Rapid 110 HL 50/2 User manual

n110 HL 50/2 # 60 010
n110 HL 200/2 # 60 011
Translation of the original operation manual GB, Stand 02 / 2019
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Weiterentwicklung im Sinne des Fortschrittes behalten wir uns vor. - Technical Modifications are subject to change. - Details techniques subject à modification sans avis préalable
O P T I M I Z E S W O R K R O U T I N E S E N V I R O N M E N T A L L Y E F F E C T I V E S E C U R E

1.
1. Safety instructios
· Please observe: This operation manual contains all necessary information.
Please read carefully to avoid damages and faults. All Rapid pieces of
equipment are checked carefully before delivery for their perfect composition
and function. In case of improper use all rights to claim under guarantee are
void.
· Make sure that only skilled staff is working with this device in order to prevent
damages and accidents caused by improper use.
· Environmental conditions i.e. humidity, low temperatures, sunlight and
contamination may damage device.
· Before using the device make sure that it is not contaminated to prevent any
injury. Avoid any contamination of device as well as of environment. In case of
any contamination during operation of device take care that it is immediately
and professionally removed.
· Always wear safety cloths respecting the applicable regulations for accident
prevention
· Only use this device conforming to its purpose and function. Improper use can
cause severe injuries.
· Caution – moving parts, sharp edges, hot machine parts or exhausting steam
can cause severe injuries.
· Before use always check the device for damages and leaks. In case of any
damage or leak make sure that it is repaired professionally before use.
Operation of defect device may cause severe injuries.
· In case of any sign of damage or malfunction during operation of device stop
device immediately to prevent injuries. Before next use make sure that the
device professionally repaired.
· Take care that in case of an accident all emergency measures are on hand
CONTENTS
1. Safety Instructions
2. General advice
3. Technical data
4. Description
5. Assembling / Installation
6. Spare parts and accessories
7. Operation
OPERATION MANUAL
CONTENTS Seite
1. 2
2. 3-4
3. 4
4. 4
5. 4-5
6. 6-7
7. Operation 8-9
8. 9
9. 9
10. 10
Safety Instructions
General advice
Technical data
Description
Assembling / Installation
Spare parts and accessories
Maintanance and trouble shooting
Disposal
Warranty
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2. General advice
This manual contains important warnings and information.
Read and keep for reference.
Mishandling may cause damage or destruction of equipement or serious injury or death !
The pumps 110 HL 50/2 and 110 HL 200/2 are designed to be used in pumping greases only
! Any other use can cause unsafe operating conditions and result in component rupture, fire
or explosion, which can cause injury, including fluid injection !
WARNING !
2.1 No complying with below requests will result in severely harm to your
body even death.
Equipement misuse hazard
Equipment misuse can cause the equipment to rupture or malfunction in serious injury.
2.1.1 This equipment is for professional use only
2.1.2 Read all instruction manuals, tags and labels before you operate this
equipment.
2.1.3 Do not modify this equipment. If you need to replace worn or damaged
parts immediately.
2.1.4 Check equipment daily. Repair or replace worn or damaged parts
immediately.
2.1.5 Do not exceed the maximum working pressure of the lowest rate
component in your system.
2.1.6 Use fluids and sovents which are compatible with the equipment wetted
parts. Read the fluid and manufacturer‘s warnings.
2.1.7 Forbidden on other chemical or may cause damage to the pumps body.
2.1.8 Handle hoses carefully. Do not pull on hoses to move equipment.
2.1.9 Route hoses away from traffic areas, sharp edges, moving parts and hot
surfaces.
2.1.10 Do not use low pressure hoses in the system. Before operating the
control valve, put the hoses straight. Using of the hoses should comply
with certain conditions.
2.1.11 Put on heat insulation gloves when operating the pumps.
2.1.12 Do not move or lift pressurized euqipment.
2.1.13 Comply with all applicable local, state and national fire, electrical and
safety regulations.
2.2 Skin injection hazard
Fluid from the dispensing valve, leaks or rupture components can inject
fluid into your body and cause serious injury. Fluid splashes in the eyes or
on the skin can also cause serious injury.
