Operation and Maintenance Guide - Teryair · Operation and Maintenance Guide DP14 ... Fluid Outlet ½'' NPT/BSPT Ball Material Seat Material ... Please check compatibility of fluids

Operation and Maintenance Guide

DP14

Models covered

Read this manual carefully before installing, operating or servicing this equipment.

this manual is read by the operator. Please preserve this manual

This document issued with Model No.

Product Sr No.

& are trademarks of Teryair Equipment Pvt. Ltd.

DP14PPT-BR 1/2" Bolted (PP/PTF)

Operation and Maintenance Guide

DP14, 1/2" Diaphragm Pump

Read this manual carefully before installing, operating or servicing this equipment. It’s the responsibility of the

is read by the operator. Please preserve this manual.

are trademarks of Teryair Equipment Pvt. Ltd.

" Bolted (PP/PTF)-NPT DP14PPT-BG 1/2" Bolted (PP/PTF)

the responsibility of the employer to ensure

" Bolted (PP/PTF)-BSPT

Pump Nomenclature DP 14 PP T -BR

R - NPT threading (Inlet / outlet)

G - BSP threading (Inlet / outlet)

B - Bolted

T - PTFE (PTF)

PP - Polypropylene

Size : 14 for 1/2"

Diaphragm Pump

Pump Data

Pump Data A

Model No

Wetted Material

Diaphragm Material

BackupDiaphragm

DP14PPT-BR/G

Polypropylene PTFE Neoprene

Note:- Delivery figures are at 120 PSI air supply pressure. Normal operating supply pressure is 90 PSI.

Pump Data B (Common between all variants)

Description Value

Non wetted part Polypropylene

Centre Section Polypropylene

Air inlet detail ¼'' NPT/BSPT

Air Outlet detail ¼'' NPT

Fluid Inlet ½'' NPT/BSPT

Fluid Outlet ½'' NPT/BSPT

NPT threading (Inlet / outlet)

BSP threading (Inlet / outlet)

PTFE (PTF)

Polypropylene

Size : 14 for 1/2"

Diaphragm Pump

Backup Diaphragm

Ball Material

Seat Material

O-ring Material

Suction Capacity Delivery

Neoprene PTFE PTFE PTFE 2.7mtrs 48 litres/mi

Delivery figures are at 120 PSI air supply pressure. Normal operating supply pressure is 90 PSI.

Pump Data B (Common between all variants)

FF-MM-318-REV - 00

1

Max. Delivery

Air Consumption

Weight

litres/min 13 C.F.M. 3.8Kg

Delivery figures are at 120 PSI air supply pressure. Normal operating supply pressure is 90 PSI.

Operating and Safety Precautions

Warning. Static Electricity Static sparks can cause explosion resulting in

severe injury or death.

Ground the pump and the pump connections like

hoses and containers into which or from the fluid is

being transferred. Connect the grounding wire to

any bolt on the pump.

Secure pump, connections and all contact points to

avoid vibration and generation of contact or

spark.

Check continuity of electrical path to ground at

regular intervals.

Consult local building and electrical codes for

grounding requirements where needed.

Use hoses containing a grounding

Warning: Pump Exhaust In case of a diaphragm failure, fluid being pumped

may spray out from the exhaust of the pump. This

may cause severe injury depending on the fluid

being pumped.

If the fluid is hazardous, pipe away the exhaust to a

safe remote location using a generous diameter ¾”

pipe preferably with a grounding arrangement, and

refit the muffler at the end of this arrangement.

Always wear safety glasses while in the vicinity of

an operating pump.

Warning: Overpressure/Hazardous

Pressure Do not exceed the max supply air pressure of 125

PSI.

Make sure all connected hoses and pipelines are

rated to operate safely with the pressures generated

by pump of 125 PSI.

Do not open or handle pump or hoses while

pressurized.

Disconnect air supply line and relieve pressure from

the system by carefully opening

supply lines.

Warning: Hazardous MaterialsDo not move a pump that contains hazardous fluids

trapped inside it. Please observe prescribed

handling and safety codes. Drain the pump safely,

by turning it upside down and collecting the fluid

safely, before moving the pump.

