OPERATOR’S MANUAL
670077
8-29-08
RELEASED:
REVISED:
(REV. 03)
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
10-16-09
1/2" DIAPHRAGM PUMP
1:1 RATIO (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 mate-
rial options.
637463 for fluid section repair (see page 4).
637428 for air section repair (see page 6).
PUMP DATA
Models. . . . . . . . . . . . . see Model Description Chart for “-XXX”
Pump Type. . . . . . . . . Air Operated Double Diaphragm
Material. . . . . . . . . . . . see Model Description Chart
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 lbs (2.83 kgs)
Maximum Air Inlet Pressure . . . . . . . . 100 p.s.i.g. (6.9 bar)
Maximum Material Inlet Pressure. . . 10 p.s.i.g. (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . . 100 p.s.i.g. (6.9 bar)
Air Consumption @ 40 p.s.i.. . . . . . . 1 c.f.m. / gallon (approx.)
(flooded inlet)
Maximum Flow Rate
. . . 11.9 g.p.m. (45.0 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . 0.031 gal. (0.12 lit.)
Maximum Particle Size . . . . . . . . . . . . . 3/32”dia. (2.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat
material)
E.P.R. . . . . . . . . . . . . . . . . . . . . . -60° to 280° F (-51° to 138° C)
Polypropylene . . . . . . . . . . . . 35° to 175° F (2° to 79° C)
Santoprene®. . . . . . . . . . . . . . -40° to 225° F (-40° to 107° C)
Dimensional Data. . . . . . . . . . . . . . . . . . . see page 8
Figure 1
Noise Level @ 70 p.s.i., 60 c.p.m.. . . . . . 75.0 db(A)
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MODEL DESCRIPTION CHART
The pump sound pressure levels published here have been updated to
an Equivalent Continuous Sound Level (LAeq) to meet the intent of ANSI
S1.13-1971, CAGI-PNEUROP S5.1 using four microphone locations.
c
Center Section Material
Polypropylene
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.
Fluid Connection
1/2 - 14 N.P.T.F. - 1
Fluid Cap & Manifold Material
Polypropylene
Hardware Material
Stainless Steel
Seat Material
Polypropylene
Ball Material
Santoprene
Diaphragm Material
Santoprene
INGERSOLL RAND COMPANY LTD
P.O. BOX 151 y ONE ARO CENTER y BRYAN, OHIO 43506-0151
ꢀ (800) 276-4658 y FAX (800) 266-7016
© 2009
CCN 15290232
fluids.ingersollrand.com
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OPERATING INSTRUCTIONS
= Hazards or unsafe practices which
could result in severe personal injury,
death or substantial property damage.
= Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
WARNING
CAUTION
NOTICE
Always flush the pump with a solvent compatible with
the material being pumped if the material being pumped
is subject to “setting up” when not in use for a period of
time.
Disconnect the air supply from the pump if it is to be in-
active for a few hours.
The outlet material volume is governed not only by the
air supply, but also by the material supply available at the
inlet. The material supply tubing should not be too small
or restrictive. Be sure not to use hose which might col-
lapse.
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.
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= Important installation, operation or
maintenance information.
GENERAL DESCRIPTION
The ARO diaphragm pump offers high volume delivery even
at low air pressure and a broad range of material compatibil-
ity options are 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 dif-
ferential in the air chambers to alternately create suction and
a positive fluid pressure 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 pressure and will stop cycling once maxi-
mum line pressure is reached (dispensing device closed) and
will resume pumping as needed.
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Secure the diaphragm pump legs to a suitable surface to
insure against damage by vibration.
MAINTENANCE
Certain ARO “Smart Parts” are indicated which should be
available for fast repair and reduction of down time.
Provide a clean work surface to protect sensitive internal
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
Keep good records of service activity and include the
pump in preventive maintenance program.
Service kits are available to service two separate dia-
phragm pump functions: 1. AIR SECTION, 2. FLUID SEC-
TION. The Fluid Section is divided further to match typical
active Material Options.
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AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
A filter capable of filtering out particles larger than 50
microns should be used on the air supply. There is no lu-
brication required other than the “O” ring lubricant which
is applied during assembly or repair.
