PD15E-XXX-XXX
OPERATOR’S MANUAL
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
RELEASED: 6-15-05
REVISED:
11-15-10
(REV. 05)
1-1/2” DIAPHRAGM PUMP
1:1 RATIO (CONDUCTIVE NON-METALLIC)
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.
SERVICE KITS
Refer to Model Description Chart to match the pump material options.
637389 for air section repair (see page 6).
637391-XXforfluidsectionrepair(seepage4).NOTE:Thiskitalsocon-
tains several air motor seals which will need to be replaced.
637390-7 major air valve assembly (see page 7).
PUMP DATA
Models . . . . . . . . . . see Model Description Chart for “-XXX”.
Pump Type . . . . . . . Non-MetallicAir Operated Double Diaphragm
Material . . . . . . . . . . see Model Description Chart.
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 43.14 lbs (19.57 kgs)
Maximum Air Inlet Pressure . . . . . . . . . 120 p.s.i.g. (8.3 bar)
Maximum Material Inlet Pressure . . . . . 10 p.s.i.g. (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . . 120 p.s.i.g. (8.3 bar)
Maximum Flow Rate (flooded inlet) . . . . 123.1 g.p.m. (465.9 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . . 0.617 gal. (2.34 lit.)
Maximum Particle Size . . . . . . . . . . . . 1/4” dia. (6.4 mm)
Figure 1
PD15E-FES-PXX
Maximum Temperature Limits (diaphragm / ball / seal material)
E.P.R. / EPDM . . . . . . . . . . . -60_to280_F (-51_to 138_C)
HytrelR . . . . . . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)
Nitrile . . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C)
Polypropylene . . . . . . . . . . . 35_ to 175_ F (2_ to 79_ C)
SantopreneR . . . . . . . . . . . -40_to225_F (-40_to 107_C)
PTFE . . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)
VitonR . . . . . . . . . . . . . . . . -40_to350_F (-40_to 177_C)
Dimensional Data . . . . . . . . . . . . . . . . see page 8
MODEL DESCRIPTION CHART
PD15 E - F E S - P X X
Center Section Material
E - Conductive Polypropylene
Fluid Connection / Location
F - 1-1/2” A.N.S.I. / DIN Flange / End
Mounting Dimension . . . 8.687” x 14.937” (220.7 mm x 379.4 mm)
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 81.0 db(A){
Fluid Caps & Manifold Material
E - Conductive Polypropylene
The pump sound pressure levels published here have been updated to an Equivalent
Continuous Sound Level (L ) to meet the intent of ANSI S1.13-1971, CAGI-PNEU-
Aeq
Hardware Material
S - Stainless Steel
ROP S5.1 using four microphone locations.
NOTICE: All possible options are shown in the chart, however, certain
combinations may not be recommended, consult a representative or the
factory if you have questions concerning availability.
Seat Material
P - Polypropylene
Ball Material
A - Santoprene
C - Hytrel
G - Nitrile
T - PTFE
V - Viton
Diaphragm Material
A - Santoprene
C - Hytrel
T - PTFE / Santoprene
V - Viton
G - Nitrile
FLUID SECTION SERVICE KIT SELECTION
PD15E - FES - P X X
637391 - X X
EXAMPLE: Model # PD15E-FES-PAA
Fluid Section Service Kit # 637391-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET -- BRYAN, OHIO 43506
(800) 276-4658 D FAX (800) 266-7016
E2010
CCN 15244957
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GENERAL DESCRIPTION
OPERATING INSTRUCTIONS
The ARO diaphragm pump offers high volume delivery even at low air
pressure and a broad range of material compatibility options available.
Refer to the model and option chart. ARO pumps feature stall resistant
design, modular air motor / fluid sections.
Air operated double diaphragm pumps utilize a pressure differential in
theairchamberstoalternatelycreatesuctionandpositivefluidpressure
in the fluid chambers, ball checks insure a positive flow of fluid.
Pump cycling will begin as air pressure is applied and it will continue to
pump and keep up with the demand. It will build and maintain line pres-
sure and will stop cycling once maximum line pressure is reached (dis-
pensing device closed) and will resume pumping as needed.
S Always flush the pump with a solvent compatible with the material
being pumped ifthe materialbeing pumpedissubjectto “settingup”
when not in use for a period of time.
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew
hours.
PARTS AND SERVICE KITS
Refertothepartviewsanddescriptionsasprovidedonpage4through7
for parts identification and Service Kit information.
S Certain ARO “Smart Parts” are indicated which should be available
for fast repair and reduction of down time.
