service & operating manual · e = elima-matic® options e0 = solenoid kit w/24 vdc coil e1 =...

Table of Contents

CE

VERSA-MATIC PUMP • A Unit of IDEX Corporation • 6017 Enterprise Drive, Export, PA 15632 USA • Telephone (724) 327-7867 • Fax (724) 327-4300

www.versamatic.com 520-362-000

U.S. Patent #400,210,5,996,627,6,241,487

SERVICE & OPERATING MANUAL

Model E3 Non-MetallicDesign Level 2

®

Engineering Data and Temperature Limitations.................... 1

Performance Curve............................................................... 1

Explanation of Pump Nomenclature ..................................... 2

Dimensions .......................................................................... 3

Metric Dimensions ................................................................ 3

Principle of Pump Operation ................................................ 4

Installation Guide ................................................................. 4

Troubleshooting .................................................................... 5

Important Safety Information ................................................. 5

Material Codes ..................................................................... 6

Composite Repair Parts List & Drawing ............................... 7

Air Distribution Valve Servicing & Drawing .......................... 8

Pilot Valve Assembly Servicing & Drawing .......................... 9

Diaphragm Service Drawing, with Overlay ......................... 10

Diaphragm Service Drawing, Non-Overlay ........................ 10

Diaphragm Servicing .......................................................... 10

Pumping Hazardous Liquids .............................................. 11

Exhaust Conversion Drawing ............................................. 11

Converted Exhaust Illustration ........................................... 11

Modular Check Valve Servicing & Drawing ........................ 11

Dual Port Option & Drawing ............................................... 12

Model E3 Non-Metallic Design Level 2 10/01 520-362-000 Page 12

CEU.S. Patent #400,210; 5,851,109;5,996,627 and 6,241,487

1

E3 Non-MetallicDesign Level 2Ball ValveAir-PoweredAir-PoweredAir-PoweredAir-PoweredAir-PoweredDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm Pump

ENGINEERING, PERFORMANCE& CONSTRUCTION DATA

Quality SystemISO9001 Certified

MaterialsMaterialsMaterialsMaterialsMaterials

INTAKE/DISCHARGE PIPE SIZE3" ANSI Flange

or80mm DIN Flange

CAPACITY0 to 23 US gallons per minute

(0 to 901 liters per minute)

AIR VALVENo-lube, no-stall

design

SOLIDS-HANDLINGUp to .71 in. (18mm)

HEADS UP TO100 psi or 231 ft. of water

(7 bar or 70 meters)

DISPLACEMENT/STROKE.9 US Gallons / 3.41 liters

Maximum*Maximum*Maximum*Maximum*Maximum* Optimum**Optimum**Optimum**Optimum**Optimum**Operating TOperating TOperating TOperating TOperating Temperaturesemperaturesemperaturesemperaturesemperatures

Minimum*Minimum*Minimum*Minimum*Minimum*

SantopreneSantopreneSantopreneSantopreneSantoprene®®®®® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex life. Excellentabrasion resistance.

PolypropylenePolypropylenePolypropylenePolypropylenePolypropylene

PVDFPVDFPVDFPVDFPVDF

VVVVVirgin PTFE irgin PTFE irgin PTFE irgin PTFE irgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically withPTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such aschlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures.

212°F100°C

-10°F-23°C

212°F100°C

200°F93°C

150°F65°C

-35°F-37°C

10°F-23°C

50° to 212°F10° to 100°C

50° to 212°F10° to 100°C

CAUTION! Operating temperature limitations are as follows:

40°F5°C

®

0 20 40 60 80 100 120 140 160

10 (17)20 (34)

40 (68)

60 (102)

70 (119)

80 (136)

90 (153)

95 (161.5)

75 (127.5)

600500400300200100

30 (51)

50 (85)

Capacity

U.S. Gallons per minute

Liters per minute

100

90

80

70

60

50

40

30

20

10

0

BA

R

PS

I

Hea

d

1

2

3

4

5

6

7

0

30

2025

1015

5

9.1

67.6

34.5

1.5

NP

SH

R

ME

TE

RS

FE

ET

100 PSI (6.8 Bar)80 PSI (5.44 Bar)60 PSI (4.08 Bar)40 PSI (2.72 Bar)

20 PSI (1.36 Bar)Air Inlet Pressure

E3 Non-Metallic Performance Curve

Performance Curve(Versa-Matic® pumps are designed to be powered only by compressed air)


MODEL Pump Wetted Non-Wetted Diaphragm Diaphragm V alve Ball Wetted Type of OptionsTYPE Size Material Material Material Series Material Seals Construction

E3PQ6X659 3 P Q 6 X 6 5 9 –

E3PQ5T559 3 P Q 5 T 5 5 9 –

E3KQ6X659 3 K Q 6 X 6 5 9 –

E3KQ5T559 3 K Q 5 T 5 5 9 –

E3PQ6X659-E0 3 P Q 6 X 6 5 9 E0

E3PQ5T559-E1 3 P Q 5 T 5 5 9 E1

E3KQ6X659-E2 3 K Q 6 X 6 5 9 E2

E3KQ5T559-E3 3 K Q 5 T 5 5 9 E3

2

Explanation of Pump Nomenclature:

–E 3 P Q 6 X 6 5 9 XXX

PUMP SIZE3 = 3" Pipe Size

WETTED MATERIALP = PolypropyleneK = PVDF

NON-WETTED MATERIALQ = Epoxy Coated Alum.

