IPM IP02 Series User manual

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: IP - 02
~ 2:1 RATIO TRANSFERPUMP
OPERATING MANUAL
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.- IPM, INC.
Manufacturedby InternationalPumpManufacturing,Inc.
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~ IP -02
~ IP -02S
2: 1 RATIO TRANSFER PUMP
OPERATING MANUAL
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. PARTSIDENTIFICATION
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INTERNATIONAL PUMP MANUFACTURING, INC.
~ 25424 74TH AVENUE SOUTH
KENT, WASHINGTON 98032
U. S. A.
TEL: [phone]
FAX: [phone]
WARNING
I THE EQUIPMENTDESCRIBEDHEREIN MUST ONLY BE OPERATED
OR SERVICED BY PROPERLY TRAINED INDIVIDUALS, THOROUGHLY
FAMiliAR WITH THE OPERATING INSTRUCTIONS AND LIMITATIONS
OF THE EQUIPMENT.
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e TABLE OF CONTENTS
1.0 SAFETY WARNINGS 1
2. 0 INSTALLATION 4
2.1 Mounting Configurations""""",.""".".""""""""" 5
3. 0 OPERATION 6
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4. 0 TROUBLESHOOTING 7
.5.0 PARTS IDENTIFICATION... 8
5.1 IP-02 & IP-02S(Air Motor)""""""""""""""""""""""" 8
5.2 IP-02 Carbon Steel Drum Length Fluid Section""'" """" 9
5.3 IP-02 Stainless Steel Drum Length Fluid Section 10
5.4 IP-02S Carbon Steel Stubby Fluid Section 11
5.5 IP-02S Stainless Steel Stubby Fluid Section 12
6.0 APPLICATIONS AND SPECIFICATIONS 13
7.0 WARRANTY & DISCLAIMER 15
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1.0 SAFETY WARNINGS
Please read and observe all warnings contained in this operating 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
f~ should be taken to prevent over pressurization of the pump or accessories connected to it. Use only
I! 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
rdamage, fire or explosion.
, Make daily checks on the equipment and repair damaged or worn parts immediately.
Do not alter this equipment. Doing so could cause it to malfunction and could cause serious injury.
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~ MATERIALS AND FLUID COMPATIBILITY
Always ensure chemical compatibility of fluids and solvents with the wetted parts of the pump and any
components. Check the fluid manufacturer's data sheets and specifications before using fluids or
solvents in this pump.
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i PRESSURIZED HOSES
i ~ Because 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
hoses do not leak or rupture due to wear, misuse or damage.
Hoses should be handled properly. Do not pull on 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 or pressure 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 which could result in spraying of pressurized fluid on the skin or in the
eyes and cause serious bodily injury or property damage.
PRESSURE SPECIFICATIONS
The maximum working fluid pressure of this equipment is 360 psi (25 bar) at a maximum incoming air
I pressure of 180 psi (12. 5 bar). Ensure that 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 spraying 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.
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, 1. Close the air valve (D) to the pump.
rij:I!t 2. Use the air bleed down valve (see installation instructions) to relieve the air pressure in the system.
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~. 3. Relievethefluidpressurebyholdinga groundedmetalpailincontactwiththemetalpartofthe
rjliii . fluid dispense valve (E) and slowly opening the valve. r
I' I!; 4. W~tha container~eadYto catchthe f.IUidopenthe drainv~l~e.(~) (see i~stallationi~struc~ions). ..
1: : 5. It IS a good practice to leave the drain valve (E) open until It IS time to dispense fluid again. j
I 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 by
connecting or disconnecting an electrical supply cord. Sparks can also be created from the static electricity
~~ generated by the flow of fluid through the pump and hose.
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:~ Every part of the equipment must be properly grounded to prevent static electricity from generating a
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,spark and causing the pump or system to become hazardous. These sparks can cause a fire,
;explosion, and serious bodily injury or property damage. Ensure that the pump and all components
and accessories are properly grounded and that electrical supply cords are connected or disconnected
when these hazards exist. ~
Should any evidence of static eletricity (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 the pump and 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 of 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.
ii! 6. Dispensing Valve: The valve must be metal to conduct through the fluid hose to the pump which
j must be properly grounded.
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! 7. Dispensing Point: Grounding must be done according to local codes.
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1 8. Solvent Containers: Grounding must be done according to local codes. Use metal conductive ~
1 ! pails that are properly grounded. -/
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9. Grounding while dispensing, cleaning, or relieving: Maintain conductivity by firmly holding the metal
part of the dispensing valve to the side of a grounded metal container.
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~ FIGURE 1
GROUNDING THE PUMP:
i Follow these procedures for grounding the pump. Loosen the lock screw(W) to allow insertion of one
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i end of a 12 ga. (1.5 mm2)minimum size wire into the hole in the side of the lug(Z).lnsert the wire(Y)
l and tighten the lock screw (W) securely. The other end of the ground wire must be secured to a true
,. earth ground.
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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.
I 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 to prevent the
pump from starting unintentionally. Take care that moving parts present a pinching hazard to fingers
or other body parts. Stay clear of these 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.
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2. 0 INSTALLATION
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FIGURE 2
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A Pump Air Regulator
B Air Line Lubricator
C Air Line Filter
D Bleed- TypeMasterAirValve
(required,for pump)
E Fluid Drain Valve(required)
F 3/Bnpt(f) Fluid Return Inlet
G GroundedAir Hose
H GroundedFluid Hose
J Pump Fluid Inlet
K 114npt(f)Pump Air Inlet
L Bung adapter fitting
M 3/4npt(f)Pump FluidOutlet
Y Ground Wire(required;see page 2 for
installationinstructions)
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 assi- i
stance.
