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Anest Iwata DDP 90 D Instruction, Use And Maintenance Manual

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DOUBLE DIAPHRA
DOUBLE DIAPHRA
DDP 90 D
DDP 90 D
DPS 90 1 D
DPS 90 1 D
DPS 90 2 D
DPS 90 2 D
DPS 90 3 D
DPS 90 3 D
DPS 90 4 D
DPS 90 4 D
DPS 90 36 D
DPS 90 36 D
DDP 90 C WB
DDP 90 C WB
DPS 90 3 C WB
DPS 90 3 C WB
Instruction Use and Maintenance Manual
ANEST IWATA Europe s.r.l.
46, Corso Vigevano
10155 Torino - Italy
Tel. +39 011-24 80 868
Fax +39 011-85 19 44
www.anest-iwataeu.com
e-mail: info@anest-iwataeu.com
GM PUMP
GM PUMP
GB
ME008ERev.03

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Summary of Contents for Anest Iwata DDP 90 D

  • Page 1 Instruction Use and Maintenance Manual DOUBLE DIAPHRA GM PUMP DOUBLE DIAPHRA GM PUMP DDP 90 D DDP 90 D DPS 90 1 D DPS 90 1 D DPS 90 2 D DPS 90 2 D DPS 90 3 D DPS 90 3 D...
  • Page 2 ANEST IWATA EUROPE TORINO - ITALY The company ANEST IWATA EUROPE Srl mission is to supply all their product and spray painting equipment users and distributors with the STATE-OF-THE-ART of technology and with continuous innovations, to obtain the best finish at the lowest cost.

  • Page 3: Table Of Contents

    Conditions for installation ………………………………………………………………………………20 Installation of DDP 90 D and DDP 90 CE WB base models …………………………………………20 Installation of DPS 90 1 D , DPS 90 2 D, DPS 90 3 D, DPS 90 4 D, DPS 90 36 D ………………21 ……………………………………………………………………………………………………27...

  • Page 4: Use Of The Manual

    Use of The use and maintenance manual is the document accompanying the equipment from its manufactu- the manual re till its dismantling. Therefore, it is an integral part of the equipment. The manual must be read before starting ANY ACTIVITY involving the equipment including its hand- ling.

  • Page 5: Informative Letter

    Other symbols Index of the use and maintenance manual Transport Description of the equipment Installation Ordinary use Wiring and hydraulic diagrams Dismantling Informative This use and maintenance manual is an integral part of the equipment and it must be easily availa- ble to the staff in charge of its use and maintenance.
  • Page 6 THIS USE AND MAINTENANCE MANUAL DOES NOT MAKE UP FOR ANY DESIGN INADEQUA- In case of breakdown or malfunction, apply to the CUSTOMER CARE SERVICE. USTOMER ERVICE ANEST IWATA EUROPE s.r.l. C.so Vigevano, 46 - 10155 Torino Telephone +39 011.24.80.868 Telefax +39 011.85.19.44 E-mail: info@anest-iwataeu.com...

  • Page 7: Warranty

    Warranty All ANEST IWATA S.r.l. products have a one-year guarantee from the invoice date, unless otherwise stated in writing. The warranty covers all manufacturing faults and material defects. Any spare part replacement or repair operations are covered only if they are carried out by our technicians at our servicing shops.

  • Page 8: Transport And Handling

    1. TRANSPORT AND HANDLING Transport To transport the equipment only the systems described below can be used. In any case make sure that the transport and lifting device can bear the weight of the equipment with its packaging. WARNING ALWAYS KEEP THE PACKAGING IN VERTICAL POSITION. WARNING IT IS ADVISABLE THAT THE STAFF IN CHARGE OF HANDLING THE EQUIPMENT WEAR PROTEC- TIVE GLOVES AND SAFETY SHOES.

  • Page 9: Handling

    Handling To handle the cardboard packaging use a trolley. WARNING FOLLOW THE INSTRUCTIONS ON THE PACKAGING BEFORE HANDLING AND OPENING IT. HANDLING BY MEANS OF HANDLE HANDLING BY MEANS OF TROLLEY Temporary storage During transport and storage make sure the temperatures between 0 and 40° C are not exceeded. In case of storage, make sure the equipment is not put in places with an excessive humidity.

