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1. Peu STANDARD INTEGRAL MUFFLER Option i A 11 81 300 13 50 343 RI AN 2 SS EN TE 9 VI GENERAL NOTES O O E 1 STANDARD INTEGRAL MUFFLER SHOWN COVERS 1 FNPT EXHAUST PORT 4 00 102 am E FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED E APPLICATIONS O Q capu BA Al gt ur 4X 44 MTG SLOT m 10 19 259 m1fnmdl3sm rev0814 Model M1F Non Metallic Page 5 Dimensions M1F Non Metallic with Spill Containment Dimensions in Inches Dimensions in Inches Dimensional tolerance 1 9 16 TYP 4 PLACES BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES AIR INLET 1 2 NPT BOTTOM VIEW m1fnmdl3sm rev0814 FRONT VIEW 17 DISCHARGE PORT 9 16 X 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD INTEGRAL MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS SUCTION PORT 9 16 X 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION DIMENSION Standard Pump 5 5 8 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE SIDE VIEVV 10 1 4 Pulse Output Kit 5 5 8 10 1 4 Mesh Muffler Sound Dampening Muffler
2. SUCTION PORT SUCTION PORT OPTIONAL 1 FNPT 1 FNPT JAR INTEGRAL MUFFLER pa Mesh amp Sound Standard Int Muffler Option Dempening Mufor i S A 11 81 300 13 50 343 GENERAL NOTES 1 OPTIONAL SUCTION amp DISCHARGE SIDE PORTS WILL BE PLUGGED AT FACTORY NOT SHOWN STANDARD INTEGRAL MUFFLER SHOWN COVERS 1 FNPT EXHAUST PORT OR PIPING EXHAUST AIR IN SUBMERGED TI 4 06 103 2 FOR OPTIONAL MUFFLER STYLE APPLICATIONS 4X 53 13 MTG SLOT 10 09 256 m1fnmdl3sm rev0814 Model M1F Non Metallic Page 4 Dimensions M1F Non Metallic Side Ported Options Dimensions in inches Dimensions in millimeters metric dimensions in brackets DISCHARGE PORT 56 X 69 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PN10 25mm DIN FLANGE CONNECTION 496 126 17 04 433 3 62 92 MANIFOLD CAN ROTATE FROM VERTICAL CENTERLINE 2075 527 435 SUCTION PORT 56 X 69 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PN10 25mm DIN FLANGE CONNECTION Standard Integral Mesh amp Sound Muffler Option Dampening Muffler
3. nennen nnne trennt 33 Electronic Leak Detector Installation sese enn 33 Mechanical Leak Detector InstallatiON o onnnicnnnnoncninnnnncnocnnocnnonanonanann corn acnron en 33 Pulse Output Kit Drawing treni te Ree eo eei co Rep editae re 34 Pulse Output Kit Option 34 Optional Muffler Configurations Drawing ceccceceescesereeereeeceseeeeecereeeeeceeceesaeesaeecaeeeaeeeaeeeneeaees 35 Grounding The PUM Py cor tumba Rire 36 CE Declaration of Conformity Machinery 37 CE Declaraton of Conformity ATEX ss ttti vecti A EA 38 Expanation of ATEX Certifications re ara eee dee dear nee rp kae ava 39 Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA m1fnmdl3sm rev0814 Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com Copyright 2014 Warren Rupp Inc All rights reserved WARREN RUPP Quality System SO9001 Certified See pages 2 38 and 39 for ATEX ratings Environmental Management System 15014001 Certified INLINE PORTED SIDE PORTED FLUID amp METERING SOLIDS HANDLING Up to 25 in AIR VALVE No lube no stall design CAPACITY O to 53 gallons per minute 0 to 200 liters per minut
4. 13 not used with inline option Nut Hex 1 2 13 not used with inline option O ring Inner Diaphragm Plate Inner Diaphragm Plate Inner Diaphragm Plate One Piece Bonded Option Outer Diaphragm Plate Outer Diaphragm Plate Plunger Actuator Retainer Ball Retainer Ball Ring Retainer Rod Diaphragm Seal Diaphragm Rod Seal Manifold Spacer not used with inline option Seal Check Valve Seat Check Valve Seat Check Valve Washer Flat 5 16 Washer Flat 5 16 Washer Flat 1 2 not used with inline option Washer Flat 1 2 not used with inline option Washer Flat 3 8 Washer Flat 3 8 Washer Flat 3 8 Washer Flat 3 8 Manifold Suction Inline Porting Option ONLY Manifold Discharge Inline Porting Option ONLY Plug 1 NPT Pipe Inline Porting Option ONLY Model M1F Non Metallic Page 15 QTY DU Q Q A A RA HANNNN 32 NNAFPARRWANANAARNNNNNN N Ww Ww BONA SH 1 1 2 Option For Virgin PTFE Equipped Pumps Drawing M1F SPILL CONTAINMENT REPAIR PARTS LIST FOR VIRGIN PTFE EQUIPPED PUMPS Item Part Number Description Qty 43 170 114 115 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Containment 2 196 159 520 Chamber Spill Containment 2 45 286 094 600 Diaphragm Pumping 2 46 518 180 520 Manifold Spill Containment 2 Replace 518 179 520 518 180 552 Manifold Spill Containmen
5. 8 9 16 8 9 16 11 1 8 11 1 8 Model M1F Non Metallic Page 6 Metric Dimensions M1F Non Metallic with Spill Containment Dimensions in Millimeters Dimensional tolerance 3mm 14mm TYP 4 PLACES BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES ral DISCHARGE PORT 14mm X 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1255 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD INTEGRAL MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS NA TSI DR 2 Laa R7 FRONT VIEW SUCTION PORT 14mm X 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION TAT PESE A TA y EN DIMENSION Standard Pump Pulse Output Kit Q Li i DN NO LON cre HOA SS MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE SIDE VIEW Mesh Muffler Sound Dampening Muffler AIR INLET 1 2 NPT BOTTOM VIEW m1fnmdl3sm rev0814 Model M1F Non Metallic Page 7 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are con
6. Replace the o rings and spool if necessary Remove the retaining ring item 3 F from the end of the sleeve item 3 B and remove the sleeve from the valve body item 3 A Wipe clean and inspect sleeve and o rings for dirt cuts or wear Replace the o rings and sleeve if necessary STEP 3 Re assembly of the pilot valve Generously lubricate outside diameter of the sleeve and o rings Then carefully insert sleeve into valve body Take CAUTION when inserting sleeve not to shear any o rings Install retaining ring to sleeve Generously lubricate outside diameter of spool and o rings Then carefully insert spool into sleeve Take CAUTION when inserting spool not to shear any o rings Use BP LS EP 2 multipurpose grease or equivalent STEP 4 Re install the pilot valve assembly into the intermediate Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate Re install the gasket air inlet cap and capscrews Connect the air supply to the pump The pump is now ready for operation Model M1F Non Metallic Page 28 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can b