DIAPHRAGM MATERIAL5 = PTFE6 = XL (Santoprene)

PUMP MODELE = Elima-Matic®

OPTIONSE0 = Solenoid Kit w/24 VDC CoilE1 = Solenoid Kit w/24 VDC Explosion Proof CoilE2 = Solenoid Kit w/24 VAC/12VDC CoilE3 = Solenoid Kit w/24 VAC/12VDC Explosion Proof CoilE4 = Solenoid Kit w/110VAC CoilE5 = Solenoid Kit w/110VAC Explosion Proof CoilE6 = Solenoid Kit w/220VAC CoilE7 = Solenoid Kit w/220VAC Explosion Proof Coil

VALVE BALL MATERIAL5 = PTFE6 = XL

DIAPHRAGM SERIESX = Thermo-Matic™. bead styleT = Tef-Matic, 2 piece PTFE

WETTED SEALS5 = PTFE

TYPE OF CONSTRUCTION9 = Bolted Style

Available Pump ModelsE3 Non-Metallic


Dimensions: ± 1/8"E3 Non-Metallic

Dimension

Standard

Sound Dampening Muffler

A

6 9/16"

12 9/16"

Mesh Muffler 12 9/16"

Dimension

Standard

Sound Dampening Muffler

A

167mm

225mm

Mesh Muffler 225mm

3

Metric Dimensions: ± 3mm


PRINCIPLE OF PUMP OPERATIONThis ball type check valve pump is

powered by compressed air and is a 1:1ratio design. The inner side of onediaphragm chamber is alternately pres-surized while simultaneously exhaustingthe other inner chamber. This causes thediaphragms, which are connected by acommon rod secured by plates to thecentres of the diaphragms, to move in areciprocating action. (As one diaphragmperforms the discharge stroke the otherdiaphragm is pulled to perform the suctionstroke in the opposite chamber.) Air pres-sure is applied over the entire innersurface of the diaphragm while liquid isdischarged from the opposite side of thediaphragm. The diaphragm operates in abalanced condition during the dischargestroke which allows the pump to beoperated at discharge heads over 200feet (61 meters) of water.

For maximum diaphragm life, keep thepump as close to the liquid being pumpedas possible. Positive suction head inexcess of 10 feet of liquid (3.048 meters)may require a back pressure regulatingdevice to maximize diaphragm life.

Alternate pressurizing and exhaustingof the diaphragm chamber is performedby an externally mounted, pilot operated,four way spool type air distribution valve.When the spool shifts to one end of thevalve body, inlet pressure is applied toone diaphragm chamber and the otherdiaphragm chamber exhausts. When thespool shifts to the opposite end of thevalve body, the pressure to the cham-bers is reversed. The air distribution valvespool is moved by a internal pilot valvewhich alternately pressurizes one end ofthe air distribution valve spool whileexhausting the other end. The pilot valve

is shifted at each end of the diaphragmstroke when a actuator plunger is con-tacted by the diaphragm plate. Thisactuator plunger then pushes the end ofthe pilot valve spool into position toactivate the air distribution valve.

The chambers are connectedwith manifolds with a suction anddischarge check valve for each chamber,maintaining flow in one direction throughthe pump.

INSTALLATION AND START-UP

Locate the pump as close to the prod-uct being pumped as possible. Keep thesuction line length and number of fittingsto a minimum. Do not reduce the suctionline diameter.

For installations of rigid piping, shortsections of flexible hose should be in-stalled between the pump and the piping.The flexible hose reduces vibration andstrain to the pumping system. A surgesuppressor is recommended to furtherreduce pulsation in flow.

AIR SUPPLY

Air supply pressure cannot exceed100 psi (8.6 bar). Connect the pump airinlet to an air supply of sufficient capac-ity and pressure required for desiredperformance. When the air supply line issolid piping, use a short length of flexiblehose not less than ½" (13mm) indiameter between the pump and thepiping to reduce strain to the piping. Theweight of the air supply line, regulatorsand filters must be supported by somemeans other than the air inlet cap. Fail-ure to provide support for the piping mayresult in damage to the pump. A pressureregulating valve should be installed toinsure air supply pressure does notexceed recommended limits.

AIR VALVE LUBRICATION

The air distribution valve and thepilot valve are designed to operate WITH-OUT lubrication. This is the preferredmode of operation. There may be in-stances of personal preference or poorquality air supplies when lubrication ofthe compressed air supply is required.The pump air system will operate withproperly lubricated compressed air supply.Proper lubrication requires the use of anair line lubricator (available from Versa-Matic) set to deliver one drop of SAE 10non-detergent oil for every 20 SCFM(9.4 liters/sec.) of air the pump consumesat the point of operation. Consult thepump’s published Performance Curve todetermine this.

AIR LINE MOISTURE

Water in the compressed air supplycan create problems such as icing orfreezing of the exhaust air, causing thepump to cycle erratically or stop operating.Water in the air supply can be reducedby using a point-of-use air dryer to supple-ment the user’s air drying equipment.This device removes water from thecompressed air supply and alleviates theicing or freezing problems.

