IPM IP02 Series Manuale utente

IP-02

2:1 RATIO TRANSFER PUMP

OPERATING MANUAL

IPM, INC.

Manufactured by International Pump Manufacturing, Inc.

Covers models: IP02, IP02S, IP02SST and IP02S-SST Manual Number: MIP11192008

IP-02, IP-02S

IP02-SST, IP02S-SST

2:1 RATIO TRANSFER PUMP

OPERATION MANUAL

with

PARTS IDENTIFICATION

This manual contains IMPORTANT WARNINGS and INSTRUCTIONS. Read and retain for

reference.

International Pump Mfg, INC.

3107 142nd Avenue E Suite 106

Sumner, WA 98390

U.S.A.

TEL: (253) 863 2222

FAX: (253) 863 2223

Website : www.ipmpumps.com

For Technical Service Call Your Local Distributor

Printed: November 2008

WARNING: The equipment described herein must only be operated or serviced by properly

trained individuals, thoroughly familiar with the operating instructions and limitations of the

equipment.

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 IPM 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.

CONTENTS:

1.0 SAFETY WARNINGS………………………………….. 4

2.0 INSTALLATION………………………………………… 7

2.1 MOUNTING CONFIGURATION………………………… 8

3.0 OPERATIONS………………………………………….. 9

4.0 MAINTENANCE AND REPAIR SECTIONS

4.1 AIR MOTOR DISASSEMBLY…………………………… 11

4.2 AIR MOTOR ASSEMBLY……………………………….. 13

4.3 DISASSEMBLY LOWER FLUID SECTION…………. 14

4.4 ASSEMBLY LOWER FLUID SECTION…………….. 16

5.0 PARTS IDENTIFICATION

5.1 PARTS DIAGRAM FOR AIR MOTORS (IP02/IP02S).. 17

5.2 PARTS LIST FOR AIR MOTORS (IP02/IP02S)……… 18

5.3 FLUID SECTION PARTS DIAGRAM IP02…………… 19

5.4 PARTS LIST IP-02………………………………………….20

5.5 FLUID SECTION PARTS DIAGRAM IP-02SST……….. 21

5.6 PARTS LIST IP-02SST……………………………………. 22

5.7 FLUID SECTION PARTS DIAGRAM IP02-S..….……. 23

5.8 PARTS LIST IP02S………………………………….. 24

5.9 FLUID SECTION PARTS DIAGRAM IP02S-SST…….. 25

5.10 PARTS LIST IP02-SST………………………………….. 26

6.0 REPAIR KITS………………………………………………… 27

7.0 TROUBLESHOOTING…………………………………. 28

8.0 TECHNICAL SPECIFICATIONS………………………. 29

9.0 WARRANTY AND DISCLAIMER………………………. 32

1.0 SAFETY WARNINGS

Please read and observe all warnings contained in this operations manual before any attempt

to operate the equipment.

Misuse of Equipment

Misuse of the Equipment can cause serious injury. Use the equipment only for its intended

purpose. Care should be taken to prevent over pressurization of the pump or accessories

connected to it. Use only proper parts in good condition. Use the pump only with compatible

fluids. Improper use or misuse of this equipment could result in fluid being splashed on the skin

or in the eyes, serious bodily injury, property damage, fire or explosion.

Make daily check on the equipment and repair damaged or worn parts immediately.

Do not alter this equipment, doing so could cause it to function incorrectly and could cause

serious injury.

Material & Fluid compatibility

Always ensure the chemical compatibility of the fluids and solvents with the wetted parts in the

pump and any components. Check the fluid manufacturer’s data sheets and specifications

before using the fluids or solvents in this pump.

Pressurized Hoses

Because the hoses are pressurized, they present a danger should the fluid escape at high

pressure. This escaping fluid pressure can spray out and cause serious bodily injury or

property damage. Ensure that the hoses do not leak or rupture due to wear, misuse or

damage.