Warning: Explosion Please check compatibility of fluids intended to be

handled with the materials of construction of the

pump. Severe reactions and explosions may occur

if materials are incompatible

Operating and Safety Precautions

Static sparks can cause explosion resulting in

Ground the pump and the pump connections like

hoses and containers into which or from the fluid is

being transferred. Connect the grounding wire to

Secure pump, connections and all contact points to

avoid vibration and generation of contact or static

Check continuity of electrical path to ground at

Consult local building and electrical codes for

needed.

wire.

In case of a diaphragm failure, fluid being pumped

may spray out from the exhaust of the pump. This

may cause severe injury depending on the fluid

s, pipe away the exhaust to a

safe remote location using a generous diameter ¾”

pipe preferably with a grounding arrangement, and

refit the muffler at the end of this arrangement.

Always wear safety glasses while in the vicinity of

Overpressure/Hazardous

Do not exceed the max supply air pressure of 125

Make sure all connected hoses and pipelines are

rated to operate safely with the pressures generated

Do not open or handle pump or hoses while

Disconnect air supply line and relieve pressure from

carefully opening discharge and

Hazardous Materials Do not move a pump that contains hazardous fluids

trapped inside it. Please observe prescribed

ling and safety codes. Drain the pump safely,

by turning it upside down and collecting the fluid

Please check compatibility of fluids intended to be

handled with the materials of construction of the

pump. Severe reactions and explosions may occur

Caution: Chemical CPlease check that the fluid being pumped is

compatible with the wetted parts of the pump. Refer

Cole Parmer

(http://www.coleparmer.in/Chemical

guide for details. Note that chemical compatibility

may change with temperature;

while selecting pump mater

Caution: Structural supportPlease refer figure 1 and ensure that the piping

system is independently supported and does not

load the pump. The pump is

the continuous and often pulsating load of a piping

system. Important to use

between rigid piping and pump casings.

Caution: Running dry, disconnection of

hoses when not in use for Although these pumps can be run dry for long

periods, it is advisable to avoid this as it causes

unnecessary wear of wearing parts.

Caution: Tightening torques and timely

re checking Outer flange to Shaft 11Nm

Air disc to outer side chamber

Inlet base to outer side chamber 11 Nm

Outlet to outer side chamber 11 Nm

Air Valve Body to Housing 3.5Nm

Caution: Operator understandingPlease ensure that all operators have read this

manual and have the

safe working practices and a

equipment when working on/around the pump.

Caution: Using genuine Teryair parts and

fitting as instructed Use genuine Teryair parts to ensure correct pump

operation and maximize life

FF-MM-318-REV - 00

2

Compatibility Please check that the fluid being pumped is

compatible with the wetted parts of the pump. Refer

Cole Parmer compatibility

http://www.coleparmer.in/Chemical-Resistance)

guide for details. Note that chemical compatibility

temperature; take this into account

while selecting pump material.

Structural support and ensure that the piping

system is independently supported and does not

pump is not designed to take

the continuous and often pulsating load of a piping

system. Important to use a flexible connection

between rigid piping and pump casings.

Running dry, disconnection of

hoses when not in use for long periods. Although these pumps can be run dry for long

periods, it is advisable to avoid this as it causes

unnecessary wear of wearing parts.

torques and timely

Nm

Air disc to outer side chamber 11Nm

base to outer side chamber 11 Nm

Outlet to outer side chamber 11 Nm

Air Valve Body to Housing 3.5Nm

Caution: Operator understanding Please ensure that all operators have read this

manual and have the required understanding of

working practices and are equipped with safety

equipment when working on/around the pump.

Caution: Using genuine Teryair parts and

eryair parts to ensure correct pump

operation and maximize life

Caution: Temperature limitations

Elastomer Minimum allowable

temperature

PTFE +40° F +4°C

Suggested Lubricants

Above 27 deg C

(80 deg F)

Shell Toona R 72

Mobil Almo 529

Esso -- -- --

Caltex Rando Oil 150

Texaco Regal Oil F

Daltron Silkolene 881 Burmah Castrol RD Oil 3

BP RD 220 HP60C

Duckham Garnet 7

Sternol Merlin 87

Petrofina Purifoc 53

Chevron Vistac Oil 18X

Temperature limitations

Minimum allowable temperature

Maximum allowable temperature

+40° F +4°C

+225° F +107°C

5 deg C to 27 deg C (40 degF to

80 degF)

