ProMinent Duodos 20 PPS User manual

Duodos 20 PPS/PVT
Air-driven double diaphragm pump
Assembly and operating instructions
A2726
EN
Original operating instructions (2006/42/EC)Part number: 981452 Version: BA DUO 015 05/20 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense.
The document is always aimed equally at women, men and
gender-neutral persons. We kindly ask readers for their under‐
standing in this simplification of the text.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Warning information
Warning information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 2.1 ‘Labelling of Warning Informa‐
tion’ on page 6 .
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable documents.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
‘Display/GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
General non-discriminatory approach
Supplementary information
Supplemental directives
2

Table of contents
1 Function and identification.................................................... 4
1.1 Function........................................................................ 4
1.2 Nameplate and identification........................................ 5
2 Safety and responsibility....................................................... 6
2.1 Labelling of Warning Information.................................. 6
2.2 User qualification.......................................................... 8
2.3 Intended use................................................................. 8
2.4 General safety information on the Duodos................... 9
2.4.1 Safety information on the medium to be pumped
and the diaphragm..................................................... 9
2.4.2 Safety information on ambient conditions................ 10
3 Transport and storage......................................................... 11
3.1 Transport.................................................................... 11
3.2 Storage....................................................................... 11
4 Assembly of the pump........................................................ 12
4.1 Installation environment.............................................. 12
4.1.1 Fastening the double diaphragm pump................... 14
4.2 Outdoor installation..................................................... 14
4.3 Design of the suction side........................................... 14
4.4 Compressed air supply............................................... 15
5 Operation of the double diaphragm pump.......................... 16
6 Checking tightening torque prior to commissioning............ 17
7 Commissioning................................................................... 18
7.1 Pre-commissioning checks......................................... 18
7.2 Priming........................................................................ 19
7.3 Interruption to operation.............................................. 19
8 Troubleshooting and fault elimination................................. 20
9 Maintenance of the double diaphragm pump...................... 23
9.1 Maintenance of the diaphragm................................... 24
9.2 Maintenance of the slide rod....................................... 27
9.3 Maintenance of the ball valves................................... 28
10 Disposal of used parts........................................................ 31
11 Technical drawing............................................................... 32
11.1 Exploded drawing of the pump................................. 33
12 Spare parts......................................................................... 34
12.1 Repair set, air valve with sensor............................... 34
12.2 Repair set, diaphragm with valves............................ 35
13 Performance curves............................................................ 36
14 Technical data..................................................................... 37
15 Declaration of Conformity................................................... 38
16 Index................................................................................... 39
Table of contents
3

1 Function and identification
1.1 Function
A2984
Fig. 1: Duodos: Air-driven double diaphragm pump.
The Duodos is an air-driven double diaphragm pump.
The Duodos is run-dry safe and self-priming.
The pump capacity of the double diaphragm pump can be con‐
trolled by changing the pressure in the air supply. The air control is
designed for oil-free operation. The Duodos is suitable for the
transport of liquid chemicals (media).
The Duodos double diaphragm pump transports media up to a
delivery height of 7 metres. It is essential that you note the pump
characteristic curve Ä Chapter 13 ‘Performance curves’
on page 36 , as the pump capacity is seriously dependent on the
back pressure.
Check the material tolerability when selecting your double dia‐
phragm pump. Also consider the density, viscosity, solids content
and temperature of the medium being pumped.
Tab. 2: Permissible values for the medium
Design Temperature of the medium
PP version (PPS): 10 ... 80 °C
PVDF version (PVT): -13 ... 93 °C
Viscosity of the medium: max. 200 mPas
Solids: < 2 mm
Function and identification
4

1.2 Nameplate and identification
A2980
7
6
5
43
2
1
9
8
Fig. 2: Nameplate 1
1 Check number
2 CE mark
3 Designation of origin
4 Serial number
5 Month and year of manufacture
6 Order number
7 Model designation (type)
8 Place and country of manufacture
9 Manufacturer
A2981
www.prominent.com
Int: 1/4“ BSP(F) - Ext.: 3/4“NPT
FLUID IN / OUT:
MAX. FLUID PRESS.: 7 bar / 100 psi
AIR PRESSURE 1.5-7 bar
5
4
3
2
1
Fig. 3: Nameplate 2
1 Manufacturer’s website
2 Permissible air pressure
3 Maximum feed pressure
4 Liquid inlet and outlet
5 Dimensions/ thread, [INT] = input / [Ext.] = output
Type Pump capacity Seals Slide rod Part no.
Duodos 20 PPS 0 ... 20 l/min EPDM Corrosion-proof steel 1103381
Duodos 20 PVT 0 ... 20 l/min PTFE Hastelloy® C 1103378
Type Housing Diaphragm Valve balls Valve seats Part no.
Duodos 20 PPS PP Santoprene®PTFE Corrosion-proof
steel
1103381
Duodos 20 PVT PVDF PTFE PTFE PVDF 1103378
Nameplate
Identification and material
Function and identification
5

