2:1 Ratio Transfer Pump

Transcription

1 "Teamwork & Communication" Operating Manual with Parts Identification OP232-INST November 8, 1999 Issue 2 GUSMER CORPORATION A Subsidiary of Gusmer Machinery Group, Inc. One Gusmer Drive Lakewood, New Jersey, USA Toll Free (USA & Canada) Phone: (732) Fax: (732) Copyright 1999, GUSMER CORPORATION NOTICE: This manual contains important information for your GUSMER equipment. Read and retain for future reference.

2 NOTICE: The equipment described in this technical manual must only be operated or serviced by properly trained individuals, thoroughly familiar with the operating instructions and limitations of the equipment. For technical service, call your local distributor. Call: FOR-GSMR ( ) for the name and telephone number of your local distributor. NOTICE: All statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty or responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of GUSMER equipment are made without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated or that other measures may not be required. 2 OP232-INST, Issue 2

3 Operating Manual Contents CONTENTS LIST OF FIGURES...4 LIST OF TABLES...4 WARRANTY...5 GENERAL SAFETY INFORMATION...6 ACCEPTABLE EQUIPMENT USES...6 OPERATIONAL SAFETY PROCEDURES...7 DESCRIPTION...8 SPECIFICATIONS...8 OPTIONAL EQUIPMENT...10 INITIAL MACHINE SET-UP...12 INITIAL SETUP PROCEDURE...14 OPERATION...16 DAILY STARTUP PROCEDURES...16 DAILY SHUTDOWN PROCEDURES...16 MAINTENANCE...17 INTRODUCTION...17 DISASSEMBLY...17 PARTS IDENTIFICATION...20 TRANSFER PUMP ASSEMBLY...20 AIR MOTOR ASSEMBLY...22 INSTRUCTION MANUAL DISCREPANCY REPORT /8/99 3

4 LIST OF FIGURES FIGURE 1 MODEL OP232 SIZE PUMP SHOWN... 8 FIGURE 2 TRANSFER PUMP AIR HOSE ASSEMBLY FIGURE 3 BUNG ADAPTOR FIGURE PSI PRESSURE REGULATOR W/ GAUGE FIGURE 5 MATERIAL SUPPLY HOSE FIGURE 6 SWIVEL UNIONS FIGURE 7 FOOT VALVE FIGURE 8 AIR CLEANER FIGURE 9 TYPICAL INSTALLATION FOR A FF FIGURE 10 TYPICAL INSTALLATION FOR A H FIGURE 11 INSTALLING TRANSFER PUMP FIGURE 12 INSTALLING AIR NEEDLE VAVE AND QUICK DISCONNECT FIGURE 13 INSTALLING OUTLET FITTING FIGURE 14 INSTALLING AIR LINE FIGURE 15 INSTALLING GROUND WIRE FIGURE 16 PINCH POINTS FIGURE 17 MOUNTING IN VICE FIGURE 18 FOOT VALVE FIGURE 19 BLEED AIR VALVE FIGURE 20 STRAP LOCATION FIGURE 21 5/16" DIAMETER PINS FIGURE 22 DOWEL PIN FIGURE 23 REMOVING PISTON FIGURE 24 PACKINGS FIGURE 25 TRANSFER PUMP ASSEMBLY (PART NO. OP232C & OP242A), EXPLODED VIEW FIGURE 26 AIR MOTOR ASSEMBLY (PART NO. OP237A), EXPLODED VIEW LIST OF TABLES TABLE 1. TRANSFER PUMP ASSEMBLY, (PART NO. OP232C & OP242A), PARTS TABLE 2. AIR MOTOR ASSEMBLY, (PART NO. OP237A), PARTS OP232-INST, Issue 2

