G05 Operations Manual
Contents
1. Dimensions in Millimeters Dimensional Tolerance 3mm 260mm Discharge Port 130mm 1 2 NPT Internal 1 NPT External 3 8 NPT For Piping Exhausted Natural Gas Gas Inlet 1 4 NPT o 2 FRONT VIEW SIDE VIEW Suction Porth 6mm 1 2 NPT Internal X ub 1 NPT External Both Suction and Discharge Ports Are Available InX 1 2 BSPT Tapered Internal X 1 BSPT Tapered External mm BOTTOM VIEW Note The pump is to be mounted in a horizontal position Bruin G05 REV0408 Model G05 Metallic Page 4 Dimensions G05 Metallic Stainless Steel Model Dimensions in Inches Dimensional Tolerance s Discharge Port 1 2 NPT Internal X 1 NPT External Gas Inlet 1 4 NPT 3 8 NPT Port For X Piping Exhausted Natural Gas i EFR FRONT VIEW SIDE VIEW Suction PortX 1 2 NPT Internal X 1 NPT External Both Suction Andx Discharge Ports AreX Available InlX 1 2 BSPT Tapered Internal X 1 BSPT Tapered External BOITOM VIEW Note The pump is to be mounted in a horizontal position Bruin G05 REV0408 Model G05 Metallic Page 5 Metric Dimensions G05 Metallic Stainless Steel Model Dimensions in Millimeters Dimensional Tolerance 3mm Tes o M esi je mr amci Bruin G05 REV0408 FRONT VIEW __ l 3 Mn iE Discharge2. 377 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 540 541 542 544 550 551 552 553 555 556 558 570 580 590 591 592 600 601 602 603 604 Fluorinated Nitrile Conductive HNBR 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 Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive HDPE Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE FKM PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 649 PTFE Nitrile PTFE 656 X Santoprene Diaphragm and Check Balls EPDM Seats 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 M
3. 780 430 1777 BRUIN PUMPS Ex 28075 GO5 metallic Quality System 1SO9001 Certified CE Environmental Natural Gas Operated Management System U S Patent 1 014001 Certified 5 996 627 6 241 487 Diaphragm Pumps Other U S Patents Applied for ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY GAS VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 72 NPT or 7 BSP Tapered internal 0 to 15 gallons per minute No lube no stall Up to 125 in 3mm 100 psi or 230 7 ft of water 026 Gallon 098 liter 2 NPT or 7 BSP Tapered external 0 to 56 liters per minute design 7 Kg cm 70 meters A CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum 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 Virgin 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 Excellent resistance to sour natural gas high temperatures acids hydrogen sulfide and oils For specific applications always consu
4. Assembly Pilot Valve Assembly Intermediate Bracket Bracket Mounting Aluminum Bumper Diaphragm Bumper Diaphragm Bushing Plunger Cap Gas Inlet Capscrew Flat Socket Head 1 4 20 X 50 Aluminum Capscrew Hex 5 16 18 X 1 00 Capscrew Hex 5 16 18 X 1 25 Alum Capscrew Hex 5 16 18 X 1 25 sS Capscrew Flanged 1 4 20 X 75 Capscrew Flanged 1 4 20 X 1 50 Chamber Outer Chamber Outer Diaphragm Diaphragm Overlay Elbow Suction Aluminum Only Elbow Discharge Aluminum Only Gasket Gas Inlet Gasket Pilot Valve Gasket Gas Valve QTY BANNNN AAA PRA BO N A A O ana NNNNNDN AA ITEM PART NUMBER DESCRIPTION 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 518 157 157 518 157 157E 518 158 110 518 158 110E 518 159 110 518 159 110E 545 004 330 545 004 330 560 001 360 560 001 363 560 083 360 560 083 360 560 083 611 720 064 600 612 091 110 612 091 157 612 177 330 620 019 115 675 042 115 685 056 110 720 012 360 720 012 363 722 094 600 722 094 150 722 094 110 920 025 000 900 004 330 900 004 330 Manifold see item 29 Aluminum Only Manifold BSP Tapered Alum Only Manifold Suction SS Manifold Suction BSP Tapered SS Manifold Discharge ss Manifold Discharge BSP Tapered SS Nut Hex Flanged 5 16 18 Alum Nut Hex Flanged 5 16 18 ss O ring O ring O ring Aluminum Manifold O ring Metallic Seats Only O ring Metallic Seats