S Service kits are divided to service two separate diaphragm pump
functions: 1. AIR SECTION, 2. FLUID SECTION. The FLUID SEC-
TION is divided further to match typical part MATERIAL OPTIONS.
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
S Afiltercapableoffilteringoutparticleslargerthan50micronsshould
beusedontheairsupply. Thereisnolubricationrequiredotherthan
the “O” ring lubricant which is applied during assembly or repair.
S Iflubricatedairispresent,makesurethatitiscompatiblewiththe“O”
rings and seals in the air motor section of the pump.
MAINTENANCE
S Provide a clean work surface to protect sensitive internal moving
partsfrom contamination from dirtand foreignmatter duringservice
disassembly and reassembly.
S Keep good records of service activity and include pump in preven-
tive maintenance program.
S Before disassembling, empty captured material in the outlet man-
ifold by turning the pump upside down to drain material from the
pump.
INSTALLATION
S Verify correct model / configuration prior to installation.
S Retorque all external fasteners per specifications prior to start up.
S Pumpsaretestedinwateratassembly. Flushpumpwithcompatible
fluid prior to installation.
FLUID SECTION DISASSEMBLY
S When the diaphragm pump is used in a forced-feed (flooded inlet)
situation, it is recommended that a “Check Valve” be installed at the
air inlet.
1. Remove (61) outlet manifold and (60) inlet manifold.
2. Remove (22) balls, (19 and 33) “O” rings and (21) seats.
3. Remove (15) fluid caps.
NOTE: Only PTFE diaphragm models use a primary diaphragm (7) and
a backup diaphragm (8). Refer to the auxiliary view in the Fluid Section
illustration.
4. Removethe(6)diaphragmwasher,(7)or(7/8)diaphragms,and(5)
backup washer.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
S Material supply tubing should be at least the same diameter as the
pump inlet manifold connection.
S Material supply hose must be reinforced, non-collapsible type com-
patible with the material being pumped.
S Piping must be adequately supported. Do not use the pump to sup-
port the piping.
S Use flexible connections (such as hose) at the suction and dis-
charge. These connections should not be rigid piped and must be
compatible with the material being pumped.
FLUID SECTION REASSEMBLY
S Secure the diaphragm pump legs to a suitable surface (level and
flat) to insure against damage by vibration.
S Reassemble in reverse order. Refer to the torque requirements on
page 5.
S Clean and inspect all parts. Replace worn or damaged parts with
new parts as required.
S Pumpsthat need to besubmersedmust havebothwet and non-wet
components compatible with the material being pumped.
S Submersed pumps must have exhaust pipe above liquid level. Ex-
haust hose must be conductive and grounded.
S Lubricate (1) diaphragm rod and (144) “U” cup with LubriplateR
FML-2 grease (94276 grease packet is included in service kit).
S FormodelswithPTFEdiaphragms:Item(8)Santoprenediaphragm
is installed with the side marked “AIR SIDE” towards the pump cen-
ter body. Install the PTFE diaphragm (7) with the side marked
“FLUID SIDE” towards the (15) fluid cap.
S Flooded suction inlet pressure must not exceed 10 p.s.i.g. (0.69
bar).
S Re-check torque settings after pump has been re-started and run a
while.
S VitonRand HytrelR are trademarks of the DuPont Company S LoctiteR and 242R are registered trademarks of Henkel Loctite Corporation S AROR is a registered trademark of Ingersoll-Rand Company S
S SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P., S LubriplateR is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) S
S 271R is a trademark of Henkel Loctite Corporation S
PD15E-XXX-XXX (en)
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PARTS LIST / PD15E-XXX-XXX FLUID SECTION
L 637391-XX FLUID SECTION SERVICE KITS INCLUDE: BALLS (see Ball Option, refer to -XX in Service Kit chart below), DIAPHRAGMS (see Diaphragm
Option, refer to -XX in Service Kit chart below), and items 19, 33, 70, 144, 175 and 180 (listed below) plus 174 and 94276 Lubriplate FML-2 grease
(page 6).
SEAT OPTIONS
PD15E-FES-XXX
“21”
BALL OPTIONS
PD15E-FES-XXX
L “22” (2” dia.)
MATERIAL CODE
[B] = Nitrile
[C] = Carbon Steel
[Co] = Copper
[E] = E.P.R.
