Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 1(14)
1 AIR OPERATED DIAPHRAGM PUMP, TYPE DL..........................................................2
1.1 Operation ...............................................................................................................4
1.2 Maintenance...........................................................................................................4
1.2.1 Replacement of elastomer parts .....................................................................5
1.2.2 Replacement of the internal control valve .......................................................7
1.2.3 Replacement of the external Q-control valve ..................................................9
1.2.4 Assembly of pump...........................................................................................9
1.2.5 Assembly of new clamp bands........................................................................9
1.2.6 Installation of the cone valves .......................................................................10
1.2.7 Tightening torques ........................................................................................11
1.3 Trouble shooting...................................................................................................12
1.4 Spare parts...........................................................................................................13
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 2(14)
1 AIR OPERATED DIAPHRAGM PUMP, TYPE DL
Before any maintenance work:
- Disconnect the pump from the compressed air supply.
- Depressurize the pump
- The equipment must be switched off and secured against
unintentional or unauthorised starting
Any alterations and conversions to the pump are prohibited.
However, this does not include minor changes, which do not effect
the safe operation of the pump, or measures to improve the safety.
Maintenance work must only be carried out by qualified and
authorised personnel.
Depressurise hydraulic or pneumatic equipment before starting to
work on it.
Moving parts must be locked in initial or parking position.
Pumps, which are used for pumping dangerous product must be
decontaminated.
Take care when handling hazardous (caustic, harmful) liquids.
Do not touch pump or pipes during operation. Danger of injury!
Do not subject the pump to sudden temperature changes. This can
cause leakages.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 3(14)
1 Discharge manifold
2 Upper valve ball (always closed during suction operation)
3 Diaphragm
4 Pump chamber
5 Silencer
6 Lower valve ball (open. Product can flow into the chamber)
7 Upper valve ball (open. Product is displaced)
8 Air chamber (the air displaces the product via the diaphragm and pulls
the second diaphragm back at the same time)
9 Lower valve ball (always closed during pumping)
10 Suction manifold
11 Air control unit
12 Outer piston cap
13 Inner piston cap
The air operated diaphragm pumps are oscillating positive displacement
pumps with two back to back pump chambers. These are each divided
by a diaphragm into an air and a fluid area.
Both diaphragms are connected by a piston rod, with the effect that
during one pumping stroke medium is pressed out of the one pump
chamber, while medium is being drawn into the other pump chamber.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 4(14)
1.1 Operation
Under most operating conditions the air operated diaphragm pumps are
selfpriming.
After the connection of suction and pressure lines and the connection of
the pressure air supply the pump is ready for operation and can be
started.
An empty pump must never be immediately subjected to high pressure.
In case of automatic pump control via solenoid valve installation of a slow
start up valve ir recommended.
The pumping capacity of the pump can be controlled via pressure and
quantity of the pressure air supply. To ensure perfect operation of the
pump even in case of pressure fluctuations, controlling the capacity via
the air quantity is recommended. The air pressure should be noticeably
higher than the pumping pressure. To increase the lifetime of wear items
like diaphragm, ball valves and air control valve, the pump should be
operated at a stroke frequency as low as possible.
If the product contains solids, chemicals or oils, the pump chambers must
be flushed before the pump is shut down. This avoids deposits of solids
or chemical attacks and destruction of the diaphragm during restarting.
The pump will stop when the air supply is shut off. As the ball valves on
the suction and discharge sides act as non-return valves the rising part of
the pressure pipe will always remain filled with product. This must be
taken into account when removing the discharge line and opening the
pump. The pump itself can be partly drained through the plug holes on
the side of the pump (option).
1.2 Maintenance
The pump should be visually inspected every week. In dependence on
type and/or duration of use disassembly and exchange of wear items at
intervals of 4 weeks to 6 months is recommended.
All pipes and fittings should be checked regularly for leaks and visible
external damage. The faults must be eliminated immediately!
Mechanical cleaning procedures should preferably be applied instead of
cleaning with chemical cleansing agents.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 5(14)
1.2.1 Replacement of elastomer parts
- Unscrew the screws and disassemble discharge and suction
manifold (Fig. 5).