The hoses should be handled properly - do not pull on the hoses to move the equipment

around. Use the hoses only for fluids in which they are compatible both for the inner liner of the

hose and the outer covering. Use care not to exceed the temperature rating of the hose.

Before each use, ensure that the fluid couplings are tight and that the entire length of hose is

not worn or damaged. Check the entire hose for leaks, bulging cover, damage, abrasion or

cuts. These conditions may cause the hose to fail that could result in splashing of pressurized

fluid on the skin, or in the eyes and cause serious bodily injury or property damage.

Pressure Specification

The maximum working fluid pressure of this equipment is 180 psi (12.5bar) at the maximum

incoming air pressure of 180 psi (12.5bar). Ensure all equipment and accessories used with

this pump are rated to withstand the maximum working pressure of this pump. Never exceed

the maximum working pressure of the pump or any device attached to the pump.

Procedure for Pressure Relief

In order to avoid the risk of serious bodily injury such as splashing fluid on the skin or in the

eyes, or risk of injury from moving parts, the following procedure should be used. This

procedure should be used when shutting down the pump, when servicing or repairing the

pump or any part of the system, when replacing or cleaning components, or when pumping of

fluid is stopped.

1. Close the air valve to the pump.

2. Use the air bleed down valve (see installation instructions) to relieve the air pressure in

the system.

3. Relieve the fluid pressure by holding a grounded metal pail in contact with the metal

part of the fluid dispense valve and slowly opening the valve.

4. With a container ready to catch the fluid open the drain valve (see installation

instructions).

5. It is a good practice to leave the drain valve open until it is time to dispense fluid again.

If you are unsure that the fluid pressure has been relieved (due to a blockage in a component

or a hose) be careful to relieve the pressure by slowly loosening the hose end coupling to allow

the fluid pressure to escape slowly. After the pressure has been relieved, the fitting can be

removed completely and any blockages removed.

Hazards from Fire or Explosion

Hazards exist when sparks can ignite vapors or fumes from flammable or combustible

materials or other hazardous conditions (explosive dusts, etc.). These sparks can be created

from plugging in or unplugging an electrical supply cord. Sparks can also be created from the

static electricity generated by the flow of fluid through the pump and hose.

Every part of the equipment must be properly grounded to prevent static electricity from

generating a spark and causing the pump or system to become hazardous. These sparks can

cause a fire, explosion, and serious bodily injury and property damage. Ensure that the pump

and all components and accessories are properly grounded and that electrical supply cords

are not plugged in or unplugged when these hazards exist.

Should any evidence of static electricity (sparks or small shocks while in contact with the

equipment) exists, discontinue the operation immediately. Investigate the source of the static

electricity and correct the grounding problem. Do not use the system until the grounding

problem is repaired.

Grounding Procedures

Grounding of the pump and all other dispensing equipment is necessary to minimize the

possibility of sparks due to static electricity. Grounding must be in compliance with local

electrical codes. Check with the local authorities for requirements in your area and with the

type of equipment being used. Ensure that all the following equipment is grounded:

1. Air Compressor: Follow the grounding procedures as recommended

by the manufacturer.

2. Air Hoses: Use grounded air hoses.

3. Fluid Container used to

supply the system: Grounding must be done according to local codes.

4. Pump: Follow the procedures included referring to Figure 1.

5. Fluid Hoses: Use grounded fluid hoses.

6. Dispensing Valve: The valve must be metal to conduct through the fluid hose to

the pump which must be properly grounded.

7. Dispensing Point: Grounding must be done according to local codes.

8. Solvent Containers: Grounding must be done according to local codes. Use

metal conductive pails that are properly grounded.

9. Grounding while Maintain conductivity by firmly holding the metal part of the

dispensing, cleaning, dispensing valve to the side of a grounded metal container.

or relieving:

FIGURE 1

Grounding the Pump:

Follow these procedures for grounding the pump. Loosen the lock screw (W) to allow insertion

of one end of a 12 ga. (1.5 mm2) minimum size wire into the hole in the side of the lug (Z).

