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Operations & maintenance manual – ASTRA evo (DDE)

ARGALAIR 2020 | Rev. 6

The air connection is blocked

Check / clean the air supply connection

The 3-way air valve is defective

Clean / replace complete the 3-way air valve

Damaged pneumatic exchanger

Replace the pneumatic exchanger

Pump discharge and/or suction

closed

Open the valves, or remove the pipes and
check if the pump starts

Diaphragms breakdown

Replace diaphragms

Silencer is blocked

Check / clean / replace silencer

Dirt in the pump fluid chambers

Remove debris from the fluid chambers

The pump works but it does not
pump

Valve balls do not close / Valve seats
are worn

Disassemble the manifolds and clean the seats
or replace the balls and the seats if worn

Suction connection is not tight

Tighten the suction line

Suction line is blocked

Clean the suction line

Silencer is blocked

Check / clean / replace silencer

Pump starts with high pressure

Start the pump slowly (follow the indications
into the use manual)

Air in suction / discharge line

Vent suction / discharge line

Excessive suction height

Reduce the suction height

Too viscous fluid

Install pipes with greater size especially for
intake and decrease the pumps cycles

The pump works with slow cycles

Excessively viscous fluid

No remedy

Clogged discharge pipe

Check and clean

Clogged suction pipe

Check and clean

Insufficient suction

Suction connections not tightened

Check and re-tighten the connections

Clogged suction pipe

Check / clean / replace

Silencer is blocked

Check / clean / replace silencer

Valve balls do not close / Valve seats
are worn

Disassemble the manifolds and clean the seats
or replace the balls and the seats if worn

The pump works irregularly

Internal pneumatic exchanger

clogged or defective

Replace the pneumatic exchanger

Diaphragms breakdown

Replace diaphragms

Valve balls do not close / Valve seats
are worn

Disassemble the manifolds and clean the seats
or replace the balls and the seats if worn

Air valves are defective

Clean / replace the air valves

Worn shaft

Replace the pneumatic exchanger

Ice on the discharge

Dehumidify and filter air

Insufficient air volume or pressure

Check the pressure with a gauge installed on
the pump and with running pump. If pressure in
that point is too low related to the mains
pressure, check all the air connections. Check
that all the air control devices have a sufficient
flow rate

Содержание ASTRA Evo DDE 030

Страница 1: ...OPERATIONS MAINTENANCE MANUAL DEALER For Maintenance Date of commissioning Position system reference Service ...

Страница 2: ...ION 1 7 FIRST START UP 1 8 OPERATION 1 9 STOP OF THE PUMP 2 SAFETY RISKS 2 0 GENERAL PRESCRIPTIONS 3 MAINTENANCE 3 1 OPERATORS FOR INSTALLATION AND START UP 3 2 OPERATORS FOR OPERATION AND MAINTENANCE 3 3 OPERATORS FOR REPAIR 3 4 PUMP INSPECTION 3 5 COMPLETE INSPECTION 3 6 TROUBLESHOOTING AND POSSIBLE CAUSES 3 7 PARTS LISTS RECOMMENDED SPARE PARTS DDE 030 3 8 PARTS LISTS RECOMMENDED SPARE PARTS DD...

Страница 3: ... ASTRA evo series is with the suction placed to the left of the air connection while the discharge is positioned in the upper part of the pump on the left side of the air connection 0 3 PUMP LABELING RANGE MODEL MATERIALS CONNECTIONS CONFIGURATION CHAMBERS VERSION DIAPHRAGM BALLS SEATS O RING TYPE SUCTION DISCHARGE DDE 160 WR N Y T P V G L L 030 G 1 2 WR PP GFR N STD M TPV T PTFE P PP D EPDM G BSP...

Страница 4: ...nd the ATEX classification see the paragraph 0 4 1 Check these data upon receiving the goods Any discrepancy between the order and the discharge must be communicated immediately In order to be able to trace data and information the descriptive code model and serial number of the pump must be quoted The label is placed on the center block 0 4 STANDARDS REFERENCE MODEL MANUFACTURER DATA DESCRIPTIVE ...

