AD25A-X-X
OPERATOR’S MANUAL
RELEASED: 4-22-05
REVISED:
(REV. 03)
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
5-20-10
1” DIAPHRAGM PUMP
1:1 RATIO (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.
637436 for air section repair (see page 6).
637425-XX for fluid section repair (see page 4).
PUMP DATA
Models . . . . . . . . . . see “Model Description Chart” for “-XXX”
Pump Type . . . . . . . Metallic Air Operated Double Diaphragm
Material . . . . . . . . . . see “Model Description Chart”
Weight . . . AD25A-XAX-XXX . . . . . . . 22.0 lbs (10.0 kg)
AD25A-XCX-XXX . . . . . . 35.3 lbs (16.0 kg)
AD25A-XSX-XXX . . . . . . . 37.9 lbs (17.2 kg)
Maximum Air Inlet Pressure . . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Material Inlet Pressure . . . . . 10 p.s.i. (0.69 bar)
AD25A-XXX-XXX
1’’ DIAPHRAGM PUMP
Maximum Outlet Pressure . . . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Flow Rate (flooded inlet) . . . 35 g.p.m. (133 l.p.m.)
Maximum Particle Size . . . . . . . . . . . . 1/8” dia. (3.2 mm)
Maximum Temperature Limits (diaphragm / ball / seat material)
E.P.R. / EPDM . . . . . . -60_ to 280_ F (-51_ to 138_ C)
HytrelR . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)
Polypropylene . . . . . . . 35_ to 150_ F (2_ to 66_ C)
SantopreneR . . . . . . . -40_ to 225_ F (-40_ to 107_ C)
PTFE . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)
VitonR . . . . . . . . . . . . -40_ to 350_ F (-40_ to 177_ C)
Dimensional Data . . . . . . . . . . . . . . . . see page 8
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 64.5 db(A)*
MODEL DESCRIPTION CHART
AD25 A - X X X - X X X
CENTER SECTION MATERIAL
A - Aluminum
THREAD
A - 1” N.P.T.F. - 1
B - Rp 1 - 11 BS
FLUID CAPS & MANIFOLD MATERIAL
A - Aluminum
C - Cast iron
S - Stainless Steel
*
The pump sound pressure levels published here have been updated to an Equivalent Continuous
SoundLevel(L )tomeettheintentofANSIS1.13-1971, CAGI-PNEUROPS5.1using fourmicro-
Aeq
phone locations.
HARDWARE MATERIAL
P - Carbon Steel
S - Stainless Steel
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
F - Aluminum
P - Polypropylene
S - 316 Stainless Steel
BALL MATERIAL
A - Santoprene
C - Hytrel
T - PTFE
DIAPHRAGM MATERIAL
A - Santoprene
C - Hytrel
T - PTFE
FLUID SECTION SERVICE KIT SELECTION
AD25A - XXX - X X X
637425 - X X
EXAMPLE: MODEL # AD25A-ASS-SAA
FLUID SECTION SERVICE KIT # 637425-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY
209 NORTH MAIN STREET -- BRYAN, OHIO 43506
(800) 276-4658 D FAX (800) 266-7016
E2010
CCN 15242605
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GENERAL DESCRIPTION
MAINTENANCE
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.
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.
S Provide a clean work surface to protect sensitive internal moving
partsfromcontaminationfromdirtandforeignmatter 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.
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 If lubricated air is present, make sure that it is compatible with the
Nitrile “O” rings in the air motor section of the pump.
FLUID SECTION DISASSEMBLY
1. Remove top manifold(s).
2. Remove (22) balls, (19) “O” rings, (21) seats.
3. Remove (15) fluid caps.
NOTE:OnlyPTFEdiaphragmmodelsuseaprimarydiaphragm(7)anda
backup diaphragm (8). Refer to the auxiliary view in the Fluid Section il-
lustration.
4. Remove the (6) nut, (7) or (7 / 8) diaphragms and (5) washers.
5. Remove (3) “O” rings.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
OPERATING INSTRUCTIONS
S Always flush the pump with a solvent compatible with the material
beingpumpedifthematerialbeingpumpedissubjectto“settingup”
when not in use for a period of time.
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew
hours.
S Theoutletmaterialvolumeisgovernednotonlybytheairsupplybut
alsobythematerialsupplyavailableattheinlet.Thematerialsupply
tubing should not be too small or restrictive. Be sure not to use hose
which might collapse.
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.
S Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
FLUID SECTION REASSEMBLY
S Reassemble in reverse order.
S Clean and inspect all parts. Replace worn or damaged parts with
new parts as required.
S Lubricate(1)diaphragmrodand(2)“O”ringwithKey-LubeR grease.
S UseAROpn/98930-Tbullet(installationtool)toaidininstallationof
(2) “O” ring on (1) diaphragm rod.