5 Operating Manual with Parts Identification Warranty WARRANTY Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) of Gusmer manufactured parts and equipment (Product) against any defects in material or workmanship for a period of one year from the date of shipment from Gusmer facilities. In the event Product is suspected to be defective in material or workmanship, it must be returned to Gusmer, freight prepaid. If Product is found to be defective in material or workmanship, as determined solely by Gusmer, Gusmer will issue full credit to Customer for the freight charges incurred in returning the defective Product, and either credit will be issued for the replacement cost of the Product or a replacement part will be forwarded no-charge, freight prepaid to Customer. This warranty shall not apply to Product Gusmer finds to be defective resulting from: installation, use, maintenance, or procedures not accomplished in accordance with our instructions; normal wear; accident; negligence; alterations not authorized in writing by Gusmer; use of look alike parts not manufactured or supplied by Gusmer; or Product used in conjunction with any other manufacturer's pumping or proportioning equipment. Further, the terms and conditions of this warranty shall not apply to services or repairs made to Product by any third party not authorized in writing by Gusmer. For such Product, a written estimate will be submitted to Customer at a nominal service charge, itemizing the cost for repair. Disposition of Product will be done in accordance with the terms stated on the written estimate. The warranty provisions applied to product that are not manufactured by Gusmer will be solely in accordance with the warranty provided by the original manufacturer of the product. GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF, OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY PARTICULAR PURPOSE. CREDIT FOR, OR REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESSED OR IMPLIED ON ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED BY AN OFFICER OF GUSMER. Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, or special indirect, incidental or consequential damages. Further, Gusmer shall have no liability for any expenses including, but not limited to personal injury or property damage resulting from failure of performance of the product, use of the product, or application of the material dispensed through the product. Any information provided by Gusmer that is based on data received from a third source, or that pertains to product not manufactured by Gusmer, while believed to be accurate and reliable, is presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Gusmer through the sale, lease, or rental of Product in no way expresses or implies a license for the use of, nor encourages the infringement of any patents or licenses. To insure proper validation of your warranty, please complete the warranty card and return it to Gusmer within two weeks of receipt of equipment. Revised 11/12/98 11/8/99 5

6 GENERAL SAFETY INFORMATION It is necessary to understand and follow the instructions in this manual to insure proper and safe operation of the equipment. As with most mechanical equipment, certain safety precautions must be taken when the equipment discussed in this manual is operated or serviced. Severe bodily injury or damage to equipment and property may result if the instructions and precautions listed throughout this manual are not followed. Needless to say, sufficient guidelines cannot be developed to eliminate the need for good common sense in the use and servicing of this equipment, and in the use and application of the products, this equipment has been designed to process. Users of this equipment must therefore, make their own determination as to the suitability of the information contained in this manual to their specific operation and requirements. There should be no assumption made that the safety measures and instructions contained herein are allinclusive, and that other safety measures may not be required for specific use or application. The following safety guidelines are generally applicable to the safe and efficient use of the equipment. Acceptable Equipment Uses The equipment is designed for the dispensing of polyurethane foams, two-component coating systems, and some two-component epoxy systems, specifically polyureas. Under no circumstances should any acid or corrosive chemicals be used in the unit. Consult GUSMER if there is any doubt about the compatibility of the chemical system to be used in this equipment. Any use of this equipment other than as indicated above constitutes misuse unless express written approval is obtained from GUSMER. 6 OP232-INST, Issue 2

7 Operating Manual with Parts Identification General Safety Information Operational Safety Procedures This safety information will not be repeated in the text of this manual. The symbols pertaining to this information will appear where appropriate to alert the operator to potential hazards. Solvents and Chemicals WARNING: THE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BETAKEN SO AS TO AVOID EXCEEDING THE THRESHOLD LIMIT VALUE (TLV) OF THE PRODUCTS BEING USED, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) OR OTHER QUALIFIED AGENCY. INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS. High Voltage WARNING: TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND INTERRUPTING SUPPLY VOLTAGE AT THE SOURCE. THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY A QUALIFIED ELECTRICIAN. High Pressure WARNING: THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS BODILY INJURY FROM HYDRAULIC INJECTION OF FLUID, NEVER OPEN ANY HYDRAULIC CONNECTIONS OR SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO. Personal Protective Equipment WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT. THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES, SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED. High Temperature WARNING: THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES. TO PREVENT SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL, NEVER ATTEMPT TO SERVICE THE EQUIPMENT BEFORE ALLOWING IT TO COOL. WARNING: FAILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE LISTED HAZARDS Warning 11/8/99 7

8 DESCRIPTION Specifications Figure 1 Model OP232 Size Pump Shown (Dimensions in parenthesis are for Model OP242A 3/4 Length Pump) 8 OP232-INST, Issue 2