5. Port 1 2 NPT Internal X 1 NPT External 3 8 NPT Port For X Piping Exhausted Natural Gas Gas InletiX 1 4 NPT SIDE VIEW Suction PortX 1 2 NPT Internal X 1 NPT External Both Suction AndX Discharge Ports Are Available Ind 1 2 BSPT Tapered Internal X 1 BSPT Tapered External BOTTOM VIEW Note The pump is to be mounted in a horizontal position Model G05 Metallic Page 6 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by sweet natural gas 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 connected 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 Gas 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
6. S Patent 5 996 627 6 241 487 Other U S Patents Applied for Available Service and Conversion Kits 12 Composite Repair Parts List c cineieeeeeeit tette ritenere 13 Natural Gas Distribution Valve Assembly Drawing and Parts List 14 Natural Gas Distribution Valve Servicing see 15 Pilot Valve Servicing Assembly Drawing amp Parts List sseesssss 16 Diaphragm Service Drawing with Overlay see 17 Diaphragm Service Drawing Non Overlay eseeeen 17 Diaphragm Servicing e nets 18 Overlay Diaphragm Servicing 0 cece eee eeeeeeeeeeee stents eeeeeeeeeneeeeeaeeseeaeeenneeeee 19 Actuator Plunger Servicing sseeeeeeene enn eene 19 Check Valve Servicing 2 eerte te iieiaei korterina keresia 20 Check Valve Drawing 2 center Eo eei tein i Dd a ver aea rund ERR EUR 20 Provision for Piping Gas Exhaust emen 21 Pumping Hazardous Liquids ccccccecesceceeeeeeeeeceeeeeeeaeeeeeeseaeaeeeeseeeeeeeeeetes 21 Piping Exhaust Natural Gas scssi emen nnns 21 Exhaust INUStration eire eec ett Ern eden ho mesa iaraa 21 Grounding Bru 22 ATEX Declaration of Conformity essen eem 23 CE Declaration of Conformity sessssseseeeeeenenn enne 24 BRUIN INSTRUMENT CORPORATION Edmonton Alberta Phone
7. reassembly What to Check Pumped fluid in gas exhaust line Corrective Action Disassemble 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 Fluid 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 fluid pumping chamb
8. Only Seal Aluminum Manifold Plate Outer Diaphragm Plate Outer Diaphragm Plate Inner Diaphragm Pin Actuator Ring Retaining Rod Diaphragm Seal U Cup Shaft Seal U Cup Shaft Seat Check Valve Seat Check Valve see item 27 must use 8 Seat Check Valve see item 27 must use 8 Ground Strap 5 16 Lock Washer Alum 5 16 Lock Washer SS o 125558 quic dich Boro 2M BOoROR OROROMN NON ON ON d 0 0 M M o O9 Co A N Model G05 Metallic Page 13 Gas Distribution Valve Assembly Drawing MAIN AIR VALVE ASSEMBLY PARTS LIST ITEM 1 1 A 1 1 1 1 1 nmuoou ITEM 1 1 A 1 F PART NUMBER 031 174 000 031 188 000 095 106 157 132 038 357 165 128 157 171 076 330 560 101 379 PART NUMBER 031 174 363 031 188 363 560 101 363 DESCRIPTION Valve Assembly Sleeve and Spool Set Valve Body Bumper End Cap Hex Flange Capscrew 1 4 20 x 75 O ring DESCRIPTION Valve Assembly Sleeve and Spool Set O ring includes all other items used on 013 174 000 Bruin G05 REV0408 o lt AONN gt gt 22 4 o RABAT lt Model G05 Metallic Page 14 NATURAL GAS DISTRIBUTION VALVE SERVICING To service the natural gas valve first shut off the compressed gas bleed pressure from the pump and disconnect the gas supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 3 8 wrench or socket remove the four hex capscrews items 12 Remove the gas
9. SERVICE amp OPERATING MANUAL Model GO5 Metallic Design Level 1 Natural Gas Operated Diaphragm Pumps Table of Contents Engineering Data and Temperature Limitations 0 ccccceseseeceeeeeeeeeeeeeeeeeaes 1 Performance QUEIVe 6c HR pti rere ssseszcaastenesdanesteacsena ties 2 Dimensions Aluminum Model esseen emen 3 Metric Dimensions Aluminum Model sssssssssseneneeeenennn 4 Dimensions Stainless Steel Model eee 5 Metric Dimensions Stainless Steel Model ee 6 Principle of Pump Operation ssssssssssssssseseeenennenereen enne 7 Installation and Start Up sssssssssssssssssseeeeeeee ennt nennen nennen nennen 7 Natural Gas Supply ATTIE 7 Natural Gas Valve Lubrication ssseeeeeen een 7 Natural Gas Line Moisture essssseeneeneen mener 7 Natural Gas Inlet and Priming ssenem e 7 Betweeri USCS esis cct te OR AREE ER rere saepe ec Peas OEE PREASAN O EEEE TEE A EEERS 7 Installatiori Guld6e eer rire eR ERE Rent enhn secs 8 Troubleshooting sssssssssssssssesseeeeeee enne nnerenennnnne nets ren nnne nere nn nrnnn nns 9 VASTE TR MEETS TE EE E AAEE AE A CREER 9 hills 10 Important Safety Information emen 10 Material Cod s ca 11 Composite Repair Parts Drawing seen 12 x II 2GD T5 CE U
