E3 non metallic pump svc man.p65 - Versa
Contents
1. PUMP MODEL TYPE OF CONSTRUCTION E Elima Matic 9 Bolted Style PUMP SIZE WETTED SEALS 3 3 Pipe Size 5 PTFE WETTED MATERIAL VALVE BALL MATERIAL P Polypropylene 5 PTFE K PVDF 6 XL DIAPHRAGM SERIES NON WETTED MATERIAL X Thermo Matic bead style Q Epoxy Coated Alum T Tef Matic 2 piece PTFE OPTIONS DIAPHRAGM MATERIAL E0 Solenoid Kit w 24 VDC Coil 5 PTFE E1 Solenoid Kit w 24 VDC Explosion Proof Coil 6 XL Santoprene E2 Solenoid Kit w 24 VAC 12VDC Coil E3 Solenoid Kit w 24 VAC 12VDC Explosion Proof Coil E4 Solenoid Kit w 110VAC Coil E5 Solenoid Kit w 110VAC Explosion Proof Coil E6 Solenoid Kit w 220VAC Coil E7 Solenoid Kit w 220VAC Explosion Proof Coil Model E3 Non Metallic Design Level 2 10 01 520 362 000 Page 2 Dimensions 1 8 E3 Non Metallic DISCHARGE PORT SC 3 8 3 STANDARD 1254 FLANGE CONFIGURATION a 16 11 16 3 4 DIA 4 HOLES EQUALLY SPACED el 5 ON A 6 DIA BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS FRONT VIEW A 3 16 oe SUCTION PORT 6 5 32 bag 3 STANDARD 1254 FLANGE CONFIGURATION 03 4 TYP h 12 5 16 2 1 2 3 4 DIA 4 HOLES EQUALLY SPACED 8 PLACES2. 520 362 000 Page 4 TROUBLESHOOTING Possible Symptoms Pump will not cycle e Pump cycles but produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e 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 pressure 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 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 the Externally Serviceable Air Distribu tion Sy
3. U S Patent 400 210 5 851 109 5 996 627 and 6 241 487 IDEX CORPORATION AIR VALVE No lube no stall design INTAKE DISCHARGE PIPE SIZE CAPACITY 3 ANSI Flange or 80mm DIN Flange A CAUTION Operating temperature limitations are as follows 0 to 23 US gallons per minute 0 to 901 liters per minute Materials Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance 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 PVDF Polypropylene SOLIDS HANDLING Up to 71 in 18mm _VERSA MATIC E3 Non Metallic Design Level 2 Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA HEADS UP TO 100 psi or 231 ft of water 7 bar or 70 meters Maximum 212 F 100 C 212 F 100 C 200 F 93 C 150 F 65 C DISPLACEMENT STROKE 9 US Gallons 3 41 liters Operating Temperatures Minimum Optimum 10 F 50 to 212 F 23 C 10 to 100 C 35 F 50 to 212 F 37 C 10 to 100 C 10 F 23 C 40 F 5 C CAUTION Plastic pumps and components are not UV stabilized Ultraviolet radiation can damage these parts and
4. as they will go Step 5 Re install the pilot valve ssembly 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 20 air inlet cap item 8 capscrews and washers items 10 and 39 Connect the air supply to the pump Remove the safety clip item 1 F from the end cap item 1 E The pump is now ready for operation DESCRIPTION Pilot Valve Assembly Body Pilot Valve Bushing Ring Retaining Spacer Wiper Spool Pilot QTY OONMNN ch WARNING Read these safety warnings 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 520 362 000 Page 9 Diaphragm Service Drawing Non Overlay Diaphragm Service Drawing with Overlay Diaphragm Servicing To service the diaphragms first shut off 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 Bel wrench or socke
5. flushed clean prior to disassembly WARNING Airborne particles and loud noise hazards Wear ear and eye protection 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 520 362 000 Page 5 The Last 3 Digits of Part Number 000 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 Aluminium 2024 T4 Aluminium 6061 T6 Aluminium 6063 T6 Aluminium 2024 T4 Aluminium 2023 T351 Almag 35 Aluminium 356 T6 Aluminium 356 T6 Aluminium Die Cast Aluminium Alloy 380 Aluminium Alloy SR 319 Anodized Aluminium Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc Copper Alloy Carbon Steel Gray Epoxy Coated Ca
6. 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 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 manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing Model E3 Non Metallic Design Level 2 10 01 3 ANSI STYLE FLANGE CONNECTION FOUR 9 75 HOLES ON A 96 00 BOLT CIRCLE WARNING Read these safety warnings 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 fa