AIR INLET AND PRIMING

To start the pump, open the air valveapproximately ½ to ¾ turn. After the pumpprimes, the air valve can be opened toincrease air flow as desired. If openingthe valve increases cycling rate, but doesnot increase the rate of flow, cavitationhas occurred. The valve should be closedslightly to obtain the most efficient airflow to pump flow ratio.

BETWEEN USES

When the pump is used for materialsthat tend to settle out or solidify whennot in motion, the pump should be flushedafter each use to prevent damage. (Prod-uct remaining in the pump between usescould dry out or settle out. This couldcause problems with the diaphragms andcheck valves at restart.) In freezingtemperatures the pump must becompletely drained between uses in allcases.

4

1

2

3

4

Surge Dampener

Filter/Regulator

Lubricator

Air Dryer

Available from Versa-Matic

1

2 3

4

INSTALLATION GUIDETop Discharge Ball Unit

SurgeDampenerLimited to

125 psi

CAUTIONThe air exhaust should be piped to an area for safe disposition of the product being pumped, in the event of a diaphragm failure.


TROUBLESHOOTINGPossible Symptoms:• Pump will not cycle.• Pump cycles, but produces no

flow.• Pump cycles, but flow rate is

unsatisfactory.• Pump cycle seems unbalanced.• Pump cycle seems to produce

excessive vibration.

What to Check: Excessive suctionlift in system.Corrective Action: For liftsexceeding 20 feet (6 meters), fillingthe pumping chambers with liquidwill prime the pump in most cases.

What to Check: Excessive floodedsuction in system.Corrective Action: For floodedconditions exceeding 10 feet (3meters) of liquid, install a backpressure device.

What to Check: System headexceeds air supply pressure.Corrective Action: Increase theinlet air pressure to the pump. Mostdiaphragm pumps are designed for1:1 pressure ratio at zero flow.

What to Check: Air supply pressureor volume exceeds system head.Corrective Action: Decrease inletair pressure and volume to thepump as calculated on the publishedPERFORMANCE CURVE. Pump iscavitating the fluid by fast cycling.

What to Check: Undersized suctionline.Corrective Action: Meet or exceedpump connection recommendationsshown on the DIMENSIONALDRAWING.

What to Check: Restricted orundersized air line.Corrective Action: Install a largerair line and connection. Refer to airinlet recommendations shown inyour pump’s SERVICE MANUAL.

What to Check: Check ESADS, theExternally Serviceable Air Distribu-tion System of the pump.Corrective Action: Disassembleand inspect the main air distributionvalve, pilot valve and pilot valveactuators. Refer to the parts drawingand air valve section of theSERVICE MANUAL. Check forclogged discharge or closed valvebefore reassembly.

What to Check: Rigid pipeconnections to pump.Corrective Action: Install flexibleconnectors and a Warren Rupp®

Tranquilizer® surge suppressor.

What to Check: Blocked air exhaustmuffler.Corrective Action: Remove mufflerscreen, clean or de-ice and reinstall.Refer to the Air Exhaust section ofyour pump SERVICE MANUAL.

What to Check: Pumped fluid in airexhaust muffler.Corrective Action: Disassemblepump chambers. Inspect fordiaphragm rupture or loosediaphragm plate assembly. Refer tothe Diaphragm Replacement sectionof your pump SERVICE MANUAL.

What to Check: Suction side airleakage or air in product.Corrective Action: Visually inspectall suction side gaskets and pipeconnections.

What to Check: Obstructed checkvalve.Corrective Action: Disassemblethe wet end of the pump andmanually dislodge obstruction inthe check valve pocket. Refer tothe Check Valve section of thepump SERVICE MANUAL fordisassembly instructions.

What to Check: Worn or misalignedcheck valve or check valve seat.Corrective Action: Inspect checkvalves and seats for wear andproper seating. Replace if neces-sary. Refer to Check Valve sectionof the pump SERVICE MANUALfor disassembly instructions.

What to Check: Blocked suctionline.Corrective Action: Remove or flushobstruction. Check and clear allsuction screens and strainers.

What to Check: Blocked dischargeline.Corrective Action: Check forobstruction or closed discharge linevalves.

What to Check: Blocked pumpingchamber.Corrective Action: Disassembleand inspect the wetted chambersof the pump. Remove or flush anyobstructions.

What to Check: Entrained air orvapor lock in one or both pumpingchambers.Corrective Action: Purge chambersthrough tapped chamber vent plugs.PURGING THE CHAMBERS OF AIRCAN BE DANGEROUS! Contact theVersa-Matic Technical ServicesDepartment before performing thisprocedure. Any model with top-porteddischarge will reduce or eliminateproblems with entrained air.If your pump continues to performbelow your expectations, contactyour local Versa-Matic Distributor orfactory Technical Services Group fora service evaluation.

Warranty: This pump is warrantedfor a period of five years againstdefects and workmanship.

5

Important Safety Information:

Before pump operation, inspect all gasketedfasteners for looseness caused by gasketcreep. Re-torque loose fasteners to preventleakage. Follow recommended torques statedin this manual.

CAUTION!

Before doing any maintenance on the pump,be certain all pressure is completely ventedfrom the pump, suction, discharge, piping, andall other openings and connections. Be certainthe air supply is locked out or madenon-operational, so that it cannot be startedwhile work is being done on the pump. Becertain that approved eye protection andprotective clothing are worn all times in thevicinity of the pump. Failure to follow theserecommendations may result in serious injuryor death.