9 Operating Manual Description Pressure Ratio: 2.25:1 Output (Cont. duty): Output (Int. duty): 5.5 gpm (20.8 liters) 11 gpm (41.6 liters) Cycles Per Gallon: 18.5 Cycles Per Liter: 4.88 Stroke: Air Pressure: Air Inlet: Fluid Output: Air Consumption: Weight: Wetted Parts: 4 in. (10.16 cm) 180 psi (1,241 kilopascals) 1/4 NPT (F) 3/4 NPT (F) 2.0 cfm per gallon psi cc/sec per liter kilopascals 30 lbs (13.6 kg) Stainless Steel, Viton, Teflon 11/8/99 9

10 Optional Equipment Transfer Pump Air Hose Assembly OP234-F OP234-H Figure 2 Transfer Pump air Hose Assembly Bung Adaptor OP233A Figure 3 Bung Adaptor PSI Pressure Regulator W/ Gauge OP235 1/4 NPT Inlet 1/4 NPT (F) Swivel Outlet Figure PSI Pressure Regulator W/ Gauge Material Supply Hoses OP6157A-A-10 OP6157A-10 OP5157-A OP5157 3/4 x 10' A Supply Hose (1/2 NPT) 3/4 x 10' R Supply Hose (3/4 NPT) 1" x 10' A Supply Hose (3/4 NPT) 1" x 10' R Supply Hose (1 NPT) Figure 5 Material Supply Hose 10 OP232-INST, Issue 2

11 Operating Manual Description Swivel Unions OP /2 NPT x 1/2 NPT (F) /2 NPT x 3/4 NPT (F) OP /4 NPT x 1/2 NPT (F) /4 NPT x 3/4 NPT (F) OP /4 NPT x 1" NPT (F) " NPT 3/4 NPT (F) /2 NPT x 1" NPT (F) Figure 6 Swivel Unions Foot Valve OP /1 NPT (F) Figure 7 Foot Valve Air Cleaner 0571A 1/4 NPT (F) Inlet & Outlet Figure 8 Air Cleaner 11/8/99 11

12 INITIAL MACHINE SET-UP Figure 9 Typical Installation for a FF OP232-INST, Issue 2

13 Operating Manual with Parts Identification Initial Machine Set-Up Figure 10 Typical Installation for a H /8/99 13

14 Initial Setup Procedure On custom installations consult Figure 1 for any dimensions required. 1. Make sure the Gasket (Part No. OP ) is in place on the threaded end of the Adaptor and screw the Bung Adaptor tightly into the bunghole of the drum. With the second Gasket in place, insert the Transfer Pump through the adaptor, and lock it in place. Figure 11 Installing Transfer Pump 2. Use thread sealer on the male threads of the Air Needle Valve and Quick Disconnect Plug. Figure 12 Installing Air Needle Vave and Quick Disconnect 3. Use thread sealer on the male Outlet Fitting (not supplied as part of the pump assembly) and thread the fitting into the outlet port. Figure 13 Installing Outlet Fitting 14 OP232-INST, Issue 2

15 Operating Manual with Parts Identification Initial Machine Set-Up 4. Install air lines as required. Gusmer recommends using a 3/8" ID or larger air line to deliver air to the Transfer Pump. Figure 14 Installing Air Line WARNING: WHENEVER YOU ARE USING, FLAMMABLE MATERIALS ALWAYS CONNECT A GROUND WIRE TO THE PUMP AIR MOTOR. CONSULT THE NATIONAL ELECTRIC CODE, STATE, AND LOCAL CODES FOR ADDITIONAL INFORMATION. 5. Connect Ground Wire to the Grounding Lug in accordance with National, State and Local Electric Codes. The Transfer Pump installation is complete. Figure 15 Installing Ground Wire WARNING: THE TRANSFER PUMP INCORPORATES A WET TUBE TO PREVENT BUILD-UP OF CHEMICAL AND DIRT ON THE PUMP SHAFT, WHICH WOULD DAMAGE THE PACKINGS AS THE SHAFT MOVES THROUGH THEM. THE WET TUBE MUST BE FULL WHEN STORING A TRANSFER PUMP OUTSIDE THE PROTECTED ENVIRONMENT OF A SEALED DRUM WITHOUT FIRST THOROUGHLY FLUSHING AND CLEANING THE PUMP. WHEN INSTALLING A TRANSFER PUMP INTO A PARTIALLY FILLED DRUM WHERE THE LIQUID LEVEL IS BELOW THE TOP OF THE WET TUBE, MANUALLY FILL THE TUBE WITH THE PROPER CHEMICAL PRIOR TO INSERTING THE TRANSFER PUMP INTO THE DRUM. IF A DRUM WITH A TRANSFER PUMP INSTALLED TIPS OVER, INSURE THAT THE WET TUBE IS FULL AFTER RIGHTING THE DRUM. THE TRANSFER PUMP PUMPS BOTH RESIN AND ISOCYANATE. TO REDUCE THE POSSIBILITY OF INADVERTENTLY USING THE TRANSFER PUMP WITH THE WRONG CHEMICAL GUSMER RECOMMENDS COLOR CODING THE TRANSFER PUMPS RED FOR ISOCYANATE AND BLUE FOR RESIN. 11/8/99 15