Below 5 deg C

( 40 deg F)

Toona R 41 Toona R 27

Almo 527 Almo 525

Arox EP 65 Arox EP 45

Rando Oil 100 Rando Oil 46

Regal Oil PE Regal Oil B

Silkolene 548 Silkolene 773

RD Oil Light Megna SPX

RD150 HP20C RD80 HP10C

Garnet 6 Zero Flo 5

Merlin 71 Merlin 54

Purifoc 46 Purifoc 32

Vistac Oil 19X Vistac Oil 9X

FF-MM-318-REV - 00

3

Intended use and Prohibitive useThese conditions are adequately described in operating and safety precautions. The list of chemical and fluids are too huge to list

here. Standard industry practice is to refer a accepted chemical compatibility guide such as Cole Parmeretc to establish

compatibility. See section caution: Chemical compatibility earlier in

Suggested site selection and Installation recommendations

Location selection Pump location must be easily accessible with

reasonable space around for maintenance

operations.

Pump dimensional data for each variant is available

in section showing exploded views

Air supply Compressed air at 90 PSI (Stroke

max of 125PSI), free from moisture and having an

oil mist is essential. Use of a filter (50 microns), a

lubricator and a regulator is highly recommended

and should be installed as close as possible to the

pump inlet. Ensure correct grade of oil is used in

bowl. Too thick oil may slow down the valve shifting

mechanism and affect pump performance. See

suggested lubricants below.

Prohibitive use adequately described in operating and safety precautions. The list of chemical and fluids are too huge to list


caution: Chemical compatibility earlier in this document.


Figure 1

Pump location must be easily accessible with

reasonable space around for maintenance

imensional data for each variant is available

in section showing exploded views

pumps can take a

max of 125PSI), free from moisture and having an

oil mist is essential. Use of a filter (50 microns), a

and a regulator is highly recommended

and should be installed as close as possible to the

Ensure correct grade of oil is used in the lubricator

may slow down the valve shifting

mechanism and affect pump performance. See

Suction Ensure that the suction head after installation is well

within the pumps suction capabilities

For DP 14 pump fitted with PTFE the suction head

is 3 meters.

Muffler Use of supplied muffler is recommended to bring

pump operation sounds down

in case of hazardous fluids handling, please read

section of safety regarding piping away of exhaust

see Warning: Pump Exhaust

manual.

FF-MM-318-REV - 00

4

adequately described in operating and safety precautions. The list of chemical and fluids are too huge to list



Ensure that the suction head after installation is well

within the pumps suction capabilities

fitted with PTFE the suction head

Use of supplied muffler is recommended to bring

pump operation sounds down to comfortable levels,

in case of hazardous fluids handling, please read

section of safety regarding piping away of exhaust

Warning: Pump Exhaust earlier in this

Piping See section on safety if used in hazardous area

See Figure 1.

Suction side ½ inch or larger, non-

Delivery side ½ inch or larger.

A minimum number of bends and fittings to be used.

A flexible connection between suction, delivery and

air supply piping is highly recommended such that

piping stresses and loads do not transfer to pump

housing.

Select piping materials such that chemical

compatibility is maintained with the fluid being

pumped.

Operating InstructionsThe Teryair Stroke diaphragm pump generates a alternate stroking of the diaphragms against the fluid in the liquid chambers o

Pump. This reciprocatory action is responsible for the fluid being pumped.

It is possible to control the output of the pump

It is also possible to control the output of the pump by throttling action on the fluid flowing in the outlet piping by means

such a valve is shut completely the pressure in the discharge piping incr

equals it and the pump comes to a stop. This causes no damage to the pump and the pump consumes no more energy.

Upon opening of the valve, the pump starts reciprocating once again and resumes fluid deliv

Troubleshooting

Sr. No Description

1 Pump stopped and will not start.

2 Pump runs slowly, poor delivery

afety if used in hazardous area

-collapsible

A minimum number of bends and fittings to be used.

A flexible connection between suction, delivery and

air supply piping is highly recommended such that

piping stresses and loads do not transfer to pump

Select piping materials such that chemical

compatibility is maintained with the fluid being

Operating Instructions The Teryair Stroke diaphragm pump generates a alternate stroking of the diaphragms against the fluid in the liquid chambers o

Pump. This reciprocatory action is responsible for the fluid being pumped.