WARNING!

WARNING!Read these safety warnings and instructionsin this manual COMPLETELY, beforeinstallation and start-up of the pump. It is theresponsibility of the purchaser to retain thismanual for reference. Failure to comply withthe recommendations stated in this manualwill damage the pump, and void factorywarranty.

WARNING!Before maintenance or repair, shut off thecompressed air line, bleed the pressure, anddisconnect the air line from the pump. Thedischarge line may be pressurized and mustbe bled of its pressure.

WARNING!Take action to prevent static sparking. Fire orexplosion can result, especially when handlingflammable liquids. The pump, piping, valves,containers or other miscellaneous equipmentmust be grounded.

IMPORTANT!This pump is pressurized internally with airpressure during operation. Always makecertain that all bolting is in good conditionand that all of the correct bolting is reinstalledduring assembly.

WARNING!When used for toxic or aggressive fluids, thepump should always be flushed clean priorto disassembly.

WARNING!Airborne particles and loud noisehazards. Wear ear and eye protection.

WARNING!In the event of diaphragm rupture, pumpedmaterial may enter the air end of the pump,and be discharged into the atmosphere. Ifpumping a product which is hazardous ortoxic, the air exhaust must be piped to anappropriate area for safe disposition.


MATERIAL CODESThe Last 3 Digits of Part Number000 ......... Assembly, sub-assembly;

and some purchased items010 ......... Cast Iron012 ......... Powered Metal015 ......... Ductile Iron020 ......... Ferritic Malleable Iron025 ......... Music Wire080 ......... Carbon Steel, AISI B-1112100 ......... Alloy 20110 ......... Alloy Type 316 Stainless Steel111 ......... Alloy Type 316 Stainless Steel

(Electro Polished)112 ......... Alloy “C” (Hastelloy equivalent)113 ......... Alloy Type 316 Stainless Steel

(Hand Polished)114 ......... 303 Stainless Steel115 ......... 302/304 Stainless Steel117 ......... 440-C Stainless Steel (Martensitic)120 ......... 416 Stainless Steel

(Wrought Martensitic)123 ......... 410 Stainless Steel (Wrought Martensitic)148 ......... Hardcoat Anodized Aluminium149 ......... 2024-T4 Aluminium150 ......... 6061-T6 Aluminium151 ......... 6063-T6 Aluminium152 ......... 2024-T4 Aluminium (2023-T351)154 ......... Almag 35 Aluminium155 ......... 356-T6 Aluminium156 ......... 356-T6 Aluminium157 ......... Die Cast Aluminium Alloy #380158 ......... Aluminium Alloy SR-319159 ......... Anodized Aluminium162 ......... Brass, Yellow, Screw Machine Stock165 ......... Cast Bronze, 85-5-5-5166 ......... Bronze, SAE 660170 ......... Bronze, Bearing Type,

Oil Impregnated175 ......... Die Cast Zinc180 ......... Copper Alloy305 ........ Carbon Steel, Gray Epoxy Coated306 ........ Carbon Steel, Black PTFE Coated307 ........ Aluminium, Gray Epoxy Coated308 ........ Stainless Steel, Black PTFE Coated309 ........ Aluminium, Black PTFE Coated310 ......... Kynar Coated330 ......... Zinc Plated Steel331 ......... Chrome Plated Steel

332 ......... Aluminium, Electroless Nickel Plated333 ......... Carbon Steel, Electroless

Nickel Plated335 ......... Galvanized Steel336 ......... Zinc Plated Yellow Brass337 ......... Silver Plated Steel340 ......... Nickel Plated342 ......... Filled Nylon353 ......... Geolast; Color: Black354 ......... Injection Molded #203-40 Santoprene- Duro 40D +/-5;

Color: RED355 ......... Thermal Plastic356 ......... Hytrel357 ......... Injection Molded Polyurethane358 ......... (Urethane Rubber) (Compression Mold)359 ......... Urethane Rubber360 ......... Buna-N Rubber. Color coded: RED361 ......... Buna-N363 ......... Viton (Flurorel). Color coded: YELLOW364 ......... EPDM Rubber. Color coded: BLUE365 ......... Neoprene Rubber.

Color coded: GREEN366 ......... Food Grade Nitrile368 ......... Food Grade EPDM370 ......... Butyl Rubber. Color coded: BROWN371 ......... Philthane (Tuftane)374 ......... Carboxylated Nitrile375 ......... Fluorinated Nitrile378 ......... High Density Polypropylene405 ......... Cellulose Fibre408 ......... Cork and Neoprene425 ......... Compressed Fibre426 ......... Blue Gard440 ......... Vegetable Fibre465 ......... Fibre500 ......... Delrin 500501 ......... Delrin 570502 ......... Conductive Acetal, ESD-800503 ......... Conductive Acetal, Glass-Filled505 ......... Acrylic Resin Plastic506 ......... Delrin 150520 ......... Injection Molded PVDF Natural color540 ......... Nylon541 ......... Nylon542 ......... Nylon544 ......... Nylon Injection Molded550 ......... Polyethylene551 ......... Glass Filled Polypropylene