7. can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment AWARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly A WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly A WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death WARNING Airborne particles and loud noise hazards Wear ear and eye protection Model M1F Non Metallic Page 10 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 Assembly sub assembly and some purchased items Cast Iron Powered Metal Ductile Iron Ferritic Malleable Iron Music Wire Carbon Steel AISI B 1112 Alloy 20 Alloy Type 31
8. item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until it touches the bumper on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 20 to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model M1F Non Metallic Page 21 Air Valve Assembly Drawing With Stroke Indicator Option m1fnmdl3sm rev0814 AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 146 000 Air Valve Assembly 1 1 A 031 143 000 Sleeve and Spool Set 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 559 Cap Muffler 1 1 E 165 098 147 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O ring 2 For Pumps with Alternate Mesh Muffler or Piped Exhaust 1 031 147 000 Air Valve Assembly Includes all item
9. 00 M1FB3PNPPUSOOO 00 M1FB3K1KPUSO000 0 00 M1FB3K2KPUS000 0 00 Note Models listed in the table are for reference only See nomenclature below for other models Pump Brand Diaphragm Check Valve Materials Porting Options Pump Options Continued Kit Options Continued M MARATHON 1 Santoprene Santoprene N NPT Thread 4 Expanded Clearance Air Valve A E3 Solenoid Kit with 12VDC Pump Size 2 PTFE Santoprene Backup PTFE U Universal Fits ANSI and DIN w Sound Dampening Muffler Explosion Proof Coil 1F 1 Full Flow 3 PTFE Pumping PTFE Santoprene Dual Peg Expanded eee valve KIE Goil Backup Driver PTFE 8 Top Dual Porting ANSI w Mesh Muffler A E5 Solenoid Kit with 110VAC Check Valve Type 45 Santoprene Pumping Santoprene 9 Bottom Dual Porting ANSI A 6 Metal Muffler Explosion Proof Coil B Ball BANANE Pump Style 7 Metal Muffler with Grounding E6 Solenoid Kit with 220VAC Coil pesan d G PTFE Neoprene Backup PTFE D With Electronic Leak A E da P 85Ign eve N Neoprene Neoprene Detection 110 V it Options a Wi E8 Solenoid Kit with 110VAC 50 Wetted Material V FKM FKM ES dr A E DE Pulse Output Kit Es clon ron Coil i etection 10 ulse Output Ri AF TFE Bondsa l Inline Bains NOT Threads P1 Intrinsically Safe 5 30VDC A E9 Solenoid Kit with 230VAC 50 Hz c Conductive Polypropylene Be One Piece BondediPt FE ci ee ee Beca biga e A
10. 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the small unthreaded hole in the end cap Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 20 to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model M1F Non Metallic Page 23 Solenoid Shifted Air Valve Drawing SOLE
11. 50 Special Conditions For Safe Use A fuse corresponding to its rated current max 3 1 rat according IEC 60127 2 1 or a motor protecting switch with short circuit and thermal instantaneous tripping set to rated current shall be connected in Series to each solenoid as short circuit protection For very low rated currents of the solenoid the fuse of lowest current value according to the indicated IEC standard will be sufficient The fuse may be accommodated in the associated supply unit or shall be separately arranged The rated voltage to the fuse shall be equal to or greater than the stated rated voltage of the magnet coil The breakage capacity of the fuse link shall be as high as or higher than the maximum expected short circuit current at the location of the installation usually 1500 A A maximum permissible ripple of 2096 is valid for all magnets of direct current design m1fnmdl3sm rev0814 Model M1F Non Metallic Page 24 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION MARATHON s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your MARATHON s speed The solenoid coil is connected to a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate OPERATION The Solenoid Shifted MARATHON has a solenoid operated air distribution valve in place of the standard MARATHON s pilot operated air distribution
12. A thermoplastic polymer Moderate tensile and flex strenght Resists strong acids and alkalie Attacked by chlorine fuming nitric acid and other strong oxidizing agents For specific applications always consult the Warren Rupp Chemical Resistance Chart CAUTION Nonmetallic pumps and plastic components are not UV stabilized Ultraviolet radiation can damage these parts and negatively affect material properties Do not expose to UV light for extended periods of time m1fnmdl3sm rev0814 MARATHON A WARREN RUPP INC BRAND Non Metallic Design Level 3 Ball Valve Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA DISPLACEMENT STROKE 19 gallon 72 liter HEADS UP TO 100 psi or 231 ft of water 7 bar or 70 meters Operating Temperatures Maximum Minimum Maximum and Minimum Temperatures are the limits for which these materials can be operated Temperatures coupled with pressure affect the longevity of diaphragm pump components Maximum life should not be expected at the extreme limits of the temperature ranges Model M1F Non Metallic Page 1 Explanation of Pump Nomenclature M1F Non Metallic Design Level 3 Ball Valve Diaphragm Non Wetted PIER Shipping Wetted Check Valve Material Porting Pump Pump Weight Material Materials Options Style Options Ibs kg M1FB3P1PPUSO000 S Em M1FB3P2PPUSO0O00 00 M1FB3PBPPUSOO00 00 M1FB3PGPPUSOO00