2.2.1 Do not point the dispensing valve at anyone or at any part of the body.
2.2.2 Do not stop or deflect leaks with your hand, body, glove ir rag.
2.2.3 Do not use greases which have been polluted,
2.2.4 Use only extensions and no-drip tips which are designed for use with
your dispensing valve. Follow the pressure relief procedure it the grease
fitting coupler clogs and before you clean or service this equipment.
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2.2.5 Check the hose, tubes and couplings daily. Replace worn or damaged
parts immediately. Do not repair high pressure couplings; you must
replace the entire hose.
2.3 Moving parts hazard
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
2.3.1 Keep clear of all moving parts when you start or operate the pump.
2.3.2 Before you service this equipment, follow the pressure relief procedure
to prevent the equipment from starting unexpectedly.
2.3.3 Before operating the pumps, moving parts should not be exposed
outside.
2.4 Fire and explosion hazard
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous
condition and result in a fire or explosion and serious injury.
2.4.1 Ground the equipment and the object being dispensed to.
2.4.2 Effective lubricate to the moving parts.
2.4.3 If there is any static sparking or you feel an electric shock while using this
equipment, stop dispensing immediately. Do not use the equipment until
you identify and correct or the fluid being dispensed.
2.4.4 Provide fresh air ventilation to avoid the buildup of flamable fumes from
solvents or the fluid being dispensed.
2.4.5 Keep the dispensing area free of debris, includiong solvent, rags and
gasoline.
2.4.6 Do not smoke in the dispensing area.
3. Technical data
4. Description
The pumps 110 HL 50/2 and 110 HL 200/2 are designed to be used in pumping greases
5. Assembling / Installation
5.1 Grounding
5.1.1 Warning: before operating the pump, cvheck the grounding of whole
system. And avoid occurring of fire and explosion.
5.1.2 To reduce the risk oft static sparking, effectively ground all of this
equipment.
Model 110 HL 50/2 110 HL 200/2
Art.No. 60 010 60 011
Grease oulet pressure max.
Ratio
Output
Outlet
Suction tube 740 mm 940 mm
Air inlet
Air inlet max.
Air motor diameter 76 mm
600 bar
50:1
1800 g/min
1/4" BSP
5-10 bar
12 bar
Model 110 HL 50/2 110 HL 200/2
60 010 60 011
600 bar
Ratio 50:1
Output 1800 g/min
1/4" BSP
740 mm 940 mm
5-10 bar
12 bar
76 mm
Art.No.
Grease oulet pressure max.
Outlet
Suction tube
Air inlet
Air inlet max.
Air motor diameter
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5.1.2.1 Pump: Refer to fig.2. Use a ground wire and clamp
as shown in fig.2. Remove the ground screw 1,
onto the pump and tighten securely. Connect the other
end of the ground wire to a true earth ground. Insert
through the eye of the ring terminal at end of the
ground wire 2. Fasten the ground screw back.
5.1.2.2 Air and fluid hoses: Effectively grounding.
5.1.2.3 Air compressor: Follow the manufacturer‘s
recommendations.
5.1.2.4 Control valve: Use proper grounding line to connect
the pump. Keep the metal part of the control valve
connected with the grounding equipment.
5.1.2.5 Barrel: Use the barrel which is under the permission of local area. If it is a
metal barrel, put in on the ground which is with electric capability. If noc
grounding paper or board, it is not allowed to put on the surface of non-
conductor directly.
5.1.2.6 Other components: Comply with local grounding requests.
5.1.2.7 Keep effective grounding when working or pressure releasing.
5.2 Installation
5.2.1 Typical installation: Refer to fig.3:
1 Bleed-type master air valves
2 Air line filter
3 Air regulator with gauge
4 Air line lubricator
5 Pump runaway valve
6 Drum cover
7 Follower plate
8 Hose reel
Above typical installation is not for whole system
design. If any help needed, please contact us or local agent.
5.2.2 Installation of air line
5.2.2.1 Note: Do not hang any equipment to the air inlet as it may cause falling
down by poor hanging equipment.
5.2.2.2 Process
5.2.2.2.1 Install a pump on drum cover (see fig.3 part 6) and then tp barrel.
5.2.2.2.2 On the main line of air compressor, connect bleed-type master air valves
which controls on and off air motor (see fig.3 part 2)
5.2.2.2.3 Install an air line filter (see fig.3 part 2) to remove harmful dirt and
contaminants from your compressed air supply.