2 Safety and responsibility
2.1 Labelling of Warning Information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed warning information and are provided as clear step-
by-step instructions.
The warning information and notes are categorised according to
the following scheme. A number of different symbols are used to
denote different situations. The symbols shown here serve only as
examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger.
Description of hazard
– Denotes an immediate threatening danger. If
the situation is disregarded, it will result in fatal
or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in fatal
or very serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor injuries.
Material damage.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in slight
or minor injuries. May also be used as a
warning about material damage.
NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
– Denotes a possibly damaging situation. If the
situation is disregarded, the product or an
object in its vicinity could be damaged.
Introduction
Safety and responsibility
6

Type of information
Hints on use and additional information.
Source of the information. Additional measures.
– Denotes hints on use and other useful informa‐
tion. It does not indicate a hazardous or dam‐
aging situation.
Safety and responsibility
7

2.2 User qualification
WARNING!
Danger of injury with inadequately qualified per‐
sonnel
The operator of the system / equipment is respon‐
sible for ensuring that the qualifications are ful‐
filled.
If inadequately qualified personnel work on the unit
or loiter in the hazard zone of the unit, this could
result in dangers that could cause serious injuries
and material damage.
– All work on the unit should therefore only be
conducted by qualified personnel.
– Unqualified personnel should be kept away
from the hazard zone.
The pertinent accident prevention regulations, as
well as all other generally acknowledged safety
regulations, must be adhered to.
Training Definition
Instructed personnel An instructed person is deemed to be a person who has been instructed and,
if required, trained in the tasks assigned to him and possible dangers that
could result from improper behaviour, as well as having been instructed in the
required protective equipment and protective measures.
Trained user A trained user is a person who fulfils the requirements made of an instructed
person and who has also received additional training specific to the system
from the manufacturer or another authorised distribution partner.
Trained, qualified per‐
sonnel
A trained, qualified employee is deemed to be a person who is able to assess
the tasks assigned to him and recognize possible hazards based on his
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. A trained, qualified employee must be able to perform the tasks
assigned to him independently with the assistance of drawing documentation
and parts lists. The assessment of a person's technical training can also be
based on several years of work in the relevant field.
Electrical technician An electrical technician is able to complete work on electrical systems and rec‐
ognise and avoid possible dangers independently based on his technical
training and experience as well as knowledge of pertinent standards and regu‐
lations. An electrical technician must be able to perform the tasks assigned to
him independently with the assistance of drawing documentation, parts lists,
terminal and circuit diagrams. The electrical technician must be specifically
trained for the working environment in which the electrical technician is
employed and be conversant with the relevant standards and regulations.
Service The Service department refers to service technicians, who have received
proven training and have been authorised by the manufacturer to work on the
system.
2.3 Intended use
Correct and proper use:
nThe pump is intended for the transport of liquids.
nOnly use the pump in accordance with the technical data and
specifications set out in these operating instructions.
Safety and responsibility
8

2.4 General safety information on the Duodos
2.4.1 Safety information on the medium to be pumped and the diaphragm
Please ensure when handling hazardous substances that you have
read the latest material safety data sheets provided by the manu‐
facturer of the hazardous substances. The measures required are
described in the material safety data sheet. Check the material
safety data sheet regularly and replace, if necessary, as the hazard
potential of a substance can be re-evaluated at any time based on
new findings.
The system operator is responsible for ensuring that the material
safety data sheets are available and that they are kept up to date,
as well as for producing an associated hazard assessment for the
workplaces affected.
The service life of the diaphragm cannot be precisely specified.
You therefore need to assume that the diaphragm will rupture and
that liquid will then escape.
You should also prevent particles of the faulty diaphragm entering
the medium being pumped. You can prevent contamination,
for example by filtration, installation of a hose rupture indicator or
other measures appropriate for the respective process.
In the event of a diaphragm rupture, the pumped medium can enter
the air system of the double diaphragm pump and from there into
the atmosphere. If the feed chemical is a dangerous, harmful or
toxic substance, the air outlet must be routed to a suitable area
where safe disposal is possible.
Danger from hazardous substances!
Fig. 4: Handling hazardous sub‐
stances
Service life of the diaphragm
A2992
Fig. 5: The service life of the dia‐
phragm
In the event of a diaphragm rupture
Safety and responsibility
9