Lower the pump with the bung adapter attached into the drum and turn the bung adapter into the bung
hole. Tighten it. Keep the pump 1/2" (13 mm) above the bottom of the drum and tighten the bung
adapter taper to hold the pump. To avoid a vacuum, unscrew the vent plug. ~
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2.1 Mounting Configurations
Install the necessary accessories in sequence using figure 2 as a guide. To minimize the risk of serious
- bodily injury such as spraying fluid on the skin or in the eyes; or risk of injury from moving parts, install
(;S the following accessories in your system:
1. Air Line lubricator (B). It provides air motor lubrication automatically when properly adjusted.
2. Bleed-oft master air valve(D). This valve relieves air trapped within the system after the pump
is stopped or the valve is closed. Air trapped between this valve and the pump can cause the pump
to reciprocate unintentionally causing harm to the operator. For best results, install this valve close
\ to the pump and downstream from the air regulator.
~ 3. Air regulator(A).The air regulatorcontrolspumpspeedand outletpressurewhenthe air pressure
\ to the pump is adjusted. Install the regulator upstream from the bleed-oft master air valve and
close to the pump.
. 4. Air line filter(C). The filter, like any filter in an air line system, removes harmful dirt and moisture
from the compressed air supply.
5. A second bleed-off air valve (D). When you need to service the pump, use this valve to isolate the
air line accessories. Locate this valve upstream from all other air line accessories installed.
6. Fluid Drain Valve(E). 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, at times is inadequate if there is a clog or restricted
passage in the hose or the dispensing valve. Usecare when removing a fluid line that is suspected of
being blocked. Loosenthe fitting very slowly and allow the pressure to dissipate before removing
the fitting.
Connect a grounded air supply hose to supply air to the pump's 114 npt(f) air inlet(K). Connect a
~ grounded fluid hose(H)to the fluid outlet(M)3/4 npt(f). Remove the pipe plug and connect a fluid return
line to the 3/8 npt(f) return port(F) in a recirculating system.
Ground the pump and all accessories before operation. Observe all OSHA regulations and other safety
regulations.
WARNING: ,
A bleed-off master air valve(D)and a fluid drain valve (E) are required in your ~
sy~te~. These valves reduce. the ris~ ?f serious bo~ily injury !ncluding spr~yi~g i
fluid In the eyes or on the skin, and Injury from moving parts If you are adjusting J
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'- or servicIng the pump. 1
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PIPE
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3.0 OPERATION
Procedure for Pressure Relief
In orderto avoid the risk of seriousbodily injurysuch as spraying 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 1he 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-off valve (see installation instructions) to relieve the air pressure in the system.
3. Relieve the fluid pressure by slowly opening the drain valve. (Use a grounded metal pail in contact
with the metal part of the fluid drain valve)
4. With a container ready, catch the fluid by opening the drain valve(see installation instructions).
5. It is good practice to leave the drain valve open until it is time to dispense fluid again.
If you are unsure if the fluid pressure has been relieved (due to a blockage in a component or a hose),
carefully 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.
Startup andAdjustmentof the pump ~
Ensure that installation is fully completed before proceeding to start up operations.
1. Ensure that the air regulator(A)and the bleed-off master air valve(D)are closed. ~
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2. Into a grounded metal container, open the dispensing valve slowly. Ensure metal-to-metal contact
between the container and the valve.
3. Open the bleed-off air valve and adjust the air regulator (A)slowly for pressure just enoughto start
the pump. This is to prime the system. After all the air has been expelled from the lines, close the
dispensing valve. Duringthe priming ofthe pump, the pump should run when the dispensing valve is
opened andstop when the valve is closed.
4. Turn the air regulator slowly until sufficient flow from the dispensing valve is achieved. Remember r
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 without fluid to pump. When running empty, the pump will
accelerate and probably damage itself. During operation, should the pump be found running 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 operating again. Flush the pump or leave it filled with a compatible solvent
when not in use.
6. Always follow the Pressure Relief Procedure when the pump will be shut down for any extended
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. J
2. Drain the moisture trapped in the air filter.
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Clean and flush the pump thoroughly with appropriate cleaning fluid to obtain maximum service '1
life of the equipment. ;
~ 4.0 TROUBLESHOOTING
Problem Causes RecommendedSolutions
Pumpdoes not operate. Air supplyor pressureis Increaseair pressure.Checkfor
inadequate.Air linesrestricted. any restrictionsin air line.
Dispensingvalveis notopenor it Openand/or clearvalve.
is clogged.
Cloggedfluidlines,valves,hoses, Followpressurereliefprocedure
etc to clearobstruction.
Damagedair motor. Serviceair motor.Replaceparts
as necessary.
Depletedor exhaustedfluid Refillfluid.Primesystemor flush
supply. it.
Non-stopair exhaust. Wornor damagedair motor Serviceair motor.Replaceparts
gasket,packing,seal,etc as necess8;.!Y. J
Erraticpumpoperation. Intakevalveor packingsworn. Refillfluid.Primesystemor flush
it.
~ Intakevalveisnotcompletely Clearobstructionandservice
closed. pump.Replacepartsasnecessary.
Lowoutputon upstroke. Clogged or worn piston valve. Clear obstruction and service
pump.
Replace parts as necessary.
Low output on down stroke. Clogged or worn intake valve. Clear obstruction and service
pump.
Replace partsasnecessary.
Low output on both strokes. Restriction in air lines or air Increase air pressure or supply.
pressure low.
Closed or clogged valves. Open valve or clear valve.
Fluid supply is insufficient or Refill fluid. Prime system or flush
exhausted. it.
Obstructions in fluid lines, hoses, Follow pressure relief procedure
valves, etc. to clear obstruction.
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