552 ......... Unfilled Polypropylene553 ......... Unfilled Polypropylene555 ......... Polyvinyl Chloride556 ......... Black Vinyl570 ......... Rulon II580 ......... Ryton590 ......... Valox591 ......... Nylatron G-S592 ......... Nylatron NSB600 ......... PTFE (virgin material)

Tetrafluorocarbon (TFE)601 ......... PTFE (Bronze and moly filled)602 ......... Filled PTFE603 ......... Blue Gylon604 ......... PTFE607 ......... Envelon606 ......... PTFE610 ......... PTFE Encapsulated Silicon611 ......... PTFE Encapsulated Viton632 ......... Neoprene/Hytrel633 ......... Viton/PTFE634 ......... EPDM/PTFE635 ......... Neoprene/PTFE637 ......... PTFE, Viton/PTFE638 ......... PTFE, Hytrel/PTFE639 ......... Buna-N/TFE643 ......... Santoprene®/EPDM644 ......... Santoprene®/PTFE656 ......... Santoprene Diaphragm and

Check Balls/EPDM Seats

Delrin, Viton and Hytrel areregistered tradenames of E.I. DuPont.

Gylon is a registered tradename of Garlock, Inc.

Nylatron is a registered tradename ofPolymer Corp.

Santoprene is a registered tradename of Monsanto Corp.

Rulon II is a registered tradename ofDixion Industries Corp.

Hastelloy-C is a registered tradename of Cabot Corp.

Ryton is a registered tradename ofPhillips Chemical Co.

Valox is a registered tradename ofGeneral Electric Co.

6


Composite Repair PartsDrawing

7

1 031-140-000 Air Valve Assembly 1031-140-002 Air Valve Assembly w/PTFE 1

coated Hardware031-141-000 Air Valve Assembly 1

(No Encapsulated Muffler)2 095-089-000 Pilot Valve Assembly 13 050-039-354 Ball, Check 4

050-039-600 Ball, Check 44 114-021-307 Intermediate Assembly 1

114-021-309 Intermediate Assembly 15 115-133-080 Bracket, Mounting 2

115-133-115 Bracket, Mounting 2115-133-305 Bracket, Mounting 2

6 132-019-360 Bumper, Diaphragm 27 135-032-506 Bushing, Plunger 28 165-099-307 Cap, Air Inlet 1

165-099-309 Cap, Air Inlet 19 170-017-115 Capscrew, Hex HD 5/8-11 x 1.75 4

170-017-308 Capscrew, Hex HD 5/8-11 x 1.75 410 170-052-115 Capscrew, Hex HD 3/8-16 x 2.25 4



170-112-308 Capscrew, Soc HD 5/8-11 x 3.75 3213 170-171-004 Capscrew, Soc HD 1/2-13 x 1.25 614 171-053-115 Capscrew, Soc HD 3/8-16 x 2.75 4

171-053-308 Capscrew, Soc HD 3/8-16 x 2.75 415 196-151-520 Chamber, Outer 2

196-151-552 Chamber, Outer 216 196-152-307 Chamber, Inner 2

196-152-309 Chamber, Inner 217 286-077-354 Diaphragm 218 286-078-600 Diaphragm, Overlay 219 312-103-520 Elbow 4

312-103-552 Elbow 420 360-090-360 Gasket, Air Inlet 121 360-091-360 Gasket, Inner Chamber 222 360-092-360 Gasket, Pilot Valve 123 360-093-360 Gasket, Main Air Valve 124 518-133-520 Manifold 2

518-133-520E Manifold, 80mm DIN 2518-133-552 Manifold 2518-133-552E Manifold, 80mm DIN 2

25 530-027-000 Muffler 1530-010-000 Muffler 1

27 545-009-110 Nut, Hex 5/8 72545-009-308 Nut, Hex 5/8 72

28 560-001-360 O-ring 229 612-161-520 Assembly, Outer Diaphragm Plate 2

612-161-552 Assembly, Outer Diaphragm Plate 230 612-162-150 Assembly, Inner Diaphragm Plate 231 620-017-115 Plunger, Actuator 232 670-047-520 Retainer, Ball 4

670-047-552 Retainer, Ball 433 685-051-120 Rod, Diaphragm 134 685-052-115 Rod, Support 2

685-052-308 Rod, Support 235 720-010-375 Seal, Diaphragm Rod 236 720-039-600 Seal, Manifold Spacer 837 720-043-600 Seal, Check Valve Assembly 438 722-076-520 Seat, Check Valve 4

722-076-552 Seat, Check Valve 439 770-055-520 Spacer, Manifold 4

770-055-552 Spacer, Manifold 440 901-047-115 Washer, Flat 5/8" 140

901-047-308 Washer, Flat 5/8" 14041 901-048-115 Washer, Flat 3/8" 8

901-048-308 Washer, Flat 3/8" 8

Repair Parts List:


Air Distribution Valve Assembly DrawingS30 Design Level 2

1-J

1-D

1-F

1-G

1-H

1-G

1-E

1-C

1-A

1-A

1-B

1-C

1-E

1-G

1-H

MAIN AIR VALVE ASSEMBLY PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY1 031-140-000 Main Air Valve Assembly 11-A 031-139-000 Spool Assembly 11-B 095-094-551 Body, Air Valve 11-C 132-029-552 Bumper 21-D 165-096-551 Cap, Muffler 11-E 165-115-552 Cap, End 21-F 530-028-550 Muffler 11-G 560-020-360 O-Ring 81-H 675-044-115 Ring, Retaining 21-J 710-015-115 Screw, Self-tapping 4