2.4.2 Safety information on ambient conditions
Before working on the double diaphragm pump, check whether it is
necessary to close the compressed air lines and vent the double
diaphragm pump.
Before undertaking any maintenance and repair work, close off the
compressed air supply, discharge the compressed air and detach
the air supply line from the double diaphragm pump. These meas‐
ures depend on the configuration of your compressed air supply.
The line to the discharge side of the double diaphragm pump may
be under pressure and must likewise be vented if required.
The pump can also become hot when conveying hot liquids. There
can then be hot surfaces on the pump. Bear this in mind and take
suitable measures to reduce any hazards.
Depending on the operating conditions, the maximum sound pres‐
sure level of the device can reach 88 dB ± 3 dB. Bear this in mind
and take appropriate measures to reduce any impact caused by
this sound pressure level. The type and implementation of suitable
measures depends on the local circumstances and is the responsi‐
bility of the system operator.
nTake suitable measures to protect the device from environ‐
mental influences when operating outside such as:
– UV radiation
– Humidity
– Frost, etc.
Check that all fastening elements with sealing rings are correctly
seated before commissioning the double diaphragm pump. The
seals may “creep” so that the fastening elements may come loose
over time.
Fig. 6: Ambient conditions
Compressed air
Hot surfaces
Maximum pump sound pressure level
91 dB
Operation in the open air and out‐
doors
Check the fastening elements are cor‐
rectly seated
Safety and responsibility
10

3 Transport and storage
nUser qualification, transport and storage: trained user
Ä Chapter 2.2 ‘User qualification’ on page 8 .
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
3.1 Transport
Transport:
nUse cardboard packaging to protect the pump.
nYou can reuse the packaging material.
nObserve the ambient conditions.
3.2 Storage
Store the unit fully drained.
Tab. 3: Permissible storage conditions
All versions: + 5°C ... 60 °C
All versions: < 95% relative air humidity (non-condensing)
Transport and storage
11

4 Assembly of the pump
nUser qualification, installation: trained and qualified personnel
Ä Chapter 2.2 ‘User qualification’ on page 8 .
Observe the permissible ambient conditions.
Tab. 4: Permissible ambient conditions for operation
All versions: - 10 °C ... 40 °C
All versions: < 95% relative air humidity (non-condensing)
4.1 Installation environment
Upright installation
Install the double diaphragm pump upright and
plumb. The valves of the double diaphragm pump
operate when loaded by gravity. The valve balls
are pressed by gravity into the valve seat and then
seal it off. Installation outside the vertical axis
impairs the function of the valves.
Nominal width of the pipework
The threaded connectors must not reduce the
nominal width of the pipework or the double dia‐
phragm pump. The hydraulic connectors have
internal and external threads. Do not screw
threaded fittings on to the internal thread as this
would lead to a reduction of the nominal width.
Keep the suction line short and the number of pipe fittings minimal.
Do not reduce the diameter of the suction line.
If a rigid pipework system is used, it is essential that short flexible
sections of hose are inserted between the double diaphragm pump
and pipework to protect the double diaphragm pump against vibra‐
tion and from tensile and compressive forces.
We recommend installing a pulsation damper to reduce pulsation
in the medium to be pumped.
Permissible ambient conditions
Assembly of the pump
12

output
Liquid
input
Outlet
drainage
valve
input
max. 7 bar
OPTION
OPTION
OPTION
Inlet
drainage
valve
A2727
Liquid
Liquid
input
Compressed air
Fig. 7: Recommended installation
WARNING! Protect the pump from overload: Install a
relief valve in the discharge line. The relief valve protects the
pump from overload if a valve is closed or the line is blocked
in another way.
An optional kit is needed for the compressed air remote outlet.
A2728
Fig. 8: Compressed air remote outlet with silencer
1. Loosen the 4 screws and remove the air cap.
ðAn outlet opening is visible.
2. Connect a hose to the new outlet opening and install the
silencer on the end of the hose.
NOTE: Use a hose with the same diameter as the outlet
opening 3/8” NPT.
Recommended installation
Compressed air remote outlet with
silencer
Assembly of the pump
13