13. Conversion Drawing CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 MUFFLER aa LIQUID LEVEL SUCTION LINE ESE lllustration 2 Pe 1 DIAMETER AIR EXHAUST PIPING MUFFLER pe _ LIQUID 3 LEVEL SUCTION LINE Illustration 3 Model 1 DIAMETER AIR EXHAUST PIPING M1F Non Metallic Page 29 MODULAR CHECK VALVE SERVICING Before servicing the check valves first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the modular check valve remove the elbows items 18 and 19 from pump composite repair parts drawing Use a 9 16 wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seenin the cavities of the outer chamber items 14 Next remove the check valve seal item 36 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 31 for cuts abrasive wear o
14. actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 1 2 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and filters must be supported by some means other than the air inlet cap Failure to provide support for the piping may result in damage to the pump A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended l
15. rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional TPE pumping diaphragms item 55 These diaphragms are installed with the natural concave curve toward m1fnmdl3sm rev0814 the outer chamber items 15 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in
16. the suction then shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump composite repair parts drawing and the diaphragm servicing illustration Using a 9 16 wrench or socket remove the 16 capscrews items 8 hex flange nuts and washers that fasten the elbows items 18 and 19 to the outer chambers items 14 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a 9 16 wrench or socket remove the 16 capscrews items 10 hex flange nuts and washers that fasten the outer chambers diaphragms and inner chambers items 15 together Step 3 Removing the diaphragm assemblies Use a 1 35mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 33 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 28 m1fnmdl3sm rev0814 Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use a 13 5 wrench or socket to remove the outer diaphragm plate item 29 by turning counter clockwise Inspect the diaphragm item 116 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Instal
17. valve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard MARATHON pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage m1fnmdl3sm rev0814 Before wiring remove terminal block from conduit connector Y r Wiring Diagram A 2 Terminal Neutral Negative 3rd Terminal for ground 1 Terminal Power Positive Model M1F Non Metallic Page 25 Diaphragm Service Drawing Diaphragm Service Drawing with Overlay Non Overlay DA lt IRS NS JJ AL Y A Field conversion kit 475 258 000 available for NO SOS conversion from PTFE Overlay to One Piece STS SN 7 bonded Diaphragm SU LE i ee Part Description Qty 55 P S 286 115 000 One Piece Diaphragm 2 US 9 612 220 150 Plate Inner Diaphragm 2 m1fnmdl3sm rev0814 Model M1F Non Metallic Page 26 DIAPHRAGM SERVICING To service the diaphragms first shut off
18. 031 147 000 050 042 354 050 042 360 050 042 363 050 042 365 050 042 600 095 110 558 114 024 551 d 114 024 559 132 035 360 135 034 506 165 125 551 dh 165 125 559 170 020 115 170 020 308 170 030 115 170 030 308 170 052 115 170 052 308 170 069 115 170 069 308 171 053 115 171 015 115 171 015 308 196 157 520 196 157 521 196 157 552 196 157 557 196 177 551 196 177 559 286 107 354 286 107 360 286 115 000 286 107 363 286 107 365 286 108 600 312 104 520 4 312 104 521 4312 104 557 m1fnmdl3sm rev0814 DESCRIPTION Air Valve Assembly Air Valve Assembly No Muffler Air Valve Assembly w PTFE Coated Hardware Air Valve Assembly No Muffler Air Valve Assembly No Muffler Air Valve Assembly No Muffler PTFE Hardware Air Valve Assembly With Stroke Indicator Option Air Valve Assembly No Muffler w Stroke Indicator Ball Check Ball Check Ball Check Ball Check Ball Check Pilot Valve Assembly Intermediate Assembly Intermediate Assembly Bumper Diaphragm Bushing Plunger Cap Air Inlet Cap Air Inlet Capscrew Hex HD 3 8 16 x 2 00 Capscrew Hex HD 3 8 16 x 2 00 QTY y ix TA OR RSS RR c3 UA cd oat 16 Capscrew Hex HD 1 2 13 x 2 00 not used with inline option 16 Capscrew Hex HD 1 2 13 x 2 00 not used with inline option 16 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 5 16 18 x 1 75 Capscrew Hex HD 5 16 18
19. 1F Non Metallic Page 9 RECYCLING Many components of MARATHON Metallic AODD pumps are made of recyclable materials see chart on page 11 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed m1fnmdl3sm rev0814 IMPORTANT SAFETY INFORMATION IMPORTANT Read these safety vvarnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty CAUTION Before pump operation inspect all gasheted fasteners for looseness caused by gashet creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual A WARNING Before maintenance or repair shut off the compressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure da WARNING In the event of diaphragm rupture pumped material may enter the air end of the pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition AWARNING Take action to prevent static sparking Fire or explosion
20. 6 Stainless Steel Alloy Type 316 Stainless Steel Electro Polished Alloy C Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 Almag 35 Aluminum 356 T6 Aluminum 356 T6 Aluminum Die Cast Aluminum Alloy 380 Aluminum Alloy SR 319 Anodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc m1fnmdl3sm rev0814 180 305 306 307 308 309 310 330 331 332 333 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 Copper Alloy Carbon Steel Black Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 4203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compressi
21. 70 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Containment 2 196 159 520 Chamber Spill Containment 2 46 518 180 520 Manifold Spill Containment 2 Replace 518 179 520 518 180 552 Manifold Spill Containment 2 Replace 518 179 552 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Threaded Bushing 4 618 031 308 Threaded Bushing 4 lo SE 52 835 005 110 4 SS 835 005 308 Tee Pipe 4 y QNel N q 53 860 056 606 Tube Sight 2 7 A SALT A 54 866 060 110 Connector Tube 4 MAS EJ 55 286 092 354 Diaphragm Pumping 2 PU i4 y 18 286 108 600 Diaphragm Overlay is not used 2 AN TL AS Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing A Item 55 The diaphragm is to be installed with the convex side facing toward the outer chambers m1fnmdl3sm rev0814 Model M1F Non Metallic Page 18 OPTION FOR EQUIPPED PUMPS CONCEPT The spill containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm
22. AIR CAN BE DANGEROUS Contact the MARATHON Technical Services Department before performing this procedure A model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local MARATHON Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed MARATHON Warranty Certificate Model M1F Non Metallic Page 12 m1fnmdl3sm rev0814 Model M1F Non Metallic Page 13 Composite Repair Parts Drawing Torque 140 in Ibs AVAILABLE SERVICE AND CONVERSION KITS 476 217 000 AIR END KIT For Polypropylene Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 218 000 AIR END KIT Stroke Indicator Option For Polypropylene Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 197 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and PTFE Seals 476 197 360 WETTED END KIT Nitrile Diaphragms Nitrile Balls and PTFE Seals 476 197 363 WETTED END KIT FKM Diaphragms FKM Balls and PTFE Seals 476 197 365 WETTED END KIT Neoprene Diaphragms Neoprene Balls and PTFE Seals 476 197 635 WETTED END KIT Neoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals 476 197 654 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms TFE Balls and TFE S
23. C IM1c IM2c Note Pumps are only ATEX pliant when ordered with wetted material option C or V non wetted material option C pump option 0 6 or 7 and kit option O Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option 1 m1fnmdl3sm rev0814 Model M1F Non Metallic Page 2 Performance Curve Model M1F Non Metallic Design Level 3 Performance based on the following elastomer fitted pump flooded suction water at ambient conditions The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 15 25 5 SCFM M hr 17 SML 63 20 84 lt 0 2 n 7 100 90 686 EE 80 i E SS 5 I 70 PD o Q 4 60 Z Li 50 e E 1 Lu 3 ES n la 40 3 gt 2 30 Lr 30 9 7 25 7 6 20 16 15 45 10 13 5 11 5 0 U S Gallons per minute 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Liters per minute CAPACITY m1fnmdl3sm rev0814 Model M1F Non Metallic Page 3 Dimensions M1F Non Metallic Inline Ported Option Polypropylene Wet End Models ONLY Dimensions in inches Dimensions in millimeters metric dimensions in brackets A DISCHARGE PORT OPTIONAL 1 FNPT 4 96 126 2X 2 15 55 19 94 506 DISCHARGE PORT 1 FNPT AIR INLET 1 2 FNPT zo L 50 13
24. ERR Solenoid Shifted Air Distribution Valve OptiON oooococccnnocociooccconccconnnconononnonononnnnonnnnnnnn nono ncnonnnnnnns Diaphragm Service Drawing Non Overlay ccecceeceeeeeeneeeeeeeeeeeeeceeeceneseeesereeeeeaeeeaeeeeeeeeneneeenees Diaphragm Service Drawing with Overlay Diaphragm Servicing ice tte ete SU Ei Overlay Diaphragm Service nono ES GE EN Pilot Valve Servicing Assembly Drawing amp Parts List 28 Pumping Hazardous Liquids 52 eda e end aa pce cia aa 29 Converting the pump for piping the exhaust air 29 Exhaust Conversion Drawing 2 1 riii tte PERLE e EE deo 29 Converted Exhaust Illustration 29 Modular Check Valve Servicing irridet teen netter eei imt perite Se EE dit dedere pend o EE 30 Modular Check Valve Drawing csscceceececeeeeeesereeeeeseeeaeeeeeeeneceeceecnesaeesereeseseaeseaeseneeeeeeneeenness 30 Dual Port Option Drawing 2 2 reet p e 31 Dual Porting Options cocco tds 32 Dual porting of both suction and discharge ends of the pump 32 Single porting of the suction and dual porting of the pump 32 Dual porting of the suction and single porting of the pump 32 Leak Detection Options
25. M20 M30 MSB1 MHDF1 MHDF2 MHDF3 MT Series Surge Suppressors Marking 112 G Ex ia c IIC 5 11 3 2 G Ex ia c IIC 5 112 D Ex c iaD 20 IP67 T100C Il 2 G EEx mc II T5 Il 3 2 G EEx mc II T5 II 2 D c IP65 T100C Il 1 GcT5 Il 3 1 Gc T5 Il 1 Dc T100 C IM1c IM2c Il2GcT5 Il 3 2 G c T5 Il 2 D c T100 C II 2 G T5 Il 3 2 G T5 Il 2 D T100C EC Type Certificate No Pumps O9ATEX0071 X Type Certificate No Pumps O9ATEX0072 X Type Certificate No Suppressors 09ATEX0073 MX O9ATEX0071 X CE 0344 O9ATEX0071 X CE 0344 O9ATEX0071 X O9ATEX0072 X CE 0344 O9ATEX0072 X CE O9ATEX0073 CE ATEX Summary of Markings Listed In KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X KEMA O9ATEX0071 X 09ATEX0072 X 09ATEX0072 X 09ATEX0072 X 09ATEX0072 X KEMA O9ATEX0073 KEMA O9ATEX0073 KEMA O9ATEX0073 Non Conductive Fluids IBEX CORPORATION Declaration of Conformity
26. NOID SHIFTED AIR VALVE PARTS LIST Includes All Items Used on Composite Repair Parts List Except as Shown Ite 56 57 58 59 60 m Part Number 893 097 000 219 001 000 219 004 000 219 002 000 219 003 000 241 001 000 170 029 330 618 051 150 APPROVED Description Solenoid Valve NEMA4 Solenoid Coil 24VDC Solenoid Coil 24VAC 12VDC Solenoid Coil 120VAC Solenoid Coil 240VAC Connector conduit Capscrew Hex HD 5 16 18 x 1 50 Plug IEC EEX m T4 SB A For Explosion Proof Solenoid Coils used in North America and outside the European Union 57 57 219 009 001 219 009 002 219 009 003 219 009 004 219 009 005 219 009 006 Solenoid Coil 120VAC 60 Hz Solenoid Coil 240VAC 60 HZ Solenoid Coil 12VDC Solenoid Coil 24VDC Solenoid Coil 110VAC 50 Hz Solenoid Coil 230VAC 50 Hz Note 58 Conduit Connector is not required Il 2G EEx mc II 5 Il 3 2 G Ex mc II T5 Il 2D c IP65 100 For ATEX Compliant Solenoid Coils used in the European Union 219 011 001 219 011 002 219 011 003 219 011 004 Solenoid Coil Single mounting 12 VDC 3 3W 267mA Solenoid Coil Single mounting 24 VDC 3 3W 136mA Solenoid Coil Single mounting 110 120 VAC 3 4W 29 Solenoid Coil Single mounting 220 240 VAC 3 4W 15mA Qty NA a m i i 2A c cn aaa Note 37 Conduit Connector is not required Compressed Air Temperature Range Maximum Ambient Temperature to plus
