the compressors of maximum 0.1 mg/m³ for HEES-liquids, bio-oils or max. 5mg/m³ permitted for mineral oils) and appropriately dried compressed air (ISO 8573-1, class 4 with 3 °C PDP).

Our recommendation is that the pressure dew point must be at least 10 °C below the ambient temperature.

Suitable compressed air supply The system operator is responsible for the provision of

a suitable compressed air supply. In doing so, observe ISO 8573.

Lubrication of the air valves

Layout the compressed air supply with generous dimensions. Your compressed air supply must be able to supply the double dia‐ phragm pump with sufficient compressed air at any time and under all operating statutes. In this respect also consider the air con‐ sumption of other devices and machinery connected to the same compressed air supply. Considerable pressure fluctuations can occur in the compressed air supply when switching compressed air consumers on and off.

The air pressure of the supplied air must not exceed 7 bar (100 psi). Connect the air inlet of the double diaphragm pump to a com‐ pressed air supply, which is designed to provide the required pump capacity in terms of air quantity and pressure. To guarantee the supply pressure remains within the specified values, a control valve should be connected upstream of the double diaphragm pump.

In there is a rigid air supply line insert a short piece of flexible hose between the double diaphragm pump and the pipework.

The weight of the air supply line, control valve, and filters must not weigh upon the air connection fitting of the double diaphragm pump, rather it must be supported in a suitable manner. Otherwise the double diaphragm pump can be damaged.

Based on their design, the air valve and the pilot valve do not require any lubrication and indeed must not be lubricated.

Moisture in the air line

Water in the compressed air can lead to the exhaust air freezing or the double diaphragm pump icing up. The possible consequences are malfunctions or failure of the double diaphragm pump. It is rec‐ ommended that an air dryer is fitted. This extracts the water from the compressed air and protects against icing up.

Page 15

Operation of the double diaphragm pump

5 Operation of the double diaphragm pump

n User qualification: operation instructed personnel, see

Ä Chapter 2.2 ‘Users' qualifications’ on page 6

The double diaphragm pump is fully integrated into the customer provided system and is then controlled from this system. It is not possible to operate the double diaphragm pump directly.

Page 16

Commissioning

6 Commissioning

n User qualification, commissioning: trained user, see

6.1 Checks prior to commissioning

Ä Chapter

2.2 ‘Users' qualifications’ on page 6

Check the fastening elements are correctly seated. Before commissioning the double diaphragm pump,

you must check that all fastening elements with sealing rings are correctly seated. The seals may ‘creep’ , so that the fastening elements come loose over time.

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

The following checks are to be carried out:

n Ensure that the device has not been damaged during transpor‐

tation or storage. Immediately report any damage to the sup‐ plier

n Check that the air pressure is suitable for the device. n Ensure that the device is suitable for the liquid to be conveyed

and that it will not be attacked.

n Make sure that the temperature of the liquid does not exceed

the recommended temperature range

n Install a manometer in the discharge line if the back pressure

value is unknown

n Under the operating conditions, check the values for flow, pres‐

sure, etc.

n Install a pressure relief valve in the discharge line in order to

protect the pump in the event that a valve is unintentionally closed off or the line is blocked in another way.

Page 17

6.2 Priming

6.3 Interrupting operation

Commissioning

1. To start the double diaphragm pump, open the air value by approximately 1/2 to 3/4 of a turn

Cavitation If opening of the air valve causes the stroke rate

of the double diaphragm pump to increase, but not however the flow volume passing through the double diaphragm pump, then cavitation is the cause. Slightly turn back the air valve so that the air consumption and feed rate of the double dia‐ phragm pump are set in an optimum ratio.

Once the double diaphragm pump is filled with water, open the air valve further to set the required air flow.

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

Rinse through the double diaphragm pump after every use if liquids are used which when stationary have a tendency to form deposits or to solidify. This avoids damage to the double diaphragm pump. Liquid residues remaining in the double diaphragm pump may dry out and form deposits. When restarting the double diaphragm pump, this can lead to problems at the diaphragms and the ball valves. At temperatures below 0 °C the double diaphragm pump must always be completely drained.

Page 18

A2249

3,4 Nm

2,2 Nm

Checking Tightening Torque Prior to Commissioning

7 Checking Tightening Torque Prior to Commissioning

Lasting tightness Check that the threaded connectors have the correct

torque during commissioning.