- Loosen the clamp bands (if necessary lubricate with oil to avoid
seizing of stainless steel nuts and screws) (Fig. 6). On polished
stainless steel versions (DB, DH) open the DIN screws.
- Removing the pump chambers:
o Loosen the outer piston cap and take it off with the diaphragm
(Fig. 7). On plastic pumps unscrew the plastic cap beforehand
(Fig. 8).
- Replacing the PTFE diaphragm
o Pumps of types DL 40, 50 and 80 with PTFE diaphragms are
fitted with internal piston cap with bolted on shims for reduction
and relocation of the stroke. For subsequent change-over to
PTFE diaphragms the respective plates must be used (Fig.
10).
o PTFE diaphragms are generally delivered with an EPDM
backup diaphragm. This must be assembled facing towards the
pressure air side.
- Assembly of pump chamber:
o Assembly of diaphragm, fixation by fastening the outer piston
cap as specified in the table of tightening torques. Pump
chambers must generally be assembled with the diaphragm in
suction position (press diaphragm plate into air chamber) (Fig.
11). Tighten screws on clamping strap or mounting flange.
Assemble the second diaphragm in the same way. The flange
faces of the pump housing must be in line (Fig. 12).
- Assembly of PTFE valve seats
o PTFE valve seats are generally delivered with 2 O-rings. In
order to ensure leak tightness of the pump, these O-rings must
always be renewed after disassembling the connections.
o Valve seats for product range PM (only one O-ring) must be
completely replaced after each disassembly of the
connections.
o On plastic pumps from DL25 and higher the O-rings in the
outer piston cap must be replaced after each disassembly.
- For assembly of suction and discharge manifold refer to the table of
tightening torques.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 6(14)
AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 7(14)
1.2.2 Replacement of the internal control valve
- Depending on the application, air operated diaphragm pumps can be
delivered with various elastomer materials. The following materials
are available:
NRS marked yellow
NBR (Buna N)* marked red
EPDM (Nordel)* marked blue
EPDM-grau without marking colour
FKM (Viton)* marked white
PTFE (Polytetra without marking fluorethylene)*
The specified colour markings apply only for valve balls and valve
seats. Diaphragms are marked with the corresponding letters.
Before assembling a new set of diaphragms check valve seats and
valve balls to determine whether the existing material is appropriate
for the application (see compatibility list). If the defect parts in the
pump are not the result of normal mechanical wear, but of chemical
attacks, you should use a different material.
- Unscrew the air chambers from the central block (only on metal
pumps, exception: DB diaphragm pumps, DH) (Fig. 9).
- Press the air control valve out of the central block.
- The air control valve is replaced as a complete unit (Fig. 13)
- For assembly of plain bearings and seal ring it is recommended to
use the piston rod as guide. Please take care to mount the plain
bearings with the slits offset to each other (Fig. 14).
- In contrast to the assembly instructions for plain bearings on pump
range DL 25 – DL 80, which are equipped with two plain bearings,
the procedure on pumps of size DL 15 with only one plain bearing is
different.
The plain bearing has two grooves as seats for the outer O-rings. In
order to prevent the O-rings from being damaged by the milled
recess inside the bore, these O-rings must not be pushed past this
milled recess. For this purpose an O-ring is rolled over the plain
bearing, this bearing is inserted into the bore with the side without
O-ring forward and pressed in, until the groove becomes visible on
the opposite side. Now the second O-ring is placed into this grooved
and the complete plain bearing is pressed back into the bore, until it
is flush.
The piston rod is only delivered as a completely assembled unit with
shell and O-rings.
Replacement of the shell rings is not possible for technical reasons.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 8(14)
AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 9(14)
1.2.3 Replacement of the external Q-control valve
Loosen the four fastening screws on the control block. You can now pull
out the complete control valve including the pilot control. This is also
possible without having to disassemble the pump beforehand! (Fig. 15)
1.2.4 Assembly of pump
For assembly positions of individual parts please refer to the exploded
view.
When assembling the gasket make sure that the air supply bores remain
open (this applies also for assembly of the air chambers).