For pumps equipped with PTFE Coated Hardware1 031-140-002 Air Valve Assembly 1

(Includes all items used on 031-140-000 except:)1-J 710-015-308 Screw Self tapping 41-H 675-044-308 Ring, Retaining 2

For pumps equipped with PTFE coated hardware option:1 031-141-000 Air Valve Assembly 1

(Includes all items used on 031-140-000 minus items 1-D, 1-F & 1-J)

For pumps with alternate Mesh or Sound Dampening mufflersor piped exhaust:1 031-041-002 Air Valve Assembly 1

(Includes all items used on 031-141-000 except:)1-H 675-044-308 Ring, Retaining 2

To service the air valve firstshut off the compressed air, bleedthe pressure from the pump, anddisconnect the air supply line fromthe pump.

STEP #1: SeeComposite Repair and PartsDrawing.

Using a 5/16" Allenwrench, remove the four hex socketcapscrews (item 14) and four flatwashers (item 41). Remove the airvalve assembly from the pump.

Remove and inspectgasket (item 23) for cracks ordamage. Replace gasket if needed.

STEP #2; Disassembly ofthe air valve.

To access the internal airvalve components first remove thetwo retaining rings (item 1-H) fromeach end of the air valve assemblyusing clip ring pliers.

Next remove the two endcaps (item 1-E). Inspect the o-rings(item 1-G) for cuts or wear. Replacethe o-rings if necessary.

Remove the two bumpers(item 1-C). Inspect the bumpers forcuts, wear or abrasion. Replace ifnecessary.

Remove the spool (partof item 1-A) from the sleeve. Becareful not to stratch or damage the

outer diameter of the spool. Wipe spoolwith a soft cloth and inspect forscratches or wear. Inspect the innerdiameter of the sleeve (part of item1-A) for dirt, scratches, or othercontaminates. Remove the sleeve ifneeded and replace both the sleeveand spool with a new sleeve and spoolset (item 1-A).

STEP #3: Reassembly of the air valve.Install one end cap (item

1-E) with an o-ring (item 1-G) and onebumper (item 1-C) into one end of theair valve body (item 1-B). Install oneretaining ring (item 1-H) into the grooveon the same end.

Remove the new sleeve andspool set (item 1-A) from the plasticbag. Carefully remove the spool fromthe sleeve. Install the six o-rings (item1-G) into the six grooves on the sleeve.Apply a light coating of grease to theo-rings before installing the sleeve intothe valve body (item 1-B), align theslots in the sleeve with the slots in thevalve body. Insert the spool into thesleeve. Be careful not to scratch ordamage the spool during installation.Push the spool in until it touches thebumper on the opposite end.

Install the remainingbumper, end cap with o-ring, andretaining ring.

Fasten the air valveassembly (item 1) and gasket (item 23)

WARNING!

Read these safety warnings andinstructions in this manualCOMPLETELY, before installationand start-up of the pump. It is theresponsibility of the purchaser toretain this manual for reference.Failure to comply with therecommendations stated in thismanual will damage the pump, andvoid factory warranty.

to the pump.Connect the compressed air

line to the pump. The pump is nowready for operation.

Air Distribution Valve Servicing


PILOT VALVE ASSEMBLY PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY2 095-089-000 Pilot Valve Assembly 12-A 095-081-551 Body, Pilot Valve 12-B 135-033-506 Bushing 22-C 675-055-115 Ring, Retaining 22-D 770-049-175 Spacer 52-E 917-001-374 Wiper 62-F 775-033-506 Spool, Pilot 1

Pilot Valve Assembly Drawing

wear. Replace any wipers asnecessary.

Step #3: Re-assembly of thepilot valve.

First install a spiral retaining ringto one end of the pilot valve body.Install one bushing making sure thestep side faces toward the wiper.Apply a light coating of grease to theoutside diameter of each wiper. Next,gently push in the wipers and spacersuntil they are against the installedretaining ring in the opposite end ofthe pilot valve body. Install theremaining bushing making sure thestep side faces the wiper. Install theremaining retaining ring using clip ringpilers.

Apply a light coating of greaseto the inner diameter of each wiper. Alsoapply a light coating of grease to theouter diameter of the pilot valve spooland gently push the spool through eachwiper.

Step #4: Inspect the actuatorplungers.

See PUMP ASSEMBLYDRAWING.

The actuator plungers (items31) can be reached through the stemcavity of the pilot valve in theintermediate assembly (item 4).

Remove the plungers (items 31)from the bushings (item 7) in each endof the cavity. Inspect the installed

To service the pilot valve firstshut off the compressed air supply,bleed the pressure from the pump,and disconnect the air supply linefrom the pump. Insert the safety clip(item 1-F from Air Distribution Valveassembly drawing) into the smallerunthreaded holes in the end cap(item 1-E from air distribution valveassembly drawing).

Step #1: See PUMPASSEMBLY DRAWING.

Using a 9/16" wrench or socket,remove the four capscrews (items 10)and four flat washers (items 41).Remove the air inlet cap (item 8) andair inlet gasket (item 20). The pilotvalve assembly (item 2) can now beremoved for inspection or service.