Insert the wire (Y) and tighten the lock screw securely. The other end of the ground wire must

be secured to a true earth ground.

Hose Grounding:

It is very important that the hoses used for both air and the fluid be a grounding type and that

this ground continuity is maintained. Regular checks of the hose ground resistance (with a

resistance meter using a suitable range) and a comparison to the Manufacturer’s Specification

will ensure the ground is within specifications. If it is not within specified limits it should be

replaced immediately.

Solvent Cleaning:

While cleaning the system with solvent, hold the metal part of the dispensing valve in contact

with a grounded metal pail to minimize the possibility of splashing fluid on the skin or in the

eyes or static sparks. Use low fluid pressure for additional safety.

Hazards From Moving Parts:

Use the Pressure Relief Procedure (page 9) to prevent the pump from starting unintentionally

when not desired. Please observe that moving parts present a pinching hazard to fingers or

other body parts. Always stay clear of moving parts when starting or operating the pump.

Safety Standards:

Safety standards have been established by the United States Government under the

Occupational Safety and Health Act. These standards should be consulted as they apply to the

hazards and type of equipment being used.

2.0 INSTALLATION

FIGURE 2

Figure 2 depicts a typical installation provided as a guide for your reference. Select and install

optional accessories required. Feel free to call an IPM representative or the IPM Technical

Department for assistance.

2.1 Mounting Configuration

Install the necessary accessories in sequence using Figure 2 as a guide. An Air Control Valve

(K) for Controlling air flow is required with the equipment. To minimize the risk of serious bodily

injury such as splashing fluid on the skin or in the eyes; or risk of injury from moving parts,

install the following accessories in your system.

1. Bleed-off master air valve (D)

This valve will relieve the air trapped within the system after the pump is stopped. Air

that is trapped between this valve and the pump can cause the pump to reciprocate

unintentionally, which may cause harm to the operator.

2. Fluid Drain Valve (G)

The fluid drain valve (use a metal valve for grounding purposes) is installed to relieve

fluid pressure in the pump, hose or the dispensing valve when the pump is stopped. The

relief of pressure by the dispensing valve, which at times is inadequate if there is a clog

or restriction in the hose or the dispensing valve, can be achieved by using the fluid

drain valve (G).

3. Low level cut-off valve or runaway safety valve

The low level cut-off valve should be installed at the fluid intake port of the pump. It

shuts off the fluid intake when the fluid level is too low, causing the pump to stall. This is

to prevent the pump from running empty. If not, then a runaway safety valve should be

installed. This valve shuts off the air supply to the pump if the pump accelerates beyond

the pre-set value when the fluid level is too low and the pump is pumping air, or there is

insufficient fluid for normal pump operation.

Connect an air lubricator (C). The lubricator provides proper lubrication to the air motor. (see

daily maintenance check). Next, install a bleed-off master air valve (D). This valve is required

in your system to relieve trapped air (as explained above).

Air Filter (E) helps to remove dirt and foreign particles from the supply air, water moisture also

will be trapped within this filter. Be sure to release the trapped water daily as a good

housekeeping practice (Also see daily maintenance check). Connect a grounded air supply

hose for the supply of air.

For the fluid section, connect one fluid drain valve (G) directly after the outlet of the pump. Be

sure to connect it pointing downwards for safety. Connect a grounded fluid hose (M) to the fluid

outlet 3/4” NPTF.

Grounding of the pump and accessories are to be ensured before operation. Observe all

OSHA regulations and other safety regulations.

3.0 OPERATION

Start up and Adjustment of the Pump (Refer figure 2, page 7)

Ensure that installation is fully completed before proceeding to start up operations.

