Ranpump TUV NORD G80-SX Operating instructions

RAN 3” G80-SX MODEL
DIAPHRAGM PUMP
OPERATING AND MAINTENANCE
MANUAL
MANUAL
CONTENTS
1.0. IMPORTANT SAFETY REQUIREMENTS
2.0. TECHNICAL DATA TABLE
3.0. DEFINITION OF DIAPHRAGM PUMP
4.0. HANDLING, MOVING, OPENING DIAPHRAGM PUMP PACKAGE
5.0. MOUNTING AND CONNECTING OF DIAPHRAGM PUMP
6.0. INSTRUCTIONS AND MANUAL OF DIAPHRAGM PUMP
7.0. ASSEMBLY AND DISMANTLING OF PARTS
8.0. PERIODIC MAINTENANCE
9.0. STORAGE OF DIAPHRAGM PUMP
10.0. PRECAUTIONS ON DISPOSING OF DIAPHRAGM PUMP
11.0. SERVICE POINTS
12.0. ORDERING SPARE PARTS
Attachment-1 Pump Performance Charts
Attachment-2 Gisan Warranty
Gisan Machinery Industry and Trade Co. Ltd.
www.ranpump.com
ISO 9001

2
1.0. IMPORTANT SAFETY REQUIREMENTS
a-
This equipment is for professional use only. Observe all warnings. Read and
understand all instruction manuals, warning labels, and tags before you operate the
equipment.
b-
CAUTION: This manual contains important instructions and safety cautions on
diaphragm pumps. Read and understand all of it before first use of the pump.
Manufacturer is not responsible for damages and injuries caused by
inappropriate usage of the pump.
c-
Diaphragm pump usage is limited to within the area defined in this manual. Refer to
GİSAN for any further questions.
d-
Never let unqualified / unauthorized people operate a diaphragm pump.
e-
Never alter or modify any part of this equipment; doing so could cause it to
malfunction. Use only genuine RAN™ Pump parts and accessories.
f-
Illuminate the environment thoroughly for proper usage and maintenance of the
equipment.
g-
Do not make changes to the pump that may affect ıts working systems.
h-
Pump maintenance and repair should only be carried out by qualified personnel.
i-
Do not surpass the strength of minimum system compound.
j-
Learn hazards or potential dangers of your fluid.
k-
Choose the wet pump parts’ material resistant to your fluids. Refer to the Proper
Material-Fluid Chart or your supplier for further information.
l-
Use an approved container for the hazardous media.
m-
Do not pull the pump by the hoses.
n-
Do not let the hoses twist.
o-
Make sure that hose connections to the pump are tight to avoid air suction.
p-
Do not lift or move the pump while it is pressurised.
r-
If you are working with flammable or toxic fluids, be sure the system is properly
ventilated for your type of installation. You must vent the exhaust to a safe place,
away from people, animals, food, and all sources of ignition when pumping
flammable or hazardous fluids. Note that when there is a tear on the diaphragm, the
media in the pump will be exhausted together with the air. Refer to the Figure 9 Air
Exhaust.
s-
The diaphragm pump in this technical file is sold only as a pump unit. A control unit is
not supplied with the pump. Operator is responsible for installing a suitable control
system if needed.
t-
Tightly connect the proper hose for your media to one end of the pump and the other
to the tank where the media will be stored.