27. SERVICE amp OPERATING MANUAL Original Instructions MARATHON A WARREN RUPP INC BRAND Model M1F Non Metallic Design Level 3 Table of Contents Engineering Data and Temperature Limitations ooonnocnnnnnnnccnnonccinocannncncnnano nara no rancia rnrn cnn enn 1 Explanation of Pump Nomenclature Performance Curve Model M1F Non Metallic Design Level 3 Dimensions for Inline Ported Models Dimensiions for Side Ported Models Dimensions M1F Spill Containment Metric Dimensions M1F Spill ContainMment ooooocccnnocccinccccooccnonnncnoncnonnnonono nono ncnonnnnnnn nennen nnne 7 Principle of Purnp Operation 5 2 2 adas 8 Installation and Start up este e Do ctr EA 8 Alt SUp ply C 8 Alt Valve E brication es oet d etre t e EN e T Mc SS epe dd a ES ene ED 8 PX Mr MOS O EE 8 Air Inlet and Primilg a QR PARE de 8 Between USES eser erue pesto cu cen a ee Ree tel ORE EUR 8 Installation Guide inin secs Important Safety Information Malterial Codes etica AAA Ii caidas Warranty Composite Repair Parts Drawing ccscceceeceeeeceeeceresereeeeeeeeeeaeeeaeseeeeeeeeseeceesaeesarseaeeeaeseeteneeenes 14 Overlay Option Drawing 5 22 tc ener a cs 14 Composite Repair Parts List sed A e eret DA il 15 Spill Cont
28. V Ciu NC P OE Leak Detection Pulse Output Kit SP Stroke Indicator Pins Check Valve Seat S Standard P2 110 120 or 220 240VAC A1 Solenoid Kit with 12 VDC K PVDF V With Visual Leak Detection Pulse Output Kit ATEX Compliant Coil P Polypropylene A E0 Solenoid Kit with 24VDC Coil A2 Solenoid Kit with 24 VDC Non Wetted Material Options ie A Solenoid KEWIN 006 M ATEX Compliant Coil P Polypropylene j 1 Sound Dampening Muffler Explosion F roof Coil A3 Solenoid Kit with 110 120 VAC 1 40 Glass Filled Polypropylene 2 Mesh Muffler E2 Solenoid Kit with 24VAC 12VDC Col _ 50 60 Hz ATEX Compliant Coil with PTFE hardware 3 Expanded Clearance Air Valve A4 Solenoid Kit with 220 240 VAC 50 60 Hz ATEX Compliant Coil 3 2G EEx II T5 4 Ex 1 3 2 2G EEx m c II T5 IEC EEX m T4 SB 1 2D c IP65 T100 C APPROVED Note Pumps ordered with the Note Pump models equipped with these options listed in 1 to the left are A explosion proof solenoid kit options E1 ATEX compliant when ordered with E5 E7 E8 or E9 are certified and kit option A1 A2 A3 or A4 Com approved by the above agencies They are pressed Air Temperature Range Maximum NOT ATEX compliant Ambient Temperature to plus 50 Note See page 24 for Special Conditions For Safe Use A C Conductive Polypropylene w Integral Muffler 1 Il 1Gc T5 2 2G Ex iac IIC 5 Il 3 1 Gc T5 II 3 2 G Ex iac IIC 5 Il 1D c T100 C 1 2D Ex c ia 20 IP67 T100
29. ainment Option for Virgin PTFE Equipped Pumps esee 16 Spill Containment Repair Parts 1151 Spill Containment Concept aei rn era add pa axe gegen o RAN REA Spill Containment Option Diaphragm Servicing seen Filling Spill Containment Chambers with Liquid Spill Containment Option for Equipped Pumps Spill Containment Repair Parts 1151 Spill Containment Concept with TPE Diaphragms eccceceeeeeeereeereeeeeeeeeeeeeeeeeteneeeneeeeneeeneeaees Spill Containment Option with TPE Diaphragm cecceeeeseeeceeeecereeereeeeeeeeeaeeeeeseeeeeeeeneesenesereeates Air Distribution Valve Assembly Drawing seen eene nennen nene Main Air Valve Assembly Parts List esssssssesssseeseeeeeeneen nnne rennen enn rin nene enne See pages 2 38 and 39 for ATEX ratings Air Distribution Valve Service 21 Air Distribution Valve with Stroke Indicator Options sssssssssessseeeneeerenee ene 22 Air Distribution Valve with Stroke Indicator Parts List sss 22 Air Distribution Valve with Stroke Indicator Servicing Solenoid Shifted Air Valve Drawing ceccesceeseeeeeceeceeecerecereeeeeeseeeaeeeaeseaeseaesaecenesenesereenreeneeeaeeeaes Solenoid Shifted Air Valve List ret reinen e n t e He e PE PD
30. ak detectors remove the bottom 4 NPT pipe plug on the visual sight tube item 53 Insert leak detector into the 74 pipe tee item 52 Model M1F Non Metallic Page 33 Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the Stroke Counter Batch Controller or user control devices such as a PLC The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the air valve and senses each stroke of the main spool Consult the factory for further information and availability Pulse Output Kits 475 244 001 10 30 VDC 475 244 002 110 220 VAC 475 244 003 Intrinsically Safe 10 30VDC 110VAC and 220 VAC m1fnmdl3sm rev0814 Model M1F Non Metallic Page 34 Optional Muffler Configurations Drawing OPTION 0 530 028 550 Integral Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to hold it in place OPTION 1 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body Ex dh ATEX Compliant Option 0 Option 1 and 2 Option 6 m1fnmdl3sm rev0814 Mod
31. charge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional virgin PTFE pumping diaphragms item 45 These diaphragms are installed with the natural convex curve toward the outer chamber items 14 from the m1fnmdl3sm rev0814 pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING CHAMBERS WITH LIQUID The chambers are filled with water at the factory If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifo
32. crews item 12 and four flat washers item 38 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 20 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter ofthe spool Wipe spool with a soft cloth and inspect for scratches or wear m1fnmdl3sm rev0814 Inspect the inner diameter of the Sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body
33. e INTAKE DISCHARGE PIPE SIZE 1 ANSI Flange or PN10 25mm DIN Flange A CAUTION Operating temperature limitations are as follows Materials Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons PVDF A durable fluoroplastic with excellent chemical resistance Excellent for UV applications High tensile strength and impact resistance NEOPRENE All purpose Resistant to vegetable oils Generally not affected by moderate chemicals fats greases and many oils and solvents Generally attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocarbons PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures FKM Fluorocarbon shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydro carbons acids animal and vegetable oils Hot water or hot aqueous solutions over 70 F will attack FKM Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance Polypropylene