We also recommend checking these threaded connec‐ tors for correct torque at least once a year because the pump material yields and the tightening torque is then reduced.

Fig. 2: Checking tightening torque prior to commissioning.

1. Tighten all screws (37) to 2.2 Nm.

2. Tighten the screw (11) to 3.4 Nm.

3. Tighten the nut (25) at position I by instinct as there is no torque specified for this nut.

Page 19

Maintenance of the double diaphragm pump

8 Maintenance of the double diaphragm pump

n User qualification, wait: instructed personnel, see

2.2 ‘Users' qualifications’ on page 6

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

Before all work Before all work on the double diaphragm pump, dis‐

connect the double diaphragm pump from the com‐ pressed air supply and the feed and discharge lines, vent and decontaminate. Always observe the safety data sheet for the chemicals to be conveyed.

Ä Chapter

8.1 Troubleshooting

Possible symptoms

n Double diaphragm pump does not cycle n Double diaphragm pump cycles, but does not pump n Double diaphragm pump cycles, but insufficient feed rate n Double diaphragm pump cycles irregularly n Double diaphragm pump vibrates strongly

Cause: Measure:

Suction lift of the system too high For suction lifts above 6 metres, priming of the pump can in most

cases be induced by pre-filling the pump chambers

Too high priming pressure on the suction side of the system

Back pressure of the medium higher than the air pressure

Compressed air pressure higher than the back pressure of the medium

If there is a priming pressure of more than 3 metres water column, pro‐ vide a back pressure valve in the air outlet of the double diaphragm pump

Increase the air inlet pressure to the double diaphragm pump

Adjust the feed air pressure according to the performance curve of the double diaphragm pump. At high stroke rates, cavitation in the medium may occur

Suction line of too small nominal width

Observe the recommendations of the dimensioned drawing for the cross-section of the suction line

Page 20

Maintenance of the double diaphragm pump

Cause: Measure:

Air line of too small nominal width Observe the recommendations for dimensioning of the air inlet line in

the operating instructions of the double diaphragm pump

Air distribution system of the

Dismantle and examine the air valve, pilot valve and control pins

double diaphragm pump

Rigid pipe connections at the

Use flexible connections and a pulsation damper

pump

Exhaust air silencer blocked Remove the silencer. Then clean or de-ice and refit.

Pumped medium in the exhaust air silencer

Dismantle pump chambers and determine whether a diaphragm is broken or a diaphragm flange is loose

Ball valve blocked Dismantle the liquid end of the double diaphragm pump and clear the

blockage

Ball valve or valve seat worn or distorted

Check the ball valves and valve seats for wear and correct seating Replace as necessary

Suction line blocked Clear blockage or check and clean suction line

Discharge line blocked Check for blockage. Valves in the discharge line may be closed

Pump chamber blocked Dismantle the liquid end and inspect the diaphragm chambers of the

double diaphragm pump

8.2 Air valve maintenance

To carry out maintenance on the air valve first discon‐ nect the compressed air supply, vent the double dia‐ phragm pump and remove the air supply line from the double diaphragm pump.

Page 21

10.

11.

24.

23 .

20 .

13 .

14 .

15 .

10 .

16 .

12.

21.

22.

A1137

Maintenance of the double diaphragm pump

Fig. 3: Air valve maintenance

Dismantle the air valve

Reassemble the air valve

1. Remove the 4 screws (11)

2. Remove the air valve housing (1)

3. Remove the seals (8 and 12).

Check the seals and replace as necessary.

4. Using pliers, remove the two safety collars (7) of the air valve and the two end stops (6)

Replace the O-rings (3) as necessary.

5. Pull the piston (2) out of the control cylinder. Ensure that the piston is not scratched or damaged

6. Clean the piston with a soft cloth

7. Check the piston for scratches and signs of wear

Replace the piston as necessary.

8. Check whether the control cylinder (is one part of 2) is dirty on the inside or scratched

Replace the control cylinder and piston (2) as necessary.