S Be certain (7) or (7 / 8) diaphragm(s) align properly with (15) fluid
caps before making final torque adjustments on bolt and nuts to
avoid twisting the diaphragm.
S FormodelswithPTFEdiaphragms:Item(8)Santoprenediaphragm
is installed with the side marked “AIR SIDE” towards the pump cen-
ter body. Install the PTFE diaphragm with the side marked “FLUID
SIDE” towards the fluid cap.
S Re-check torque settings after pump has been re-started and run a
while.
S VitonR and HytrelR are trademarks of the DuPont Company, S SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. S Key-LubeR is a registered trademark of Key Industries
AD25A-X-X
Page 3 of 8
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PARTS LIST / AD25A-X-X FLUID SECTION
FLUID SECTION SERVICE KITS
L KITS INCLUDE: BALLS (See BALL Option, refer to -XX in chart below), DIAPHRAGMS (See DIAPHRAGM Option, refer to -XX in chart below),
plus “O” Ring items: 2, 3, 19 and 93706-1 Key-Lube grease.
SEAT OPTIONS
AD25A-XXX-XXX
“21”
BALL OPTIONS
AD25A-XXX-XXX
L “22” (1” dia.)
MATERIAL CODE
[A] = Aluminum
[H] = Hytrel
[B] = Nitrile
[P] = Polypropylene
[SP] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[C] = Carbon Steel
[CI] = Cast Iron
[Co] = Copper
[E] = E.P.R.
-XXX Seat
Qty [Mtl]
-XXX Ball
Qty [Mtl]
[V] = Viton
-FXX 92008
-PXX 92926
-SXX 90428
(4)
(4)
[A]
[P]
-XAX 90532-A
-XCX 90532-C
-XTX 90532-4
(4) [SP]
(4)
(4)
[H]
[T]
(4) [SS]
DIAPHRAGM OPTIONS AD25A-XXX-XXX
L Service Kit
L “7”
L “8”
L “3”
L “19”
“O” Ring
“O” Ring
-XX = (Ball)
-XX = (Diaphragm)
-XXX
Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] (1/16” x 5/8” o.d.)
Qty [Mtl] (3/32” x 1-9/16” o.d.) Qty [Mtl]
-XXA 637425-XA
-XXC 637425-XC
-XXT 637425-XT
90533-B
90533-9
93459-4
(2) [SP] - - - - -
- - -
- - -
- - - Y328-14
- - - Y328-14
(4)
(4)
(4)
[T] 90534
[T] Y327-126
[T] Y328-126
(4)
(4)
(4)
[E]
[V]
[T]
(2)
(2)
[H] - - - - -
[T] 92973-B
(2) [SP] Y328-14
MANIFOLD / FLUID CAP MATERIAL OPTIONS AD25A-XXX-XXX
ALUMINUM
CAST IRON
STAINLESS STEEL
AD25A-AAX- AD25A-BAX- AD25A-ACX- AD25A-BCX- AD25A-ASX- AD25A-BSX-
N.P.T.
BSP
N.P.T.
BSP
N.P.T.
BSP
Item Description (size)
V 6 Washer (fluid side)
15 Fluid Cap
Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
(2) 93441-2
(2) 94945
(2) 92001
[C] 93441-2
[A] 94945
[C] 93441-2
[A] 94277
[A] 94278
[C] 93441-2
[C] 93441-1 [SS] 93441-1 [SS]
[CI] 91045 [SS] 91045 [SS]
[CI] 94278-1 [CI] 91044 [SS] 91044-1 [SS]
[CI] 94277
16 Manifold
[A] 92001-1
HARDWARE OPTIONS AD25A-XXX-XXX
Carbon Steel
Stainless Steel
AD25A-XXP-XXX AD25A-XXS-XXX
Item Description (size)
26 Bolt (5/16” - 18 x 1”)
29 Nut (5/16” - 18)
Qty Part No.
(8) Y6-55-C
(16) Y12-5-C
[Mtl] Part No.
[C] Y6-55-T
[C] Y12-5-S
[Mtl]
[SS]
[SS]
COMMON PARTS
Item Description (size)
V 1 Rod
Qty Part No.
(1) 98724-1
(1) Y330-113
(2) 93441-2
[Mtl]
Item Description (size)
Qty Part No.
(2) 93189-1
(2) Y5-85-T
(1) 93004
[Mtl]
[SS]
[SS]
[Co]
[C]
9
Washer (0.505” i.d.)
L 2 “O” Ring (3/32” x 3/4” o.d.) k
[B]
14 Screw (1/2” - 20 x 1”)
5
Washer - (air side) (3-5/8” o.d.)
[C]
43 Ground Lug (see page 7)
Service Note: Part No. 98930-T installation tool is available separately for use with items 1 and 2.
