PP20A-XXX-XXX-EN 粉末泵

CCN 15235526

OPERATOR’S MANUAL

PP20A-XXX-XXX

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE

RELEASED: 6-2-05REVISED: 6-21-10(REV. 04)

2" DRY POWDER DIAPHRAGM PUMP

1:1 RATIO (METALLIC)

READ THIS MANUAL CAREFULLY BEFORE INSTALLING,

OPERATING OR SERVICING THIS EQUIPMENT.

It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.

SERVICE KITS

Refer to Model Description Chart to match the pump mate-rial options.

7102 valve kit for repair of H254PS control valve.

104255 for repair of P 29122-100 fi

lter / regulator.118597-002 spool kit for repair of A212PD 4-way alpha valve.637309-XX for fl uid section repair (see page 6). NOTE: This kit also contains several air motor seals which will need to be replaced.

637421 for air section repair (see page 8).

PUMP DATA

Models . . . . . . . . . . . . . see Model Description Chart for “-XXX”Pump Type . . . . . . . . . Metallic, Dry Powder, Diaphragm Pump Material . . . . . . . . . . . . see Model Description Chart Specifi c Application for pumping powders up to 50 lb. / ft 3Weight . . . PP20A-XAX-XXX . . . . . . . . . . 99.4 lbs (45.1 kgs) PP20A-XSX-XXX . . . . . . . . . . 157.8 lbs (71.6 kgs)Maximum Air Inlet Pressure . . . . . . . . 50 p.s.i.g. (3.4 bar)Maximum Fluidizing Pressure . . . . . . 100 p.s.i.g. (6.9 bar)Maximum Particle Size . . . . . . . . . . . . . 1/4” dia. (6.4 mm)Maximum Temperature Limits (diaphragm / ball / seal materials)

Nitrile . . . . . . . . . . . . . . . . . . . . 10° to 180° F (-12° to 82° C)Santoprene? . . . . . . . . . . . . . . -40° to 225° F (-40° to 107° C)Dimensional Data . . . . . . . . . . . . . . . . . . . see page 12

Mounting Dimension . 9-1/16” x 10-1/16” (230 mm x 256 mm)Noise Level @ 70 p.s.i., 50 c.p.m. . . . . 83.0 db(A)

Tested with 94085 muffl

er assembly installed. The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound Level (L Aeq ) to meet the intent of ANSI S1.13-1971, CAGI-PNEUROP S5.1 using four microphone locations.NOTICE: All possible options are shown in the chart, however, certain combinations may not be recommended. Consult a representative or the factory if you have questions concerning availability.

Figure 1

MODEL DESCRIPTION CHART

PP20A - X X X - X X X

Fluid Connection A - 2 - 11-1/2 N.P .T.F. - 1B - 2 - 11 BSP

C - 2-1/2” Tri-Clamp

Ball Material A - Santoprene

M - Medical Grade Santoprene Fluid Section Service Kit Selection EXAMPLE: Model #PP20A-AAS-AAA Fluid Section Service Kit # 637309-AA

PP20A - XXX - X X X Ball Diaphragm

637309 - X X Fluid Cap & Manifold Material A - Aluminum S - Stainless Steel Diaphragm Material A - Santoprene

M - Medical Grade Santoprene Seat Material A - Santoprene S - Stainless Steel

Hardware Material P - Plated Steel S - Stainless Steel PP20A-XXX-XXX Powder Pump

PP20A-XAX-XXX

PP20A-XSX-XXX

PP20A-CXX-XXX

INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET – BRYAN, OHIO 43506

(800) 495-0276 FAX(800) 892-6276

? 2010

WARNING EXCESSIVE AIR PRESSURE. Can cause per-sonal injury, pump damage or property damage.

Do not exceed the maximum inlet air pressure as

stated on the pump model plate.

Be sure material hoses and other components are able

to withstand fl uid pressures developed by this pump.

Check all hoses for damage or wear. Be certain dispens-ing device is clean and in proper working condition.

WARNING STATIC SPARK. Can cause explosion result-ing in severe injury or death. Ground pump and

pumping system.

Use the pump grounding screw terminal provided.

Use ARO? part no. 94829 ground kit or connect a suit-able ground wire (12 ga. minimum) to a good earth

ground source.

Secure pump, connections and all contact points to

avoid vibration and generation of contact or static

spark.

Consult local building codes and electrical codes for

specifi c grounding requirements.