10. c installations and or CAN CGA B149 installation codes WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves con tainers or other miscellaneous equipment must be grounded Bruin G05 REV0408 Model G05 Metallic Page 22 Declaration of Conformity ATEX 100a This pump complies with EN809 Pumping Directive Directive 98 37 EC Safety of Machinery and Directive 94 9 EC EN13463 1 Equipment for use in Potentially Explosive Environments The Technical File No AX1 is stored at KEMA Notified Body 0344 under Document 203040000 Models Air or Natrual Gas Operated Double Diaphragm Metallic Pumps Series G and S Il 2G D T5 hhi has 5 13 2008 Slope e of authorized person Date of issue Darrel He hes Voce feis dent Printed name of authorized person Title Rev D 4 April 2008 tu Declaration of Conform j TA UW apy uosiad pezuouine jo aweu pajulud EPEY 77 anssi JO oje 800C L S uosiad pazuouine jo enjeu eoueuu0Juoo JIJ9A 0 p1epuejs peziuowey sjueuieJinbed Ajejes uouiulo spinbr 104 sug dung pue sduing 608 NJ pesn sey jonpoud siu Asauiyoey jo Ajayes 03 4 86 e noeuig AUNWWOD ueedoun3 eui uim Ajduioo sdwnd oeza y Senes s pue 5 wWHheiydeig ajqnog ey s p VAIvNvo eueqiy uojuouip3 uone 0djo2 1ueuinajsu umg jUJJ0JUO2 JO uomneJe oeq Declaratio
11. ch o ring and re install the plungers in to the bushings Push the plungers in as far as they will go Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 19 gas inlet cap item 8 and capscrews items 13 Connect the gas supply to the pump The pump is now ready for operation PLUNGER BUSHING O RING AND RETAINING RING SERVICING To service the plunger bushing components first remove the two retaining rings items 31 using a small flat screwdriver Note It is recommended that new retaining rings be installed Next remove the two plunger bushings items 7 Inspect the bushings for wear or scratches Replace the bushings as necessary Inspect the two o rings 26 for cuts and or wear 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 G05 Metallic Page 19 CHECK VALVE SERVICING Before servicing the check valve components first shut off the suction line and then the discharge line to the pump Next shut off the compressed natural gas supply bleed gas pressure from the pump and dis
12. connect 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 check valve components remove the manifold manifold assembly Use a 1 2 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 34 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled reconnected and returned to operation Bruin G05 REV0408 Check Valve Drawing Model G05 Metallic Page 20 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the natural gas end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust gas must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The natural gas e
13. 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 gas 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 Bruin G05 REV0408 body the pressure to the chambers is reversed The gas distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end ofthe valve while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a 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 gas 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 conductive hose should be installed between the pump and the piping The flexible conductive hose reduces vibration and strain to the pumping system A surge suppressor is reco
14. e 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 G05 Metallic Page 16 Diaphragm Service Drawing Diaphragm Service Drawing Non Overlay with Overlay Diaphragm Orientation Diaphragm Orientation Install diaphragm os shown obove Install diaphragm ond overlay as shown above Bruin G05 REV0408 Model G05 Metallic Page 17 DIAPHRAGM SERVICING To service the diaphragm first shut off the suction then shut off the discharge lines to the pump Shut off the natural gas supply bleed the pressure from the pump and disconnect the natural gas 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 1 2 wrench or socket remove 8 capscrews items 10 amp 11 washers and nuts that fasten the discharge elbows item 18 or the discharge manifold item 24 Remove the elbows and manifold assembly items 18 amp 22 or manifold item 24 Use the same procedure to remove the suction elbows item 17 or suction manifold item 23 Step 2 Removing the outer chambers Using a 1 2 wrench or socket remove the 16 capscrews items 10 amp 11 washers and nuts that fasten the outer chambers item 14 diaphragms items 15 amp 16 and i
