ARO PP30A Series Operator's Manual

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Brand:	ARO
Category:	Water Pump
Model:	PP30A Series (Operator's Manual)
File Type:	PDF
File Size:	—
Pages:	12

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INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET - BRYAN, OHIO 43506  (800) 495-0276  FAX (800) 892-6276 © 2018 CCN 15235534 arozone.com OPERATOR’S MANUAL PP30A-XXX-XXX INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE RELEASED: 10-17-05 REVISED: 12-21-18 (REV: G) 3" 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 P39124-100 Filter / Regulator. 118597-2 Spool Kit for repair of A212PD 4-way alpha valve. 637303-XX for Fluid 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). 637374-7 Major Air Valve assembly (see page 9). PUMP DATA Models . . . . . . . . . . . . . see Model Description Chart for “-XXX” Pump Type . . . . . . . . . Metallic, Dry Powder, Diaphragm Pump Material . . . . . . . . . . . . see Model Description Chart Specific Application for pumping powders up to 50 lb. / ft3 Weight . . . PP30A-XAX-AAA . . . . . . . . . . 137.5 lbs (62.4 kgs) PP30A-XSX-AAA . . . . . . . . . . 236.8 lbs (107.4 kgs) Maximum Air Inlet Pressure . . . . . . . . 50 psig (3.4 bar) Maximum Fluidizing Pressure . . . . . . 100 psig (6.9 bar) Maximum Particle Size . . . . . . . . . . . . . 3/8” dia. (9.5 mm) Maximum Temperature Limits (diaphragm / ball / seat materials) Nitrile . . . . . . . . . . . . . . . . . . . . 10° to 180° F (-12° to 82° C) Santoprene® . . . . . . . . . . . . . . -40° to 225° F (-40° to 107° C) PTFE. . . . . . . . . . . . . . . . . . . . . . 40° to 225° F (4° to 107° C) Dimensional Data . . . . . . . . . . . . . . . . . . . see page 12 Mounting Dimension . 10-5/32” x 12-1/16” (258.0 mm x 306.4 mm) Noise Level @ 70 psig, 50 cpm . . . . . . 83.0 dB(A)  Tested with 94085 muffler assembly installed.  The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound Level (LAeq) 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 PP30A - X X X - X X X Fluid Connection A - 3 - 8 NPTF- 1 B - 3 - 11 BSP Ball Material A - Santoprene Fluid Section Service Kit Selection EXAMPLE: Model #PP30A-AAS-AAA Fluid Section Service Kit # 637303-AA PP30A - XXX - A A A Ball Diaphragm 637303 - X X Fluid Cap and Manifold Material A - Aluminum S - Stainless Steel Diaphragm Material A - Santoprene Seat Material A - Santoprene Hardware Material P - Carbon Steel S - Stainless Steel PP30A-XXX-XXX Powder Pump PP30A-XAX-AAA PP30A-XSX-AAA