9. Insert an end stop (6) with O-ring (3) and safety collar (7) in the air valve housing (1)

10. Remove the new control cylinder and piston (2) from the plastic bag and pull the piston out of the control cylinder

11. Push the six O-rings (3) on to the control cylinder and press the O-rings into the recesses

12. Coat the O-rings thinly with grease prior to fitting the control cylinder in the air valve housing

13. Align the slots in the control cylinder with the slots in the air valve housing (1)

Page 22

Maintenance of the double diaphragm pump

14. Push the piston into the control cylinder up to the already mounted end cover. Ensure this does not cause any scratches.

15. Fit the second end stop complete with an O-ring

16. Fit the remaining safety collar

17. Now you can refit the air valve housing in the pump

18. Place the cover (9), the valve house seal (8), the air valve housing (1), with the five rectangular recesses pointing towards the cover, and the seal (12) with the four hexagon head screws on the double diaphragm pump

19. Push the silencer (14) and the cover (15) on to the screws

20. Fit the washers (10) and the hexagon nuts (16) and tighten the nuts to 3.4 Nm.

21. Switch the compressed air supply back on

The double diaphragm pump is now ready for use.

Page 23

8.3 Maintenance of the pilot valve

10.

11.

24.

23 .

20 .

13 .

14 .

15 .

10 .

16 .

12.

21.

22.

A1137

Maintenance of the double diaphragm pump

To carry out maintenance on the pilot valve first dis‐ connect the compressed air supply, vent the double diaphragm pump and remove the air supply line from the double diaphragm pump.

Fig. 4: Maintenance of the pilot valve

Dismantle the pilot valve

Reassemble the pilot valve

1. Remove both tensioning straps

2. Screw out the outer diaphragm flange, diaphragms and inner diaphragm flange together in an anti-clockwise direction

3. To be able to remove the piston (23) of the pilot valve, you must remove the O-ring (24) at one end of the piston

4. Press the piston out of the control cylinder and inspect the Orings (24) for damage and wear

Replace damaged O-rings

5. To remove the control cylinder, remove the safety collar (22)

6. Examine the inside of the control cylinder (20) of the pilot valve to determine if it is dirty or scratched or has any other defects

If necessary replace the control cylinder (20)

7. Lightly grease the six O-rings (21)

8. Push the control cylinder from the chamfered end of the hole into the pump housing (13)

9. Secure the control cylinder using the safety collar (22).

10. Lightly grease the four inner O-rings of the piston (23)

11. Insert the piston (23) in the control cylinder

Page 24

Maintenance of the double diaphragm pump

12. Pull the remaining O-rings (24) onto the piston

13. Screw the outer diaphragm flange, diaphragms and inner dia‐

14. Fit both tensioning straps

8.4 Maintenance of the ball valves

phragm flange together in a clockwise direction on to the piston rod

An inspection or maintenance is normally indicated if upon starting the double diaphragm pump:

–

primes badly

–

provides less capacity

–

cycles irregularly

–

cycles, but does not pump

Before maintenance work

1. First close the suction line of the double diaphragm pump

2. Close the discharge line of the double diaphragm pump

3. Shut-off the compressed air supply

4. Vent the double diaphragm pump

5. Remove the air supply line from the double diaphragm pump

6. If necessary remove any liquid which may remain in the double diaphragm pump

Now the double diaphragm pump can be removed for

maintenance.

Page 25

39.

37.

34.

33.

37.

32.

38.

A1138

Maintenance of the double diaphragm pump

Ball valve assembly

After maintenance work

Fig. 5: Maintenance of the ball valves

1. Unscrew the screws (37) with which the connection fittings are fastened to the pumping housings

2. Check the surfaces of the valve balls (34) and valve seats (33) for wear and damage

Replace worn or damaged parts.

3. Push the two seals (32) into the grooves of the valve seat (33) and insert the valve seat in the pumping housing

4. Place the valve ball (34) on the valve seat and screw the pipe elbows (39) to the pumping housing

1. Attach the air supply line to the double diaphragm pump

2. Open the compressed air supply

3. Open the discharge line of the double diaphragm pump

4. Open the suction line of the double diaphragm pump

Now the double diaphragm pump can pump again

Check all connectors for leak-tightness

8.5 Maintenance of the diaphragms

Before maintenance work

1. First close the suction line of the double diaphragm pump

2. Close the discharge line of the double diaphragm pump

3. Shut-off the compressed air supply

4. Vent the double diaphragm pump

5. Remove the air supply line from the double diaphragm pump

Page 26

19.