15. e with local fire and environmental codes or an industry or nationally recognized code having jurisdiction over specific installations and or CAN CGA B149 Installation Codes NATURAL GAS EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 2 DIAMETER NATURAL X GAS EXHAUST PIPING SAFE NATURAL GASN EXHAUSTM DISPOSALNX AREA Illustration 1 SAFE NATURAL GASK EXHAUSTX DISPOSAL AREA ALIM S 1 2 DIAMETER NATURAL N LIQUIDX GAS EXHAUST PIPING LEVEL SUCTIONN LINE Illustration 2 d LEVEL SUCTIONN LINE SAFE NATURAL X GASN EXHAUSTX DISPOSALX AREA 1 2 DIAMETER NATURAL X GAS EXHAUST PIPING Illustration 3 Model G05 Metallic Page 21 Grounding The Pump To be fully grounded the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet is installed to a true earth ground Requires a maximum 5 16 or 8mm maximum diameter blot This 8 foot long 244 centimeters Ground Strap Item 35 is shipped with the eyelet end fastened to the pump hardware One eyelet is fastened to the pump hardware 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 or in the absence of local codes an industry or nationally recognized code having jurisdiction over specifi
16. ers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact your Technical Services Group before performing this procedure Any 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 Distributor or factory Technical Services Group for a service evaluation Model G05 Metallic Page 9 RECYCLING Many components of Natural Gas Operated Metallic pumps are made of recyclable materials see chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed AWARNING Do not smoke near the pump or use the pump near an open flame Fire or explosion could result AWARNING This pump must not be used for fluid transfer into aircraft Certified to CSA Technical Letter No R 14 CERTIFIED Certified to CSA Requirement 2 01 US Pump complies with EN809 Pumping x Il 2GD T5 Directive Directive 98 37 EC Safety of Machinery and Directive 94 9 EC EN13463 1 Equipment for use in Potentially Explosive CE Environments The Technical File No AX1 is stored at KEMA Notified Body 0344 under Document 203040000 Bruin G05 REV0408 IMPORTANT SAFETY INFORMATION A IMPORTANT Read these safety warnings and instructions in th
17. essive 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 Whatto Check System head exceeds natural gas supply pressure Corrective Action Increase the inlet gas pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Natural gas supply pressure or volume exceeds system head Corrective Action Decrease inlet gas pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling Bruin G05 REV0408 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 gas line Corrective Action Install a larger gas line and connection Refer to gas inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check the externally serviceable gas distribution system of the pump Corrective Action Disassemble and inspect the natural gas distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before
18. h the recommendations stated in this manual will damage the pump and void factory warranty Model G05 Metallic Page 18 Intermediate Assembly Drawing INTERMEDIATE REPAIR PARTS LIST ITEM PART NUMBER DESCRIPTION QTY 4 114 023 157 Bracket Intermediate 1 7 135 036 506 Bushing Plunger 2 26 560 001 360 O Ring 2 560 001 363 O Ring 2 30 620 019 115 Plunger Actuator 2 31 675 042 115 Ring Retaining 2 NOTE It is recommended that when plunger components are serviced new retaining rings be installed Bruin G05 REV0408 Intermediate Assembly Servicing ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the natural gas supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 3 8 wrench or socket remove the four capscrews items 13 Remove the gas inlet cap item 8 and air inlet gasket item 19 The pilot valve assembly item 3 can now be removed Step 2 Servicing the actuator plungers See PUMP ASSEMBLY DRAWING The actuator plungers items 30 can be reached through the stem cavity of the pilot valve in the intermediate bracket item 4 To service bushings o rings and retaining rings see Intermediate Drawing Remove the plungers items 30 from the bushings item 7 in each end of the intermediate cavity Inspect for wear or damage Replace plunger as needed Apply a light coating of grease to ea