3
WARNING !
Always wear appropriate clothing and equipment, such as
eye protection and breathing apparatus, to protect yourself.
WARNING !
Improper handling, splashing in the eyes, ingestion, or bodily
contamination of hazardous fluids or inhaling toxic vapors can
cause extremely serious injury or death. Observe all the
following precautions when handling known or potentially
hazardous fluids.
WARNING !
Altering or modifying any part of this equipment, using eroded
or damaged spare parts, or using this pump for inappropriate
media may cause the parts to break or be damaged. Thus, the
media inside the pump may spill or squirt onto people in the
vicinity and sensitive areas, such as eyes. Moreover, it may
cause a fire, blast, or physical damage.Use only genuine RAN™
parts and accessories.
WARNING !
Running the pump with hot liquids may cause the surface of
the pump to heat up above 80 Co. Under these conditions, it
is pump owner’s responsibility to place a warning for the
operator not to touch the pump without appropriate
protective equipment to reduce the risk of severe burns.
1.1. WARNING SYMBOLS ON DIAPHRAGM PUMP
No
Warning
Location on
Pump
Instruction
1
Pump Name Plate
On fluid covers
Pump Data
1.2. CONFORMITY TO EU DIRECTIVES AND STANDARDS
All the diaphragm pumps produced comply with the below listed EC directives and standards.
2006/42/EC Safety of Machinery
EN ISO 12100 Safety of machinery -- General principles for design-
Risk assessment and risk reduction
DIN EN 809 Pumps and pump units for liquids - Common safety requirements
EN ISO 4414Pneumatic fluid power -- General rules and safety requirements for systems and their
components

4
2.0. DIAPHRAGM PUMP TECHNICAL DATA
3’’ STAINLESS STEEL PUMP
Description
Unit
Value
Pump Type
Inch
3’’ 316l Stainless Steel
Max. fluid working pressure
Bar
8 (0.8 Mpa, 120 Psi)
Air feeding pressure range
Bar
1.0 to 8
(0.10 - 0.8 Mpa, 120 Psi)
Max. Air consumption
m3/min
4.7
Fluid per cycle
lt/cycle
7.6
Max. Head (for water viscosity)
m
70
Max. Suction depth
m
6.3
Max. Particle allowance
mm
9.5
Noise power level (at 5 bar)
dBA
78
Max. Capacity
lt/min
907
Max. Cycle per minute
cycle/min
120
Max. Fluid temperature
⁰C
80 ºC
Min. environment temp.
⁰C
5 ºC
Max. environment temp.
⁰C
40 ºC
Air inlet
Inch
1/2”
Air outlet
Inch
1”
Fluid inlet
Inch
3”Clamped
Fluid outlet
Inch
3”Clamped
Pump housing material
316l Stainless Steel
Weight
kg
70
2.1. DIAPHRAGM RUNNING TEMPERATURE DATA
Diaphragm Material
Temperature limits
BUNA-N
-12,2 ⁰C
65,6 ⁰C
PTFE (teflon)
4 ⁰C
104,4 ⁰C
Santoprene
-28,9 ⁰C
104,4 ⁰C
Polyurethane
-12,2 ⁰C
65,6 ⁰C
VİTON
-40 ⁰C
176,7 ⁰C
Neoprene
-17,8 ⁰C
93,3 ⁰C
EPDM
-51,1 ⁰C
137,8 ⁰C
3.0. DIAPHRAGM PUMP DEFINITION
This diaphragm pump works by using compressed air coming from a compressor. Pump
working principle is shown in the illustration below.
There are two valves distributing air in the pump. Outer valve is distributing the air to the
diaphragms. Inner air valve is rotating the outer valve.
Running a pump fast does not always mean working it most productively. If a pump
works at highest capacity continuously, it will have diaphragm and valve problems
sooner. It is advisable to choose a higher capacity pump and it should not be used at
maximum pressure for long periods.
Diaphragm pump is mounted on the ground or on a tripod from its legs with bolts.
Air operated diaphragm pumps are suitable for transferring fluids up to 50,000 cP viscosity.