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PP30A-XXX-XXX (en) WARNING EXCESSIVE AIR PRESSURE. Can cause per- sonal injury, pump damage or property damage. y Do not exceed the maximum inlet air pressure as stated on the pump model plate. y Be sure material hoses and other components are able to withstand fluid 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. y 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. y Secure pump, connections and all contact points to avoid vibration and generation of contact or static spark. y Consult local building codes and electrical codes for specific grounding requirements. y 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. y Submerse the outlet hose end, dispensing valve or device in the material being dispensed if possible. (Avoid free streaming of material being dispensed.) y Use hoses incorporating a static wire. y Use proper ventilation. y Keep inflammables away from heat, open flames and sparks. y 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. y In the event of a diaphragm rupture, material can be forced out of the air exhaust muffler. y Pipe the exhaust to a safe remote location when pumping hazardous or inflammable materials. y Use a grounded 1” minimum ID hose between the pump and the muffler. 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. y 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- let hose or piping from pump. WARNING HAZARDOUS MATERIALS. Can cause serious 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. y Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions. WARNING EXPLOSION HAZARD. Models containing aluminum parts cannot be used with 1,1,1-trichlo- roethane, methylene chloride or other halogenated hydrocarbon solvents which may react and explode. y Check pump motor section, fluid caps, manifolds and all wetted parts to assure compatibility before using with solvents of this type. WARNING MISAPPLICATION HAZARD. Do not use mod- els containing aluminum wetted parts with food prod- ucts for human consumption. Plated parts can contain trace amounts of lead. 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 substances being pumped, flushed or circulated. For specific fluid compatibility, consult the chemical manufacturer. CAUTION Maximum temperatures are based on 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 on page 1 of this manual. CAUTION Be certain all operators of this equipment have been trained for safe working practices, under- stand it’s limitations, and wear safety goggles / equip- ment when required. CAUTION Do not use the pump for the structural sup- port of the piping system. Be certain the system com- ponents are properly supported to prevent stress on the pump parts. y Suction and discharge connections should be flex- ible connections (such as hose), not rigid piped, and should be compatible with the substance being pumped. CAUTION Prevent unnecessary damage to the pump. Do not allow pump to operate when out of material for long periods of time. y Disconnect air line from pump when system sits idle for long periods of time. CAUTION Use only genuine ARO replacement parts to assure compatible pressure rating and longest service life. NOTICE Replacement warning labels are available upon request: “Static Spark & Diaphragm Rupture” pn \ 94080. WARNING = Hazards or unsafe practices which could result in severe personal injury, death or substantial property damage. CAUTION = Hazards or unsafe practices which could result in minor personal injury, product or property damage. NOTICE = Important installation, operation or maintenance information. EXCESSIVE AIR PRESSURE STATIC SPARK HAZARDOUS MATERIALS HAZARDOUS PRESSURE

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pump. The material inlet supply tubing should not be too 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. y 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. y If lubricated air is present, make sure that it is compatible with the “O” rings and seals in the air motor section of the pump. NOTE: When using air for powder fluidization, make sure it is filtered and very dry. INSTALLATION WARNING THE PUMPING SYSTEM MUST BE GROUND- 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 y Consult local building codes and electrical codes for specific requirements. y Must comply with all applicable Local and National codes for such applications. y Grounding is accomplished through the ground lug and strap provided on the pump. Keep the grounding strap as short as possible. y Safe operating conditions are the responsibility of the installer and operator. y 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. 1. Connect air supply to (263) main air supply control valve (30 - 40 psig / 2.1 - 2.8 bar). 2. Turn the air on. 3. Attach air (or gas) to (248) filter / regulator. CAUTION Do not apply excessive Fluidization Gas* Pressure (refer to note under “Theroy Of Opetration”). 4. Verify that the (253) flow control is fully open. 5. 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 flow-ability and the same settings may not work universally. Factors such as den- sity and humidity can require changing the mixture of flow rate and fluidization 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 filter / regulator to allow the pump to function. Powder will accu- mulate in the fluid caps if the pump is not allowed to expel GENERAL DESCRIPTION The ARO diaphragm pump offers 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 / fluid 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 flow of fluid. 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-fluid state. This system incorporates the use of special valves to intro- duce air or inert gas* into the fluid chambers simultaneously to a pumping cycle in a timed sequence which keeps the powder in a fluidized 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 fluid chambers during the pumping cy- cle to fluidize the powder as the diaphragm moves through the discharge stroke. The flow of air supplied to the fluid 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 flow of air into the fluid chamber that will dispense first 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 fluid cham- ber and fluidizes the powder in the second chamber. The air induction orifice (76) increases the air velocity prior to injection point because of the orifice 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 3” pump can be rather expensive because of the high volume needed. Separate air / gas inputs allow the fluidizing 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 EXCESSIVE AIR PRESSURE. Can cause pump damage, personal injury or property damage. The pump air supply must be limited to 50 psig (3.4 bar) maximum inlet air pressure. y The air supply line or hose to the pump should be ad- equately sized to carry a sufficient volume of air to the