Step #2: Disassembly of thepilot valve.

Remove the pilot valve spool(item 2-F). Wipe clean, and inspectfor dirt, scratches or wear. Replacethe spool if necessary.

Remove the two retainingrings (items 2-C) from each end ofthe pilot valve body using clip ringpilers.

Remove the two pilot valvebushings (items 2-B), five spacers(items 2-D), and six spool wipers(items 2-E) by pushing gently fromother end of the pilot valve body.Inspect the wipers for cuts and/or

o-ring (items 28) for cuts and/or wear.Replace the o-rings if necessary.Apply a light coating of grease to eacho-ring and re-install the plungers in tothe bushings. Push the plungers inas far as they will go.

Step #5: Re-install the pilotvalve ssembly into the intermediateassembly.

Be careful to align the ends ofthe stem between the plungers wheninserting the stem of the pilot valveinto the cavity of the intermediate.

Re-install the gasket (item 20),air inlet cap (item 8), capscrews andwashers (items 10 and 39).

Connect the air supply to thepump. Remove the safety clip (item1-F) from the end cap (item 1-E). Thepump is now ready for operation.

WARNING!


Pilot Valve Servicing


Diaphragm Service Drawing,Non-Overlay

Diaphragm Service Drawing,with Overlay

32

25

15

13

6

28

17

16

29

9

1424

24

32

25

15

13

6

28

17

29

9

1424

24

WARNING!


set screw into the smaller tapped holein the inner diaphragm plate (item 30).Insert the protruding stud and the 1/4-20 fastener loosely into a vise. Use a13/8" wrench or socket to remove theouter diaphragm plate (item 29) byturning counterclockwise. Inspect thediaphragm (item 17) for cuts,punctures, abrasive wear or chemicalattack. Replace the diaphragms ifnecessary.

Step #4: Installing thediaphragms.

Push the threaded stud of theouter diaphragm plate through thecenter hole of the diaphragm. Threadthe inner plate clockwise onto the stud.Use a torque wrench to tighten thediaphragm assembly together to 480in Lbs. (54.23 Newton meters). Allow aminimum of 15 minutes to elapse aftertorquing, then re-torque the assemblyto compensate for stress relaxation inthe clamped assembly.

Step #5: Installing thediaphragm assemblies to the pump.

Make sure the bumper (item 6)is installed over the diaphragm rod.

Thread the stud of the onediaphragm assembly clockwise into thetapped hole at the end of thediaphragm rod (item 33) until the innerdiaphragm plate is flush to the end ofthe rod. Insert rod into pump.

Align the bolt holes in thediaphragm with the bolt pattern in the

inner chamber (item 16). Make surethe molded directional arrows on thediaphragm point vertically.

Fasten the outer chamber (item15) to the pump, using the capscrews(items 9 & 12), hex nuts and flatwashers.

On the opposite side of thepump, pull the diaphragm rod out asfar as possible. Make sure the bumper(item 6) is installed over the diaphragmrod.

Thread the stud of theremaining diaphragm assemblyclockwise into the tapped hole at theend of the diaphragm rod (item 33) asfar as possible and still allow foralignment of the bolt holes in thediaphragm with the bolt pattern in theinner chamber. The molded directionalarrows on the diaphragm must pointvertically.

Fasten the remaining outerchamber (item 15) to the pump, usingthe capscrews (items 9 & 12), hex nutsand flat washers.

Step #6: Re-install the elbow/spacer/manifold assemblies to thepump, using the capscrews (items

11)hex nuts and flat washers.

The pump is now ready to bere-installed, connected and returnedto operation.

To service the diaphragms firstshut off the suction, then shut offthe discharge lines to the pump. Shutoff the compressed air supply, bleedthe pressure from the pump, anddisconnect the air supply line fromthe pump. Drain any remaining liquidfrom the pump.

Step #1: See the pumpcomposite repair parts drawing, andthe diaphragm servicing illustration.

Using a 9/16" wrench or socket,remove the 16 capscrews (items 11),hex nuts and washers that fastenthe elbows (items 19) to the outerchambers (items 15). Remove theelbows with the manifolds andspacers attached.

Step #2: Removing the outerchambers.

Using a 9/16" wrench or socket,remove the 20 capscrews (items 9 &12), hex nuts and washers thatfasten the outer chambers,diaphragms, and inner chambers(items 16) together.

Step #3: Removing thediaphragm assemblies.

Use a 13/8" (35mm) wrench orsix pointed socket to remove thediaphragm assemblies (outer plate,diaphragm, and inner plate) from thediaphragm rod (item 33) by turningcounterclockwise.

Insert a 1/4-20 capscrew or

OVERLAY DIAPHRAGM SERVICINGThe PTFE overlay diaphragm

(item 18) is designed to fit snugly overthe exterior of the standard TPEdiaphragm (item 17).

The molded directional arrowson the overlay diaphragm must pointvertically.

Follow the same proceduresdescribed for the standard diaphragmfor removal and installation.

Diaphragm Servicing


SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING



MUFFLER

LIQUIDLEVEL

SUCTIONLINE

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

MUFFLER

CONVERTED EXHAUSTILLUSTRATION

Exhaust Conversion Drawing

Illustration #2

When a diaphragm fails, thepumped liquid or fumes enter the airend of the pump. Fumes areexhausted into the surroundingenvironment. When pumpinghazardous or toxic materials, theexhaust air must be piped to anappropriate area for safe disposal.See illustration #1 at right.