V “Smart Parts” keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
Page 4 of 8
AD25A-X-X
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PARTS LIST / AD25A-X-X FLUID SECTION
COLOR CODE
DIAPHRAGM
COLOR
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS
BALL
COLOR
3
2
1
4
MATERIAL
Hytrel
Santoprene
Santoprene
(Backup)
PTFE
Cream
Cream
Cream
N/A
(14) Diaphragm bolt 25 - 30 ft lbs (33.9 - 40.7 Nm), apply Loctite 271 to threads.
(26) Bolts and (29) nuts 120 - 140 in. lbs (13.6 - 15.8 Nm).
Cream
*
5
7
8
6
Green
White
White
LUBRICATION / SEALANTS
k Apply Key-Lube to all “O” rings, “U” Cups & mating parts.
Apply anti-seize compound to threads and bolt and nut flange heads which
contact pump case when using stainless steel fasteners.
See item 8 in inset below.
*
d NOTE: Radius edge of parts (5 and 6) is against diaphragm.
Torque Sequence
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7
AIR
INLET
2 k
1
3 k 5 d
7
26 ,
16
22
3 k
14 ,
19 k
21
29 ,
15
Countersink
6 d
9
22
21
AIR SIDE
FLUID SIDE
SANTOPRENE
(GREEN when
used as backer)
PTFE
19 k
16
(WHITE)
8
7
FLUID
SIDE
26 ,
AIR
SIDE
AIR
SIDE
FLUID
SIDE
CROSS SECTION VIEW OF DIAPHRAGMS
View for AD25A-XXX-XXT (PTFE diaphragm) configuration only.
Figure 1
AD25A-X-X
Page 5 of 8
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PARTS LIST / AD25A-X-X AIR MOTOR SECTION
n Indicates parts included in 637436 Air Section Service Kit.
SERVICE KIT NOTE: Service Kit 637436 is a general repair kit for all 1” and larger ARO diaphragm pump air motors.
It contains extra “O” Rings and extra parts that may not be needed to service this model.
Item Description (size)
101 Motor Body
Qty Part No.
(1) 94743
[Mtl]
[A]
Item Description (size)
V 116 Spacer
Qty Part No.
(1) 92006
(1) 92004
(1) 93309-1
(4) 93075
(3) 115959
(2) 98723-1
(2) 94820
(4) Y154-41
[Mtl]
[Z]
n102 “O” Ring (1/16” x 1” o.d.)
V 103 Sleeve
(2) Y325-20
(1) 94527
[B]
n117 Gasket
[B/Ny]
[C]
[D]
118 Pilot Rod
n104 Retaining Ring, TruArc (0.925” i.d.)
(2) Y145-25
[C]
n119 “O” Ring (1/8” x 3/4” o.d.)
120 Spacer
[U]
105 Screw/Wshr (1/4”-20 x 5/8”) (AD25A-XXP-) (8) 93860
[C]
[Z]
Cap Screw (1/4”-20 x 5/8”) (AD25A-XXS-)
106 Lockwasher (1/4”) (AD25A-XXS-)
107 Leg (AD25A-XXP-)
(8) Y6-42-T
(8) Y14-416-T
(2) 92003
[SS]
[SS]
[C]
121 Sleeve Bushing
n122 “O” Ring (3/32” x 9/16” o.d.)
n123 Screw (#8 - 32 x 3/8”)
[Bz]
[U]
[C]
(AD25A-XXS-)
(2) 92003-1
(1) 92878
[SS]
[B/Ny]
[D]
124 Stud (5/16” - 18 x 1-3/4”) (AD25A-XXP-) (16) 92866
[C]
n108 Gasket (with notch)
V 109 Piston
(5/16” - 18 x 1-3/4”) (AD25A-XXS-)
128 Pipe Plug (1/8 - 27 N.P.T. x 1/4”)
(16) 92866-1
(1) Y227-2-L
(1) Y14-416-T
(2) 94987
(1) 94987-1
(1) 93110
[SS]
[C]
(1) 92011
n110 “U” Cup (3/16” x 1-3/8” o.d.)
V 111 Spool
(1) Y186-51
(1) 92005
[B]
133 Lockwasher (1/4”)
[SS]
[SS]
[SS]
[C]
[A]
197 Button Head Screw (1/4” - 20 x 1/4”)
198 Button Head Screw (1/4” - 20 x 3/8”)
201 Muffler
V 112 Washer (1.557” o.d.)
n113 “O” Ring (small) (1/8” x 1-1/4” o.d.)
n114 “O” Ring (large) (3/32” x 1-9/16” o.d.)