18.

17.

25.

28.

43.

29.

26.

27.

30.

A1139

Maintenance of the double diaphragm pump

6. If necessary remove any liquid which may remain in the

Fig. 6: Maintenance of the diaphragms

1. Remove both tensioning straps (28)

2. Screw out the outer diaphragm flange (27), diaphragms (26)

Assembly the diaphragms in the

reverse sequence

double diaphragm pump

Now the double diaphragm pump can be removed for

maintenance.

and inner diaphragm flange (25) together in an anti-clockwise direction

The inherent curvature of the diaphragms (26) points outwards when fitting.

After maintenance work

Place the outer diaphragm flange (27) on the outside of the diaphragms. When doing so, ensure that the side of the inner diaphragm flange (25) with the larger radius points towards the diaphragms.

4. Tighten the outer diaphragm flange to approx. 3 Nm. The dia‐ phragm must not turn freely with the diaphragm flange when tightening.

1. Attach the air supply line to the double diaphragm pump

2. Open the compressed air supply

3. Open the discharge line of the double diaphragm pump

4. Open the suction line of the double diaphragm pump

Now the double diaphragm pump can pump again

Check all connectors for leak-tightness

Page 27

9 Disposal of Used Parts

Disposal of Used Parts

n User qualification: instructed user, see

Ä Chapter 2.2 ‘Users'

qualifications’ on page 6

NOTICE! Regulations governing the disposal of used parts – Note the national regulations and legal standards

that currently apply in your country

The manufacturer will take back decontaminated used units pro‐ viding they are covered by adequate postage.

Decontaminate the unit before returning it for repair. To do so, remove all traces of hazardous substances. Refer to the Material Safety Data Sheet for your feed chemical.

A current Declaration of Decontamination is available to download on the ProMinent website.

Page 28

198

167

179

II.

III.

IV.

A1140

Technical Drawing – Duodos 10

10 Technical Drawing – Duodos 10

Fig. 7: Technical Drawing – Duodos 10

I. Suction connector II. Discharge connector

III. Optional IV. Compressed air connector

Page 29

10.1 Exploded drawings and parts lists

A1141

Exploded drawing – Duodos 10 PP

Technical Drawing – Duodos 10

Fig. 8: Exploded drawing – Duodos 10

Parts list Duodos 10 PP

Item Quan‐

tity

Part no. Reference

no.

Description Remark

1 1 1043218 095-077-551 Air valve housing Polypropylene, glass fibre-

reinforced

2 1 1043113 031-106-000 Control cylinder and piston, air

Subassembly

valve

3 8 1043183 560-101-360 O-ring Buna-N

6 2 1043233 165-074-551 End stops Polypropylene, glass fibre-

reinforced

7 2 1043124 675-051-115 Safety collar Stainless steel 302/304

8 1 1043247 360-085-360 Seal, air valve housing Buna-N

9 1 1043259 165-072-551 Cover, air inlet Polypropylene, glass fibre-

reinforced

10 8 1043105 901-037-115 Washer 1/4" Stainless steel 302/304

11 4 1043140 170-103-115 Hexagon head screw 1/4-20 5" Stainless steel 302/304

12 1 1043241 360-084-360 Seal, pump housing Buna-N

13 1 1043170 114-019-551 Pump housing Polypropylene, glass fibre-

reinforced

14 1 1043145 530-022-550 Silencer polyethylene

Page 30

Technical Drawing – Duodos 10

Item Quan‐

tity

Part no. Reference

no.