-XXX Seat
-PXX 96070-1
Qty [Mtl]
(4) [P]
-XXX Ball
Qty [Mtl]
(4) [Sp]
[GP] = Groundable Polypropylene
[H] = Hytrel
-XAX 95826-A
-XCX 95826-C
-XGX 95826-2
-XTX 95826-4
-XVX 95826-3
[P] = Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
(4)
(4)
(4)
(4)
[H]
[B]
[T]
[V]
[V] = Viton
DIAPHRAGM OPTIONS PD15E-FES-XXX
L Service Kit
-XX = (Ball)
-XXX -XX = (Diaphragm) Diaphragm
L “7”
L “8”
L “19”
L “33”
“19”
“O” Ring
“O” Ring
Qty [Mtl] (3/16”x3-1/4”o.d.) Qty [Mtl] (3/16” x 4” o.d.) Qty [Mtl]
Qty [Mtl] Diaphragm
(2) [Sp] - - - - -
-XXA 637391-XA
-XXC 637391-XC
-XXG 637391-XG
-XXT 637391-XT
-XXV 637391-XV
96166-A
96166-C
96166-G
96165-T
95820-3
- - -
- - -
- - -
- - - 96059
(4)
(4)
(4)
(4)
(4)
[E] 95912
(4)
(4)
(4)
(4)
(4)
[E]
[B]
[B]
[T]
[V]
(2)
(2)
(2)
(2)
[H] - - - - -
[B] - - - - -
[T] 96164-A
[V] - - - - -
- - - Y325-336
- - - Y325-336
[B] Y325-342
[B] Y325-342
[T] 95910
(2) [Sp] 96057
- - - - - - Y327-336
[V] Y327-342
COMMON PARTS
Item
Description (size)
Qty Part No.
[Mtl]
Item
Description (size)
Qty Part No.
[Mtl]
[GP]
[GP]
[GP]
[B]
61 Outlet Manifold
68 Air Cap
(1) 95973-3
(1) 95971-5
(1) 95971-6
(2) 95843
1
5
6
Rod
Backup Washer
(1) 95824
(2) 95819-1
(2) 95975-1
(2) 95972-3
(20) 93360-1
(16) 95925
(20) 96030
(20) 96229
(1) 93004
[C]
[SS]
[P]
Diaphragm Washer
69 Air Cap
15 Fluid Cap
[GP]
[SS]
[SS]
[SS]
[SS]
[Co]
[GP]
L n 70 Gasket
24 Washer (0.406” i.d.)
131 Screw (M10 x 1.5 - 6g x 110 mm)
Ln144 “U” Cup (3/16” x 1-1/4” o.d.)
Ln175 “O” Ring (3/32” x 13/16” o.d.)
Ln180 “O” Ring (3 mm x 15 mm o.d.)
195 Nut (M10 x 1.5 - 6h)
(4) 96056
[SS]
[B]
26 Screw (M10 x 1.5 - 6g x 45 mm)
27 Screw (M8 x 1.25 - 6g x 65.5 mm)
29 Flange Nut (M8 x 1.25 - 6h)
43 Ground Lug (see page 7)
(2) Y186-50
(2) Y325-114
(8) 96291
[B]
[B]
(4) 94992
[SS]
60 Inlet Manifold
(1) 95974-3
n Items included in air section service kit, see page 6.
Page 4 of 8
PD15E-XXX-XXX (en)
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PARTS LIST / PD15E-XXX-XXX FLUID SECTION
COLOR CODE
DIAPHRAGM
COLOR
BALL
COLOR
3
2
1
4
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7
MATERIAL
5
7
8
6
Hytrel
Nitrile
Cream
Black
Tan
Cream
Red (S)
Tan
Santoprene
Santoprene
(Backup)
PTFE
Green
N / A
9
10
White
Yellow (-)
(-) Dash
White
Yellow (S)
(S) Dot
Viton
26 , U
24
Torque Sequence
61
68
131 ,x
70 k
A
A
7
144 k 70 k 69
27 U
22
19
21
33
29 , U
15
144 k 175 k 175 k
1 k 195 180 k
5
6 , ~
60
22
19
21
33
24
26 , U
Figure 2
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ALL FASTENERS ARE METRIC.
(6) Diaphragm washer, 50 - 55 ft lbs (67.8 - 74.6 Nm), lubri-
cate face with Lubriplate grease.
(26) Screws and (29) nuts, 15 - 20 ft lbs (20.3 - 27.1 Nm).
(131) Screws, 12 - 17 ft lbs (16.3 - 23.0 Nm).
AUXILIARY VIEW A-A
VIEW OF TWO PIECE PTFE DIAPHRAGM
LUBRICATION / SEALANTS
k 180
k
Apply Lubriplate FML-2 grease to all “O” rings, “U”
Cups & mating parts.
24
x Apply LoctiteR 242R to threads at assembly.