Страница 5: ...ARD version fulfill the requirements of ATEX Directive 2014 34 EU with the following rating II 3 3 GD IIB c T4 Equipment group II machines intended for use on the surface not in mines Category group 3 equipment that guarantee a normal level of protection II 3 3 GD The first number indicates that the internal space of the equipment is intended to be used to transfer potentially explosive fluids see...

Страница 6: ...PP Carbon Fiber PP CFF20 G 1 2 G 1 G 1 1 2 G 2 II 2 2GD c IIB T4 ASTRA evo STANDARD ZONE 2 WRN FCN ALN SSN SPN Pump made in conductive materials WRN Center Block Fluid Chambers Manifolds PP Glass Fiber PP GF30 FCN Fluid Chambers Manifolds PVDF Carbon Fiber PVDF CFF15 Center Block PP Glass Fiber PP GF30 ALN Fluid Chambers Manifolds ALUMINIUM AL EN AC46100 Center Block 1 PP Glass Fiber PP GF30 for m...

Страница 7: ...of people or things in the vicinity of the pump All technical data are referred to a STANDARD PUMP see TECHNICAL FEATURES but we remember that for a constant technological innovation and quality research the characteristics reported in this Manual may change without notice The drawings and all the other documents delivered with the machine are the property of the manufacturer which reserves all ri...

Страница 8: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 8 ...

Страница 9: ...bassemblies CAUTION this symbol indicates to the personnel that the described operation may cause damage to the machine and or its components and consequent risks for the operator and or the environment if not carried out in compliance with the safety regulations If you ignore the caution described and operate the pump in an improper manner there is the danger of personal injury or property damage...

Страница 10: ...or pressure and the environment must be compatible with the pump characteristics The best knower of the fluid is who buys the pump The buyer is responsible for choosing the materials used for the parts in contact with the fluid The configuration of the pump wetted parts is defined in the ordering phase and is indicated on the nameplate ASTRA evo pumps are suitable for pumping corrosive abrasive ag...

Страница 11: ...er of glycol from tanks CONSTRUCTION Fuel transfer Concrete batching plants Site dehydration Dosage and mixing of asphalt additives Municipal use WATER TREATMENT Waste water discharge and chemical waste Movement of sludge deriving from activated sludge sludge treatment process Sludge thickening and digestion Filter press feed Neutralization and flocculation transfer and distribution of coagulant f...

Страница 12: ...erate the vacuum The purchaser of the pump must be sure that he has correctly evaluated the chemical physical characteristics of the fluid Note The maximum temperature of water in continuous operation DESIGN TEMPERATURE depends on the type of construction materials indicated on the nameplate VERSION MAX TEMPERATURE C F WRN WRX 60 140 FCN FCX 90 194 ALN ALX 100 212 SSN SSX 100 212 SPN SPX 100 212 T...

Страница 13: ...l between pump and free surface of the fluid to be sucked The pumped fluid may contain particles suspended in different dimensions in accordance with the constructive materials of pump MODEL 030 060 100 160 400 650 MATERIAL WR_ FC_ AL_ SS_ SP_ WR_ FC_ AL_ SS_ SP_ WR_ FC_ AL_ SS_ SP_ WR_ FC_ AL_ SS_ SP_ WR_ FC_ AL_ SS_ SP_ WR_ FC_ AL_ SS_ SP_ MAX DIMENSION mm 3 3 5 3 2 3 8 5 5 6 7 9 Table 4 0 6 2 A...

Страница 14: ...nt the entry of bulk particles The filter removes harmful dirt and moisture from the compressed air supply Air quality according to ISO 8573 1 2010 Contaminants and purity classes Particles class IV Water class IV Oil class IV For most demanding applications H 40 m c w for extended periods the water content in the air must not exceed the specifications dictated by class II WARNING Dirt in the air ...

Страница 15: ... risk that ice accumulates in high quantity and the pump stops To avoid this it is very important to maintain the air quality as prescribed within this Manual WARNING ice may form into the pneumatic exchanger SCRUPULOUSLY FOLLOW THE INSTRUCTIONS WRITTEN IN THIS PARAGRAPH TO PREVENT THE ICE FORMATION 0 6 3 OPERATING PRINCIPLE The ASTRA evo pumps are volumetric The suction and discharge cycles are s...