19. is 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 gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual WARNING Before maintenance or repair shut off the compressed natural gas line bleed the pressure and disconnect the gas line from the pump The discharge line may be pressurized and must be bled of its pressure WARNING In the event of diaphragm rupture pumped material may enter the natural gas end of the pump and be discharged into the atmosphere The gas exhaust must be piped to an appropriate area for safe disposition A 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 A WARNING This pump is pressurized internally with natural gas pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly WARNING When used for toxic or aggressive fluids the pump should al
20. lt Chemical Resistance Chart Technical Bulletin These G05 models are designed to be powered by natural gas The minimum pump operating temperature is 10 F The maximum operating temperature is 180 F Bruin G05 REV0408 Model G05 Metallic Page 1 Performance Curve G05 Model Metallic Design Level 1 MODEL G05 Metallic Performance Curve 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 6 5 Q 4 QD T ee I 3 LLI S 2 9 1 7 6 6 P 4 5 3 1 5 0 U S Gallons per minute 0 10 20 30 40 50 60 Liters per minute CAPACITY Bruin G05 REV0408 Model G05 Metallic Page 2 Dimensions G05 Metallic Aluminum Model Dimensions in Inches Dimensional Tolerance s Discharge Port 1 2 NPT Internal X 1 NPT External 3 8 NPT For Piping Exhausted Natural Gas Gas Inlet 1 4 NPT FRONT VIEW SIDE VIEW Suction Port 1 2 NPT Internal X 1 NPT External 1 3 4 be 3 3 8 Both Suction And Discharge Ports Are Available Inl 1 2 BSPT Tapered Internal 1 BSPT Tapered External BOTTOM VIEW Note The pump is to be mounted in a horizontal position Bruin G05 REV0408 Model G05 Metallic Page 3 Metric Dimensions G05 Metallic Aluminum Model
21. m 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 Bruin G05 REV0408 180 305 306 307 308 309 310 330 331 332 333 334 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 MATERIAL CODES The Last 3 Digits of Part Number 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 Cast Iron Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compression Mold Urethane Rubber Nitrile Rubber Color coded RED 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 375
22. m gas supply is 250psi Full line pressure needs to be regulated below 250psi prior to the regulator installation position CAUTION VENTING WARNING This regulator is equipped with a 1 4 NPT vent The natural gas exhaust must be port In the event of a diaphragm rupture natural gas can be exhausted PE a E oed berg into the surrounding environment Connect a conductive hose or pipe pumped in the event of a to the vent port to send the escaping natural gas to a safe area for gas diaphragm failure reclamation Make sure to ground the regulator hose and or pipe Flexible Conductive Connection Gas Shut Off Valve P t IE obuia Regulator Natural gas Natural Gas Exhaust TOF wiGauge Filter E aa ae ted atura as Exhaus zen DISCHARGE piping must be supporte DIAPHRAGM Shut Off PUMP Ey Valve Natural Gas Inlet Flexible SUCTION MSN Ld Connection Hwss Drain Port The pump must be rigidly mounted in the horizontal position with fasteners to a conductive base or natural ground Bruin G05 REV0408 Model G05 Metallic Page 8 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 Exc
23. mately 1 2 to 3 4 turn After the pump primes the valve can be opened to increase gas 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 gas flow to pump flow ratio 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 AWARNING Natural gas exhaust is to be vented to low pressure safe location using conductive Nitrile rubber hose or metal Piping in accordance with local fire and environmental codes or an industry or nationally recognized code having jurisdiction over specific installations and or CAN CGA B149 Installation Codes Model G05 Metallic Page 7 1 020 062 000 Filter INSTALLATION GUIDE VENTING WARNING This filter is equipped with a stainless steel manual drain The port is 1 8 NPT When draining moisture from the Top Discharge Ball Valve Pump filter first shut off the natural gas supply 020 057 000 REGULATOR WITH GAGE 2 PRESSURE WARNING This regulator is to be installed at point of use with the pump The maximu