After grounding, periodically verify continuity of

electrical path to ground. Test with an ohmmeter

from each component (e.g., hoses, pump, clamps, con-tainer, spray gun, etc.) to ground to insure continuity.

Ohmmeter should show 0.1 ohms or less.

Submerse the outlet hose end, dispensing valve or

device in the material being dispensed if possible.

(Avoid free streaming of material being dispensed.)

Use hoses incorporating a static wire.

Use proper ventilation.

Keep infl ammables away from heat, open fl ames and

sparks.

Keep containers closed when not in use.

WARNING Pump exhaust may contain contaminants.

Can cause severe injury. Pipe exhaust away from work

area and personnel.

In the event of a diaphragm rupture, material can be

forced out of the air exhaust muffl er.

Pipe the exhaust to a safe remote location when

pumping hazardous or infl ammable materials.

Use a grounded 1” minimum i.d. hose between the

er.

WARNING HAZARDOUS PRESSURE. Can result in seri-ous injury or property damage. Do not service or

clean pump, hoses or dispensing valve while the sys-tem is pressurized.Disconnect air supply line and relieve pressure from the system by opening dispensing valve or device and / or carefully and slowly loosening and removing out-WARNING injury or property damage. Do not attempt to return a pump to the factory or service center that contains hazardous material. Safe handling practices must comply with local and national laws and safety code requirements.

OPERATING AND SAFETY PRECAUTIONS

READ, UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.

Obtain Material Safety Data Sheets on all materials

WARNING minum wetted parts cannot be used with 1,1,1-trichlo-roethane, methylene chloride or other halogenated hydrocarbon solvents which may react and explode.Check pump motor section, fl uid caps, manifolds and all wetted parts to assure compatibility before using WARNING els containing aluminum wetted parts with food prod-ucts for human consumption. Plated parts can contain CAUTION 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 substances being pumped, fl ushed or circulated. For specifi c fl uid compatibility, CAUTION mechanical stress only. Certain chemicals will signifi -cantly reduce maximum safe operating temperature. Consult the chemical manufacturer for chemical com-patibility and temperature limits. Refer to PUMP DATA CAUTION have been trained for safe working practices, under-stand it’s limitations, and wear safety goggles / equip-CAUTION port of the piping system. Be certain the system com-ponents are properly supported to prevent stress on the pump parts.Suction and discharge connections should be flex-ible connections (such as hose), not rigid piped, and should be compatible with the substance being CAUTION Do not allow pump to operate when out of material for long periods of time.Disconnect air line from pump when system sits idle CAUTION assure compatible pressure rating and longest service life.NOTICE Replacement warning labels are available WARNING

CAUTION

small or restrictive, which will inhibit material flow. The outlet material volume is governed not only by the air supply, but also by the material volume available at the inlet.

Air supply provided should be filtered to provide clean, dry air. A filter capable of filtering out particles larger than 40 microns should be used on the air supply. There is no lubrication required other than the “O” ring lubricant which is applied during assembly or repair.

If lubricated air is present, make sure that it is compatible with the Nitrile “O” rings in the air motor section of the pump.

NOTE: When using air for powder fl

uidization, make sure it is fi ltered and very dry.

INSTALLATION

WARNING

ED TO PREVENT STATIC DISCHARGE. THIS INCLUDES THE PUMP AND ALL INPUT AND OUTPUT SUPPLY LINES AND RELATED SYSTEM DEVICES AND ACCESSO-RIES. FAILURE TO DO SO CAN RESULT IN EXPLOSION AND SERIOUS PERSONAL INJURY.

SYSTEM GROUNDING

Consult local building codes and electrical codes for specifi c requirements.

Must comply with all applicable Local and National codes for such applications.

Grounding is accomplished through the ground lug and strap provided on the pump. Keep the grounding strap as short as possible.

Safe operating conditions are the responsibility of the installer and operator.

Secure the diaphragm pump legs to a suitable surface to avoid damage by excessive vibration.

OPERATING INSTRUCTIONS

START-UP

NOTE: PRIOR TO START-UP , MAKE SURE THE GROUNDING INSTRUCTIONS WERE FOLLOWED.

Connect air supply to (263) main air supply control valve (30 - 40 p.s.i. / 2.1 - 2.8 bar).Turn the air on.

Attach air (or gas) to (248) fi lter / regulator. CAUTION: Do not apply excessive Fluidization Gas* Pressure (refer to note under “General Description”).