V 115 Spacer
(5) 92877
[Z]
(5) Y325-214
(6) Y325-126
(4) 92876
[B]
[B]
n
Key-Lube “O” Ring Lubricant
10 Pak of Key-Lube
(1) 93706-1
637175
[Z]
n Parts Y145-26 (1.156” i.d.) (Qty 2) Retaining Rings and Y325-24 “O” Rings
AIR MOTOR SECTION SERVICE
(Qty 2) are included in the Service Kit for the repair of larger pumps.
MATERIAL CODE
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
GENERAL REASSEMBLY NOTES:
[A] = Aluminum
[B] = Nitrile
[Bz] = Bronze
[C] = Carbon Steel
[D] = Acetal
[U] = Polyurethane
[SS] = Stainless Steel
[Z] = Zinc
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 metallic surfaces, and nicks or cuts in “O” rings.
S Take precautions to prevent cutting “O” rings upon installation.
S Lubricate “O” rings with Key-Lube grease.
S Do not over-tighten fasteners, refer to torque specification block on
view.
S Re-torque fasteners following restart.
[Ny] = Nylon
MAJOR VALVE DISASSEMBLY
1. Remove (107) plate (or leg depending on model), (108 and 117)
gaskets.
2. On the side opposite the air inlet, push on the inner diameter (111)
spool.Thiswillforcethe(109)pistonout.Continuepushingthe(111)
spool and remove. Check for scratches and gouges.
3. Reach into the air section (exhaust side) and remove (116) spacer,
(115) spacers, (113) “O” rings, (114) “O” rings, (112) washers, etc.
Check for damaged “O” rings.
PILOT VALVE DISASSEMBLY
1. Remove (104) retaining ring.
2. Remove (123) screws and (122) “O” rings.
3. Remove (118) piston rod, (121) sleeve bushing, (119) “O” rings and
(120) spacers from the (101) motor body.
MAJOR VALVE REASSEMBLY
4. Remove (103) sleeve and (102) “O” rings.
1. Replace (112) washer, (114) “O” ring and (113) “O” ring onto (115)
spacer and insert etc.
PILOT VALVE REASSEMBLY
NOTE: Be careful to orient spacer legs away from blocking in-
ternal ports.
1. Replace two (102) “O” rings if worn or damaged and reinstall (103)
sleeve.
2. Install one of the (121) sleeve bushings, (119) “O” rings, (120)
spacers and the remaining (121) bushing.
3. Carefully push (118) pilot rod into bushings etc. and retain on each
end with the two (122) “O” rings, retain with (123) screws.
4. Replace (104) retaining rings.
2. Lubricate and carefully insert (111) spool.
3. Install (117) gasket and (107).
4. Lubricate and install (110) packing cup and insert (109) piston into
(airinletside)cavity,the(110)packingcuplipsshouldpointoutward.
5. Install (108) gasket and replace (107).
V “Smart Parts” Keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
Page 6 of 8
AD25A-X-X
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PARTS LIST / AD25A-X-X AIR MOTOR SECTION
IMPORTANT
BE CERTAIN TO ORIENT (115) SPACER LEGS
AWAY FROM BLOCKING INTERNAL PORTS
WHEN REASSEMBLING AIR SECTION.
111
117
115
k 114
116
k 113
112
107
MAJOR VALVE
See cross section detail figure 3.
201
Figure 2
Z 128
101
z 197
104
z 123
121
124
197 z
102 k
103 k
43
133
102 k
z 198
104
106
119 k
109
. 105
121
123 z
110 k
107
118 k
108
120
122 k
PILOT
VALVE
MAJOR VALVE CROSS SECTION DETAIL
109 110 k 112
114 k 113 k 115 111 k 116
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS
(105) 40 - 50 in. lbs (4.5 - 5.6 Nm).
LUBRICATION / SEALANTS
Apply Key-Lube grease to all “O” rings, “U” Cups &
mating parts.
k
Figure 3
z Apply Loctite 271 to threads.
Z Apply pipe sealant to threads.
AD25A-X-X
Page 7 of 8
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TROUBLE SHOOTING
Product discharged from exhaust outlet.
S Check for diaphragm rupture.
S Check tightness of diaphragm nut.
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 fluid caps.
S Check tightness of diaphragm nut.
S Inspectthepumpforsolidobjectsloggedinthediaphragmchamber
or the seat area.
DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
8” (203 mm)
8-9/16” (217.5 mm)
1 - 11-1/2 N.P.T.F.-1
(AD25A-AXX-XXX)
1 - 11 B.S.P.
Outlet
(AD25A-BXX-XXX)
12-1/2”
(318 mm)
11-9/16”
(294 mm)
Air Inlet
1/4 - 18 N.P.T.
6-11/16”
(169.8 mm)
Inlet
1-1/4” (32 mm)
6-1/4” (159 mm)
7-5/16” (186 mm)
4” (102 mm)
13/32” Slot
(10 mm)
Figure 4
PN 97999-1151
AD25A-X-X
Page 8 of 8
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