7. negatively affect material properties Do not expose to UV light for extended periods of time Performance Curve Versa Matic pumps are designed to be powered only by compressed air E3 Non Metallic Performance Curve SCFM M i e Ga Performance based on water at ambient temperature 7 100 is 30 61 00 90 Lee el b i Ox 40 68 80 i SCH 50 85 do ZS 2 5 79 rer AL i660 102 T KA Ke 60 KO 5 Kei gt nt Sen Ze aos Ir A VIS A N 0 9 50 WF k L ay D Re ao es I al Oe eS d SOR OSA 80 136 iy e E 40 k Ser uo y Si 40 BS Y 2 2 30 9 O gt 30 9 1 E2 90 153 75 127 5 25 176 20 7 gt 20 46 1 20 Pei 95 161 5 15145 10 1 36 8 10 43 ol Jar er pe a e 5 4415 020406080100120140160 U S Gallons per minute pae a ee a a a a a ee a as ed EN 200 300 400 Liters per minute Capacity Model E3 Non Metallic Design Level 2 10 01a 520 362 000 Page 1 Available Pump Models E3 Non Metallic MODEL Wetted Non Wetted Diaphragm Diaphragm Valve Ball Wetted Type of Options TYPE Material Material Material Series Material Seals Construction E3PQ6X659 P Q 6 X 6 5 E3PQ5T559 E3KQ6X659 E3KQ5T559 E3PQ6X659 E0 E3PQ5T559 E1 E3KQ6X659 E2 E3KQ5T559 E3 Explanation of Pump Nomenclature E 3 PQ6X 6 5 9 XXX
8. 5 099 307 165 099 309 170 017 115 170 017 308 170 052 115 170 052 308 170 111 115 170 111 308 170 112 115 170 112 308 170 171 004 171 053 115 171 053 308 196 151 520 196 151 552 196 152 307 196 152 309 286 077 354 286 078 600 312 103 520 Air Valve Assembly Air Valve Assembly w PTFE coated Hardware Air Valve Assembly No Encapsulated Muffler Pilot Valve Assembly Ball Check Ball Check Intermediate Assembly Intermediate Assembly Bracket Mounting Bracket Mounting Bracket Mounting Bumper Diaphragm Bushing Plunger Cap Air Inlet Cap Air Inlet Capscrew Hex HD 5 8 11 x 1 75 Capscrew Hex HD 5 8 11 x 1 75 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 5 8 11 x 3 25 Capscrew Hex HD 5 8 11 x 3 25 Capscrew Hex HD 5 8 11 x 3 75 Capscrew Soc HD 5 8 11 x 3 75 Capscrew Soc HD 1 2 13 x 1 25 Capscrew Soc HD 3 8 16 x 2 75 Capscrew Soc HD 3 8 16 x 2 75 Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Overlay Elbow Model E3 Non Metallic Design Level 2 10 01 OVERLAY OPTION SE EE a zb zz P P 3 ShM bhM bM bMhMhM PP O 20 22 23 24 MUFFLER OPTION 312 103 552 360 090 360 360 091 360 360 092 360 360 093 360 518 133 520 518 133 520E 518 133 552 518 133 552E 530 027 000 530 010 000 545 009 110 545 009 308 560 001 360 612 161 520 612 161 552 612 162 150 620 017 115 670 047 520 670 047 552 685 051 120
9. 685 052 115 685 052 308 720 010 375 720 039 600 720 043 600 722 076 520 722 076 552 770 055 520 770 055 552 901 047 115 901 047 308 901 048 115 901 048 308 Elbow Gasket Air Inlet Gasket Inner Chamber Gasket Pilot Valve Gasket Main Air Valve Manifold Manifold 80mm DIN Manifold Manifold 80mm DIN Muffler Muffler Nut Hex 5 8 Nut Hex 5 8 O ring Assembly Outer Diaphragm Plate Assembly Outer Diaphragm Plate Assembly Inner Diaphragm Plate Plunger Actuator Retainer Ball Retainer Ball Rod Diaphragm Rod Support Rod Support Seal Diaphragm Rod Seal Manifold Spacer Seal Check Valve Assembly Seat Check Valve Seat Check Valve Spacer Manifold Spacer Manifold Washer Flat 5 8 Washer Flat 5 8 Washer Flat 3 8 Washer Flat 3 8 Mo fFARHRRHRONNNHFAANNNNNMNNHA HNNNNHHDYH FA Nh Pp BA oo 520 362 000 Page 7 Air Distribution Valve Assembly Drawing S30 Design Level 2 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 capscrews item 14 and four flat washers item 41 Remove the air valve assembly from the pump Remove and inspect gasket item 23 for cracks or damage Replace gasket if needed STEP 2 D
10. ON A 6 DIA BOLT CIRCLE BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES 7 H 16 7 8 AR et amp BOTTOM VIEW 3 4 NPT j 1 27 32 14 1 2 16 feo 846mm sl K DISCHARGE PORT 3 STANDARD 125 FLANGE CONFIGURATION ba 423mm 3 4 DIA 4 HOLES EQUALLY SPACED ON A 6 DIA BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER __ STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS l FRONT VIEW Si 5mm SS SUCTION POST 156mm e or STANDARD Vi FLANGE CONFIGURATION 03 4 TYP fe 313mm 64mm 3 4 DIA 4 HOLES EQUALLY SPACED 8 PLACES ON A 6 DIA BOLT CIRCLE ja 19 32mm BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES SIDE VIEW Fo 429mm gt 28mm F ba E E 47mm AIR INLET 368mm SCENE Sound Dampening Muffler 406mm F Mesh Muffler Model E3 Non Metallic Design Level 2 10 01 520 362 000 Page 3 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 ch
11. SERVICE amp OPERATING MANUAL VERSA MATIC Model E3 Non Metallic Design Level 2 Table of Contents Engineering Data and Temperature Limitations 1 Performance CUI G i eege eege 1 Explanation of Pump Nomenclature ssssseseeeeeeeeerrrennrrennee 2 DIMENSIONS eegene 3 Metric a 3 Principle of Pump Operation EE 4 Installation C10 E 4 Troubleshooting WE 5 Important Safety Information cceeeeeeeeeeeeeeeeeeeeeeeeeeeeaees 5 ee EE 6 Composite Repair Parts List A Drawing eeeeseeeeeeeeeeeene 7 Air Distribution Valve Servicing amp Drawing eeeeeeeeeeeeeee 8 Pilot Valve Assembly Servicing amp Drawing eeeeeeeeeeeee 9 Diaphragm Service Drawing with Overlay eee 10 Diaphragm Service Drawing Non Overlay s es 10 Diaphragm Genicimg 10 Pumping Hazardous Liquids aseaaeeeeeneeee eneee eeeee erneer 11 Exhaust Conversion Drawing AEN 11 Converted Exhaust Illustration eeseseeeeeeeeseeeereeeerrreeeeeeee 11 Modular Check Valve Servicing A Drawing eeeessseeeeeee 11 Dual Port Option amp Drawing eeceeeeeeeeee eee eeeeeeeeeeeeeeees 12 U S Patent 400 210 5 996 627 6 241 487 VERSA MATIC IDEX AODD Inc A Unit of IDEX Corp 800 N Main St P O Box 1568 Mansfield OH 44901 USA Tel 419 526 7296 Fax 419 526 7289 www versamatic com 520 362 000 10 01a VERSA MATIC PUMP Quality System 1S09001 Certified