Страница 16: ...in the intake phase since it is dragged by the shaft that connects it to the other diaphragm A that is under pressure air present behind it is discharged into the environment through the flow rate regulator present on the pump while a pressure drop is created in the fluid chamber which sucks the fluid from the suction circuit When the diaphragm A under pressure reaches the stroke limit the distrib...

Страница 17: ...ored prior to installation place it in a clean location Do not remove the protective covers from the suction discharge and air connections which have been fastened to keep pump internals free of debris The pump has to be protected from wetness coldness dirtying UV radiation Store the pump in an original packaging The package should be stored raised from the ground in a closed clean and dry environ...

Страница 18: ...FORE STARTING THE PUMP Make sure that the pump is installed according to the contents of this manual Before starting the pump is not necessary to fill it with liquid if not previously agreed in special cases To verify the absence of losses we recommend to conduct a run test to make sure that the pump operates correctly and does not leak Check the tightening torque of screws After one week of opera...

Страница 19: ...ous fluids use pipes with nominal diameter greater than the diameter of the pump connections It is essential that the suction pipe is leak proof for the pump self priming operation Position the pump as close as possible to the point of suction It is better to use a short suction pipe to avoid air pockets Check that the connections hose pump are correctly tight and there are no leaks Avoid installi...

Страница 20: ...ng of the pump 4 Use suction and discharge pressure gauges with pressure switches for additional protection Cut off the pump when there is an excessive discharge pressure to protect the system and an excessive suction depression to protect the pump 5 Use pipe anchoring 6 Place shut off valves on both suction and discharge piping for pump isolation The pump performance can be adjusted by normal flo...

Страница 21: ... labels in accordance with the related standards do not install the pump near heat source do not install pump in places with the risk of falling solids and or fluids do not install the pump close to fixed workshop or at places with high human traffic install additional protection shield for the pump or operator as appropriate WARNING In the event of diaphragm failure the fluid may contaminate the ...

Страница 22: ...r circuit The performance of the pump can be adjusted by using the air flow regulator valve and the pressure reducer supplied with the air regulation KIT The performance can also be adjusted by the two way valve on the discharge side of the system With supply pressure value below 2 bar the pump may not work properly with pressure value above 8 bar the pump may breakdown and or yields with conseque...

Страница 23: ...Stop the pump and close the valves if leakages are observed Wash with water only if it is chemical compatibility alternatively use a suitable solvent that does not generate hazardous exothermic reactions Consult the fluid supplier to decide the most suitable fire prevention method Empty the pump if it is not in use for a long period of time especially for fluids that tend to crystallize Check that...

Страница 24: ... explosion proof areas maintenance repair operations must be carried out only after a careful evaluation of the practicability and with appropriate tools WARNING Safety requirements and explosion risk prevention in case the pump was installed in an explosive atmosphere are not fulfilled if the pump is not earthed or is incorrectly earthed or the other equipment like hoses pipes containers are prop...

Страница 25: ... CAUTION The increase in temperature can cause damage to the pump and or pipes DANGER for the personnel in vicinity of the plant pump and piping Avoid rapid temperature variations and do not exceed the maximum temperature specified when ordering the pump RESPECT THE MAX TEMPERATURE VALUES BASED ON WATER WITHIN THIS MANUAL If a hot or cold temperature below 0 C product is pumped the pump must not r...

Страница 26: ... piping to prevent that the pumped fluid entering into the pneumatic circuit in case of the diaphragms breakage is expelled into the compressed air circuit DANGER OF FLUID ENTERING COMPRESSED AIR CIRCUIT AND DISCHARGING INTO THE ENVIRONMENT WARNING The use of pumps made with non conductive material which become charged with electrostatic and without suitable grounding for flammable liquids is forb...

Страница 27: ...nal protection works when the pump is installed in places with high human traffic against splashes of fluorescent fluid in case of accidental breakage and always direct possible leakages towards collection tanks C wear appropriate Protective Person Equipment PPE when operating on the pump D make sure that the intake and discharge valves are correctly closed during the disassembly E make sure that ...

