Graco REGULUS 003.175-DP Operation manual

USER INFORMATION 6000300E

PLEASE KEEP SAFE FOR FUTURE USE Rev. C

B.6.50.80-GB

Diaphragm pump REGULUS ®3:1

*5$&2

GRACO N.V.

Industrieterrein “Oude Bunders”

Loc. 2206 - Slakweidestraat 31

3630 Maasmechelen - Belgium

Tel.: 32 89 770 700 Fax: 32 89 770 777

The original manufacturer’s nameplate is on the diaphragm pump.

Please compare the data and supplement if possible.

In this manual important information is marked with the following symbols:

Please pass on all safety information to other users.

Information which affects your safety.

Information important to functional running.

Read and observe the operating and safety instructions before

commissioning!

*5$&2

VERFAHRENSTECHNIK GMBH

D-33647 BIELEFELD

[

Translation of nameplate]

AIR OPERATED

DIAPHRAGM PUMP

Model 003.175-DP

Production no.

Year of construction

Material

volume flow max.: 114 l/min.

Temperature max.: 80 °C

Excess pressure max.: 18 bar

Air inlet

pressure max.: 6 bar

Transmission ratio: 3:1

CONTENTS OF USER INFORMATION

Page

OPERATING INSTRUCTIONS

CORRECT USE 2

FUNCTIONAL DIAGRAM 3

DESCRIPTION OF FUNCTIONS 3

COMPONENT PARTS OF APPLIANCE - IMPORTANT INFORMATION 4

LIST OF TOOLS 9

INSTALLATION 10

COMMISSIONING 13

IMPORTANT INFORMATION CONCERNING COMMISSIONING AND OPERATION 14

OPERATION 15

MAINTENANCE AND INSPECTION, REPAIRS 15

TORQUE MOMENTS 21

DECOMMISSIONING 21

SOLVING BREAKDOWNS 22

NOTES 23

Self monitoring 23

User information 23

DIAPHRAGM PUMP 003.175-DP

*5$&2

79990 025029-2/5

We reserve the right to make amendments

Proc. 11.12.98 Voigt B.6.50.80-B-GB

10.99

F22.060.01, Ausg. 07.97

Checked - OPERATING INSTRUCTIONS -

USER INFORMATION Issued

Continued on pages 02 to 23

2 B.6.50.80-B-GB

CONTENTS CONTINUED

Page

TECHNICAL DESCRIPTION OF PRODUCT

DESCRIPTION OF DIAPHRAGM PUMP 01

SUITABILITY; MATERIAL 02

TECHNICAL DATA 03

Key to designation 03

Product range; data 03

Sound emission 04

Construction materials used in surface areas in contact with fluid material 05

Dimensions, connection threads, nominal diameters, extensions 06

NOTES 06

LIST OF REPLACEMENT PARTS

REPLACEMENT DIAPHRAGM PUMPS, REPLACEMENT ACCESSORIES (Extract from sales

catalogue)

Includes:

TEST CERTIFICATE (final inspection)

EC DECLARATION OF CONFORMITY

BRIEF USER INSTRUCTIONS (can be adhered to pump)

BRIEF OPERATING INSTRUCTIONS, WARNING SIGNS

CORRECT USE

The diaphragm pumps 003.175-DP are exclusively manufactured for the usual applications in

surfacing technology (to convey coatings or auxiliary agents or for spraying) or similar work.

Any other purpose above and beyond this is considered incorrect use. We are not responsible for

any damage or injury resulting from this; the user bears the sole responsibility in such cases.

Correct use includes observing the operating, maintenance and inspection conditions and

regulations laid down by us.

003.175-DP diaphragm pumps may only be used, maintained and repaired by personnel familiar

with, and trained to recognise the inherent dangers.

The relevant accident prevention regulations as well as safety and medical rules must be observed.

Unilateral changes to the appliance will cause us to waive our responsibility for any damage or injury

caused.

The user is responsible for the correct installation of the appliance.

3 B.6.50.80-B-GB

FUNCTIONAL DIAGRAM

D DIAPHRAGM PUMP 1 Pressure tank 7 Safety valve

E COMPRESSED AIR SUPPLY 2 Pipeline or hose 8 Sound absorber

F EXHAUST AIR SOUND

SUPPRESSION 3 Pressure regulation valve 9 Vessel

G MATERIAL SUCTION DEVICE 4 Ball cock bl Suction pipeline

H MATERIAL PRESSURE

SYSTEM 5 Ball cock bm Pressure pipeline

I SUPPORT 6 Safety valve bn Sieve

DESCRIPTION OF FUNCTIONS

The compressed air is supplied to the diaphragm pump Dfrom a pressure tank 1via a pipe or

hose 2and a pressure control valve 3. The air supply from the pressure tank to the diaphragm

pump can be interrupted by the ball cock 4.