24. mmended to further reduce pulsation in flow NATURAL GAS SUPPLY Natural gas inlet pressure must be regulated to 100 7 bar psi with a pressure regulator Connect the pump gas inlet to an gas supply of sufficient capacity and pressure required for desired performance When the gas supply line is solid piping use a short length of flexible conductive hose not less than 3 4 19mm in diameter between the pump and the piping to reduce strain to the piping The weight of the gas supply line regulators and filters must be supported by some means other than the gas 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 gas supply pressure does not exceed recommended limits VALVE LUBRICATION The natural gas 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 gas supplies when lubrication of the supply is required The pump system will operate with properly lubricated supply Proper lubrication requires the use of an gas line lubricator set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of gas the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this GAS INLET AND PRIMING To start the pump open the gas valve approxi
25. n of Conformitu
26. ntermediate bracket item 4 together Step 3 Removing the diaphragm assemblies Use a 3 4 19mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 32 by turning counterclockwise Bruin G05 REV0408 Insert a 6 32 set screw into the smaller tapped hole in the inner diaphragm plate item 29 Insert the protruding stud and the 6 32 fastener loosely into a vise Use a 3 4 wrench or socket to remove the outer diaphragm plate item 28 by turning counterclockwise Inspect the diaphragm item 15 amp 16 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise onto the stud Insert the loose assembly with the above 6 32 fastener back into the vise Use a torque wrench to tighten the diaphragm assembly together to 7 5 ft Ibs 10 17 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 6 is installed over the diaphragm rod Thread the stud ofthe one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 32 until the inne
27. obile 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 Model G05 Metallic Page 11 Composite Repair Parts Drawing Available Service Kits 476 237 000 and 476 237 363 476 238 360 476 238 649 476 238 672 Gas End Kit Seals O Rings Gaskets Bumpers Retaining Rings Valve Assembly Pilot Valve Assembly Gas End Kit FKM Seals O Rings Gaskets Bumpers Retaining Rings Valve Assembly and Pilot Valve Assembly Wetted End Kit Nitrile Diaphragms Nitrile Check Balls and PTFE Seats Wetted End Kit Nitrile Diaphragm PTFE Overlay Diaphragm PTFE Check Balls and PTFE Seats Wetted End Kit Nitrile Diaphragms PTFE Check Balls PTFE Seats Bruin G05 REV0408 OVERLAY OPTION Model G05 Metallic Page 12 Composite Repair Parts List ITEM 1 Co 10 11 12 13 14 15 16 17 18 19 20 21 PART NUMBER 031 174 000 031 174 363 050 022 600 050 027 360 095 116 000 095 116 363 114 023 157 115 152 151 132 034 360 132 034 363 135 036 506 165 110 157 171 017 330 170 044 330 170 045 330 170 045 330 171 076 330 171 077 330 196 171 110 196 171 157 286 095 360 286 096 600 312 110 157 312 111 157 360 100 379 360 108 360 360 102 360 Bruin G05 REV0408 DESCRIPTION Gas Valve Assembly Gas Valve Assembly Ball Check Ball Check Pilot Valve
28. r 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 intermediate item 4 Fasten the outer chamber item 14 to the pump using the capscrews items 10 and 11 washers and nuts 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 32 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber Install diaphragms with convolutions facing towards center of pump See sectional view on previous page Fasten the remaining outer chamber item 14 to the pump using the capscrews items 10 and 11 washers and nuts Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews item 10 and 11 washers and nuts item 25 The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 16 is designed to fit snugly over the exterior of the standard TPE diaphragm item 15 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 wit