34. e submerged if the pump materials of construction are compatible with the liquid being pumped The air exhaust must be piped above the liquid level See illustration 2 at right Piping used for the air exhaust must not be smaller than 1 2 54 cm diameter Reducing the pipe size will restrict air flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the exhaust higher than the product source to prevent siphoning spills See illustration 3 at right CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Use a 8 Torx or flat screwdriver to remove the four self tapping screws item 1 L Remove the muffler cap and muffler items 1 E and 1 G The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed IMPORTANT INSTALLATION NOTE m1fnmdl3sm rev0814 The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be physically supported Failure to support these connections could also result in damage to the air distribution valve body Exhaust
35. eals 476 197 659 WETTED END KIT One Piece Bonded Diaphragms PTFE Balls PTFE Seals 476 198 655 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 476 198 354 WETTED END KIT Santoprene Diaphragms Santoprene Pumping Diaphragms Santoprene Check Balls and PTFE Seals 476 198 659 WETTED END KIT One Piece Bonded Diaphragms PTFE Pumping Diaphragms PTFE Balls PTFE Seals ELECTRONIC LEAK DETECTOR KITS 032 037 000 110 VAC 220 VAC 032 045 000 12 32 VDC NLINE DISCHARGE MANIFOLD OPTION Torque 140 in Ibs 200 in Ibs Torque 180 in Ibs Torque 320 in Ibs Torque 200 in Ibs Torque 160 in Ibs INLINE SUCTION MANIFOLD OPTION ONE PIECE BONDED OPTION IMPORTANT NOTE Polypropylene pumps are shipped with the 1 NPT Pipe Plug Item 64 installed in the end ports of both suction and discharge one piece manifolds To convert to the Inline porting positions for pump installation and operation first remove the pipe plugs and re install in the center ports Apply PTFE tape or pipe sealant to threads of the plug before installation m1fnmdl3sm rev0814 Model M1F Non Metallic Page 14 Composite Repair Parts List ITEM 1 10 11 12 13 14 15 16 17 18 PART NUMBER 031 140 000 A 031 140 001 031 140 002 031 141 000 031 141 001 031 141 002 031 146 000
36. ed name of authorized person Title August 23 2012 Date of revision Revision Level F CORPORATION P Declaration of Conforrnitu ANUJJOJUOS JO UOIeJej3atg ARATHON M A WARREN RUPP INC BRAND N EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Equipment intended for use in potentially explosive environments Manufacturer Warren Rupp Inc A Unit of IDEX Corportion 800 North Main Street P O Box 1568 Mansfield OH 44901 1568 USA EN 60079 25 2011 For pumps equipped with Pulse Output ATEX Option Applicable Standard Quality B V 0344 EN13463 1 2009 EN13463 5 2011 AODD Pumps and Surge Suppressors For Type Examination Designations see page 2 back AODD Air Operated Double Diaphragm Pumps EC Type Examination Certificate No Pumps O9ATEX0071 X DEKRA Certification B V 0344 Meander 1051 6825 MJ Arnhem The Netherlands DATE APPROVAL TITLE avi 14 MAY 2014 David Roseberry Engineering Manager FLUID amp METERING Declaration of Conformity ANUJJOJUOS JO UOIneJej3atg MARATHON A WARREN RUPP INC BRAND EC Declaration of Conformity Pump types M05 M1F M15 M20 and M30 provided with the pulse output option Pump types M05 M1F M15 M20 and M30 provided with the integral solenoid option Pump types MPB1 4 MO5 M1F M15 M20 M30 MSB1 MHDF1 MHDF2 without the above listed options no aluminum parts Pump types MPB1 4 MO5 M1F M15
37. el M1F Non Metallic Page 35 Grounding The Pump To be fully groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet end is fastened to the pump hardware This optional 8 foot long 244 centimeters Ground The other end is installed to a true earth ground Strap 920 025 000 is available for easy ground connection To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded m1fnmdl3sm rev0814 Model M1F Non Metallic Page 36 ANUJJOJUOS JO UOIneJej3atg ARATHON M A WARREN RUPP INC BRAND N Declaration of Conformity Manufacturer Warren Rupp Inc 800 Main Street P O Box 1568 Mansfield Ohio 44901 1568 USA certifies that Air Operated Double Diaphragm Pump Series M Non Metallic M Metallic and Surge Suppressors comply with the European Community Directive 2006 42 EC on Machinery according to Annex VIII This product has used Harmonized Standard EN809 1998 A1 2009 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance Signature of authorized pers Date of issue David Roseberry Engineering Manager Print
38. ifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model M1F Non Metallic Page 32 Leak Detection Options Drawing Qty of 2 710 014 330 Self tapping Screws MUFFLER CAP E l For pumps 530 028 550 Enclosed Muffler For pumps with Alternate Mufflers m1fnmdl3sm rev0814 710 009 115 SELF TAPPING SCREWS OF 4 LEAK DETECTION OPTION A ELECTRONIC Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz Rit 032 045 000 12 32VDC To install electronic leak detectors remove the bottom 74 NPT pipe plug on the visual sight tube item 53 Insert leak detector into the 74 pipe tee item 52 Leak Detection Option B Mechanical Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical le
39. imits AIR VALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the preferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required The pump air system will operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from MARATHON set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing or freezing of the exhaust air causing the pump to cycle erratically or stop operating Water in the air supply can be reduced by using a point of use air dryer to supplement the user s air drying equipment This device removes water from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 1 2 to 3 4 turn After the pump primes the air valve can be opened to increase air flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient air flow to pump flow rat