This pump can be submergedif the pump materials of constructionare compatible with the liquid beingpumped. The air exhaust must bepiped above the liquid level. Seeillustration #2 at right. Piping used forthe air exhaust must not be smallerthan 1" (2.54 cm) diameter. Reducingthe pipe size will restrict air flow andreduce pump performance. When thepumped product source is at a higherlevel than the pump (flooded suctioncondition), pipe the exhaust higherthan the product source to preventsiphoning spills. See illustration #3 atright.

The following steps arenecessary to convert the pump to pipethe exhaust air away from the pump.

Use a #8 Torx or flatscrewdriver to remove the sixself-tapping screws (item 1-J).

Remove the muffler cap andmuffler (items 1-D and 1-F). The 1"NPT molded threads in the air Illustration #3

Illustration #1

distribution valve body (item 1-B).Piping or hose may now beinstalled.

The manufacturerrecommends installing a flexible hoseor connection between the pump andany rigid plumbing. This reducesstresses on the molded plastic threadsof the air exhaust port. Failure to doso may result in damage to the airdistribution valve body.

Any piping or hose connectedto the pump’s air exhaust port mustbe physically supported. Failure tosupport these connections could alsoresult in damage to the airdistribution valve body.

Modular Check Valve DrawingBefore servicing the check

valves, first shut off the suction lineand then the discharge line to thepump. Next, shut off the compressedair supply, bleed air pressure from thepump, and disconnect the air supplyline from the pump. Drain anyremaining fluid from the pump. Thepump can now be removed forservice.

To access the modular checkvalve, remove the elbows (items 19from pump composite repair partsdrawing). Use a 9/16" wrench or socketto remove the fasteners. Once theelbows are removed, the modularcheck valves can be seen in thecavities of the outer chamber (items15).

Next remove the check valveseal (item 37). Inspect the seal forcuts or pinched areas. Replace sealas needed.

Disassemble the componentparts of each modular check valve.Inspect the check valve retainer (item32) for cuts, abrasive wear, orembedded materials. Replace asneeded.

Inspect the check balls (items3) for wear, abrasion, or cuts on thespherical surface. The check valveseats (items 38) should be inspectedfor cuts, abrasive wear, or embeddedmaterial on the surfaces of both theexternal and internal chamfers. The

spherical surface of the check ballsmust seat flush to the surface of theinner chamfer on the check valveseats for the pump to operate to peakefficiency. Replace any worn ordamaged parts as necessary.

Remove the remaining checkvalve seal (item 37). Inspect the sealfor cuts or pinched areas. Replaceseal as needed.

Re-assemble the modularcheck valve. The seat should fit snuglyinto the retainer.

Place a check valve seal (item37) into the cavity of the outerchamber (item 15). Make sure thechamber side of the seal faces out.Insert the modular check valve intothe outer chamber with the retainerfacing up. Install a check valve seal(item 37). Make sure the chamber sideof the seal faces the chamber on thecheck valve seat or retainer.

The pump can nowreassembled, reconnected andreturned to ooperation.

11

Modular Check Valve Servicing

Pumping Hazardous Liquids

Converting The Pump ForPiping The Exhaust Air

Important Installation Note


Dual Port Option Drawing3" ANSI STYLE FLANGE CONNECTIONFOUR ø.75 HOLES ON A ø6.00 BOLT CIRCLE

3" ANSI STYLE FLANGE CONNECTIONFOUR ø.75 HOLES ON A ø6.00 BOLT CIRCLE

DUAL PORTING OPTIONSSeveral dual porting options

are possible. The pump can beconverted to a dual port arrangementon both the suction and the dischargeends. The porting can be configuredto a single suction and a dualdischarge. The porting can bechanged to a dual suction and a singledischarge.

The above changes arepossible because the porting flangeof the elbows (items 19) are designedto mate with standard 125# ANSI style4-bolt, 3" pipe flanges.

Dual porting of both suction anddischarge ends of the pump

Converting the pump from thestandard single suction and dischargeporting configuration to dual portingat each end is easy. Simply removethe manifold seals, spacers, andmanifolds (items 36, 39, and 24 frompump assembly drawing) from thepump.

The discharge and suctionelbows can be rotated at 90°increments (see arrows and optionalpositioning in the Dual PortingDrawing.

Single porting of the suction anddual porting of the pump discharge

To convert the pump from thestandard single suction and singledischarge porting configuration to adual discharge porting arrangementremove the only the discharge

manifolds, spacers, and manifoldseals. Position the discharge elbowsin the desired direction at 90°increments. (See arrows and optionalpositioning in the Dual PortingDrawing.)

Dual porting of the suction andsingle porting of the pump discharge

To convert the pump from thestandard single suction and singledischarge porting configuration to adual suction porting arrangementremove the only the suction (bottom)manifolds, spacers, and manifoldseals.

Position the suction elbows inthe desired direction at 90°increments. (See arrows and optionalpositioning in the Dual PortingDrawing.)

WARNING!


12

service & operating manual · e = elima-matic® options e0 = solenoid kit w/24 vdc coil e1 =...

Documents