  • Page 10: Product Identification

    It must not be removed at all, even if the equipment is resold. For any communication with the manu- facturer always mention the serial number written on the plate itself. Max fluid working ANEST IWATA DIAPHRAGM PUMP pressure Model DPS 90 Serial number MAX AIR W.

  • Page 11: The Different Models

    DPS 90 2 D: Pump type DDP 90 D mounted on a 20 l. tank with PR 3E (or PR5) paint pressure regulator, paint filter unit, fluid recirculation, 2 safety devices (1 overpressure valve, 1 three-way valve), 2 air pressure reducers (for pump and gun).

  • Page 12: Technical Specifications

    Technical specifications DDP 90 D DIAPHRAGM PUMP MODEL DDP 90 D DDP 90 CE WB Dimensions 235 x 155 x 210 mm Weight 3,400 kg Air inlet G 1/4” Entrata materiale G 1/2” Fluid inlet G 3/8” Fluid delivery filter...
  • Page 13 DPS 90 1 D MODELS DPS 90 1 D DPS 90 2 D DPS 90 2 D Dimensions 500x430x1015 mm 360x335x760 mm Weight 11,900 Kg 11,120 Kg Air inlet G 1/4” Fluid outlet G 3/8” Fluid suction filter 50 mesh Fluid delivery filter 100 mesh Max air working pressure...
  • Page 14 DPS 90 3 D MODELS DPS 90 3 D DPS 90 3 C WB DPS 90 3 C WB Dimensions 500x500x1055 mm 500x500x1055 mm Weight 15,900 Kg 15,900 Kg Air inlet G 1/4” Fluid outlet G 3/8” Fluid suction filter 50 mesh Fluid delivery filter 100 mesh...
  • Page 15 DPS 90 4 D MODELS DPS 90 4 D Dimensions 360x260x600 mm Weight 11,400 Kg Air inlet G 1/4” Fluid outlet G 3/8” Fluid suction filter 50 mesh Fluid delivery filter 100 mesh Max air working pressure 7.0 bar Min air working pressure 2.0 bar Max fluid working pressure (See PR 3E or PR5)
  • Page 16 DPS 90 36 D MODELS DPS 90 36 D Dimensions 535x500x1055 mm Weight 16,600 Kg Air inlet G 1/4” Fluid outlet G 3/8” Fluid suction filter 50 mesh Fluid delivery filter 100 mesh Max air working pressure 7.0 bar Min air working pressure 2.0 bar Max fluid working pressure (See PR 3E or PR5)

  • Page 17: Safety Systems

    Safety systems Several safety systems have been conceived during the diaphragm pump design and manufacture to safeguard the operator, in compliance with pr EN 12621 Directive about paint. SAFETY VALVE A 8 bar calibrated safety valve is installed to ensure the pump working pressure does not exceed the limits inside the feeding circuit.

  • Page 18: Workable Products

    The Company ANEST IWATA is not to be held responsible for any accident due to the pump use by an UNAUTHORIZED and non qualified staff using it for purposes that are different from the above mentioned ones.

  • Page 19: Operation

    3. DDP 90 CE PUMP OPERATION Operation description Based on a simple manufacture, the operation consists in two diaphragm movement, which are both fixed at the end of a rod, pressurizing and sending the paint. The compressed air enters the air chamber from side A in picture 1. The diaphragm is moved to the left, by pushing the paint.

  • Page 20: Installation And Starting

    WITH A RIGHT VENTILATION TO AVOID CONCENTRATING INFLAMMABLE VAPOURS COMING FROM SOLVENTS OR PAINTS. Installation of DDP 90 D and DDP 90 CE WB base models: - Place the pump on a stable support, to avoid movements during use. - The distance between the pump and the fluid (height of suction) must be as short as possible.