Check air filter and silencer for blockage and replace if necessary
1.2.5 Assembly of new clamp bands
When assembling new clamp bands tighten these first with the tensioning
screws, then tap the pump chamber with a plastic hammer to achieve
settling. Only tighten the tensioning screws after the clamp bands have
settled properly.
Retighten clamp bands after a few operating hours.
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 10(14)
1.2.6 Installation of the cone valves
If required, cone valves are installed instead of valve seats and ball
valves.
Disassembly of pump
- Depending on the application, air operated diaphragm pumps can be
delivered with various elastomer materials. The following materials
are available:
NRS marked yellow
NBR (Buna N)* marked red
EPDM (Nordel)* marked blue
EPDM-grau without marking colour
FKM (Viton)* marked white
PTFE (Polytetra without marking fluorethylene)*
The specified colour markings apply only for valve balls and valve
seats. Diaphragms are marked with the corresponding letters.
Before assembling a new set of diaphragms check valve seats and valve
balls to determine whether the existing material is appropriate for the
application (see compatibility list). If the defect parts in the pump are not
the result of normal mechanical wear, but of chemical attacks, you should
use a different material.
The tip of the valve must point in flow direction, i.e. if the suction port of
the pump is at the bottom, the valve tip must point upwards.
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INSTRUCTION MANUAL 11(14)
1.2.7 Tightening torques
Tightening torques range L, also type DH
Airchamber Air Air Control Diaphragm Air
Size / pump control
inlet block plate chambe
DL15 - - - 2,5 Nm 6 Nm -
DL25 25 Nm 50 Nm 8 Nm - 70 Nm 20 Nm
DL40 25 Nm 50 Nm 8 Nm - 90 Nm 20 Nm
DL50 49 Nm 85 Nm 8 Nm - 150 Nm 39 Nm
DL80 - 85 Nm 8 Nm - 150 Nm 39 Nm
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INSTRUCTION MANUAL 12(14)
1.3 Trouble shooting
Fault Possible cause Remedy
Pump runs, but no Pump draws air Seal the suction line
delivery Suction valve closed Open the valve
Suction capacity Change the arrangement
exceeded
Valve ball and seat on Replace seats and balls
suction side worn
Pump delivery too low Silencer blocked Clean or replace
Air intake blocked Clean or replace
Insufficient air supply Check the air supply line
Pipe work blocked Clean
Viscosity too high Change the conditions
Pump slows down, stops, Icing of the control valve Use dry air.
starts again Add anti-freeze agent to
the inlet air.
Use a heavy-duty silencer
Flow rate too low, Valve ball on suction side Remove blockage from
excessive blocked valve ball
pulsation
Product runs out of Diaphragm cracked Replace the diaphragm
silencer
Air in product Diaphragm cracked Replace the diaphragm
Pump stops after filling Air pressure too low Increase the air pressure
the Viscosity too high
lines Discharge pressure too
high
Pump does not work, Silencer blocked Clean and replace
despite Air inlet filter blocked Clean and renew
air supply Valve ball sticks to the Loosen, use PTFE balls, if
valve seat necessary
Valve balls deformed Chemical attack Use different material
Mechanical attack Use different material
Pump leaks at clamp Clamp band broken Replace
band Diaphragm not correctly Reassemble
centered during
assembly
PTFE diaphragm cracked Large solids in product Install a filter
after short time Sudden opening of Install a needle valve
pressure air
Insufficient suction lift Ball valves leaking Replace
Pump completely dry Fill the suction line
Pump runs very loud, Control valve worn Replace
rattling Excessive supply on Use heavier valve balls or
noise suction side use cone valves. Restrict
suction line.
Piston rod hard to move Inlet air too dry Add slight amount of oil to
(instrument air) air
Temperature too high Cool
Compressed air dirty Use a filter
Piston rod worn Replace
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Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 13(14)
1.4 Spare parts
Please state the following when ordering spare parts:
- Type of pump
- Serial no.
- Spare parts no.
If the materials for various parts have been changed at a later date, you
should always mention this when ordering spare parts.
AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030
FIN-20101 TURKU Fax + 358 204 86 5031
Wärtsilä id: DBAB178186 -
INSTRUCTION MANUAL 14(14)
Typ DL25-80, Metall
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