40. io BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model M1F Non Metallic Page 8 Available from MARATHON ACAUTION The air exhaust should be piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure TYPICAL INSTALLATION GUIDE For Non Metallic Pumps Surge Suppressor Limited to 100 psi i Pipe Connection irs Style Optional Line Gauge Flexible Shut Off Valve Connection Tn AH DISCHARGE A LI a Drain Port Flexible Connection Air Shut Off Valve Pipe Connection Style Optional TOP i Filter Regulat Air Exhaust n BOUE ilter Regulator i DIAPHRAGM Shut Off PUMP al AIR INLET O Flexible SUCTION ruo Y Connection z L 11111111 Drain Port m1fnmdl3sm rev0814 Model M
41. ld and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 K into the smaller unthreaded hole in one end cap item 1 E This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber The volume of fluid is 1198 ml 40 49 fl oz It is important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug item 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top
42. ling the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole ofthe diaphragm Thread the inner plate clockwise onto the stud Use a torque wrench to tighten the diaphragm assembly together to 27 ft Lbs 36 61 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 5 is installed over the diaphragm rod Thread the stud of the one diaphragm assembly clockwise into the tapped hole atthe end of the diaphragm rod item 33 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 15 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 14 to the pump using the capscrews items 10 hex flange nuts and flat washers On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 33 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber The molded directional arrows
43. n be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model M1F Non Metallic Page 19 Air Distribution Valve Assembly Drawing AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 140 000 Air Val
44. nected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end ofthe valve body inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool shifts to the opposite end of the valve body the pressure to the chambers m1fnmdl3sm rev0814 is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a
45. of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model M1F Non Metallic Page 17 Option For Equipped Pumps Drawing M1F SPILL CONTAINMENT REPAIR PARTS LIST FOR TPE EQUIPPED PUMPS Item Part Number Description Qty 43 170 114 115 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 1
46. on Mold Urethane Rubber Nitrile Rubber Color coded RED FDA Accepted Nitrile FKM Fluorocarbon Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 553 555 556 557 558 559 570 580 590 591 592 600 601 602 603 High Density Polypropylene Conductive Nitrile Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Conductive PVDF Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive Polypropylene Conductive HDPE Glass Filled Conductive Polypropylene Rulon 11 Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon 604 606 607 608 610 611 632 633 634 635 637 638 639 643 644 650 654 656 661 PTFE PTFE Envelon Conductive PTFE PTFE Integral Silicon PTFE Integral FKM Neoprene Hytrel FKM Fluoroca
47. on the diaphragm must point vertically Fasten the remaining outer chamber item 14 to the pump using the capscrews items 10 hex flange nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 8 hex flange nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 17 is designed to fit snugly over the exterior of the standard TPE diaphragm item 16 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty One Piece Bonded DIAPHRAGM SERVICING Bonded PTFE with integral plate The one piece bonded diaphragm item 17 has a threaded stud installed in the integral plate at the factory The inner diaphragm plate has a through hole instead of a threaded hole Place the inner plate over the diaphragm stud and thread the first diaphragm inner plate onto the dia phragm rod only until the inner plate contacts the rod Do not tighten A small amountof grease ma
48. porting can be configured to a single suction and a dual discharge The porting can be changed to a dual suction and a single discharge The above changes are possible because the porting flange of the elbows items 18 and 19 are designed to mate with standard 1254 ANSI style 4 bolt 1 pipe flanges DUAL PORTING OF BOTH SUCTION AND DISCHARGE ENDS OF THE PUMP Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals spacers and manifolds items 35 and 23 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows and optional positioning in the Dual Porting Drawing m1fnmdl3sm rev0814 SINGLE PORTING OF THE SUCTION AND DUAL PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing DUAL PORTING OF THE SUCTION AND SINGLE PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds spacers and man
49. r embedded materials Replace as needed Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats items 37 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chamfers The spherical surface of the check balls must seat flush to the surface of the inner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary m1fnmdl3sm rev0814 Remove the remaining check valve Seal item 36 Inspect the seal for cuts or pinched areas Replace seal as needed Re assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 36 into the cavity of the outer chamber item 14 Make sure the chamfer side ofthe seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 36 Make sure the chamfer side of the seal faces the chamfer on the check valve seat or retainer The pump can now reassembled reconnected and returned to operation Modular Check Valve Drawing Model M1F Non Metallic Page 30 Dual Port Option Drawing m1fnmdl3sm rev0814 Model M1F Non Metallic Page 31 DUAL PORTING OPTIONS Several dual porting options are possible The pump can be converted to a dual port arrangement on both the suction and the discharge ends The