16 OPERATION Daily Startup Procedures 1. Determine that the Air Needle Valve is closed. 2. Connect the air line quick disconnect coupler to the Transfer Pump. 3. Turn on the main air supply. 4. Slowly open the Air Needle Valve until the Transfer Pump runs slowly Use the Air Needle Valve to control the pump speed. WARNING: NEVER ALLOW THE PUMP TO RUN DRY OF PUMPING MATERIAL. A DRY PUMP WILL QUICKLY ACCELERATE TO A HIGH SPEED AND POSSIBLY CAUSE PERSONAL INJURY AND/OR DAMAGE THE PUMP. IF THE PUMP ACCELERATES QUICKLY OR STARTS RUNNING TOO FAST, STOP IT IMMEDIATELY AND INSPECT. DO NOT ATTEMPT TO OPERATE THE PUMP WHEN IT IS NOT SECURLY MOUNTED IN A DRUM. KEEP HANDS CLEAR OF THE AREA SHOWN IN FIGURE 16 ALL TIMES AS PERSONAL INJURY MAY OCCUR. Figure 16 Pinch Points Daily Shutdown Procedures 1. Disconnect the air line coupler. 2. After the air pressure has bled off, close the air line Needle Valve. For Extended Period Shutdown Flush, disassemble and thoroughly clean the Transfer Pump before storing in a dry place. 16 OP232-INST, Issue 2

17 Operating Manual with Parts Identification Maintenance MAINTENANCE Introduction WARNING: TO AVOID PERSONAL INJURY, ALWAYS DISCONNECT THE AIR COUPLER AND RELIEVE ALL AIR AND HYDRAULIC PRESSURES BEFORE SERVICING THE PUMP. Before proceeding note the following: All threads are hand-tight. When using a repair kit to service the pump use all the parts provided in the kit regardless of the condition of the old ones. This will reduce the possibility of having to rebuild the pump sooner than normal. Disassembly 1. Place the Transfer Pump in a vice. Figure 17 Mounting in Vice WARNING: DO NOT CLAMP THE TRANSFER PUMP TIGHTLY NOTE: It might be necessary to place a strap wrench around the lower end of the suction tube when removing the Foot Valve 2. Remove the Foot Valve housing using a 1 5/8" open-end wrench. Figure 18 Foot Valve 11/8/99 17

18 NOTE: Be sure to replace the Bleed Air Plug when reassembling the cylinder. Failure to do so will prevent the Transfer Pump from operating 3. Remove the air bleed from the Transfer Pump Air Cap prior to disassembly of the air cylinder to bleed off any air pressure trapped in the cylinder. The proper procedures are as follows: a) Disconnect the air line to the Transfer Pump b) Open the Air Needle Valve c) Remove the Bleed Air Plug Figure 19 Bleed Air Valve WARNING: THE AIR CYLINDER CONTAINS PRESSURIZED AIR, WHICH MUST BE COMPLETELY EXHAUSTED PRIOR TO DISASSEMBLY. FAILURE TO DO SO MAY CAUSE SERIOUS INJURY TO PERSONNEL AND/OR PROPERTY DAMAGE. 4. Place a strap wrench around the lower end of the Air Cylinder and unthread. Figure 20 Strap Location 5. Use a 5/16-inch diameter pin to keep the Piston Rod Plunger from rotating. Unthread the piston. Figure 21 5/16" Diameter Pins 18 OP232-INST, Issue 2

