Model 1120-015S
Contents
1. sse 18 Air Inlet and Priming 6 Converting Pump for Piping Exhaust Air sesssssseeeeene 18 Between USeS M 6 Converted Exhaust Illustration eessennen em 18 Installation G ilde rero ete het a 7 Grounding The Pump ees a aie se YI A Pepe e S 19 Troubleshooting retient inne tenere cedit ipei dee ee P edet nos 8 lucu 20 eas ashe ied aes eee ie E a ce 9 Important Safety Information een 9 Composite Repair Parts Drawing seem 10 Composite Repair Parts List amp Available Service and Conversion Kits 10 Air Distribution Valve Assembly Drawing and Parts 11 Balcrank Corporation 115 Reems Creek Road Weaverville NC 28787 Telephone 800 747 5300 Fax 800 763 0840 www balcrank com Model 1120 0155 c UL US LISTED 1TA3 INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING 1 internal 0 to 45 gallons per minute No lube no stall Up to 25 in 6mm O to 170 liters per minute design CAUTION Operating temperature limitations are as follows Materials Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like aceton2. Model 1120 0155 Page 12 Pilot Valve Servicing Assembly Drawing 4 Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION 4 Pilot Valve Assembly 4 A Valve Body 4 B Sleeve With O rings 4 C O ring Sleeve 4 D Spool With O rings 4 E O ring Spool 4 F Retaining Ring 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 STEP 1 See pump assembly drawing Using a 1 2 wrench or socket remove the four capscrews item 12 Remove the air inlet cap item 8 and air inlet gasket item 18 The pilot valve assembly item 4 can now be removed for inspection and service bc1020 015Sdl1sm rev0312 QTY T 1 1 1 6 1 3 1 STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 D Wipe clean and inspect spool and o rings for dirt cuts or wear Replace the o rings and spool if necessary Remove the retaining ring item 4 F from the end of the sleeve item 4 B and remove the sleeve from the valve body item 4 A Wipe clean and inspect sleeve and o rings for dirt cuts or wear Replace the o rings and sleeve if necessary STEP 3 Re assembly of the pilot valve Generously lubricate outside diameter of the sleeve and o rings Then carefully insert sleeve into valve body Take CAUTION when inserting sleeve not to shear any o rings Install retaining ring
3. Valve Seats Air End Seal Kit 833103 O rings Gaskets Retaining Rings Bumpers Bushings and Seals bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 10 Air Valve Assembly Drawing Parts List AIR VALVE ASSEMBLY PARTS LIST I QTY TE DESCRIPTION Valve Assembly 1 1 A Valve Body 1 1 B Sleeve and Spool Set 1 1 C Bumper 2 1 D O Ring 10 1 E Cap End 2 1 F Capscrew 8 bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 11 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump STEP 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex head capscrews item 10 Remove the air valve assembly from the pump Remove and inspect gasket item 16 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex caprscrews item 1 F that fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect two o rings items 1 D on each end cap for damage or wear Replace the o rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear bc1020 015Sdl1sm rev0312 In
4. plungers See ILLUSTRATION AT RIGHT The actuator plungers items 25 can be reached through the pilot valve cavity in the intermediate assembly item 5 Remove the plungers item 25 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 22 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 as they will go To remove the bushings item 7 first remove the retaining rings item 26 by using a flat screwdriver NOTE It is recommended that new retaining rings be installed bc1020 015Sdl1sm rev0312 Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 18 air inlet cap item 8 and capscrews item 11 Connect the air supply to the pump The pump is now ready for operation ACTUATOR PLUNGER SERVICING 44 IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model 1120 0155 Page 16 CHECK VALVE SERVICING Before servicing the check va
5. 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 bc1020 015Sdl1sm rev0312 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 Distribution System 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 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 W