5.2.2.2.4 Install the air regulator to control pump speed and pressure. (See fig.3
part 3)
5.2.2.2.5 Install an air line regulator for automatic air motor lubrication (see fig.3
part 4).
5.2.2.2.6 Install a pump run-away valve to shut off the air to the pump if the pump
accelerates beyond the pre-adjusted setting. A pump that runs too fast
can be seriously damaged. (See fig.3 part 5)
5.2.2.2.7 Connect outlet line.
Fig.2
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6. Spare party and accessories
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Part.No. Description Qty Part.No. Description
1 Tube 1 30 Rod
2* Gasket 2 31 Shovel washer
3 Adapter 1 32* U Seal
4 Nut 1 33 Copper ring
5* Seal 1 34 Connector
6 Screw M5x10 1 35* Seal
7 Piston 1 36 Gasket
8* Seal 2 37 Rod
9 Gasket 2 38 Tube
10 Screw 2 39 Screw
11 Nut 2 40 Right silencer
12 Rod 2 41 Left silencer
13* Lock-wire 2 42 Screw
14* Clip spring 2 43 Quick plug
15 Arm 2 44 Rocker
16 Nut 1 45* Spring
17 Rod 1 46 Pin
18 Yoke 1 47* O-Ring
19 Cylinder 1 48* Sponge
20* Gasket 2 49 Ball
21* Gasket 2 50 Tube
22 Actuator 1 51 Adapter
23* O-Ring 1 52 Shaft
24* O-Ring 1 53 Oil inlet
25* O-Ring 1 54 Spring
26* Gasket 1 55 Nut
27 Nut 1 56 Nu
28 Base 1 57 Label
29* Pin 4x18 1
Note: The part no. with * are the wearing parts
1 Tube 1 30 1
2* 2 31 1
3 Adapter 1 32* 1
4 Nut 1 33 1
5* 1 34 1
6 1 35* 1
7 1 36 1
8* 2 37 1
9 2 38 Tube 1
10 2 39 12
11 Nut 2 40 1
12 2 41 1
13* 2 42 6
14* Clip spring 2 43 1
15 Arm 2 44 Rocker 2
16 Nut 1 45* Spring 2
17 1 46 Pin 2
18 1 47* O-Ring 1
19 1 48* 2
20* 2 49 Ball 2
21* 2 50 Tube 1
22 1 51 Adapter 1
23* O-Ring 1 52 1
24* O-Ring 1 53 1
25* O-Ring 1 54 Spring 1
26* 1 55 Nut 2
27 Nut 1 56 Nu 2
28 Base 1 57 Label 2
29* Pin 4x18 1
Part.No. Description Qty Part.No. Description Qty
Rod
Gasket Shovel washer
U Seal
Copper ring
Seal Connector
Screw M5x10 Seal
Piston Gasket
Seal Rod
Gasket
Screw Screw
Right silencer
Rod Left silencer
Lock-wire Screw
Quick plug
Rod
Yoke
Cylinder Sponge
Gasket
Gasket
Actuator
Shaft
Oil inlet
Gasket
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7. Operation
7.1 Pressure relieve
7.1.1 Skin injection hazard: The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury from pressurized fluid, fluid
from the valve or splashing fluid, follow this procedure whenever you:
7.1.1.1 Are instructed to relive pressure
7.1.1.2 Stop dispensing
7.1.1.3 Check, clean or service any system equipment.
7.1.1.4 Install or clean dispensing devices.
7.1.2 Pressure relieve procedure
7.1.2.1 Close the pump air regulator and the bleed-type master air valve.
7.1.2.2 Hold a metal part of the dispensing valve firmly to a grounded metal wast
container and trigger the valve to relieve the fluid pressure.
7.1.2.3 Open the air line valve and grease valve.
7.1.2.4 Close the control valve.
7.1.2.3 When occurs:
1) Problems on control valve, flexible hose, rigid tube or manual tip, autotip
2) Pressure relieved very slowly until relieved throughly. Please clear obstruction
of grease system.
7.2 Procedure
7.2.1 Note: When the pump is primed and with sufficient air supplied, the pump starts
when the dispensing valve is opened and shuts off when it is closed.