The other ball cock 5is used for manually releasing condensation (an automatic steam trap would

be preferable here).

The safety valve 6protects the pressure tank against inadmissible rises in air pressure (e.g. in the

event of heating).

There is also a safety valve 7on the diaphragm pump because as a rule the compressed air supply

Eis not installed for the diaphragm pump only, and because it is obligatory.

Fig. 1

Compressor

4 B.6.50.80-B-GB

During operation, compressed air escapes into the atmosphere from the propulsion mechanism of

the diaphragm pump via the integrated sound absorber 8. This unburdens it.

The material (coating or auxiliary agents) is sucked out of a material receptacle 9via the suction

line bl by the diaphragm pump and fed on under pressure via the pipe or hose line bm to the

withdrawal point.

A sieve (dirt trap) bn protects the diaphragm pump against foreign bodies which have unintentionally

entered the material.

COMPONENT PARTS OF APPLIANCE - IMPORTANT INFORMATION

The following must be fulfilled if the appliance is to be considered ready for operation:

DTHE DIAPHRAGM PUMP

For the description of the functions of the diaphragm pump see "Technical Description of

Product B. 6.50.80-P“.

ETHE COMPRESSED AIR SUPPLY

The compressed air supply consists of the compressor, the pressure tank with steam trap,

possibly a compressed air drier and pipeline. The compressed air supply is generally already

available to the user.

 If a compressed air supply must be installed the relevant accident prevention regulations,

safety rules and user information, in particular information from the compressor

manufacturer, must be applied.

There must be a flexible connection between the diaphragm pump and the compressed air line

(avoids fractures caused by vibrations). A hose line is most suitable

 nominal diameter 13 or bigger

 operational pressure = max. mains pressure, preferably•16 bar

 air and local temperature -20 to 50 °C

 free of materials detrimental to paint such as silicone

In areas with a danger of explosion the compressed air line and the hose line must be

electrically conductive (to avoid electrostatic charging).

- leakage resistance < 106Wto earth.

The pressure control valve is in most cases directly fitted to the diaphragm pump.

 efficient rate of flow

at 6 bar and 25 m/s > 114 m³/h

 air inlet pressure 16 bar

 air and local temperature 0° C to 50 °C

5 B.6.50.80-B-GB

It goes without saying that the pressure control valve can be situated between the hose line

and the compressed air line.

The manometer connected 3.1 in function diagram enables exact setting and control of

the air pressure required.

 display range 0 to 16 bar

 air and local temperature 0 to 50 °C

 damped construction

A shutoff mechanism (e.g. ball cock) should be fitted between the pressure control valve and

the hose line in all cases, or between the hose line and the compressed air line. This enables a

quick and safe diaphragm pump switch-off before operating pauses, maintenance work and in

cases of breakdown.

There is no change to the value set on the pressure control valve:

 Nominal pressure 16 bar

 Material CuZn, nickel-plated

For ball cocks the following must be observed: stopcock transverse to flow direction =

pipe is closed off

There are no special requirements as regards the quality of the compressed air supplied to the

diaphragm pump.

 condensation and residue oil from the compressor are trapped

(pressure tank, compressed air filter)

 oiling of compressed air not necessary

 temperature of compressed air 10°C to 50 °C

FEXHAUST AIR SOUND ABSORBER

The sound emissions of a compressed air powered diaphragm pump is damaging to hearing in

the absence of a sound absorber [> 100 dB(A)]. Every diaphragm pump is therefore fitted with

an integrated sound absorber.

Do not use PTFE or hemp to seal connections (causes pressure control valve

malfunction due to residue from compressed air supply).

In painting processes the compressed air must be free of substances which could

lead to the formation of craters (oil, silicone).

- This also applies to component parts of the compressed air supply.

6 B.6.50.80-B-GB

As there is a connection between sound absorption and the formation of ice on the diaphragm

pump control system, the sound level cannot be reduced with a sound absorber as much as

would be desired [not < 70 db(A)].

The diaphragm pump may not be used without the sound absorbing components.

- The decision to wear ear protection depends on the operating pressure and the

resulting sound level.