If lubricated air is present, make sure that it is compatible
with the “O” rings and seals in the air motor section of the
pump.
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Before disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
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Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. Loctite® and 242® are registered trademarks of Henkel Loctite Corporation
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Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) ARO® is a registered trademark of Ingersoll-Rand Company
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670077 (en)
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PARTS LIST / 670077 FLUID SECTION
637463 Fluid Section Service Kits include: 22 balls, 7 diaphragms, and items 19 and 20 (listed below) plus items 144, 174 and
n
94276 Lubriplate® FML-2 grease (page 6).
FLUID SECTION PARTS LIST
(size)
(size)
Item Description
Qty Part No.
(1) 96379
(2) 94645
(2) 93103-1
(2) 93465
(2) 93105-1
(4) 93763
(2) 93761
(4) 93098-10
[Mtl]
[SS]
[GFN]
[P]
Item Description
Qty Part No.
(4) 93100-E
(8) 93109
[Mtl]
[Sp]
[SS]
[SS]
[SS]
[P]
(3/4” o.d.)
1
5
6
7
Connecting Rod
22 Ball
26 Bolt
27 Bolt
o
n
(5/16” - 18 x 1-1/2”)
(5/16” - 18 x 1-1/4”)
Diaphragm Washer
(5/16” - 18)
Diaphragm Nut
Diaphragm
(8) 93095
(5/16” - 18)
[Sp]
[P]
29 Hex Flange Nut
41 Ball Cage
(24) 93886
(4) 93097-1
(1) 93802-1
(1) 93801-1
(2) 93897-1
n
15 Fluid Cap
19 “O” Ring
20 “O” Ring
21 Seat
(3/32” x 1-5/16” o.d.)
(3/32” x 1-18” o.d.)
[E]
60 Inlet Manifold
61 Outlet Manifold
[P]
n
n
[E]
[P]
(1/2 - 14 N.P.T.)
[P]
63 Pipe Plug
[P]
“Smart Parts”, keep these items on hand in addition to the service kit for fast repair and reduction of down time.
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MATERIAL CODE
[E]
= E.P.R.
[GFN] = Glass Filled Nylon
[P] = Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
TYPICAL CROSS SECTION
Figure 2
Page 4 of 8
670077 (en)
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PARTS LIST / 670077 FLUID SECTION
29
61
63
(
e
FOR THE AIR MO-
TOR SECTION, SEE
PAGES 6 & 7.
(
d
19
41
22
20
21
26
c
27
1
5
7
6
124
e
c
(
f
e
c
e
15
29
(
e
e
26
41
22
21
19
60
63
29
Figure 3
(
(
d
e
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ASSEMBLY TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(6) diaphragm nut, 95 - 105 in. lbs (10.7 - 11.9 Nm).
(29) nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-
torque after initial run-in.
3
2
1
4
(63) plugs, 25 in. lbs (2.8 Nm) maximum.
5
7
8
6
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease (94276) to all “O” rings, “U” cups and
mating parts.
c
Apply pipe sealant to threads.
d
e
Apply anti-seize compound to threads and bolt and nut flange heads
which contact pump case when using stainless steel fasteners.
Apply Loctite® 242® to threads.
f
Torque Sequence
Note: Lubriplate FML-2 is a white food grade petroleum grease.
670077 (en)
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PARTS LIST / 670077 AIR MOTOR SECTION
Indicates parts included in 637428 air section repair kit.
p
AIR MOTOR PARTS LIST
(size)
(size)
139 “U” Cup Packing
140 Valve Insert
Item Description
Qty Part No.
(1) 96315
(1) 96091
(1) 96351
(1) 96353
(1) 95919
(2) 97111
(2) 96092
(8) 96093
(8) 93249
(1) 67367
(1) 96214-1
(4) 94871
(1) 96204
(1) 96352
(3) Y325-29
(1) 94395
[Mtl]
[PPG]
[D]
Item Description
Qty Part No.