5
RIGHT STROKE
Compressed air is directed to
the back side of diaphragm B
by the air valve. The
compressed air moves the
diaphragm away from the
center block. The compressed
air pushes the liquid column
separated by elastomeric
diaphragm, forcing the fluid
through the fluid outlet. At the
same time, the opposite
diaphragm is pulled in by the
shaft connected to the
pressurized diaphragm. So,
diaphragm A is on its suction
stroke: the air behind
diaphragm A is forced out to
the atmosphere through the
exhaust port of the pump. The
movement of diaphragm B
away from the center block of
the pump creates a vacuum
within chamber A. The vacuum
force sucks the fluid into the
inlet manifold forcing the inlet
valve ball off its seat. The fluid
is free to move past the inlet
valve ball and fill liquid
chamber A.
MIDDLE STROKE
When the pressurized
diaphragm, diaphragm B,
reaches the limit of its
discharge stroke, the air valve
redirects compressed air to
the back side of diaphragm A.
The pressurized air forces
diaphragm A away from the
center block while, at the
same time, the connected
shaft pulls diaphragm B to the
center block. Diaphragm A is
now on its discharge stroke.
Diaphragm A forces the inlet
valve ball onto its seat due to
the hydraulic forces
developed in the liquid
chamber and manifold of the
pump. These same hydraulic
forces lift the discharge valve
ball off its seat, while the
opposite discharge valve ball
is forced onto its seat, forcing
the fluid to flow through the
pump discharge. The
movement of diaphragm B
toward the center block of the
pump creates a vacuum
within liquid chamber B.
Atmospheric pressure forces
the fluid into the inlet manifold
of the pump. The inlet valve
ball is forced off its seat
allowing the fluid being
pumped to fill the liquid
chamber.
LEFT STROKE
At completion of the stroke,
the air valve again redirects
air to the back side of
diaphragm B, which starts
diaphragm A on its exhaust
stroke. As the pump
reaches its original starting
point, each diaphragm has
gone through one exhaust
and one discharge stroke.
This constitutes one
complete pumping cycle.
The pump may take several
cycles to completely prime
depending on the conditions
of the application

6
3.1.Diaphragm pump has the name plate shown on diagram 1
Figure 1- Pump Name Plate
3.2. Diaphragm pump coding system
X X - X
DIAPHRAGM
MATERIAL
INLET
OUTLET
BODY
MATERIAL
DIAPHRAGM
MATERIAL
A = 1/4”
A = Aluminium
0 = Buna- N
B = 1/2”
P =
Polypropylene
1 = PTFE (teflon)
BODY MATERIAL
C = 3/4”
C = Cast Iron
S = Santoprene
INLET OUTLET
D = 1”
S= Stainless
Steel
E = 1 ½”
F = 2”
G = 3”
3.3. Main parts of diaphragm pump.
Figure 2 - Diaphragm pump main parts.
No
Description
1
Center section
2
Air valve
3
Cover
4
Diaphragm
5
Body
6
Manifold
7
Clamp
8
Exhaust
9
Leg
10
Fitting

7
3.4. Diaphragm pump main dimensions.
Figure 3 –Diaphragm pump main dimensions.
4.0. HANDLING, MOVING, OPENING THE PACKAGE OF DIAPHRAGM PUMP
Handle the pump from manifolds to move. We pack the pumps in carton boxes.
.
Figure 4 –Pump Package.
Pump package must be at least 130 grams and produced from the kraft carton. It must be fully
covered with packaging separators.

8
5.0. MOUNTING AND CONNECTION OF DIAPHRAGM PUMP
A typical setup configuration is shown in figure 7. Further information and consultation on pump
setup can be provided by your Ran Pump distributor.
ALWAYS USE ORIGINAL RAN PUMP PARTS AND ACCESSORIES. FAILURE TO DO SO
WILL INVALIDATE THE GUARANTEE
Pump should fixed firmly to the ground or platform and should be fitted in a perpendicular
position as shown in Figure 5. Never place the pump at an angle, lying on the ground or upside
down. The pump will not run correctly and check valves and diaphragms will wear out very
quickly due to constant dry running.
When installing the pump ensure that it is balanced correctly when using a lifting device.(Figure
5)
5.1. Mounting Pump
Keep the points below in mind when choosing the pump mounting place.
-Easy access when operating or maintaining.
-(Air valves, inlet and outlet manifolds of air and fluid, etc.)
-Pump weight in relation to the ground/platform.
-Vibration emission to the ground and other equipment.
Figure 5 –Minimum space requirement around the diaphragm pump.