It is possible to control the output of the pump by controlling the supply air pressure.

It is also possible to control the output of the pump by throttling action on the fluid flowing in the outlet piping by means

such a valve is shut completely the pressure in the discharge piping increases to a point when the pressure at pump discharge


Upon opening of the valve, the pump starts reciprocating once again and resumes fluid delivery.

Causes Remedial action

Pump stopped and will not start. Insufficient Air Pressure Check air pressure is as recommended at the pump air inlet

Air Filter Blocked Check if debris has clogged the inlet filter on inlet air valve ( some models have air filter on the air inlet valve ) and ensure clear passage of air

Internal damage or excessive wear on components Proceed to dismantle the pump, examine component for wear, replace any worn components, re assemble carefully as instructed in this manual and re start the pump.

Pump runs slowly, poor delivery Cavitation Check if cavitation is occurring in the suction side, if so reduce suction vacuum by slowing down the pump.

Worn Balls and Seats Check proper sealing action of balls against seals, these components need to be replaced as a set if they are worn.

Insufficient or wrong lubricant in the air supply.

FF-MM-318-REV - 00

5

The Teryair Stroke diaphragm pump generates a alternate stroking of the diaphragms against the fluid in the liquid chambers of the

It is also possible to control the output of the pump by throttling action on the fluid flowing in the outlet piping by means of a valve. if

eases to a point when the pressure at pump discharge


Check air pressure is as recommended at the pump air inlet

Check if debris has clogged the inlet filter on the FRL unit/pump inlet air valve ( some models have air filter on the air inlet valve )

Internal damage or excessive wear on

Proceed to dismantle the pump, examine component for wear, components, re assemble carefully as instructed

Check if cavitation is occurring in the suction side, if so reduce suction vacuum by slowing down the pump.

Check proper sealing action of balls against seals, these components need to be replaced as a set if they are worn.

Insufficient or wrong lubricant in the air

3 Pump air valve freezes

4 Air bubbles in pump discharge or Product spraying out of exhaust

Maintenance Regular inspection and maintenance schedules will greatly enhance the life of the pump and will ensure a

working environment with little chance of breakdowns.

Follow the instructions clearly for disassembly and assembly of the pump and in the troubleshooting section.

Use genuine Teryair spares and if possible mention the serial number of

Always replace elastomers as a set, eg diaphragms, balls and seats

Disassembly and Re assemblyShut off air supply and allow residual Pressure to bleed off.

Disconnect air supply, disconnect suction and discharge pip

Turn pump upside down allow process fluid to drain away. If fluid is hazardous due care should

be taken.

Make a mark to indicate the positioning of each liquid chamber relative to the housing.

1) Replacement of Diaphragma. Unscrew both bolt (26) & nut (2

to remove the outlet & inlet

b. Leg (4) also can be disassembled by removing screw (35).

Ensure that the lubricant is as per the recommended chart, a thicker lubricant often makes the air valve work sluggishly.

Internal damage or excessive wear on components Proceed to dismantle the pump, examine component for wear, replace any worn components, reassemblein this manual and re start the pump.

Excessive moisture in supply air line. Ensure that the dew point of the supplied air is low enough. Install an air dryer or moisture separator on the supply line.

Air bubbles in pump discharge or Product 1. Broken Diaphragm 2. Improper seal between inner

and shaft. 3. Air leakage into product from balls / seats area4. Air sucked into suction pipeline due to insufficiently

tight joints on suction pipeline.Proceed to dismantle the pump, examine component for wear, replace any worn components, re assembly carefully as instructed in this manual and re start the pump.

Regular inspection and maintenance schedules will greatly enhance the life of the pump and will ensure a

working environment with little chance of breakdowns.


spares and if possible mention the serial number of the pump when ordering spares.

Always replace elastomers as a set, eg diaphragms, balls and seats.

Disassembly and Re assembly

Shut off air supply and allow residual Pressure to bleed off.

nnect suction and discharge piping


Make a mark to indicate the positioning of each liquid chamber relative to the housing.

Replacement of Diaphragm ) & nut (28) as shown in the exploded view and proceed

& inlet respectively.

Leg (4) also can be disassembled by removing screw (35).

FF-MM-318-REV - 00

6

Ensure that the lubricant is as per the recommended chart, a lubricant often makes the air valve work sluggishly.