~ Apply Loctite 271t to threads at assembly.
U Apply anti-seize compound to threads and bolt and nut
flange heads which contact pump case when using
stainless steel fasteners.
7 PTFE
Z Lubriplate FML-2 is a white food grade petroleum grease.
Santoprene 8
PD15E-XXX-XXX (en)
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PARTS LIST / PD15E-XXX-XXX AIR SECTION
n Indicates parts included in 637389 Air Section Service Kit shown below and items (70), (144), (175) and (180) shown on page 4.
AIR MOTOR PARTS
Item
Description (size)
Qty Part No.
(1) 95970-1
(1) 95823
(4) 95886
(2) 95840
(1) 96293
(2) 95839
(2) 95123
(1) 96170
(5) 95931
(6) 95887
(1) 95834-5
(1) 95833
(1) 95844
(1) Y186-53
(1) Y186-49
(1) 95838
(1) 95837
(1) 96171
(1) 67164
(2) 94433
[Mtl]
[GP]
[D]
Item
Description (size)
Qty Part No.
(1) Y240-9
(1) 94081
[Mtl]
[B]
101 Center Body
169 “U” Cup (1/8” x 7/8” o.d.)
170 Piston Sleeve
103 Bushing
[Br]
[B]
105 Screw (M6 x 1 - 6g x 130 mm)
107 End Plate
[SS]
[SS]
[D]
n 171 “O” Ring (3/32” x 1-1/8” o.d.)
n 172 “O” Ring (1/16” x 1-1/8” o.d.)
n 173 “O” Ring (3/32” x 1-3/8” o.d.)
K n 174 “O” Ring (1/8” x 1/2” o.d.)
n 176 Diaphragm (check valve)
181 Roll Pin (5/32” o.d. x 1/2” long)
n 200 Gasket
(1) Y325-119
(1) Y325-22
(2) Y325-123
(2) Y325-202
(2) 95845
[B]
111 Spool
[B]
118 Actuator Pin
[SS]
[D]
[B]
121 Sleeve
[Sp]
[SS]
[B]
n 132 Gasket
[B]
(4) Y178-52-S
(1) 95842
133 Washer (M6)
[SS]
[SS]
[GP]
[P]
134 Screw (M6 x 1 - 6g x 20 mm)
135 Valve Block
201 Muffler
(1) 350-568
(1) 95832
233 Adapter Plate
[P]
136 End Cap
236 Nut (M6 x 1 - 6h)
(4) 95924
[SS]
n 137 Gasket
[B]
L n Lubriplate FML-2 Grease
Lubriplate Grease Packets (10)
(1) 94276
n 138 “U” Cup (3/16” x 1-5/8” o.d.)
n 139 “U” Cup (3/16” x 1-1/8” o.d.)
140 Valve Insert
[B]
637308
[B]
MATERIAL CODE
[AO] = Alumina Oxide
[B] = Nitrile
[Br] = Brass
[D] = Acetal
[GP] = Groundable Polypropylene
[AO]
[AO]
[B]
[P] = Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
[U] = Polyurethane
141 Valve Plate
n 166 Gasket
n 167 Pilot Piston (includes 168 and 169)
[D]
168 “O” Ring (3/32” x 5/8” o.d.)
[U]
K
Items included in fluid section service kit, see page 4.
AIR MOTOR SECTION SERVICE
MAJOR VALVE DISASSEMBLY
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
GENERAL REASSEMBLY NOTES:
1. Remove (135) valve block and (233) adapter plate, exposing (132
and 166) gaskets and (176) checks.
2. Insertasmallflatbladescrewdriverintothenotchinthesideof(135)
valveblockandpushinontabtoremove(233)adapterplate,releas-
ing (140) valve insert, (141) valve plate and (200) gasket.
3. Remove (136) end cap and (137) gasket, releasing (111) spool.
S Air Motor Section Service is continued from Fluid Section repair.
S Inspect and replace old parts with new parts as necessary. Look for
deep scratches on surfaces, and nicks or cuts in “O” rings.
S Take precautions to prevent cutting “O” rings upon installation.
S Lubricate “O” rings with Lubriplate FML-2 grease.
S Do not over-tighten fasteners, refer to torque specification block on
view.
S Re-torque fasteners following restart.
S SERVICE TOOLS -- To aid in the installation of (168) “O” rings onto
the (167) pilot piston, use tool # 204130-T, available from ARO.
MAJOR VALVE REASSEMBLY
1. Install new (138 and 139) “U” cups on (111) spool -- LIPS MUST
FACE EACH OTHER.