12. amber is alternately pres surized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centres of the diaphragms to move ina reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pres sure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates ina 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 of the 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 cham bers is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution va
13. amber side of the seal faces the chamber on the check valve seat or retainer The pump can now reassembled reconnected and returned to ooperation Model E3 Non Metallic Design Level 2 10 01 CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA SAFE AIR EXHAUST DISPOSAL AREA 1 DIAMETER AIR EXHAUST PIPING Illustration 1 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Illustration 2 ie MUFFLER y 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Illustration 3 520 362 000 Page 11 Dual Port Option Drawing 3 ANSI STYLE FLANGE CONNECTION FOUR 9 75 HOLES ON A 96 00 BOLT CIRCLE 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 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 19 are designed to mate with standard 125 ANSI style 4 bolt 3 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 36 39 and 24
14. 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 23 Model E3 Non Metallic Design Level 2 10 01 MAIN AIR VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION 1 031 140 000 Main Air Valve Assembly 1 A 031 139 000 Spool Assembly 1 B 095 094 551 Body Air Valve 1 C 132 029 552 Bumper 1 D 165 096 551 Cap Muffler 1 E 165 115 552 Cap End 1 F 530 028 550 Muffler 1 G 560 020 360 O Ring 1 H 675 044 115 Ring Retaining 1 J 710 015 115 Screw Self tapping For pumps equipped with PTFE Coated Hardware 1 031 140 002 Air Valve Assembly Includes all items used on 031 140 000 except 1 J 710 015 308 Screw Self tapping 1 H 675 044 308 Ring Retaining For pumps equipped with PTFE coated hardware option 1 031 141 000 Air Valve Assembly Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J For pumps with alternate Mesh or Sound Dampening mufflers or piped exhaust 1 031 041 002 Air Valve Assembly Includes all items used on 031 141 000 except 1 H 675 044 308 Ring Retaining to the pump Connect the compressed air line to the pump The pump is now ready for operation CS WARNING 2 Mie Maw eee aie Read these safety warnings and instructions in this manual COMPLETELY before installa
15. ction Molded PVDF Natural color 520 lon Injection Molded ethylene Glass Filled Polypropylene 551 Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE GOT e PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE Envelon PTFE PTFE Encapsulated Silicon PTFE Encapsulated Viton Neoprene Hytrel Viton PTFE EPDM PTFE Neoprene PTFE PTFE Viton PTFE PTFE Hytrel PTFE Buna N TFE Santoprene EPDM Santoprene PTFE Santoprene Diaphragm and Check Balls EPDM Seats GESSRRREER el elrin Viton 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 Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co 520 362 000 Page 6 Composite Repair Parts Drawing Repair Parts List 1 17 18 19 031 140 000 031 140 002 031 141 000 095 089 000 050 039 354 050 039 600 114 021 307 114 021 309 115 133 080 115 133 115 115 133 305 132 019 360 135 032 506 16
16. ctory warranty 520 362 000 Page 12
17. e 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 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 Model E3 Non Metallic Design Level 2 10 01 AX 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 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 IMPORTANT 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 WARNING When used for toxic or aggressive fluids the pump should always be
18. e 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 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 AIR CAN BE DANGEROUS Contact the Versa Matic Technical Services Department 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 Versa Matic Distributor or factory Technical Services Group for a service evaluation Warranty This pump is warranted for a period of five years against defects and workmanship CS WARNING Read these safety warnings 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 WARNING Befor