(1) 96383
(1) 93276
(1) 96173
(2) Y187-48
(1) Y325-24
(1) 67382
(2) 96459
(1) 96384
(1) 96090
(2) Y325-17
(2) Y325-115
(2) Y325-105
(1) 96364
[Mtl]
[U]
[Ck]
[Ck]
[B]
(1/8” x 1-7/16” o.d.)
101 Center Body
p
(right side)
103R Cover
103L Cover
(left side)
[D]
141 Valve Plate
(3/16” x 1” o.d.)
107 Plug, Small
111 Major Valve Spool
118 Actuator Pin
121 Washer
[D]
144 “U” Cup Packing
p
p
p
(1/16” x 1-1/4” o.d.)
[D]
166 “O” Ring
[B]
(includes 168 and 169)
[SS]
[D]
167 Pilot Piston
[D]
[U]
[U]
[D]
[B]
(1/16” x 7/16” o.d.)
168 “O” Ring
p
p
(#4 - 20 x 1/2”)
(1/8" x 5/8" o.d.)
123 Screw
[SS]
[SS]
[PPG]
[B]
169 “U” Cup Packing
170 Spool Bushing
(5/16” - 18 x 1-17/32”) (see page 5)
124 Stud
(1/16” x 13/16” o.d.)
129 Muffler Assembly
132 Air Manifold Gasket
171 “O” Ring
173 “O” Ring
174 “O” Ring
p
p
p
p
(3/32” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
[B]
(1/4” - 20 x 5-3/4”)
134 Flange Bolt
135 Valve Block
136 Plug, Large
[SS]
[PPG]
[D]
[B]
200 Porting Gasket
[B]
(1/16” x 1-5/8” o.d.)
137 “O” Ring
[B]
Lubriplate FML-2 Grease
(1) 94276
637308
p
p
p
(1/8” x 1” o.d.)
138 “U” Cup Packing
[U]
Lubriplate Grease, 10 Pack
MATERIAL CODE
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate or equiva-
lent “O”ring lubricant.
Connecting rod (1) should be installed using 96571 bul-
let, included in service kit.
Install (5) washers with i.d. chamfer toward diaphragm.
[B] = Nitrile
[Ck] = Ceramic
[D] = Acetal
[PPG] = Glass Filled Polypropylene
[SS] = Stainless Steel
[U] = Polyurethane
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DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
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Inspect and replace old parts with new parts as neces-
sary. Look for deep scratches on metallic surfaces, and
nicks or cuts in “O”rings.
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AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
Tools needed to complete disassembly and repair:
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7/8” socket or wrench, 1/2” socket or wrench, 3/8”
socket or wrench, 3/8” Allen wrench, T-10 Torx screw-
driver, torque wrench (measuring inch pounds), “O”
ring pick.
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Valve.
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Air Motor Section service is continued from Fluid Section
repair.
PILOT VALVE DISASSEMBLY
FLUID SECTION DISASSEMBLY
Remove (61) top manifold.
Remove (41) ball cages, (22) balls, (19 and 20) “O” rings
and (21) seats. NOTE: If cages are difficult to remove at
this step, it may be helpful to proceed through step 5 and
remove them once they are accessible from the inside of
the fluid cap.
Remove (60) bottom manifold.
Remove (19) “O”rings, (21) seats and (22) balls.
Remove (15) fluid caps.
Remove (6) diaphragm nut, (7) diaphragm and (5) washer
from (1) connecting rod.
Remove (1) connecting rod from air motor.
Carefully remove remaining (6) diaphragm nut, (7) dia-
phragm and (5) washer from (1) connecting rod. Do not
mar surface of connecting rod.
1.
2.
Remove (123) screws, releasing (103) covers, (121) wash-
ers, (118) actuator pins and (167) pilot piston.
Remove (170) spool bushing and inspect inner bore of
bushing for damage.
1.
2.
PILOT VALVE REASSEMBLY
Clean and lubricate parts not being replaced from service
1.
2.
3.
4.
3.
4.
5.
6.
kit.
Assemble (171) “O” rings to (170) bushing and assemble
bushing into (101) center body.
Lubricate and assemble (167) pilot piston assembly into
(170) bushing.
Assemble (173 and 174) “O” rings and (121) washers to
(103) covers, then insert (118) actuator pins through as-
sembly.