GMATERIAL SUCTION SYSTEM

The cross section of the suction line is so measured that

material with a kinematic viscosity of up to 750

mm²/s(cSt) can be sucked without difficulty by the

diaphragm pump. Higher viscosity can result in difficulties

ranging from a reduction in the suction performance to

interrupted suction, identifiable by an increasingly greater

fall in pressure during the change of direction (pulsating

pressure).

 Measures for improvement are:

keeping the suction line as short as

possible or a short

suction hose with a larger cross section.



Suction system characteristics are:

 Electrically conductive, maximum permissible resistance 3 . 104 W/m (tested to ISO 8031)

and leakage resistance to earth < 106W.

Suitable for use in hazardous locations.

 The individual parts of the suction system are designed to withstand an excess pressure of

12 bar (- Suitable for suction heights of up to 8.5 m).

 The suction hose and the suction sieve are resistant to the usual solvents in the surface

coating and silicone-free.

 Minimum nominal diameter 25

See "Technical Description of Product B.6.50.80-P-

GB", page

04 for more detailed information on the sound level.

Fig. 2

suction device

ALL METAL PARTS IN CONTACT WITH THE SUCT

ION AREA

MATERIAL ARE MADE OF AUSTENITIC STAINLESS STEEL.

7 B.6.50.80-B-GB



Temperature of material 10 °C to 85 °C

 Sieve mesh size 1.8

For a fixed installation the connections diaphragm pump

material loop pipe or diaphragm pump pressure tank

must be flexible (avoids fracture caused by vibrational

stresses). The characteristics of the suction pipe are the

same as those for the suction equipment.

The diaphragm pump may not be pressurised from the suction side.

- This could destroy important functional components.

The viscosity of thixotropic materials is reduced when

stirred; this can have the effect that the suction

performance of the diaphragm pump is improved

(amongst others).

The agitator is fixed to the pipe of the suction device. The

clamp (bracket) must be fixed to the vessel rim. This

ensures that the agitator propeller is in the right position

in relation to the vessel wall, the base and the suction

pipe, and that frictional contact is impossible.

The agitator is pneumatically driven, max. allowable input pressure 6 bar. Rotational speeds

can be adjusted using the butterfly valve connected. The user should determine the optimal

rotational speed for the material used.

 The agitator propeller is surrounded by an external protection ring

- Techn. Product Description B.18.10.05-P

HMATERIAL PRESSURE SYSTEM

The material pressure system is normally composed of a hose and/or pipeline.

For surface coating, the hose must have the following characteristics:

 Electrically conductive, max. permissible resistance 3 x 104W/m (tested to ISO 8031).

 The inside pipeline coating must be resistant to normal solvents, the outer coating resistant

under certain conditions.

Suction pipe

Suction device

. 4

Immersed agitator parts (shaft and propeller) are made of austenitic stainless steel

(1.4305).

8 B.6.50.80-B-GB



Free from materials detrimental to paint use such as silicone.

 Operational temperature -40 °C to 90 °C or higher.

 Meets the requirements of all relevant standards (design, identification).

 The internal hose fittings must be of austenitic stainless steel, outer fittings of galvanised

and yellow chromated steel.

 Operating pressure > max. allowable excess pressure of diaphragm pump

 Connection thread normally G1.

In most cases the material pressure connection is joined to the diaphragm pump by a pipeline

The connection must be flexible (avoids fracture caused by vibration stresses).

The characteristics of the flexible pressure line:

 Minimum nominal diameter 25

 Operating pressure > max. allowable diaphragm

pump excess pressure

 Operating pressure > max. allowable diaphragm

pump excess pressure

 Operational temperature 10 to 90 °C

 For areas subject to danger of explosion:

Electrically conductive, leakage resistance to

earth < 106W.

 The following applies to the surface coating :

resistant to normal solvents and free from

materials detrimental to paint use such as

silicone.

In an expanded material pressure system and in cases where the pressure system is

influenced by heat (sunrays, heating, etc.) it is necessary to fit a suitable non-return

valve in the pressure pipeline (to prevent damage caused by heat expansion).

F APPLIANCE SUPPORT

A wall fixing and a frame support the 003.175-DP diaphragm pump.

Fig. 5

Pipeline

Flexible

pressure pipeline

Non-return valve

All metal parts of the pressure and suction accessories supplied by us which come in

contact with the material are of austenitic stainless steel. They are suitable for use with

water lacquer.

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