19 Operating Manual with Parts Identification Maintenance 6. Remove the Dowel Pin. Figure 22 Dowel Pin 7. Push the piston out through the suction tube. Figure 23 Removing Piston NOTE: When replacing the packings pay careful attention to the packing orientation. 8. Inspect and replace the packings as required. 9. Lubricate, install, and assemble parts in reverse order. Figure 24 Packings 11/8/99 19

20 PARTS IDENTIFICATION Transfer Pump Assembly Figure 25 Transfer Pump Assembly (Part No. OP232C & OP242A), Exploded View 20 OP232-INST, Issue 2

21 Operating Manual with Parts Identification Parts Identification TABLE 1. TRANSFER PUMP ASSEMBLY, (PART NO. OP232C & OP242A), PARTS Symbol Part Number Description Quantity A Fiber Washer 1 B O-Ring 1 C Socket Set Screw 1 D Round Head Machine Screw 1 E 5812 Seal Expander 2 F Male Plug 1 G Soft Point Set Screw 1 H OP Gasket 2 J OP Socket Head Cap Screw 3 K OP Roll Pin 2 L OP Roll Pin 2 M OP Seal Retainer 2 N OP FE Packing 4 P OP Gasket 1 Q OP Standoff 3 R OP Suction Tube 1 S OP U-Cup 1 T OP Dowel Pin 1 U OP O-Ring 2 V OP Wave Ring 1 W OP O-Ring 2 X OP Wiper 2 Y OP U-Cup 1 Z OP Cup Packing 1 AA OP231-2 Needle Valve 1 AB OP231-3 Grounding Lug 1 AC OP231A-1-11 Pump Body (OP232C ONLY) 1 AD OP231A Bung Adapter 1 AE OP231A-1-16 Air Cylinder Mounting Flange 1 AF OP231A-1-17 Packing Nut 2 AG OP231A-1-19 Air Cylinder Base 1 AH OP231A-1-25 Pump Shaft (OP232C ONLY) 1 AJ OP231A-1-3 Matl Piston Valve Housing 1 AK OP231A-1-31 Foot Valve Housing 1 AL OP231A-1-9 U-Cup Retaining Collar 1 AM OP Spring 1 AN OP O-Ring 1 AP OP Displacement Plunger 1 AQ OP Air Cylinder 1 AR OP Press Relief Screw 1 AS OP Compression Spring 1 AT OP Plunger Top 1 AU OP232A-1-1 Air Cylinder Cap (Includes AV) 1 AV OP232A Bumper 1 AW OP233A-2 Bung Adapter Clamp 2 AX OP237A Air Motor Assembly 1 AY OP /4 Dia. SS Ball 2 AZ OP Snap Ring 1 BA OP Snap Ring 1 11/8/99 21

22 Air Motor Assembly Figure 26 Air Motor Assembly (Part No. OP237A), Exploded View Table 2. Air Motor Assembly, (Part No. OP237A), Parts Symbol Part Number Description Quantity A OP U-Cup 1 B OP O-Ring 1 C OP Wear Ring 1 D OP237-1 Upper Air Valve Assembly 1 E OP237-3 Spacer 3 F OP237-4 Lower Air Valve 1 G OP237-5 Socket Head Cap Screw 3 H OP237-6 Gasket Top 1 J OP237-7 Gasket Bottom 3 K OP237A-2 Air Piston 1 22 OP232-INST, Issue 2

23 Operating Manual Instruction Manual Discrepancy Report INSTRUCTION MANUAL DISCREPANCY REPORT Field Number 1 Date Field Title Description 2 Name 3 IM Number 4 Issue Number 5 Date of Issue 6 Page Number 7 Discrepancy Instructions: Complete the above fields of the form by following the instructions listed on the reverse side of this sheet and mail to: Gusmer Corporation One Gusmer Drive PO Box 2055 Lakewood, NJ /8/99 23

24 Field Field Title Number 1 Date Enter date report is submitted. Description 2 Name Enter name of person making report. 3 IM Number Enter the Part Number of the Instruction Manual from the title page. 4 Issue Number Enter the Issue number of the Instruction Manual from the title page. If there is no issue number enter NONE. 5 Date of Issue Enter the date of Issue of the Instruction Manual from the title page. If there is no issue date, enter NONE. 6 Page Number Enter the page number containing the discrepancy 7 Discrepancy Provide a brief description of discrepancy NOTE: You may send a marked copy of the page as an attachment to your submittal. 24 OP232-INST, Issue 2