29. to 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 Install the remaining bumper and end cap with o rings and fasten with the remaining hex capscrews Align hole in end cap with roll pin on valve body Fasten the natural gas valve assembly item 1 and gasket to the pump Connect the compressed gas 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 G05 Metallic Page 15 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER 3 095 116 000 3 A 095 087 157 3 B 755 051 000 DESCRIPTION Pilot Valve Assembly Valve Body Sleeve With O rings 3 C 560 033 360 3 D 775 055 000 3 E 560 023 360 3 F 675 037 080 ITEM PART NUMBER 3 095 116 363 3 B 755 051 363 3 C 560 033 363 O ring 3 D 775 055 363 3 E 560 023 363 O ring Includes all other items used on 095 116 000 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 p
30. ump STEP 1 See pump assembly drawing Using a 7 16 wrench or socket remove the four capscrews item 13 Remove the air inlet cap item 8 and air inlet gasket item 19 The pilot valve assembly item 3 can now be removed for inspection and service Bruin G05 REV0408 O ring Sleeve Spool With O rings O ring Spool Retaining Ring DESCRIPTION Pilot Valve Assembly Sleeve With O rings Spool With O rings 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 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 valv
31. valve assembly from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed Step 2 Disassembly of the natural gas valve Using a 3 8 wrench or socket remove the eight hex capscrews items 1 E that fasten the end caps to the valve body Next remove the two end caps items 1 D Inspect the two o rings items 1 F on each end cap for damage or wear Replace the o rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed 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 Bruin G05 REV0408 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 A Step 3 Reassembly of the natural gas valve Install one bumper item 1 C and one end cap item 1 D with two o rings items 1 F and fasten with four hex capscrews items 1 E to the valve body item 1 B Align hole in end cap with roll pin on valve body 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 F into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve in
32. ways be flushed clean prior to disassembly 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 natural gas 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 G05 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 316 Stainless Steel Alloy Type 316 Stainless Steel Electro Polished Alloy C Hastelloy equivalent 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 Aluminu
33. xhaust must be piped above the liquid level See illustration 2 at right Piping used for the gas exhaust must not be smaller than 1 2 1 27 cm diameter Reducing the pipe size will restrict natural gas flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the exhaust gas higher than the product source to prevent siphoning spills See illustration 3 at right PIPING THE NATURAL GAS EXHAUST The following steps are necessary to pipe the exhaust gas away from the pump The gas distribution valve assembly item 1 has 3 8 NPT threads for piped exhaust IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded threads of the natural Bruin G05 REV0408 gas exhaust port Failure to do so may result in damage to the natural gas distribution valve body Any piping or hose connected to the pump s natural gas exhaust port must be conductive and physically supported Failure to support these connections could also result in damage to the valve body If a high pressure gas spike is possible through the exhaust line a pressure regulator is required in the exhaust piping AWARNING Natural gas exhaust is to be vented to low pressure safe location using conductive Nitrile rubber hose or metal piping in accordanc
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