9
5.2. Tightening the bolts before first use
After you unpack the pump, and before you use it for the first time, check and tighten external
fasteners. Tighten the fluid cover screws first, then the manifold screws. (Refer to Figure 6 for torque
figures). This keeps the manifolds from interfering with tightening the fluid covers.
After using a day check the fasteners again and adjust the torque if necessary. Recommended
frequency for tightening fasteners varies with pump usage, a general guideline is to retighten fasteners
every two months. (Refer to Figure 6 for torque figures).
Exhaust gas may contain dirtying materials. To avoid polluting your fluid container, place the exhaust
hose away from it. (Refer to Exhaust Air section. Item 5.7) Fasten the pump foot tightly to the platform
with bolts. Always use seals (teflon, etc) when connecting with bolts.
Pump
Type
Part
Bolt
Torque
N.m
RAN 2’’ M
Air valve
M10
6.8-7.6
Body
M10
20-27
Diaphragm bolt
M16
141-169
Air cover
M10
27 - 30
Figure 6 –Pump parts tightening torque table.
5.3. COMPRESSED AIR CONNECTION
A bleed-type master air valve is required in your system to relieve air trapped between this valve and
the pump. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury,
including splashing in the eyes or on the skin, injury from moving parts, or contamination from
hazardous fluids. See Fig. 7.
1-Refer to the Figure 7 for the connection scheme. Fix these accessories to the wall or to a
bracket. The air line feeding the accessories must be grounded.
2- Install a filter - regulator to the air line. Use a 5μ (micron) air filter. The pressure of
liquid outlet should be level to air regulator’s. Air line filter is for cleaning the dust and
humidity coming out from the air of the compressor.
3- Install an air discharge valve below the pump inlet air line. It will be used to discharge
remaining air in the pump. Install the main air valve above all air line accessories and use it
to cut off the main air from the accessories while maintaining or cleaning.
4-Use a flexible air hose between the pump air inlet and accessories at minimum 3/8 inch
(9.5 mm) inner diameter and not longer than 2 meters. For a hose longer than 2 m,
enlarge the inner diameter respectively.
5.4 Important points while connecting compressed air to diaphragm pump
1- Pay attention not to let any object go into the pump before connecting to compressed air
system.
2- Before connecting to compressed air system, remove all particles from the system by
using blown air.
3-If the hose connections are sealed with teflon tape, wind the tape a few screw teeth before
the end of the connecting accessory to avoid any teflon pieces entering the system.
4- When using screw connections, note not to mis-screw or apply excessive power on the
screws.

10
Figure 7- Typical installation scheme
5.5. FLUID LINE
5.5.1. Fluid suction line
1-Use a conductive hose or pipe.
2-Screw fluid fitting into the pump inlet tightly.
3-If the inlet fluid pressure is more than 25% of the outlet working pressure, ball check valves
will not close fast enough, result will be inefficient pump operation.
4-At inlet fluid pressures greater than 15 psi (0.1MPa, 1 bar), diaphragm life will be shortened.
5.5.2 Fluid discharge line
1-Use a conductive fluid hose or pipe. The pump fluid outlet is 2”. (f).
2-Screw the fluid fitting into the pump outlet securely.
3-Install a fluid drain valve at the pump outlet.
4-Install a fluid shut off valve at the fluid outlet.
5.6 GROUND THE PUMP AS SHOWN BELOW
5.6.1 For the pump: Use a conductor (for grounding) with a cross-section of at least 1.5
mm2. Connect the conductor to the pump’s leg as shown on Fig. 7, and the other end to
the grounding line.
5.6.2 For Air or Fluid Hoses: Use hoses that are at most 150 m long and that can be
grounded.
CAUTION !
To reduce the risk of static sparking, ground the pump and all
other equipment used or located in the pumping area.