4.1.1 Fastening the double diaphragm pump
Correct securing of the device
Only switch the device on if it has been properly
fastened to the ground or its holding fixture. The
system operator is responsible for ensuring that
the ground and the fittings can hold the device
safely and under all operating conditions.
NOTE: The operator of the system must ensure that they have
appropriate installation material available (rawlplugs, screws etc.).
Use appropriate installation material to fasten the double dia‐
phragm pump in place. Tightening torque 20 Nm.
4.2 Outdoor installation
NOTICE!
Outdoor installation
Possible consequence: Damage to property and
increased wear.
Install the unit indoors. If the pump is to be
installed outdoors, make sure that it is protected
against sunlight and weathering.
When positioning the pump, ensure that there is
sufficient room for access for maintenance work.
Tab. 5: Permissible operating conditions:
All versions: - 10 °C ... 40 °C
All versions: < 95% relative air humidity (non-condensing)
4.3 Design of the suction side
1. Configure the threaded connectors to ensure that they do not
reduce the nominal width of the pipework and the double dia‐
phragm pump.
2. Design the suction side to be generously sized. Ensure that
the supply to the double diaphragm pump with the medium to
be pumped is ensured under all load and operating statuses.
Ensure that the inside diameters of the suction lines are gen‐
erously sized.
3. Install the double diaphragm pump as close as possible to
the medium to be pumped to ensure the maximum service
life of the diaphragm. The minimum air pressure to operate
the double diaphragm pump is approximately 1.5 bar.
Nominal width of the pipework
Dimensioning of the suction side
Assembly of the pump
14

4.4 Compressed air supply
INFO: Suitable compressed air supply. The system operator is
responsible for the provision of a suitable compressed air supply.
When doing so, observe ISO 8573.
Connect the double diaphragm pump to a compressed air supply in
accordance with the current state of the art (ISO 8573-1).
Requirements:
nCompressed air free of residual oil: Compressor residual oil:
– maximum 0.1 mg/m³ for HEES liquids and bio-oils,
– or maximum 5 mg/m³ for mineral oils.
nDried compressed air: ISO 8573-1, Class 4 with 3 °C pressure
dew point.
Our recommendation: ensure that the pressure dew point is at
least 10 °C below the ambient temperature.
1. Design the compressed air supply to have generous dimen‐
sions. Your compressed air supply must be capable of sup‐
plying the double diaphragm pump with sufficient com‐
pressed air at any time and under all operating statuses. In
this respect, consider the air consumption of other equipment
and machines operated by the same compressed air supply.
Considerable pressure fluctuations can occur in the com‐
pressed air supply when switching compressed air con‐
sumers on and off.
2. Do not allow the air pressure of the supplied air to exceed
7 bar (100 psi). Connect the air inlet of the double diaphragm
pump to a compressed air supply, which is designed to pro‐
vide the required pump capacity in terms of air volume and
pressure. Connect a control valve upstream of the double
diaphragm pump to guarantee the supply pressure remains
within the specified values.
3. If there is a rigid air supply line, insert a short section of flex‐
ible hose between the double diaphragm pump and the pipe‐
work.
4. Make sure that the weight of the air supply line, control valve,
and filters does not weigh down on the air connection fitting
of the double diaphragm pump, instead support it in a suit‐
able manner. Otherwise the double diaphragm pump can be
damaged.
INFO: Do not lubricate the air valves. Due to their design, the air
valves do not require any lubrication and must not be lubricated.
INFO: Moisture in the air line. Water in the compressed air can
lead to the exhaust air freezing or the double diaphragm pump
icing up. Possible consequences include malfunctions or failure of
the double diaphragm pump. We recommend installing an air dryer
in the compressed air supply. The air dryer extracts water from the
compressed air and protects it from icing up.
Compressed air supply
Do not lubricate the air valves
Moisture in the air line
Assembly of the pump
15

5 Operation of the double diaphragm pump
nUser qualification, operation: instructed user Ä Chapter 2.2
‘User qualification’ on page 8 .
The double diaphragm pump is fully integrated into the system
installed by the operator and is then controlled from this system. It
is not possible to operate the double diaphragm pump directly.
Operation of the double diaphragm pump
16