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PP30A-XXX-XXX (en) excess material before the pump shuts down. Restart can 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- cific application, they should not need to be changed. 1. Turn the flow and pressure on the (248) filter / regulator all the way up. 2. Slowly decrease pressure and flow until pump begins to labor (work harder). 3. 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 flow 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. CAUTION Failure to insure proper fluidization 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 identification and Service Kit informa- tion. y Keep good records of service activity and include pump in preventive maintenance program. y Certain ARO “Smart Parts” are indicated which should be available for fast repair and reduction of down time. y 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. y Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during service disassembly and reassembly. y Before disassembling, empty captured material in the outlet manifold by turning the pump upside down to drain material from the pump. SCHEMATIC CIRCUIT Figure 2 A212PD 12 14 4 2 Left 2 95077 Air / Nitrogen Right 4 4 1 2 Exh 24130 1 2 H254PS 94977 3 CP10-B CP10-B 119309-103 TROUBLESHOOTING Product discharged from exhaust outlet. y Check for diaphragm rupture. y Check tightness of (14) diaphragm screw. Motor blows air or stalls. y Check (176) check valve for damage or wear. y Check for restrictions in valve / exhaust. Low output volume, erratic flow, or no flow. y Check air supply. y Check for plugged outlet hose. y Check for kinked (restrictive) outlet material hose. y Check for kinked (restrictive) or collapsed inlet material hose. y Suction hose must be a non-collapsing type, conductive and capable of pulling a high vacuum (up to 30” mer- cury). y Check all joints on the inlet manifolds and suction con- nections. Connection must be air tight. y Inspect the pump for solid objects lodged in the dia- phragm chamber or the seat area. y Loctite® and 242® are registered trademarks of Henkel Loctite Corporation y ARO® is a registered trademark of Ingersoll-Rand Company y y Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. y 271™ is a trademark of Henkel Loctite Corporation y y Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) y