Internal damage or excessive wear on

Proceed to dismantle the pump, examine component for wear, assemble carefully as instructed

Excessive moisture in supply air line. Ensure that the dew point of the supplied air is low enough. Install

air dryer or moisture separator on the supply line.

Improper seal between inner pistons, outer pistons

Air leakage into product from balls / seats area Air sucked into suction pipeline due to insufficiently tight joints on suction pipeline.

pump, examine component for wear, replace any worn components, re assembly carefully as instructed

Regular inspection and maintenance schedules will greatly enhance the life of the pump and will ensure a trouble free and safe


the pump when ordering spares.


and proceed

c. Now unscrew hex head bolt

nut (25) of any one side and proceed to

the outer chamber (2). Now repeat the same

procedure to remove the second outer

(2).

d. Now with the help of two spanner hold one of the

across flat of one outer flange (

second outer flange (9) to disassemble it from

the shaft assembly. Remove

backup diaphragm (7) and

e. Now pull out the half shaft assembly out of the

shaft housing (1). Now hold the shaft (6

with proper packing. Care must be taken

damage the shaft outer surface

outer flange (9) with spanner.

f. Now replace the diaphragms (5

diaphragm (7). Ensure that dia

orientation is correct. Make sure PTFE

diaphragm faces outer chamber (2).

g. Lubricate the edge of the shaft with specified

lubricant. Slowly insert the shaft with rotating

motion. Care should be taken not to damage the

rubber rings (29).

h. Once the half shaft open portion comes out of

the bush, follow the procedure in reverse manner

as described in part (a) & (b) and assemble the

pump.

2) Replacement of Shaft O ringsa. For removing the rubber rings from bush, first follow the step a, b & c from the diaphragm replacement.

b. Now remove the seals with the help of needle Nose pliers. Care should be tak

bush.

c. Once all the old seals are have been removed, the inside of the bushing should be cleaned to ensure no debris is

left that may damage to new seals (Pressurized air is preferable).

d. These following tools can be used

● Needle Nose pliers

● Phillips Screwdriver

● Electrical Tape

e. Wrap electrical tape around each leg of the needle nose pliers (heat shrink may also be used) . This is done to

prevent damaging the inside portion of the ne

f. With a new seal in hand, place the two legs of the nose pliers inside the seal ring. Open the pliers as wide as the

seal diameter will allow, then two fingers pull down on the top portion of the seal to form kidney bean shape.

g. Lightly clamp the pliers together to hold the seal into the kidney shape. Be sure to pull the seal into as tight of a

kidney shape as possible, this will allow the seal to travel down the bushing bore easier.

h. With the seal clamped in the pliers, insert the seal into the bushi

the correct groove. Once the bottom of the seal is seated in the groove, release the clamp pressure on the pliers.

This will allow the seal to partially snap back to its original shape.

i. After the pliers are removed, you will notice a slight bump in the seal shape. Before the seal can be properly

resized, the bump in the seal should be removed as much as possible. This can be done with either the Phillips

screw driver or your finger, apply light pressure to th

almost completely eliminated.

j. Lubricate the edge of the shaft with

k. Slowly insert the shaft with rotating motion. This will complete the resizing of the seals.

l. Perform these steps for the remaining seals.

head bolt (23), washer (24) &

) of any one side and proceed to remove

. Now repeat the same

procedure to remove the second outer chamber

Now with the help of two spanner hold one of the

ross flat of one outer flange (9) and rotate the

) to disassemble it from

the shaft assembly. Remove the diaphragm (5),

backup diaphragm (7) and inner flange (8).

Now pull out the half shaft assembly out of the

Now hold the shaft (6) in a vice

Care must be taken not to

damage the shaft outer surface. Now remove the

) with spanner.

Now replace the diaphragms (5) and backup

. Ensure that diaphragm

orientation is correct. Make sure PTFE

diaphragm faces outer chamber (2).

the edge of the shaft with specified

lubricant. Slowly insert the shaft with rotating

motion. Care should be taken not to damage the

Once the half shaft open portion comes out of

the bush, follow the procedure in reverse manner

ibed in part (a) & (b) and assemble the

Replacement of Shaft O rings For removing the rubber rings from bush, first follow the step a, b & c from the diaphragm replacement.