Description Remark

15 1 1043256 165-073-551 Cover, silencer Polypropylene, glass fibre-

reinforced

16 4 1043128 545-003-115 Hexagon head screw 1/4-20

Stainless steel 302/304

UNC

17 2 1043110 449-021-551 Packing gland insert Polypropylene, glass fibre-

reinforced

18 2 1043250 720-031-359 Seal, K-R Urethane

19 1 1043188 685-046-120 Diaphragm piston rod Stainless steel 416

20 1 1043222 755-038-000 Cylinder, pilot valve Subassembly

21 6 1043179 560-066-360 O-ring Buna-N

22 1 1043125 675-047-115 Safety collar, pilot valve cyl‐

Stainless steel 302/304

inder

23 1 1043221 775-038-000 Piston, pilot valve Subassembly

24 6 1043180 560-029-374 O-ring Nitrile

25 2 1043190 612-147-150 Inner diaphragm flange Aluminium

26 2 1043213 286-069-354 Diaphragm Santoprene

27 2 1043208 612-146-552 Outer diaphragm flange Polypropylene

28 2 1043119 200-057-115 Clip Stainless steel 302/304

29 2 1043224 100-002-115 Hammer screw Stainless steel 302/304

30 2 1043127 545-027-337 Hexagon head screw 1/4-28

Steel, chromed

UNF

31 2 1043167 196-145-552 Pumping housing Polypropylene

32 8 1043240 720-032-600 Valve seal PTFE

33 4 1043089 722-073-552 Valve seat Polypropylene

34 4 1043097 050-033-354 Valve ball Santoprene

35 2 1043148 312-095-552 Elbow, suction side Polypropylene

37 24 1043126 706-023-115 Hexagon head screw 10-32

Stainless steel 302/304

UNF x 1"

38 24 1043230 544-004-115 Flange nut 10-32 UNF Stainless steel 302/304

39 2 1043152 312-096-552 Elbow, discharge side Polypropylene

40 4 1043237 720-033-600 Distributor seal PTFE

41 1 1043076 518-127-552 Distributor fitting, horizontal Polypropylene

42 1 1043074 518-128-552 Distributor fitting, vertical Polypropylene

43 2 1043245 360-086-360 Seal, diaphragm Buna-N

55 8 1043126 706-023-115 Screw 10-32x1 Stainless steel 302/304

Page 31

Parts list Duodos 10 PVDF

Technical Drawing – Duodos 10

Item Quan‐

Part no. Reference no. Description Remark

tity

1 1 1043218 095-077-551 Air valve housing Polypropylene, glass fibre-

reinforced

2 1 1043113 031-106-000 Control cylinder and piston, air

Subassembly

valve

3 8 1043183 560-101-360 O-ring Buna-N

6 2 1043233 165-074-551 End stops Polypropylene, glass fibre-

reinforced

7 2 1043124 675-051-115 Safety collar Stainless steel 302/304

8 1 1043247 360-085-360 Seal, air valve housing Buna-N

9 1 1043259 165-072-551 Cover, air inlet Polypropylene, glass fibre-

reinforced

10 8 1043105 901-037-115 Washer 1/4" Stainless steel 302/304

11 4 1043140 170-103-115 Hexagon head screw 1/4-20 5" Stainless steel 302/304

12 1 1043241 360-084-360 Seal, pump housing Buna-N

13 1 1043170 114-019-551 Pump housing Polypropylene, glass fibre-

reinforced

14 1 1043145 530-022-550 Silencer polyethylene

15 1 1043256 165-073-551 Cover, silencer Polypropylene, glass fibre-

reinforced

16 4 1043128 545-003-115 Hexagon head screw 1/4-20

Stainless steel 302/304

UNC

17 2 1043110 449-021-551 Packing gland insert Polypropylene, glass fibre-

reinforced

18 2 1043250 720-031-359 Seal, K-R Urethane

19 1 1043188 685-046-120 Diaphragm piston rod Stainless steel 416

20 1 1043222 755-038-000 Cylinder, pilot valve Subassembly

21 6 1043179 560-066-360 O-ring Buna-N

22 1 1043125 675-047-115 Safety collar, pilot valve cyl‐

Stainless steel 302/304

inder

23 1 1043221 775-038-000 Piston, pilot valve Subassembly

24 6 1043180 560-029-374 O-ring Nitrile

25 2 1043190 612-147-150 Inner diaphragm flange Aluminium

26 2 1043215 286-070-600 Diaphragm PTFE

27 2 1043206 612-146-520 Outer diaphragm flange PVDF

28 2 1043119 200-057-115 Clip Stainless steel 302/304

29 2 1043224 100-002-115 Hammer screw Stainless steel 302/304

30 2 1043127 545-027-337 Hexagon head screw 1/4-28

Steel, chromed

UNF

31 2 1043163 196-145-520 Pumping housing PVDF

32 8 1043240 720-032-600 Valve seal PTFE

Page 32

Technical Drawing – Duodos 10

Item Quan‐

Part no. Reference no. Description Remark

tity

33 4 1043085 722-073-520 Valve seat PVDF

34 4 1043101 050-034-600 Valve ball PTFE

35 2 1043146 312-095-520 Elbow, suction side PVDF

37 24 1043126 706-023-115 Hexagon head screw 10-32

Stainless steel 302/304

UNF x 1"