19. emove the elbows items 19 from pump composite repair parts drawing Use a Sie wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seen in the cavities of the outer chamber items 15 Next remove the check valve seal item 37 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 32 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 3 for wear abrasion or cuts on the spherical surface The check valve seats items 38 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 Remove the remaining check valve seal item 37 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 37 into the cavity of the outer chamber item 15 Make sure the chamber side of the seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 37 Make sure the ch
20. 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 six self tapping screws item 1 J Remove the muffler cap and muffler items 1 D and 1 F The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now beinstalled Important Installation Note 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 Conversion Drawing 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 r
21. isassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H 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 two bumpers item 1 C Inspect the bumpers for cuts wear or abrasion Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to stratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 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 end cap item 1 E with an o ring item 1 G and one bumper item 1 C 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 and 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
22. lve spool while exhausting the other end The pilot valve VERSA MATIC PUMP Available from Versa Matic is shifted at each end of the diaphragm stroke when a actuator plunger is con tacted 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 prod uct 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 in stalled 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 8 6 bar Connect the pump air inlet to an air supply of sufficient capac ity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than ein 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 Fail ure t
23. mped assembly Installing Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the one diaphragm assembly clockwise into the tapped hole at the 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 Model E3 Non Metallic Design Level 2 10 01 inner chamber item 16 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 15 to the pump using the capscrews items 9 amp 12 hex 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 on the diaphragm must point vertically Fasten the remaining outer chamber item 15 to the pump using the capscrews items 9 amp 12 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 11 hex nuts and flat washers The pump is now ready to be
24. o 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 limits OU Surge Dampener Filter Regulator D Lubricator Air Dryer Air Exhaust SUCTION Connection Le AN AIRVALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITH OUT lubrication This is the preferred mode of operation There may be in stances 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 Versa Matic 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 supple ment 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 a
25. pproximately VG to 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 ratio INSTALLATION GUIDE Top Discharge Ball Unit A CAUTION The air exhaust should be piped to an area for safe disposition of the product M being pumped in the event of a diaphragm failure Pipe Connection Style Optional Gauge Flexible 1 Shut Off Valve IW DISCHARGE E a l Drain Port Flexible Connection Air Shut Off Pipe Connection Valve Style Optional TOP 7 Air Di Soe DISCHARGE Filter Regulator ir Dryer DIAPHRAGM Shut Off PUMP Valve T LO 1 Flexible ee Connection gp l Drain Port Model E3 Non Metallic Design Level 2 10 01 BETWEEN USES When the pump is used for materials that tend to settle out or solidify when notin motion the pump should be flushed after each use to prevent damage Prod uct 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