Страница 28: ...d with complete original parts and not repaired parts the replacement of damaged parts must be carried out in a clean and dry place 3 1 OPERATORS FOR INSTALLATION AND START UP Interventions to be carried out only by skilled personnel who may delegate operations to others in accordance with specific evaluations required technical skills plumbing pneumatic and or electric qualification as appropriat...

Страница 29: ...mation is useful for checking performance as wear takes place We recommend to conduct a ROUTINE INSPECTION on the pump to detect any problems for example a change in sound of the running pump can be an indication of wearing parts Through this test we can see the presence of liquid leaks and variations in the performance of the pump itself 3 5 COMPLETE INSPECTION The intervals for a COMPLETE INSPEC...

Страница 30: ...viscous fluid Install pipes with greater size especially for intake and decrease the pumps cycles 3 The pump works with slow cycles Excessively viscous fluid No remedy Clogged discharge pipe Check and clean Clogged suction pipe Check and clean 4 Insufficient suction Suction connections not tightened Check and re tighten the connections Clogged suction pipe Check clean replace Silencer is blocked C...

Страница 31: ...suction line Clogged pipes Check and clean Too viscous fluid Install pipes with greater size especially for suction and decrease the pumps cycles Valve balls do not close Valve seats are worn Disassemble the manifolds and clean the seats or replace the balls and the seats if worn Insufficient air volume Check the pressure with a gauge installed on the pump and with running pump If pressure in that...

Страница 32: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 32 3 7 PART LIST RECOMMENDED SPARE PARTS DDE 030 ...

Страница 33: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 33 WR_ FC_ AL_ SS_ SP_ ...

Страница 34: ...anifold version SS_ FDA SP_ 1 13 Ball Runner Cage version WR_ FC_ AL_ 2 14 Ball 4 15 Ball Seat 4 17 Foot version WR_ FC_ AL_ 2 19 Manifold Connection Discharge Side Fluid Chamber 4 19 Washers Discharge Manifold Fluid Chamber 4 19b Nuts Discharge Manifold Fluid Chamber 4 20 Manifold Connection Suction Side Fluid Chamber 4 20 Washers Suction Manifold Fluid Chamber 4 20b Nuts Suction Manifold Fluid C...

Страница 35: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 35 3 8 PART LIST RECOMMENDED SPARE PARTS DDE 060 100 160 LEGEND DDE 060 100 160 WR_ FC_ AL_ SS_ SP_ ...

Страница 36: ...ide Fluid Chamber 4 19a Washers Discharge Manifold Fluid Chamber 4 19b Nuts Discharge Manifold Fluid Chamber 4 20 Manifold Connection Suction Side Fluid Chamber 4 20a Washers Suction Manifold Fluid Chamber 4 20b Nuts Suction Manifold Fluid Chamber 4 21 Connection Fluid Chamber Center Block Half Part MOD 60 100 n 6 6 MOD 160 n 8 8 21a Washers Fluid Chamber Center Block Half Part MOD 60 100 n 6 6 MO...

Страница 37: ...ons maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 37 LEGEND DDE 400 650 Pos Part name Q ty recommended spare parts start up 2 years 1 Center Block Half Part 2 2 Pneumatic Exchanger 1 WR_ FC_ AL_ SS_ SP_ ...

Страница 38: ...ion WR_ FC_ AL_ n 8 version SS_ SP_ n 6 20 Manifold Connection Suction Side Fluid Chamber version WR_ FC_ AL_ n 8 version SS_ SP_ n 6 20a Washers Suction Side Fluid Chamber version WR_ FC_ AL_ n 8 version SS_ SP_ n 6 20b Nuts Suction Side Fluid Chamber version WR_ FC_ AL_ n 8 version SS_ SP_ n 6 21 Connection Fluid Chamber Center Block Half Part MOD 400 n 8 8 MOD 650 n 10 10 21a Washers Fluid Cham...