  • Page 21: Installation Of Dps 90 1 D , Dps 90 2 D, Dps 90 3 D, Dps 90 4 D, Dps 90 36 D

    Installation of models: DPS 90 1 D - DPS 90 2 D - DPS 90 3 D - DPS 90 4 D - DPS 90 6 D Because of shipment reasons the pump is delivered overturned. Before using it 1. Support the pump and unscrew the two M8x12 screws by means of a 6 mm Allen wrench. 2.
  • Page 22 3. By means of a spanner connect the PR3 E or PR5 material pressure regulator to the swivel con- nector (1- 22 on page 51) on the paint filter. 4. Connect the feed pipe to the pump supply connection (1-38 on page 51).
  • Page 23 5. Connect the suction pipe to the suction connector (1-47 on page 51). 6. Connect the recirculation pipe to the two-way valve for paint recirculation (B on page 30).
  • Page 24 7. For gravity models, fasten the hopper by means of the two M6x10 screws. 8. Connect the pipe connecting the hopper to the pump. Connect the recirculation pipe to the two- way valve for paint recirculation. 9. For the models with wall mounting bracket the pump is already in the right position. After fastening the pump, just connect the suction pipe.
  • Page 25 11. Make sure the PR 3E (or PR5) regulator is not under pressure, otherwise turn the adjusting screw counterclockwise till the pressure is completely released. 12. Connect the air and fluid pipes to the fluid outlet connector and to the air connector (Pump and Gun).
  • Page 26 13. Connect the air supply coming from the compressor to the inlet connector. 14.Fasten the pump to the ground by means of the bracket welded on the trailer or on the stand.

  • Page 27: Use

    If the system is used improperly, it could be broken by causing serious damage. Use the diaphragm pump for professional purposes only. Do not change the system; use only Anest Iwata original spare parts. Check the system daily: repair or replace immediately all worn or damaged parts.

  • Page 28: Prewash

    Prewash 1. Make sure the pump is installed correctly (see section 4.3). 2. Soak the dip tube into the washing liquid, or fill the hopper or the tank according to the model used. 3. Put the three-way valve in the right position. 4.
  • Page 29 Adjust the PR 3E (or PR5) paint pressure regulator as required (from 0 to 3,0 bar for PR3 E, and from 0 to 6.0 bar for PR5). Adjust the spraying air by means of the reducer (Pos. F on page 30) and test the gun on a panel before using it.

  • Page 30: Daily Interruptions

    Daily interruptions When the pump is stopped: - The air supply must not be disconnected if the interruption is short. - If the interruption is long, turn the three-way valve discharge the air from the circuit and open the recirculation valve , to release the residual fluid pressure.

  • Page 31: Wrong And Dangerous Uses

    Wrong and dangerous uses A wrong earthing, an insufficient ventilation, a naked flame or a spark can cause a fire or an explosion and provoke some serious injuries. WARNING IF SOME SPARKS OR AN ELECTRIC DISCHARGE WERE PERCEIVED, INTERRUPT IMMEDIA- TELY ALL PAINTING OPERATIONS.

  • Page 32: Pressure Release Process

    Pressure release process WARNING 1. Close the air to the gun. 2. Close the air to the pump (three-way valve). 3. Make sure the recirculation pipe is not clogged. Then open gradually the recirculation two-way valve and leave it open. 4.

  • Page 33: Maintenance And Inspection

    6. MAINTENANCE AND INSPECTION General notes A suitable maintenance is important for a longer duration of the equipment in good working condi- tions and efficiency ensuring functional safety as time goes by. All maintenance operations must be carried out by a qualified staff. The pump design and the mate- rials used to manufacture it limit the maintenance interventions to a simple periodic cleaning.

  • Page 34: Double Pneumatic Valve Disassembly

    Delivery manifold (1-45) Rod (1-36) Diaphragm (1-31/1-32) “UP” trade-mark “ANEST IWATA” trade-mark Intake manifold (1-46) Double pneumatic valve disassembly Unscrew the 2 screws (1-40 on page 51) and disassemble the double pneumatic valve protecti- ve cover (Pos. 1-39 on page 51).

  • Page 35: Diaphragm Disassembly

    Diaphragm disassembly By means of 2 13 mm spanners remove the diaphragm stop nut (1-27) on a side only Nuts Remove the washer (1-28), the diaphragm seat (1-29), the sealing ring (1-30), the diaphragm (1-31), the diaphragm (1-32) and the diaphragm seat (1-33). Diaphragm (PTFE) (1-31) Diaphragm (Rubber) (1-32) Diaphragm seat (1-29)

  • Page 36: Diaphragm Reassembly

    Diaphragm reassembly Reassemble in the opposite direction to disassembly. PRECAUTIONS Pay attention to the assembly direction of the Y packings (see the picture). Lubricate the Y packing, the sealing ring and the slots with some lithium grease. Tightening pressure of nuts (1-27): 8.83 Nm. Delivery and suction valve disassembly SUCTION VALVE By means of a brass bar push the steel ball (1-19) by avoiding scoring the ball and its seat...