7.2.2 Warning: The maximum working pressure of each component in the system may
not be the same. To reduce the risk over pressurizing any component in the
system, be sure you know the maximum working pressure of each component.
Never exceed the maximum working pressure of the lowest rated component in
the system. Over pressurizing any component can result in rupture, fire,
explosion, property damage and serious injury. The maximum pressure in the
system is equal to air input pressure times pump ratio. Regulate air to the pump
so that air line or fluid line component or accessory is not over pressurized.
7.2.3 Caution: Never allow the pump to run dry of the material being pumped. A dry
pump will quickly accelerate to a high speed, possibly damaging itself. If your
pump accelerates quickly or is running too fast, stop it immediately and check
the material supply. If the supply container is empty and air has been pumped
into the lines, prime the pump an lines with material, or flush it and leave it filled
with a comatible solvent. Be sure to eliminate all air from the material lines.
7.2.4 Startup
7.2.4.1 If there are multiple pumps on the air line, close the air regulators and bleed-type
master air valves to all but one pump.
7.2.4.2 Open the master air valve from the compressor.
7.2.4.3 Open the dispensing valve into a grounded metal waste container, making firm
metal-to-metal contact between the container and valve. Open the bleed-type
master air valve and open the pump air regulator slowly, just until the pump is
running. When the pump is primed and all air has been pushed out of the lines,
close the dispense valve.
7.2.4.4 If you have moren than one pump, repeat this procedure for each pump.
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7.2.4.5 Set the air pressure to each pump at the lowest pressure needed to get the
desired results.
7.2.4.6 Never allow the pump to run dry of the material being pumped.
7.2.4.7 Relieve pressure before you check or service any system equipment.
8. Maintanence and trouble shooting
8.1 Warning:
8.1.1 To reduce the risk of serious injury whenever you are instructed to relieve
pressure.
8.1.2 Moving parts hazard: Never operate the pump with the warning plate or the
identification plate removed. These plates protect your fingers from pinching or
amputation by moving parts in the air motor.
8.2 Relieve pressure before you check or service any system equipment.
8.3 Problems, cause and solution, see sheet 4.
9. Disposal
9.1 Completely empty all parts of the equipment ( hoses,
pumps , tanks , etc ) and given case blown out with air .
9.2 Dangerous parts of the appliance must be made unusable
f.e. perforate pressure vessel , deform hose reels , etc.
9.3 Rubber , metals, glass ect. must be separated .
Dispose material fractions according to the local laws and regulations .
YOUR CONTRIBUTION TO PROTECT THE ENVIRONMENT
The pertinent regulations for the registration, setting up and operation of equipment for
dealing with materials hazardous to water must always be complied with by the user.
Problem Cause Solution
Inadequate air supply pressure or
restricted air lines
Increase air supply and/or clear
restriction
Closed or clogged pump valves Open and/or clean
Clogged fluid line, hose, valve or
other accessory
Relieve pressure. Clear obstruction
Damaged air motor Assess damage and service air
motor
Exhausted fluid supply Refill and reprime or flush
Continuous air exhaust Worn or damaged air motor gasket
or seal
Assess w ear or damage and
service air motor
Exhausted fluid supply Refill and reprime or flush
Worn up seals Replace
Damaged shovel tube Replace
Worn piston seal Replace
Worn seals Replace
Clogged fluid line, hose, valve or Relieve pressure
other accessory Clear obstruction
Grease leaking from muffler plates Worn throat seal Replace
Pump fails to operate
Erratic pump operation
Pump operates, but output low
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10. Warranty
10.1 In case of insufficient maintenance, faults on operation, use of not adequate
spare parts or attachments all liabilities and rights of claim under guarantee are
void.
10.2 The manufacturer is not liable for improper use of the container or ignoring the
safety instructions.
10.3 Technical modifications are subject to change without announcement.
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Fa x : + 49 (6 1 58 ) 9 2 98 0 -5 0 •
in f o@ r ap i d-g rou p.d e
Ra p id Gr o up Gmb H•Ba hnh ofs tra ße 53- 55•6 456 0 R ied sta dt•Tel efo n:+ 49 (61 58) 92 980 -0•
ww w .r a pi d -gr oup .de •
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