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PP30A-XXX-XXX (en) PARTS LIST / PP30A-XXX-XXX FLUID SECTION  637303-XX fluid section service kits include: Balls (item 22), diaphragms (item 7), and items 3, 70, 144, 175, 196 (listed below) plus items 174 and 94276 Lubriplate® FML-2 grease (page 8). MATERIAL CODE [A] = Aluminum [B] = Nitrile [C] = Carbon Steel [Co] = Copper [Sp] = Santoprene [SS] = Stainless Steel [T] = PTFE PARTS LIST Item Description (size) Qty Part No. [Mtl] 1 Rod (1) 97387 [C]  3 “O” Ring (1/8” x 1” OD) (2) Y328-210 [T] 5 Back-Up Washer (2) 94831-1 [C] 9 Washer (3/16” ID x 2” OD x 5/32”) (2) Y13-12-T [SS] 14 Cap Screw (3/4” - 16 x 3-1/4”) (2) Y5-134-T [SS] 68 Air Cap (1) 94030-4 [A] 69 Air Cap (1) 94030-5 [A]  70 Gasket (2) 94100 [B] 74 Pipe Plug (1/4 - 18 NPT x 7/16”) (1) Y17-51-N [C] Item Description (size) Qty Part No. [Mtl] 79 Ground Kit Assembly (not shown) (1) 94829 - - - 131 Screw (M10 x 1.5 - 6g x 120 mm) (4) 94531 [C]  144 “U” Cup (3/16” x 1-3/8” OD) (2) Y186-51 [B]  175 “O” Ring (3/32” x 1” OD) (2) Y325-117 [B]  180 Washer (0.406” ID x 0.031” thick) (4) 94098 [Co]  196 Cushion (2) 94631 [Sp] 250 Screw, Self-Tapping (1/4” - 14 x 1/2”) (2) Y334-104-C [C] SEAT OPTIONS PP30A-XXX-XXX BALL OPTIONS PP30A-XXX-XXX DIAPHRAGM OPTIONS PP30A-XXX-XXX “21”  “22” (3-1/4” diameter)  “7” -XXX Seat Qty [Mtl] -XXX Ball Qty [Mtl] -XXX Diaphragm Qty [Mtl] -AXX 94104-A (4) [Sp] -XAX 94103-A (4) [Sp] -XXA 94091-A (2) [Sp] MANIFOLD CONNECTION / FLUID CAP MATERIAL OPTIONS PP30A-XXX-XXX Aluminum Stainless Steel N.P.T. BSP N.P.T. BSP PP30A-AAX-XXX PP30A-BAX-XXX PP30A-ASX-XXX PP30A-BSX-XXX Item Description (size) Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] 6 Diaphragm Washer (2) 94802 [A] 94802 [A] 94803 [SS] 94803 [SS] 15 Fluid Cap (2) 94768 [A] 94768 [A] 94815 [SS] 94815 [SS] 60 Inlet Manifold (1) 94913 [A] 94913-2 [A] 94212-1 [SS] 94212-2 [SS] 61 Outlet Manifold (1) 94766 [A] 94766-2 [A] 94818 [SS] 94818-2 [SS] EXTERNAL HARDWARE OPTIONS PP30A-XXX-XXX PP30A-XXP-XXX PP30A-XXS-XXX Item Description (size) Qty Part No. [Mtl] Part No. [Mtl] 26 Screw (M12 x 1.75 - 6g x 45 mm) (12) 94412-1 [C] 94412-2 [SS] 27 Screw (M12 x 1.75 - 6g x 60 mm) (16) 94991-1 [C] 94991 [SS] 29 Nut (M12 x 1.75 - 6h) (16) 95053-1 [C] 95053 [SS] FLUID SECTION DISASSEMBLY 1. Remove (61) outlet manifold and (60) inlet manifold. 2. Remove (22) balls and (21) seats. 3. Remove (15) fluid caps. 4. Remove (14) cap screw, (6) diaphragm washer, (7) dia- phragm and (5) back-up washer. NOTE: Do not scratch or mar the surface of (1) diaphragm rod. FLUID SECTION REASSEMBLY y Reassemble in reverse order. Refer to the torque require- ments on page 7. y Clean and inspect all parts. Replace worn or damaged parts with new parts as required. y Lubricate (1) diaphragm rod and (144) “U” cups with Lu- briplate FML-2 grease (94276 grease packet is included in service kit). y Examine torque settings after pump has been re-started and run a while.  Air motor Kit parts, see pages 8 and 9.

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COLOR CODE 15 FOR THE AIR MOTOR SECTION SEE PAGES 8 & 9 68 7 5 21 180 131�� 175 70� 69 27�� 70 22 �144 3� 14� 9 144 � Diaphragm Ball Material Color Color Santoprene Tan Tan 8 6 4 1 2 3 5 7 Torque Sequence 22 21 61 26�� 26�� 250 1� 29� �175 74� 60 (PP30A-XAX-XXX) 26�� 60 (PP30A-XSX-XXX) 250 196 6 LUBRICATION / SEALANTS  Apply Lubriplate FML-2 grease to all “O” rings, “U” cups & mating parts.  Apply Loctite 242 to threads at assembly.  Apply PTFE tape to threads.  Apply anti-seize compound to threads and bolt and nut flange headswhich contact pump  TORQUE REQUIREMENTS  NOTE: DO NOT OVERTIGHTEN FASTENERS. ALL FASTENERS ARE METRIC. (14) diaphragm screws, apply loctite® #271 to threads, 60-70 ft lbd (81.3 - 94.9 Nm.) (26 and 27) Fluid cap / manifold screw 60 - 70 ft lbs (81.3 - 94.9 Nm). (131) Screw 65 - 70 ft lbs (88.1 - 94.9 Nm). PARTS LIST / PP30A-XXX-XXX FLUID SECTION Figure 4  Lubriplate FML-2 is a white food grade petroleum grease.