50. rbon PTFE EPDM PTFE Neoprene PTFE PTFE FKM Fluorocarbon PTFE PTFE Hytrel PTFE Nitrile TFE Santoprene EPDM Santoprene PTFE Bonded Santoprene and PTFE Santoprene Diaphragm PTFE Overlay Balls and seals Santoprene Diaphragm and Check Balls EPDM Seats EPDM Santoprene Delrin and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Exxon Mobil Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co MARATHON PortaPump and SludgeMaster are registered tradenames of Warren Rupp Inc Model M1F Non Metallic Page 11 TROUBLESHOOTING Possible 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 suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air supply press
51. s used on 031 140 000 minus items 1 D 1 F amp 1 J NOTE CHECK GAP AFTER ASSEMBLY TO INSURE COMPLETE INSTALLATION OF RETAINING RING Ex Note ATEX Compliant Model M1F Non Metallic Page 22 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See Composite Repair and Parts Drawing Using a 5 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 38 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 20 for cracks or damage Replace gasket if needed Step 42 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter ofthe spool Wipe spool with a soft cloth and inspect for scratches or wear m1fnmdl3sm rev0814 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item
52. sassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section ofthe pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF
53. t 2 Replace 518 179 520 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Threaded Bushing 4 618 031 308 Threaded Bushing 4 52 835 005 110 Tee Pipe 4 835 005 308 Tee Pipe 4 53 860 056 606 Tube Sight 2 54 866 060 110 Connector Tube 4 Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing Note Pump units with One Piece Bonded Diaphragm option will not ltem 45 include Overlay Diaphragms Items 18 and Outer Diaphragm Plate The diaphragm is y Item 30 to be installed with the convex side facing toward the outer chambers Note m1fnmdl3sm rev0814 Model M1F Non Metallic Page 16 OPTIONS FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT The spill containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the dis
54. the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 R into the smaller unthreaded hole in one end cap item 1 E This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill prevention chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber 6 Loosely reinstall one boss plug item 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This ca
55. ure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling m1fnmdl3sm rev0814 What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS Plus the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a surge suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Di
56. ve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 H 1 B 095 094 551 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 551 Cap Muffler 1 1 E 165 115 558 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 141 000 Air Valve Assembly 1 Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J A AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 140 001 Air Valve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 NONSE COMPLET nw 1 D 165 096 559 Cap Muffler 1 INSTALLATION OF RETAINING RING 1 E 165 115 558 Cap End 2 1 F 530 028 550 Muffler 1 297 1 G 560 020 360 O ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For Pumps with Alternate Mesh Muffler or Piped Exhaust 1 031 141 001 Air Valve Assembly 1 Includes all items used on 031 140 001 minus items 1 D 1 F amp 1 J Ex Note ATEX Compliant m1fnmdl3sm rev0814 Model M1F Non Metallic Page 20 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See Composite Repair and Parts Drawing Using a 5 16 Allen wrench remove the four hex socket caps
57. x 1 75 Capscrew Soc HD 3 8 16 x 2 50 Capscrew Soc HD 3 8 16 x 88 Capscrew Soc HD 3 8 16 x 88 Chamber Outer Chamber Outer Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Diaphragm One Piece Bonded Diaphragm Diaphragm Diaphragm Overlay Elbow Elbow Elbow 16 16 RI UV OC o B HA ITEM 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 62 63 64 PART NUMBER 312 104 552 312 113 520 A 312 113 521 312 113 552 A 312 113 557 360 093 360 360 103 360 360 104 360 360 104 379 360 107 360 518 179 520 A 518 179 521 518 179 552 A 518 179 557 544 002 115 544 002 308 545 008 115 545 008 308 560 001 360 612 200 157 612 200 082 612 220 150 612 204 520 612 204 552 620 020 115 670 048 520 670 048 552 675 042 115 685 058 120 720 004 360 720 044 600 720 047 600 722 079 520 722 079 552 901 038 115 901 038 308 901 046 115 901 046 308 901 048 115 901 048 308 901 049 115 901 049 308 518 203 552 518 204 552 P16NP x Note ATEX Compliant DESCRIPTION Elbow not used with inline option Elbow Suction Elbow Suction Elbow Suction not used with inline option Elbow Suction Gasket Air Valve Gasket Pilot Valve Gasket Air Inlet Gasket Air Inlet Gasket Inner Chamber Manifold Manifold Manifold Manifold Nut Hex 3 8 16 Nut Hex 3 8 16 Nut Hex 1 2
58. y be applied between the inner plate and the diaphragm to facilitate assembly Insert the diaphragm rod assembly into the pump and install the outer chamber Turn the pump over and thread the second diaphragm inner plate onto the diaphragm rod Turn the diaphragm until the inner plate contacts the rod and hand tighten the assembly Continue tightening until the bolt holes align with the inner chamber holes DO NOT LEAVE THE ASSEMBLY LOOSE Model M1F Non Metallic Page 27 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION QTY 3 095 110 558 Pilot Valve Assembly 1 3 A 095 095 558 Valve Body 1 3 B 755 052 000 Sleeve With O rings 1 3 C 560 033 360 O ring Sleeve 6 3 D 775 055 000 Spool With O rings 1 3 E 560 023 360 O ring Spool 3 3 F 675 037 080 Retaining Ring 1 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See pump assembly drawing Using a 1 2 wrench or socket remove the four capscrews item 11 Remove the air inlet cap item 7 and air inlet gasket item 22 The pilot valve assembly item 3 can now be removed m1fnmdl3sm rev0814 for inspection and service STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 3 D Wipe clean and inspect spool and o rings for dirt cuts or wear

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