  • Page 37: Pr 3E Fluid Pressure Regulator Disassembly And Maintenance

    6.10 PR 3E fluid pressure regulator disassembly and maintenance PAINT PRESSURE REGULATOR MODEL PR 3E PR 3E WB Dimensions 160 x 80 x 220 mm Weight 920 g Fluid inlet G 3/8” Fluid outlet G 3/8” Max primary pressure 7.0 bar Fluid pressure setting range from 0 to 3.0 bar Outgoing fluid maximum delivery...

  • Page 38: Pr 3E Fluid Pressure Regulator Reassembly

    Inspection and replacements 4.1 Pin (14) Replace if worn. 4.2 Ball (19) Replace if scratched or dented 4.3 Spring (20) Replace if the pin or the ball are replaced 4.4 Gaskets (16) and O ring (12) Replace every time the regulator is disassembled 4.5 Diaphragm (11) Replace if damaged 4.6 Main casing (22)
  • Page 39 PRECAUTIONS To reassemble the main casing follow the above-mentioned instructions to avoid damaging the spring (20), the tungsten carbide ball (19) and the tungsten carbide valve (15). 3. Diaphragm cover reassembly. 3.1 Place the preassembled diaphragm unit with the diaphragm holes near the main casing holes. 3.2 Assemble the spring (7) and the spring press (6).

  • Page 40: Pr 5 Fluid Pressure Regulator Disassembly And Maintenance

    6.12 PR 5 fluid pressure regulator disassembly and maintenance MODEL Weight 850 g Max. flow 2.0 l/min Max. primary pressure 25.0 bar Pressure range 6.0 bar Connection IN G 3/8” Connection OUT G 1/4”...
  • Page 41 IMPORTANT When you disassemble main body, rising pipe and pressure gauge, apply sealing agent to each threaded section to keep airtightness. Whenever disassembling ball and seat of tungsten carbide, you have be sure to confirm that there is no wear or damage. If there is any wear or damage, replace with new one. Disassembling Fully loosen handle set (22), and remove bolt with hex.

  • Page 42: Pr 5 Fluid Pressure Regulator Reassembly

    6.13 Assembling Check on each section if there are damage and foreign matter . Fit diaphragm holder (11), diaphragm (12), O ring (14), diaphragm holder (13) and spring washer (15) into diaphragm bolt (10) and tighten hex. nut (16).Tightening torque of hex. nut 9.8N-m Mount diaphragm section, adjusting spring (18), spring holder (20), and diaphragm cap (19) on main body (8), and evenly tighten bolts with hex.

  • Page 43: Paint Filter Maintenance

    IMPORTANT Fit tungsten carbide seat to main body so that tungsten carbide ball can be fitted on tapered side. Do not forget to fit packing. Wrong assembling can cause wrong movement of pointer of pressure gauge due to leakage from seat, failing performance. Pay attention to tightening torque when fitting joint (1).

  • Page 44: Troubleshooting

    7. TROUBLESHOOTING 7.1 DDP 90 D The pump does not work, it stops or does not restart. DOUBLE DIAPHRAGM PUMP Check the air sources: a) The compressed air does not reach the pump air a) Connect the compressed air. inlet b) The air pressure is too low to start the pump b) Supply a sufficient air pressure (minimum 2,0 bar).
  • Page 45 The pump works, but the fluid does not come out. The following parts are unscrewed or damaged a) Check if some tightening are loosened and tighten a) The pump suction connector (1-47) with the suction them. pipe b) Put some adhesive and tighten. b) The suction connector (1-47) c) Tighten.
  • Page 46 The outgoing paint contains some air. The following parts are unscrewed or damaged? a) Check the loosened tightening and tighten them. a) The pump suction connector (1-47) with the suction pump b) Put some adhesive and tighten. b) The suction connector (1-47) c) Tighten.
  • Page 47 The following parts are clogged with some solidified paint? a) Clean and replace the filter. a) The filter inside the paint filter b) Clean and replace the filter. b) The suction pipe filter (of the dip tube) c) Remove the solidified part. c) The suction pipe (of the dip tube) d) Remove the solidified part.