2. Insert (111) spool into (135) valve block.
3. Install(137)gasketon(136)endcapandassembleendcapto(135)
valve block, securing with (107) end plates and (105) screws.
NOTE: Tighten (105) screws to 35 - 40 in. lbs (4.0 - 4.5 Nm).
4. Install(140)valveinsertand(141)valveplateinto(135)valveblock.
NOTE: Assemble (140) valve insert with “dished” side toward (141)
valve plate. Assemble (141) valve plate with part number identifica-
tion toward (140) valve insert.
PILOT VALVE DISASSEMBLY
1. A light tapping on (118) should expose the opposite (121) sleeve,
(167) pilot piston and other parts.
2. Remove (170) sleeve, inspect inner bore of sleeve for damage.
5. Assemble(200)gasketand(233)adapterplateto(135)valveblock.
NOTE: Assemble (233) adapter plate with notched side down.
6. Assemble (132 and 166) gaskets and (176) checks and to (101)
body.
7. Assemble (135) valve block and components to (101) body, secur-
ing with (134) screws. NOTE: Tighten (134) screws to 35 - 40 in. lbs
(4.0 - 4.5 Nm).
PILOT VALVE REASSEMBLY
1. Clean and lubricate parts not being replaced from service kit.
2. Install new (171 and 172) “O” rings, replace (170) sleeve.
3. Installnew (168) “O” ringsand (169) seal -Note the lip direction. Lu-
bricate and replace (167).
4. Reassemble remaining parts, replace (173 and 174) “O” rings.
Page 6 of 8
PD15E-XXX-XXX (en)
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PARTS LIST / PD15E-XXX-XXX AIR SECTION
173 k
118
169 k 168 k
172 k
171 k
170
PILOT VALVE
PART GROUP
k 174
121
167
173 k
121
118
174 k
140
141 k
233
166 k
107
U . 105
133
135
U . 134
43
Notch
200 k
132 k 176 k
101 181 103
201
Insert screwdriver here to remove (233) adapter plate.
111
138 k
Figure 3
139 k
k 137
136
107
236
MAJOR
VALVE
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ALL FASTENERS ARE METRIC.
Torque (105 and 134) screws to 35 - 40 in. lbs (4.0 - 4.5 Nm).
LUBRICATION / SEALANTS
k
Apply Lubriplate FML-2 grease to “O” rings, “U” Cups & mating parts.
U Apply anti-seize compound to threads at assembly.
A 637390-7 replacement Major Valve Service Assembly is available separately, which includes the following:
105 (4), 107 (2), 111, 132, 135, 136, 137, 138, 139, 140, 141, 166, 176 (2), 200, 233 and 236 (4)
PD15E-XXX-XXX (en)
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TROUBLE SHOOTING
Product discharged from exhaust outlet.
S Check for diaphragm rupture.
S Check tightness of (6) diaphragm washer.
Low output volume, erratic flow, or no flow.
S Check air supply.
S Check for plugged outlet hose.
S Check for kinked (restrictive) outlet material hose.
S Check for kinked (restrictive) or collapsed inlet material hose.
S Check for pump cavitation -- suction pipe should be sized at least as
large as the inlet thread diameter of the pump for proper flow if high
viscosity fluids are being pumped. Suction hose must be a non-col-
lapsing type, capable of pulling a high vacuum.
S Check all joints on the inlet manifolds and suction connections.
These must be air tight.
Air bubbles in product discharge.
S Check connections of suction plumbing.
S Check “O” rings between intake manifold and inlet side fluid caps.
S Check tightness of (6) diaphragm washer.
Motor blows air or stalls.
S Check (176) check valve for damage or wear.
S Check for restrictions in valve / exhaust.
S Inspectthepumpforsolidobjectslodgedinthediaphragmchamber
or the seat area.
DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
14-1/8” (358.5 mm)
10-1/2” (266.3 mm)
20-15/16” (531.6 mm)
1-1/2” A.N.S.I. / DIN Flange
9-1/32”
(229.5 mm)
Outlet
24-15/32”
(621.5 mm)
21-15/32”
(545.3 mm)
Inlet
11-3/8”
(288.4 mm)
3-9/32”
(83.3 mm)
Air Inlet 1/2 - 14 N.P.T.
8-11/16”
(220.7 mm)
17/32” (13.0 mm)
9/16” (14.3 mm)
10-1/32”
(254.8 mm)
4-7/16”
(112.4 mm)
14-15/16” (379.4 mm)
Exhaust Port 3/4 - 14 N.P.T.
Figure 4
PN 97999-1160
Page 8 of 8
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