At (248), turn on air (or inert gas) supply. There will be a 3 to 8 second time delay, during which the pump will be fluidizing any powder left in the pump from an earlier dispense. This time delay will occur on all start-ups.OPERATION AND ADJUSTMENT

NOTE: Powder type materials can vary in fl ow-ability and the same settings may not work universally. Factors such as den-sity and humidity can require changing the mixture of fl ow rate and fl uidization air and some experimenting should be expected.

IMPORTANT: DO NOT TURN FILTER / REGULATOR (248) OFF.Positive air (or gas) pressure must be supplied to the fi lter / regulator to allow the pump to function. Powder will accu-mulate in the fl uid caps if the pump is not allowed to expel excess material before the pump shuts down. Restart can

1.2.3.4.GENERAL DESCRIPTION

The ARO diaphragm pump off ers high volume delivery even at low air pressure and a broad range of material compat-ibility options available. Refer to the model and option chart. ARO pumps feature stall resistant design, modular air motor / fl uid sections.

Air operated double diaphragm pumps utilize a pressure dif-ferential in the air chambers to alternately create suction and positive fluid pressure in the fluid chambers, valve checks insure a positive fl ow of fl uid.

This diaphragm pump was developed to address the unique problems associated with pumping dry powders, which can “pack out” inside the pump fluid chambers, if not kept in a semi-fl uid state.

This system incorporates the use of special valves to intro-duce air or inert gas* into the fl uid chambers simultaneously to a pumping cycle in a timed sequence which keeps the powder in a fl uidized state during the transfer process.

THEORY OF OPERATION

The main air distribution valve (252) is a double pilot actu-ated four-way valve. It is a slave to the pump major air valve.The distribution valve recognizes the signal from two pump major air valve (259) ports (air dumps). These signals are con-verted into alternating output pressure distributions, which are injected into the fl uid chambers during the pumping cy-cle to fl uidize the powder as the diaphragm moves through the discharge stroke.The fl ow of air supplied to the fl uid chamber is controlled by the (248) filter / regulator. Under normal operating condi-tions, this is the primary control.

When air is supplied to the filter / regulator (248), the dis-tribution valve directs the fl ow of air into the fl uid chamber that will dispense fi rst for 3 to 8 seconds. The time delay then supplies the start signal to open the main pump air supply valve. When the pump diaphragm reaches the end of the discharge stroke, it reverses direction. The distribution valve then shifts and shuts off the fluidizing air to the first fluid chamber as it applies a burst of air to the second fl uid cham-ber and fl uidizes the powder in the second chamber.The air induction orifi ce (76) increases the air velocity prior to injection point because of the orifi ce and it prevents clog-ging of the injector feed line.

NOTE: The restart valve (258) is a bleed valve which will stop the pump and then restart the pump by re-initiating the time delay cycle.

*NOTE: Use of other gases: Using only a gas to operate a 2” pump can be rather expensive because of the high volume needed. Separate air / gas inputs allow the fl uidizing feature of this pump to utilize special inert gas, such as Nitrogen or Argon (air), if necessary and still allow use of standard com-pressed shop air for the pumping function.

The ability to introduce special gas also means special ma-terials could be injected through the fluidization lines. Ap-plications may include such materials as colorants, foaming agents, additives, neutralizers, etc.

AIR AND LUBE REQUIREMENTS

WARNING

pump air supply must be limited to 50 p.s.i.g. (3.4 bar) maximum inlet air pressure.

The air supply line or hose to the pump should be ad-equately sized to carry a sufficient volume of air to the pump. The material inlet supply tubing should not be too

compress some powders to a solid that may cause the pump to fail. The pump should cycle until most of the powder has been purged before it is shut down.

Calibration procedure on initial start-up:

NOTE: Once these parameters are established for your spe-cifi c application, they should not need to be changed.Turn the fl ow and pressure on the (248) fi lter / regulator all the way up.

Slowly decrease pressure and fl ow until pump begins to labor (work harder).

Increase pressure and flow back to a point where the pump begins to run smoothly. This will optimize the air-to-powder mix and will help to establish the most effi-cient working parameters.If the pump should begin to cycle slowly (bog down), the powder can be purged by depressing restart button. This will stop the pump and restart the aeration cycle and allow time to increase air fl ow to the aeration ports for proper material movement.

IMPORTANT

SHUT DOWN PROCEDURE - TO HELP PREVENT PACK-OUT It is good operating practice to dry cycle the pump 5 - 10 seconds at the end of each dispense cycle. This can be ac-complished by closing off the powder source at the suction of the pump or pull wand from material. This will help clear the pump chambers of any residual powder.