38 24 1043230 544-004-115 Flange nut 10-32 UNF Stainless steel 302/304

39 2 1043150 312-096-520 Elbow, discharge side PVDF

40 4 1043237 720-033-600 Distributor seal PTFE

41 1 1043075 518-127-520 Distributor fitting, horizontal PVDF

42 1 1043063 518-128-520 Distributor fitting, vertical PVDF

43 2 1043245 360-086-360 Seal, diaphragm Buna-N

55 8 1043126 706-023-115 Screw 10-32x1 Stainless steel 302/304

Page 33

11 Spare Parts kits

Spare parts kit Part no.

Air drive for Duodos 10 1010810

Liquid end for Duodos 10 PP 1010801

Liquid end for Duodos 10 PVDF 1010806

Parts list spare parts kit - Duodos 10

Spare parts kit air drive - Duodos 10 (order no. 1010810):

Spare Parts kits

ItemQuan

tity

Part no. Reference

no.

Description Remark

2 1 1043113 031-106-000 Control cylinder and piston Subassembly

12 1 1043241 360-084-360 Seal, pump housing

8 1 1043247 360-085-360 Seal, air valve housing

3 8 1043183 560-101-360 O-ring

Buna-N

22 1 1043125 675-047-115 Safety collar, pilot valve cylinder Stainless steel 302/304

7 2 1043124 675-051-115 Safety collar Stainless steel 302/304

18 2 1043250 720-031-359 Seal, K-R Polyurethane

23 1 1043222 755-038-000 Piston, pilot valve Subassembly

20 1 1043221 775-038-000 Cylinder, pilot valve Subassembly

Spare parts kit liquid end for Duodos 10 PP (order no. 1010801):

ItemQua

ntity

34 4 1043101 050-033-354 Valve ball

26 2 1043213 286-069-354 Diaphragm

43 2 1043245 360-086-360 Seal, diaphragm

Part no. Reference

no.

Description Remark

Santoprene

Buna-N

32 8 1043240 720-032-600 Valve seal PTFE

40 4 1043237 720-033-600 Distributor seal PTFE

Spare parts kit liquid end for Duodos 10 PVDF (order no. 1010806):

ItemQua

Part no. Reference

ntity

Description Remark

no.

34 4 1043101 050-034-600 Valve ball PTFE

26 2 1043215 286-070-600 Diaphragm PTFE

43 2 1043245 360-086-360 Seal, diaphragm

Buna-N

32 8 1043240 720-032-600 Valve seal PTFE

40 4 1043237 720-033-600 Distributor seal PTFE

Page 34

Technical data

12 Technical data

Technical data – Duodos PP / PVDF

Order no. 1010793 1010797

Pump type Duodos 10 PP Duodos 10 PVDF

Capacity (max.) 900 l/h 900 l/h

Back pressure (max.) 70 m water column 70 m water column

Feed rate/stroke 0.04 l 0.04 l

Temperature of medium 5 ... 65 °C -13 ... 93 °C

Viscosity of medium max. 200 mPa·s max. 200 mPa·s

Suction lift dry 0.5 m 0.5 m

Suction lift moist 5.0 m 5.0 m

Sound pressure level Maximum 88 dB ± 3 dB Maximum 88 dB ± 3 dB

Suction connector "1/2"" NPT male

1/4"" NPT female"

Pressure connector "1/2"" NPT male

1/4"" NPT female"

Compressed air con‐

1/4" NPT female 1/4" NPT female

"1/2"" NPT male

1/4"" NPT female"

"1/2"" NPT male

1/4"" NPT female"

nector

Air consumption

0.5 ... 11 Nm3/h 0.5 ...11 Nm3/h

Max. air pressure 7 bar 7 bar

Minimum air pressure

1 bar 1 bar

approx.