26. rbon Steel Black PTFE Coated Aluminium Gray Epoxy Coated Stainless Steel Black PTFE Coated Aluminium Black PTFE Coated Kynar Coated Zinc Plated Steel Chrome Plated Steel Model E3 Non Metallic Design Level 2 10 01 MATERIAL CODES KR Aluminium Electroless Nickel Plated See Carbon Steel Electroless Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 353 Geolast Color Black 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 355 ees Thermal Plastic 356 Hytrel 357 Injection Molded Polyurethane 358 Urethane Rubber Compression Mold 359 Urethane Rubber 360 Buna N Rubber Color coded RED 361 Buna N 363 Viton Flurorel Color coded YELLOW 264 EPDM Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile 368 Food Grade EPDM 370 Butyl Rubber Color coded BROWN 371 374 Philthane Tuftane Carboxylated Nitrile 375 Fluorinated Nitrile 378 High Density Polypropylene 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Inje
27. re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 18 is designed to fit snugly over the exterior of the standard TPE diaphragm item 17 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation CS WARNING Read these safety warnings 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 520 362 000 Page 10 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 be 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
28. ry Step 3 Re assembly of the pilot valve First install a spiral retaining ring to one end of the pilot valve body Install one bushing making sure the step side faces toward the wiper Apply a light coating of grease to the outside diameter of each wiper Next gently push in the wipers and spacers until they are against the installed retaining ring in the opposite end of the pilot valve body Install the remaining bushing making sure the step side faces the wiper Install the remaining retaining ring using clip ring pilers Apply a light coating of grease to the inner diameter of each wiper Also apply a light coating of grease to the outer diameter of the pilot valve spool and gently push the spool through each wiper Step 4 Inspect the actuator plungers See DRAWING The actuator plungers items 31 can be reached through the stem cavity of the pilot valve in the intermediate assembly item 4 Remove the plungers items 31 from the bushings item 7 in each end of the cavity Inspect the installed PUMP ASSEMBLY Model E3 Non Metallic Design Level 2 10 01 PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER 2 095 089 000 2 A 095 081 551 2 B 135 033 506 2C 675 055 115 2 D 770 049 175 2 E 917 001 374 2 F 775 033 506 o ring items 28 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far
29. stem 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 Warren Rupp Tranquilizer 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 Important Safety Information What to Check Pumped fluid in air exhaust muffler 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 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 of the 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 neces sary Refer to Check Valv
30. t remove the 16 capscrews items 11 hex nuts and washers that fasten the elbows items 19 to the outer chambers items 15 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a 46 wrench or socket remove the 20 capscrews items 9 amp 12 hex nuts and washers that fasten the outer chambers diaphragms and inner chambers items 16 together Step 3 Removing the diaphragm assemblies Use a is 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 30 Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use a 1 e wrench or socket to remove the outer diaphragm plate item 29 by turning counterclockwise Inspect the diaphragm item 17 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 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 Use a torque wrench to tighten the diaphragm assembly together to 480 in Lbs 64 23 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the cla
31. tion 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 520 362 000 Page 8 Pilot Valve Assembly Drawing 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 Insert the safety clip item 1 F from Air Distribution Valve assembly drawing into the smaller unthreaded holes in the end cap item 1 E from air distribution valve assembly drawing Step 1 See PUMP ASSEMBLY DRAWING Using a wrench or socket remove the four capscrews items 10 and four flat washers items 41 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly item 2 can now be removed for inspection or service Step 2 Disassembly of the pilot valve Remove the pilot valve spool item 2 F Wipe clean and inspect for dirt scratches or wear Replace the spool if necessary Remove the two retaining rings items 2 C from each end of the pilot valve body using clip ring pilers Remove the two pilot valve bushings items 2 B five spacers items 2 D and six spool wipers items 2 E by pushing gently from other end of the pilot valve body Inspect the wipers for cuts and or wear Replace any wipers as necessa
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