1. Ensure that the air control valve (K) is closed. Open the bleed-type master air valves

(D). Connect the quick disconnect coupler to the male fitting.

2. Into a grounded metal container, open the dispensing valve (G) slowly. Ensure metal-to-

metal contact between the container and the valve.

3. Adjust the pump air control valve (K) slowly for pressure just enough to start running the

pump. This is to prime all air within the system. After all the air has been expelled from

the lines, close the dispensing valve. During the priming of the pump, the pump runs

when the dispensing valve is opened and stop when the valve is closed.

4. Turn the air regulator slowly until sufficient flow from the dispensing valve is achieved.

Remember to run the pump always at the lowest possible speed necessary to achieve

what is desired. Never exceed the maximum working pressure of any component in the

system.

5. The pump should not be left to run dry of the fluid being pumped. When running empty,

the pump speed will become very fast and probably cause damage. During operation,

should the pump be found to run too fast, stop it immediately and check the fluid supply.

Is the fluid level in the drum too low or empty? If air has gone into the system, do a

priming procedure. Ensure that all air has been expelled from the lines before beginning

operations again. Flush the pump or leave it filled with a compatible solvent when not in

use.

6. Always follow the Pressure Relief Procedure should the pump be put away for any

period of time or during system shut off at the end of the day.

Daily Maintenance Check

1. Ensure sufficient lubricant in the air lubricator.

2. Drain the moisture trapped in the air pressure regulator.

Clean and flush the pump thoroughly with care and appropriate cleaning fluid to obtain

maximum service life of the equipment.

Procedure For Pressure Relief

In order to avoid the risk of serious bodily injury such as spraying fluid on the skin or in the

eyes, or risk of injury from the moving part, the following procedure should be used. This

procedure should be used when shutting down the pump, servicing or repairing the pump or

any part of the system, replacing or cleaning components, or if the pumping of fluid has

stopped.

1. Close the air valve (D) of the pump.

2. Use the air bleed down valve (see installation instructions) to relieve the air

pressure in the system.

Warning

To reduce the risk of static sparking, splashing fluid in the eyes or on the

skin, follow the Pressure Relief Procedure before flushing.

For your safety, read the Fire or Explosion Hazard before flushing and

follow all the recommendations furnished.

3. Relieve the fluid pressure by holding a grounded metal pail in contact with metal

part of the fluid dispense valve (G) and slowly opening the valve.

4. With a container ready to catch the fluid open the drain valve (G) (see installation

instructions).

5. It is a good practice to leave the drain valve (G) open until it is time to dispense

fluid again.

If you are unsure that the fluid pressure has been relieved due to a blockage in a component

or a hose, relieve pressure by slowly loosening the hose end coupling to allow the fluid

pressure to escape. After the pressure has been relieved, the fitting can be removed

completely and any blockages removed.

Flush the Pump before Using It

1. The pump is tested with lightweight DOP oil, which is left in to protect the pump parts. If

the fluid you are pumping may contaminated by oil, Flush out the oil with a compatible

solvent before using the pump. Follow the Flushing Instruction below:

2. If you are pumping fluid that dries, hardens or sets up, flush the system with a

compatible solvent as often as necessary to prevent build-up of dried fluid in the pump

or hoses.

3. If the pump is being used to supply a circulating system, allow the solvent to circulate

through the entire system for at least 30 minutes every 48 hours- more often if

necessary to prevent any undesired settling.

4. Always fill the wet-cup 1/2 full of Throat Seal Liquid (TSL) or a compatible solvent to

keep the fluid from drying on the displacement rod and/or damaging the pump throat

packing.

5. Lubricate the throat packing frequently when you are pumping a non-lubricating fluid, or

are shutting down for more than a few days.

Shut down & care of the Pump

For overnight shut down, follow the Pressure Relief Procedure on page 9. Always stop the

pump at bottom of the stroke to prevent the fluid from drying on the exposed displacement rod,

which could damage the throat packing.

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