NOTICE: Failure to insure proper fl uidization can result in internal parts breakage and pump failure.

MAINTENANCE

Refer to the part views and descriptions as provided on page 6 through 11 for parts identifi cation and Service Kit informa-tion.

Keep good records of service activity and include pump in preventive maintenance program.

Certain ARO “Smart Parts” are indicated which should be available for fast repair and reduction of down time.

Service kits are divided to service two separate dia-phragm pump functions: 1. AIR SECTION, 2. FLUID SEC-TION. The FLUID SECTION is divided further to match typical part MATERIAL OPTIONS.

Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during service disassembly and reassembly.

Before disassembling, empty captured material in the outlet manifold by turning the pump upside down to drain material from the pump.

1.2.3. SCHEMATIC CIRCUIT

Figure 2

A212PD

12

14

42

Left

2

95077Air / Nitrogen

Right 4

41

2Exh 24130

12

H254PS 949773

CP10-B

CP10-B

119309-103

TROUBLE SHOOTING

Product discharged from exhaust outlet.Check for diaphragm rupture.

Check tightness of (14) diaphragm screw.Motor blows air or stalls.

Check (176) check valve for damage or wear.Check for restrictions in valve / exhaust.

Low output volume, erratic fl ow, or no fl ow.Check air supply.

Check for plugged outlet hose.

Check for kinked (restrictive) outlet material hose.

Check for kinked (restrictive) or collapsed inlet material hose.

Suction hose must be a non-collapsing type, conductive and capable of pulling a high vacuum (up to 30” mer-cury).

Check all joints on the inlet manifolds and suction con-nections. Connection must be air tight.

Inspect the pump for solid objects lodged in the dia-phragm chamber or the seat area.

Loctite? and 242? are registered trademarks of Henkel Loctite Corporation ARO? is a registered trademark of Ingersoll-Rand Company

Santoprene? is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P . 271? is a trademark of Henkel Loctite Corporation

Lubriplate? is a registered trademark of Lubriplate Division (Fiske Brothers Refi

ning Company)

TYPICAL CROSS SECTION

Figure 3

PARTS LIST / PP20A-XXX-XXX FLUID SECTION

637309-XX fl

uid section service kits include: Balls (item 22), diaphragms (item 7), and items 19, 70, 144, 175 (listed below) plus items 174 and 94276 Lubriplate? FML-2 grease (page 8).

MATERIAL CODE

[A] = Aluminum [B] = Nitrile [C] = Carbon Steel [Co] = Copper

[MSp] = Medical Grade Santoprene [Sp] = Santoprene [SS] = Stainless Steel

[T] =

PTFE

FLUID SECTION DISASSEMBLY

Remove (61) outlet manifold and (60) inlet manifold.

Remove (22) balls, (19) “O” rings (if applicable) and (21) seats.

Remove (15) fl uid caps.

Remove the (6) diaphragm washer, (7) diaphragm and (5) back-up washer.

NOTE: Do not scratch or mar the surface of (1) diaphragm rod.

1.2.3.4.FLUID SECTION REASSEMBLY

Reassemble in reverse order. Refer to the torque require-ments on page 7.

Clean and inspect all parts. Replace worn or damaged parts with new parts as required.

Lubricate (1) diaphragm rod and (144) “U” cups with Lu-briplate FML-2 grease (94276 grease packet is included in service kit).

Re-check torque settings after pump has been re-started and run a while.

27

15

222119

222119

1

180

131

9

17570 70

175144 1446829 6957614

74

61 (PP20A-XAX-XXX)26

63 74

61 (PP20A-CSX-XXX)

74

61 (PP20A-XSX-XXX)

250

60 (PP20A-XAX-XXX)(PP20A-XSX-XXX)26 63

60 (PP20A-CSX-XXX)

TORQUE REQUIREMENTS LUBRICATION / SEALANTS

NOTE: DO NOT OVERTIGHTEN FASTENERS.

Apply

PTFE tape to threads.(14) diaphragm screws, 65 - 70 ft lbs (88.1 - 94.9 Nm). Apply Loctite? 242? to threads at assembly.(26) screws, 30 - 40 ft lbs (40.7 - 54.2 Nm). Apply Loctite 271? to threads at assembly.