Страница 39: ... 22c WASHERS BONDED SEAL MOD 400 n 8 MOD 650 n 12 3 10 RECOMMENDATIONS WARNING Before performing any maintenance or repair work on the pump disconnect the pump from the air supply line Disconnect the hydraulic connections and discharge the fluid which is contained within the pump itself ...

Страница 40: ... clean carefully the pump disconnect the suction and discharge connections Check that the tools are compatible with the pump clamping elements Than follow the instructions below Check that the pump is completely empty turn it upside down and collect any leaking Clean all the pump external surfaces with a damp cloth TOOLS REQUIRED DDE 030 060 100 160 hex spanners 10mm 27mm DDE 400 hex spanners 10mm...

Страница 41: ...he cages the balls and the ball seats Check the status of these parts Replace worn or damaged parts STEP 4 STEP 5 STEP 6 Rotate the pump and place it on the discharge manifold side Remove the suction manifold bolts pos 20 Remove the feet then the suction manifold pos 12b NOTE keep caution during removal Remove the O rings the cages the balls and the ball seats Check the status of these parts Repla...

Страница 42: ...the diaphragms from the shaft pos 7 remove the air caps pos 6 the belleville washers pos 5 the spacers pos 47 if present then remove the pump shaft pos 3 from the center block Then remove the O ring pos 3a from the shaft pos 3 STEP 9 Remove the blots pos 22 from the center block then open up the 2 half parts pos 1 STEP 10 Remove the O rings pos 28 29 then remove the silencers pos 10 For the models...

Страница 43: ...n the thermoplastic parts clogged materials and or agglomerates caused by pumped fluid deformations and or surface lesions on the diaphragms deformations and or breakages on the valve seats Replace the parts broken cracked deformed Reopen all the clogged ducts and eliminate any chemical agglomerates Clean all the surfaces before reassembly particularly the OR gaskets seats risk of leakage CLEANING...

Страница 44: ...hambers bolts pos 21 on both sides 2 Connect the air supply line set the air pressure to 5 bar 72 5 psi then start the pump 3 In most cases air leaks will occur and the pump may not work This is normal 4 While the pump is running gradually tighten the bolts pos 21 on both sides according to a cross pattern until there are no more leaks 5 Evenly tighten the bolts pos 21 to the prescribed torque see...

Страница 45: ...on Fluid Chamber Center Block Half Part 12 22 Connection Center Block 8 8 Cap Fluid side 30 DDE 650 19 Manifold Connection Discharge Side Fluid Chamber 12 20 Manifold Connection Suction Side Fluid Chamber 12 21 Connection Fluid Chamber Center Block Half Part 12 22 Connection Center Block 12 8 Cap Fluid side 50 Table 7 4 SPARE PARTS During the operation of the pump it is normal that some parts are ...

Страница 46: ...POS DESCRIPTION Q TY KIT K3 7 DIAPHRAGM 2 13 BALL RUNNER CAGE 2 14 BALL 4 15 BALL SEAT 4 32 O RING UPPER 4 33 O RING LOWER 4 Table 11 VERSION SS_ SP_ POS DESCRIPTION Q TY KIT K3 7 DIAPHRAGM 2 14 BALL 4 15 BALL SEAT 4 33 O RING LOWER 4 Table 10 Configurations y and L respectively provide coupled diaphragm TPE PTFE TPV PTFE DIAPHRAGM AIR SIDE TPE Q TY 2 DIAPHRAGM FLUID SIDE PTFE Q TY 2 ...

Страница 47: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 47 ASTRA evo DDE 060 100 160 WR_ FC_ AL_ SS_ SP_ K1 K3 ...

Страница 48: ...S DESCRIPTION Q TY KIT K3 7 DIAPHRAGM 2 13 BALL RUNNER CAGE 2 14 BALL 4 15 BALL SEAT 4 32 O RING UPPER 4 33 O RING LOWER 4 Table 14 VERSION WR_ FC_ AL_ POS DESCRIPTION Q TY KIT K3 7 DIAPHRAGM 2 14 BALL 4 33 O RING LOWER 4 15 BALL SEAT 4 Table 13 Configurations y and L respectively provide coupled diaphragm TPE PTFE TPV PTFE PUMP MODEL DDE 060 O RING pos 28 is assembled into the pneumatic exchanger...