6 Checking tightening torque prior to commissioning
nUser qualification, pre-commissioning checks: trained qualified
personnel Ä Chapter 2.2 ‘User qualification’ on page 8 .
A2729
Fig. 9: Permanent tightness: Check the tightening torque prior to
commissioning, in the sequence shown in Fig. 9 .
1. Check the tightening torque of the screws 1 ... 8 prior to com‐
missioning. Tighten all screws to 5 Nm, in the sequence
shown in Fig. 9.
2. We also recommend checking these threaded connectors for
correct torque at least once a year because the pump mate‐
rial yields (creeps) and the tightening torque is then reduced.
Prior to commissioning, check that the
threaded connectors have the correct
torque.
Checking tightening torque prior to commissioning
17

7 Commissioning
nUser qualification, commissioning: trained user Ä Chapter 2.2
‘User qualification’ on page 8 .
Check that all fastening elements with sealing rings are cor‐
rectly seated before commissioning the double diaphragm
pump.
The seals may “creep/move” so that the fastening elements
may loosen over time.
7.1 Pre-commissioning checks
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
Perform the following tests:
1. Ensure that the unit has not been damaged during transport
or storage. Immediately report any damage to the supplier.
2. Check that the air pressure is suitable for the unit
Ä Chapter
14 ‘Technical data’ on page 37 .
3. Ensure that the unit is suitable for the liquid to be conveyed
and that it will not be attacked. To do so, refer to the Resist‐
ance List on the manufacturer’s website.
4. Make sure that the temperature of the liquid does not exceed
or fall below the recommended temperature. Ä Chapter 14
‘Technical data’ on page 37
5. INFO: Pressure gauge. Install a pressure gauge into the dis‐
charge line if the back pressure value is unknown.
6. Check the values for flow, pressure etc. under operation con‐
ditions
Ä Chapter 14 ‘Technical data’ on page 37 .
Check the fastening elements are cor‐
rectly seated
Commissioning
18

7.2 Priming
1. To start the double diaphragm pump, open the air valve by
approximately a 1/2 ... 3/4 turn.
2. INFO: Cavitation. Cavitation has occurred if opening the air
valve causes the stroke rate of the double diaphragm pump
to increase, but not the flow volume passing through the
double diaphragm pump. Close the air valve slightly so that
the air consumption and the feed rate of the double dia‐
phragm pump are at an optimum ratio to each other.
Once the double diaphragm pump is filled with liquid, open
the air valve further to produce the required air flow.
7.3 Interruption to operation
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
1. Flush through the double diaphragm pump after every use if
liquids are used which have a tendency to form deposits or
solidify when stationary.
ðThis will avoid damage to the double diaphragm pump.
INFO: Deposits. Liquid residue in the double diaphragm
pump may dry out and form deposits. When restarting
the double diaphragm pump, these deposits can lead to
problems at the diaphragms and the ball valves.
2. At temperatures below 0 °C, make sure that the double dia‐
phragm pump is always completely drained after use.
Commissioning
19

8 Troubleshooting and fault elimination
nUser qualification, troubleshooting and fault elimination: trained
qualified personnel Ä Chapter 2.2 ‘User qualification’
on page 8 .
The pump is not working.
Cause: Recommended measure:
The outlet valve on the discharge side is not
open.
Open the discharge valve on the discharge side.
No air supply. Switch on the compressor and open the air valve and the
air regulator.
The air pressure is too low. Check the compressor and the configuration of the air
line.
Air is escaping from the connecting elements. Check the connecting elements and the torque of the
screws.
The air lines or additional equipment are
blocked with foreign bodies.
Check and clean the air line and the auxiliary equipment.
The outlet opening (silencer) of the pump is
blocked with foreign bodies.
Check and clean the outlet opening and the silencer.
The liquid line is blocked with foreign bodies. Check and clean the liquid line.
The pump is blocked with foreign bodies. Remove, check and clean the pump housing.
The pump is working but no liquid is being pumped.
Cause: Recommended measure:
The valve on the suction side is not open. Open the valve on the suction side.
Too high a suction or discharge lift. Check the configuration of the installation and reduce the
height of the installation.
The outlet opening of the liquid line (including
the filter) is blocked with foreign bodies.
Check and clean the liquid line.
The pump is blocked. Dismantle the pump, then check and clean the pump.
The ball and the ball seat are worn or damaged. Check the components and replace if necessary.
Troubleshooting and fault elimination
20