(27) screws, 30 - 40 ft lbs (40.7 - 54.2 Nm). Apply Lubriplate FML-2 grease (94276) to all “O” rings, “U” cups and (131) screws, 35 - 40 ft lbs (47.5 - 54.2 Nm). mating parts.

Apply anti-seize compound to threads and bolt and nut fl

ange heads

which contact pump case when using stainless steel fasteners.

PARTS LIST / PP20A-XXX-XXX FLUID SECTION

FOR THE AIR MOTOR SECTION, SEE PAGES

8 & 9.

Figure 4

Torque Sequence

32

7

51

864

PARTS LIST / PP20A-XXX-XXX AIR MOTOR SECTION

Indicates parts included in 637421 air section repair kit, plus items 70, 144, 175 and 180 (page 6).

MATERIAL CODE

[A] = Aluminum [C] = Carbon Steel [SS] = Stainless Steel [B] = Nitrile [Ck] = Ceramic [U] = Polyurethane

[Br] = Brass [D] = Acetal [Bz] = Bronze

[Sp] = Santoprene

AIR MOTOR SECTION SERVICE

Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.

GENERAL REASSEMBLY NOTES:

Air motor section service is continued from fl

uid section repair.

Inspect and replace old parts with new parts as neces-sary. Look for deep scratches on metallic surfaces, and nicks or cuts in “O” rings.

Take precautions to prevent cutting “O” rings upon instal-lation.

Lubricate “O” rings with Lubriplate FML-2 grease.

Do not over-tighten fasteners, refer to torque specifica-tion block on view.

Re-torque fasteners following re-start.

Service Tools - To aid in the installation of (168) “O” rings onto the (167) pilot piston, use tool #204130-T, available from ARO.

PILOT VALVE DISASSEMBLY

A light tap on (118) should expose the opposite (121) sleeve, (167) pilot piston and other parts.

Remove (170) sleeve. Inspect inner bore of sleeve for damage.

PILOT VALVE REASSEMBLY

Clean and lubricate parts not being replaced from service kit.

Install new (171 and 172) “O” rings. Replace (170) sleeve.

1.2.1.2.Install new (168) “O” rings and (169) seal - Note the lip di-rection. Lubricate and replace (167) pilot piston.

Reassemble remaining parts. Replace (173 and 174) “O” rings.

MAJOR VALVE DISASSEMBLY

Remove (135) valve block and (233) adapter plate, expos-ing (166 and 132) gaskets and (176) checks.

Remove (233) adapter plate, releasing (140) valve insert, (141) valve plate, (199, 200 and 241) gaskets and (231, 243 and 244) “O” rings.

Remove (136) plug and (137) “O” ring, releasing (111) spool.

MAJOR VALVE REASSEMBLY

Install new (138 and 139) “U” cups on (111) spool - LIPS MUST FACE EACH OTHER .

Insert (111) spool into (135) valve housing.

Install (137 and 242) “O” rings on (136) plug and assemble plug to (135) valve housing, securing with (105) screws.Install (140) valve insert, (141) valve plate, (199) gasket and (231, 243 and 244) “O” rings into (135) valve hous-ing. NOTE: Assemble (140) valve insert with “dished” side toward (141) valve plate. Assemble (141) valve plate with part number identifi cation toward (140) valve insert.

Assemble (200 and 241) gaskets and (233) adapter plate to (135) valve housing, securing with (240) screws. NOTE: Tighten screws to 40 - 50 in. lbs (4.5 - 5.6 Nm).

Assemble (132 and 166) gaskets and (176) checks to (101) center body.

Assemble (135) valve housing and components to (101) center body, securing with (134) screws. NOTE: Tighten screws to 40 - 50 in. lbs (4.5 - 5.6 Nm).

3.4.1.2.3.1.2.3.4.5.6.7.

166

240 233244 140 199103168

169118172

171 170

121

174 173167

173 121118

174

243 255 231

101201

137 139 111242128 138 136

105

231 255 132 176

141 200 241 128133

135 134

Figure 5

MAJOR VALVE

PILOT VALVE PART GROUP

TORQUE REQUIREMENTS

NOTE: DO NOT OVERTIGHTEN FASTENERS.

ALL FASTENERS ARE METRIC.

(105) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).(134) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).(240) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).

LUBRICATION / SEALANTS

Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and mating parts. Apply Loctite 271 to threads at assembly.

VIEW A-A

274252271272273

246253248

254260

256

262

256

247249251

259

Figure 6

DIMENSIONAL DATA

PN 97999-1136