Assemble (144) “U” cups (note the lip direction) and (103)
covers to (101) center body, securing with (123) screws.
NOTE: Tighten (123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).
7.
8.
5.
Page 6 of 8
670077 (en)
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PARTS LIST / 670077 AIR MOTOR SECTION
PILOT VALVE PARTS
144 118 169
168
171
c
c
c
c
123
)
103L
173
c
174 121 167 170
c
140
132
107
137
166
129
144
c
c
c
135
134
138
103R
123
)
c
(
141
111
136
200
101
118 121 174
173
c
c
c
c
139
137
PILOT VALVE PARTS
c
c
) ASSEMBLY TORQUE REQUIREMENTS (
NOTE: DO NOT OVERTIGHTEN FASTENERS.
MAJOR VALVE
(123) screw, 4 - 6 in. lbs (0.45 - 0.68 Nm).
(134) bolt, 15 - 20 in. lbs (1.7 - 2.3 Nm), wait 10 minutes, then re-
torque to 15 - 20 in. lbs (0.45 - 0.68 Nm).
LUBRICATION / SEALANTS
Figure 4
c
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and
mating parts.
MAJOR VALVE DISASSEMBLY
MAJOR VALVE REASSEMBLY
1.
2.
1.
Unthread (134) bolts, releasing (129) muffler assembly.
Pull (135) valve block and components from (101) center
body.
Remove (132) gasket, (141) valve plate and (140) valve
insert from (135) valve block.
Remove (134) bolts, releasing (107 and 136) plugs and
(111) spool.
Assemble new (138 and 139) “U” cups on (111) spool -
LIPS MUST FACE EACH OTHER.
2.
3.
4.
Assemble (137) “O”rings to (136) large plug.
3.
4.
Assemble (137 and 166) “O”rings to (107) small plug.
Insert (111) spool into (136) large plug, then insert (136)
large plug into (135) valve block, being sure the (111)
spool is rotated to accept (140) valve insert.
5.
6.
Assemble (107) small plug into (135) valve block.
Assemble (140) valve insert and (141) valve plate to
(135) valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with identification dot toward (132) gasket.
Assemble (132 and 200) gaskets, (135) valve block and
(129) muffler assembly to (101) center body, securing
with (134) bolts. NOTE: Tighten (134) bolts to 15 - 20 in.
lbs (1.7 - 2.3 Nm).
7.
670077 (en)
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TROUBLE SHOOTING
Product discharged from air exhaust.
Low output volume.
Check for diaphragm rupture.
Check air supply.
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Check tightness of (6) diaphragm nut.
Check for plugged outlet hose.
For the pump to prime itself, it must be mounted in the
vertical position so that the balls will check by gravity.
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 non-collapsible type, capable of
pulling a high vacuum.
Air bubbles in product discharge.
Check connections of suction plumbing.
Check “O”rings between intake manifold and fluid caps.
Check tightness of (6) diaphragm nut.
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Pump blows air out main exhaust when stalled on either
stroke.
Check all joints on the intake manifolds and suction con-
nections. These must be air tight.
Inspect the pump for solid objects lodged in the dia-
phragm chamber or the seat area.
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Check “U”cups on (111) spool in major valve.
Check (141) valve plate and (140) insert for wear.
Check (169) “U”cup on (167) pilot piston.
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DIMENSIONAL DATA
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
L (outlet)
E
Air Inlet 1/4 - 18 P.T.F. SAE Short
F
B
G
N
D
H
M
K
J
C
L (inlet)
A
DIMENSIONS
A - 8-15/32”(214.5 mm) E - 6-23/32” (170.6 mm) J - 5-1/2" (139.7 mm)
B - 10-1/16”(255.3 mm) F - 6” (152.4 mm) K - 5/16” (8.0 mm)
N - 6-1/32" (153.0 mm)
C - 6-5/32”(155.8 mm)
D - 2”(50.9 mm)
G - 11-5/16” (287.0 mm) L - 1/2 - 14 N.P.T.F. - 1
H - 4-13/16” (122.2 mm) M - 3/8” (9.5 mm)
Figure 5
PN 97999-1336
670077 (en)
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