Now remove the seals with the help of needle Nose pliers. Care should be taken not to damage the inner face of

Once all the old seals are have been removed, the inside of the bushing should be cleaned to ensure no debris is

left that may damage to new seals (Pressurized air is preferable).

These following tools can be used to aid in the installation of new seals:

Needle Nose pliers

Phillips Screwdriver

Electrical Tape

Wrap electrical tape around each leg of the needle nose pliers (heat shrink may also be used) . This is done to

prevent damaging the inside portion of the new seals.

With a new seal in hand, place the two legs of the nose pliers inside the seal ring. Open the pliers as wide as the


iers together to hold the seal into the kidney shape. Be sure to pull the seal into as tight of a


With the seal clamped in the pliers, insert the seal into the bushing bore and position the bottom of the seal into


This will allow the seal to partially snap back to its original shape.

removed, you will notice a slight bump in the seal shape. Before the seal can be properly


screw driver or your finger, apply light pressure to the peak of the bump. This pressure will cause the bump to be

almost completely eliminated.

the edge of the shaft with specified lubricant.

Slowly insert the shaft with rotating motion. This will complete the resizing of the seals.

teps for the remaining seals.

FF-MM-318-REV - 00

7

For removing the rubber rings from bush, first follow the step a, b & c from the diaphragm replacement.

en not to damage the inner face of

Once all the old seals are have been removed, the inside of the bushing should be cleaned to ensure no debris is

Wrap electrical tape around each leg of the needle nose pliers (heat shrink may also be used) . This is done to

With a new seal in hand, place the two legs of the nose pliers inside the seal ring. Open the pliers as wide as the


iers together to hold the seal into the kidney shape. Be sure to pull the seal into as tight of a


ng bore and position the bottom of the seal into


removed, you will notice a slight bump in the seal shape. Before the seal can be properly


e peak of the bump. This pressure will cause the bump to be

Slowly insert the shaft with rotating motion. This will complete the resizing of the seals.

3) Replacement of Ball seat & Balla) Follow the step (a) of diaphragm r

(19) with new one (Refer

4) Replacement of air valve a) Unscrew bolt (22). (Refer page 9)

b) Remove the air valve assembly

c) Now use the spanner and allen key to open the both end caps. Clamp the end cap

with push pin (13) on vice and use allen key to open the end

d) Now pull out the air valve

e) Remove ring (32) with the help of a flat screw driver from both sides of air valve

and replace with new one

f) Now replace the o ring (31) from the air valve (14

g) Replace the o ring (33) from both the e

h) Now pull out the push pin (15) form the end cap (13) and replace the o

i) While assembling apply lubricants i

air valve assembly with all the seals from an

be taken so that rings (32

j) Now assemble the end caps with o

seat & Ball Follow the step (a) of diaphragm replacement. Replace the ball (17), seal (20)

figure page 9).

Replacement of air valve and o ring of end cap . (Refer page 9)

Remove the air valve assembly along with the gasket (10).

use the spanner and allen key to open the both end caps. Clamp the end cap

with push pin (13) on vice and use allen key to open the end cap(12).

the air valve (14) from the air valve body.

) with the help of a flat screw driver from both sides of air valve

and replace with new one.

eplace the o ring (31) from the air valve (14).

) from both the end caps.

Now pull out the push pin (15) form the end cap (13) and replace the o-ring (34).

While assembling apply lubricants in the bore of air valve body (11). Now push the

air valve assembly with all the seals from any one side of air valve body (11). Care to

be taken so that rings (32) move smoothly into the bore of air valve body (11).

Now assemble the end caps with o rings from both sides.

FF-MM-318-REV - 00

8

0), valve ball seat (18) & ball cage

use the spanner and allen key to open the both end caps. Clamp the end cap

) with the help of a flat screw driver from both sides of air valve (14)

(34).

). Now push the

Care to

Exploded view

DP14PPT-BR/G

FF-MM-318-REV - 00

9

Bill of material

* Mark indicates the fast moving components which are recommended for stock

Mark indicates the fast moving components which are recommended for stock

FF-MM-318-REV - 00

10

Documents

Operation and Maintenance Guide - Teryair · Operation and Maintenance Guide DP14 ... Fluid Outlet ½'' NPT/BSPT Ball Material Seat Material ... Please check compatibility of fluids