Страница 49: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 49 ...

Страница 50: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 50 WR_ FC_ AL_ ...

Страница 51: ...GALAIR 2020 Rev 6 51 ASTRA evo DDE 400 650 Table 15 VERSION WR_ FC_ AL_ SS_ SP_ POS DESCRIPTION Q TY KIT K1 2 PNEUMATIC EXCHANGER 1 28 O RING 2 29 O RING 2 VERSION WR_ FC_ AL_ POS DESCRIZIONE Q TY VERSION SS_ SP_ POS DESCRIZIONE Q TY SS_ SP_ K1 K3 ...

Страница 52: ...2 KIT K3 7 DIAPHRAGM 2 13 BALL RUNNER CAGE 2 14 BALL 4 15 BALL SEAT 4 32 O RING UPPER 4 33 O RING LOWER 4 Table 17 KIT K3 7 DIAPHRAGM 2 14 BALL 4 15 BALL SEAT 4 33 O RING LOWER 4 Table 16 Configurations y and L respectively provide coupled diaphragm TPE PTFE TPV PTFE ...

Страница 53: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 53 SS_ SP_ WR_ FC_ AL_ K1 K3 ...

Страница 54: ..._ SP_ Max flow rate L min 52 73 130 175 370 715 Max discharge head m c w 80 80 80 80 80 80 Max supply air pressure bar 8 8 8 8 8 8 Min startup air pressure bar 2 2 2 2 2 2 Max discharge pressure bar 8 8 8 8 8 8 Max suction lift dry m c w 4 4 4 4 5 4 5 4 5 Max suction lift wet m c w 9 9 9 9 9 9 Max size of passable solids mm 3 3 5 3 2 3 8 5 5 6 7 9 Noise sound pressure level Lp dB A 72 75 80 80 80 ...

Страница 55: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 55 DDE 030 DDE 060 DDE 100 ...

Страница 56: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 56 DDE 160 DDE 400 DDE 650 CAPACITY CHANGES AT DIFFERENT SUCTION HEADS 5 3 DIMENSIONAL DRAWINGS ...

Страница 57: ...perations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 57 Plastic pumps MODEL 030 060 100 160 400 THREADED 400 FLANGED 650 THREADED 650 FLANGED 030 060 100 160 450 650 WR_ FC_ AL_ 450 650 SS_ SP_ ...

Страница 58: ...60 100 160 400 650 MATERIALE AL_ SS_ SP_ AL_ SS_ SP_ AL_ SS_ SP_ AL_ SS_ SP_ AL_ SS_ SP_ AL_ SS_ SP_ DnA inch 1 2 1 2 1 1 1 1 2 2 DnM inch 1 2 1 2 1 1 1 1 2 2 A mm 194 203 203 246 247 247 292 276 274 310 312 310 467 400 594 478 B mm 107 160 170 203 263 5 345 346 B mm 317 381 C mm 205 197 203 254 248 253 289 288 335 321 5 573 501 688 694 D mm 93 65 104 80 120 89 140 100 190 160 225 220 E mm 130 95 ...

Страница 59: ... pump is a product of high quality If a defect occurs contact the MANUFACTURER S ASSISTANCE SERVICE that will help you as soon as possible Indicate in each case as follows 1 The full address of firm 2 The identification of the pump serial number 3 The description of the anomaly All ARGAL pumps are covered by WARRANTY shown on the next page Note The Warranty Service will only be carried out at our ...

Страница 60: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 60 ...

Страница 61: ...Operations maintenance manual ASTRA evo DDE ARGALAIR 2020 Rev 6 61 ...

Страница 62: ...507025 Customer service Tel 030 3507023 Web www argalpumps com E mail sales engineer argal it ASTRA evo O M manual November 18 Rev 5 Copyright 2018 ARGAL S r l Draw and text total or partial duplication is prohibited The INSTRUCTION MANUAL must be delivered to the pump user who takes diligent note of it fills in data for Maintenance Department page 1 keeps the file for subsequent reference Possibl...

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