Pump housing PP PVDF

Diaphragm

Valve balls

Santoprene

PTFE

Valve seats PP PVDF

Seals PTFE PTFE

Pump housing Polypropylene, fibreglass-rein‐

Polypropylene, fibreglass-reinforced

forced

Assembly bracket PP PVDF

Weight 2 kg 2.5 kg

Dimensions L x W x H 178 x 140 x 198 mm 178 x 140 x 198 mm

Page 35

Technical data

Operating temperatures

Material Min. op. temperature Max. op. temperature

Santoprene

Thermoplastic elastomers produced in the injection moulding process without a mesh layer. Flexible with high durability. Excellent abrasion hardness.

PTFE -37 °C 100 °C

Chemically inactive and effectively impermeable. Only a very few chemicals are know to react with Teflon®.

PVDF -13 °C 93 °C

Polypropylene 5 °C 65 °C

Repair tools

Tool Size Duodos 10

Spanner 3/8" 9.52 mm X

Spanner 7/16" 11.11 mm X

-23 °C 100 °C

Spanner 1/2" 12.7 mm X

Screw driver 7 mm 7.00 mm X

Page 36

A1160

Technical data

12.1 Performance curves

Performance curves The performance curves are based on the pumping of

water at ambient temperature (approx. 20 °C).

Fig. 9: Performance curve of Duodos 10 / Maximum air consumption 11 m³/h

I. Delivery height (m water column) II. Pump capacity in l/h

Page 37

13 Declaration of Conformity

In accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL, Appendix I, BASIC HEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C.

We,

n ProMinent GmbH n Im Schuhmachergewann 5 - 11 n D - 69123 Heidelberg, Germany,

hereby declare that the product specified in the following, complies with the relevant basic health and safety requirements of the EC Directive, on the basis of its functional concept and design and in the version distributed by us. Any modification to the product not approved by us will invalidate this declaration.

Extract from the EC Declaration of Conformity

Designation of the product: Pneumatic double diaphragm pump

Product type: Duodos

Declaration of Conformity

Serial number: see nameplate on the device

Relevant EC directives: EC Machinery Directive (2006/42/EC)

Harmonised standards applied, in particular:

Date: 01.03.2012

EN ISO 12100 / 2010

EN 809

The EC Declaration of Conformity is available to download on our homepage.

Page 38

Index

14 Index

Action, step by step ........................2

Applied harmonised standards ..............37

Correct and proper use .....................7

Counter measures .........................8

Designation of the product .................37

General non-discriminatory approach ..........2

Links to elements or sections of these instruc‐

tions or other applicable documents ...........2

More symbols ............................2

Non-discriminatory approach ................2

Operation in the open air and outdoors .........8

Protection against sunlight .................13

Protection against the weather ..............13

Relevant EC directives ....................37

Safety data sheet ......................8, 10

Serial number ...........................37

Users' qualifications .......................6

Warning information .......................5

Page 39

Page 40

ProMinent GmbH

Im Schuhmachergewann 5 - 11

69123 Heidelberg, Germany

Telephone: +49 6221 842-0

Fax: +49 6221 842-419

Email: info@prominent.com

Internet: www.prominent.com

985472, 3, en_GB

ProMinent Duodos 10 Assembly And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 Function and identification

1.1 Function

1.2 Identification

2 Safety and Responsibility

2.1 Labelling of Warning Information

2.2 Users' qualifications

2.3 Intended use

2.4 Duodos general safety notes

3 Transport and storage

3.1 Transport

3.2 Storage

4 Assembly

4.1 Installation surroundings

4.1.1 Securing the double diaphragm pump

4.2 Ambient conditions

4.3 Layout of the suction side

4.4 Compressed air supply

5 Operation of the double diaphragm pump

6 Commissioning

6.1 Checks prior to commissioning

6.2 Priming

6.3 Interrupting operation

7 Checking Tightening Torque Prior to Commissioning

8 Maintenance of the double diaphragm pump

8.1 Troubleshooting

8.2 Air valve maintenance

8.3 Maintenance of the pilot valve

8.4 Maintenance of the ball valves

8.5 Maintenance of the diaphragms

9 Disposal of Used Parts

10 Technical Drawing – Duodos 10

10.1 Exploded drawings and parts lists

11 Spare Parts kits

12 Technical data

12.1 Performance curves

13 Declaration of Conformity

14 Index