  • Page 48: Pr 3E Paint Pressure Regulator

    The paint pressure is different from the adju- 7.2 PR 3E PAINT REGULATOR sted one The primary pressure (pump pressure) is Increase the primary pressure (maximum 7,0 bar). not sufficient? Disassemble and clean the ball and its seat and The pressure on the PR 3E pressure gauge replace them if damaged.

  • Page 49: Pr 5 Paint Pressure Regulator

    7.3 PR 5 PAINT REGULATOR REMEDIS CAUSES PROBLEMS 1. Not properly seated, or foreign Clean and assemble again. The pointer of pressure gauge sur- passes max. pressure. matter 2. Replace tungsten carbide seat 2. Wear or damage on seat 3. Replace tungsten carbide ball 3.

  • Page 50: Sections With Spare Part List

    8. SECTIONS WITH SPARE PART LIST DDP 90 D – DDP 90 CE WB DIAPHRAGM PUMP Pos. DESCRIPTION QUANTITY CYLINDER FILTER SCREW FILTER BALL FILTER VALVE GASKET GASKET M 1/4” CONNECTOR 1-10 TWO-WAY VALVE FOR PAINT RECIRCULATION 1-11 90° CONNECTOR...
  • Page 51 DDP 90 D - DDP 90 CE WB DIAPHRAGM PUMP...

  • Page 52: Pr 3E / Pr 3E Wb Paint Pressure Regulator

    PR 3E / PR 3WB PAINT PRESSURE REGULATOR DESCRIPTION Pos. ADJUSTING SCREW SCREW WASHER REGULATOR COVER SPRING PRESS SPRING WASHER DIAPHRAGM SEAT DIAPHRAGM O RING SCREW VALVE GASKET 2 pieces PRESSURE GAUGE COLUMN PRESSURE GAUGE BALL SPRING CONNECTOR REGULATOR CASING FLUID CONNECTOR 90°...

  • Page 53: Pr 5 Paint Pressure Regulator

    PR 5 PAINT PRESSURE REGULATOR DESCRIPTION Pos. JOINT 3/8” VALVE SPRING BALL O RING SEAT PACKING JAM NUT MAIN BODY JOINT 1/4” DIAPHRAGM BOLT DIAPHRAGM HOLDER DIAPHRAGM DIAPHRAGM STOPPER O RING SPRING WASHER HAXAGON NUT BOLT WITH HEXAGON HOLE SPRING DIAPHRAGM CAP SPRING HOLDER HAXAGON NUT...

  • Page 54: Accessories

    9. ACCESSORIES AIR ADJUSTING UNIT Pos. Description THREE-WAY VALVE 1/4” M CONNECTOR AIR PRESSURE REDUCER 1/4” M/F/M UNION TEE PRESSURE GAUGE 90° 1/4” M CONNECTOR 1/4” M/M NIPPLE SAFETY VALVE 1/4” F/M/F UNION TEE 3-10 AUTOMATIC COUPLING 3-10 DIP TUBE WITH FILTER PIC.

  • Page 55: Supports

    SUPPORTS Fig. Description WALL MOUNTING BRACKET SUPPORT TRAILER TANK (20LITRES) HOPPER UNIT Fig. Description HOPPER SET Fig. Description...

  • Page 56: Dismantling

    10. DISMANTLING 10.1 Equipment storage If the diaphragm pump is to be stored for a certain period, the following operations are recommen- ded: Disconnect the equipment from the energy sources. Remove all residues and deposits from the pump. Cover the equipment with a waterproof tarpaulin. 10.2 Dismantling If for any reason the pump is to be dismantled, some important rules have to be followed to safe-...
  • Page 57 SERVICE NOTES Inconvenience Detected defects Intervention Main parts replaced date and anomalies date Notes:...
  • Page 58 Comments...
  • Page 59 Comments...
  • Page 60 ANEST IWATA Europe s.r.l. ANEST IWATA Deutschland 46, Corso Vigevano Trollingerweg 14 10155 Torino - Italy D-74360 Ilsfeld-Auenstein Tel. +39 011-24 80 868 Telefon-Fax:+49 (0)7062-62 290 Fax +39 011-85 19 44 European Handy: +49 (0)172-62 74 542 www.anest-iwataeu.com Sales f.e.anest-iwata@t-online.de e-mail: info@anest-iwataeu.com...

This manual is also suitable for:

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