6. to sleeve Generously lubricate outside diameter of spool and o rings Then carefully insert spool into sleeve Take CAUTION when inserting spool not to shear any o rings Use BP LS EP 2 multipurpose grease or equivalent STEP 4 Re install the pilot valve assembly into the intermediate Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate Re install the gasket air inlet cap and capscrews Connect the air supply to the pump The pump is now ready for operation Model 1120 0155 Page 13 Diaphragm Service Drawing bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 14 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the dis charge 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 assembly drawing and the diaphragm servicing illustration Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the manifolds items 19 amp 20 to the outer chambers item 13 Step 2 Removing outer chambers Using a 1 2 wrench or socket remove the 16 capscrews item 11 that fasten the outer chambers item 13 diaphragms item 14 and intermediate item 5 together Step 3 Removing the dia phragms and diaphragm plat
7. NG EXHAUST AIR IN SUBMERGED APPLICATIONS BOTTOM VIEW DISCHARGE PORT 1 NPT 301 SUCTION PORT 1 SIDE VIEW 64 Model 1120 015S Page 5 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 chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating 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 pres
8. SERVICE BULLETIN SB1113 Original Instructions Balerank bc1020 015Sdl1sm rev0312 Model 1120 015S Table of Contents Engineering Data and Temperature Limitations 1 Air Distribution Valve Servicing mes 12 Explanation of Pump Nomenclature seen 2 Pilot Valve Servicing Assembly Drawing amp Parts 13 Performance Curve ULA NANA ee Here RA LANANG NAAN 3 Diaphragm Service Drawing 14 Dimensions Lc 4 Diaphragm Servicing circiter tr ie cee ter ANA ANA 15 Metric Dimensions noie LAN eee en e e E TUE AR 5 Overlay Diaphragm Servicing ssssssssssssseneeeeeeneennenmernn 15 Principle of Pump Operation ccccccecesecceceeeeeeeeeececeeeeaeceeeeseaeeeeeeseeseeeeeeeeeeees 6 Actuator Plunger 16 Installation and Start Up oiii enne eene ende rere Dac 6 Check Valve Servicing 2 2 eiecit sede ee nep RAANG 17 6 Check Valve Drawing 2 2 AA GANA 17 Air Valve Lubrication ann 6 Muffler Drawing and Provision for Piping Air 18 PASE cm 6 Pumping Hazardous Liquids
9. ST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 MUFFLER 2598 1 DIAMETER AIR EXHAUST PIPING Ft P MUFFLER LIQUID LEVEL SUCTION LINE Illustration 3 1 DIAMETER AIR EXHAUST PIPING Model 1120 0155 Page 18 Grounding The Pump One eyelet is fastened to the pump hardware One eyelet is installed to a true earth ground Requires a 5 16 or 8mm maximum diameter bolt This 8 foot long 244 centimeters Ground Strap Item 32 is shipped with the eyelet end fastened to the pump hardware To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required or in the absence of local codes an industry or nationally recognized code having jurisdiction over specific installations and installation codes A WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves con tainers or other miscellaneous equipment must be grounded bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 19 For Warranty Information Visit www balcrank com Balcrank Corporation Distributed b
10. 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 bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 2 Performance Curve Performance based on the following elastomer fitted pump flooded suction water at ambient conditions 2 o The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 an a SCFM M3 hr 7 6 5 a i z 9 1 2 7 6 6 1 4 5 3 1 5 0 0 25 30 35 40 45 50 2 U S Gallons per minute GAT Kb GC Gid 0 20 40 60 80 100 120 140 160 180 Liters per minute CAPACITY bc1020 015Sdl1sm rev0312 Model 1120 0155 Page Dimensions Dimensions in Inches Dimensional Tolerance s 10 1 4 k5 1 8 5 16 Al 7 8 b4 1 8 8 1 4 FRONT VIEW AIR INLET 1 2 NPT bc1020 015Sdl1sm rev0312 12 23 32 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS BOTTOM VIEW DISCHARGE PORT 1 NPT 11 27 32 1 SIDE VIEW 2 1 2 Model 1120 0155 Page 4 Metric Dimensions Dimensions in Millimeters Dimensional Tolerance 3mm QO ja kal AIR INLET 1 2 bc1020 015Sdl1sm rev0312 FRONT VIEW 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPI
11. e 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 WARNING products to ensure public Do not use this pump with potable water safety or fluids for human consumption Wear ear and eye protection bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 9 Composite Repair Parts List Composite Repair Parts Drawing ITEM DESCRIPTION QTY 1 Air Valve Assembly Ball Check Nitrile 3 Bushing 4 Pilot Valve Assembly 5 Intermediate 6 Bumper 7 8 9 ATTACH EYELET TO ONE OF THE FOUR CAPSCREWS ITEM 11 Bushing Cap Air Inlet Assembly Capscrew Hex Hd 5 16 18 X 1 00 10 Capscrew Hex Hd 5 16 18 X 1 25 11 Capscrew Hex Hd 5 16 18 X 1 75 12 Capscrew Hex Hd 3 8 16 X 1 00 13 Chamber Outer 14 Diaphragm Nitrile 16 Gasket Air Valve 17 Gasket Pilot Valve 18 Gasket Air Inlet 19 Manifold Suction 20 Manifold Discharge 21 O Ring 23 Plate Inner Diaphragm 24 Plate Outer Diaphragm Assembly 25 Pin Actuator 26 Ring Retaining 27 Rod Diaphragm 28 Seal U Cup 29 Seat Check Ball PTFE 30 Lockwasher 31 Flatwasher 32 Ground Strap 33 Metal Muffler gt gt Air End Kit 832973 Seals O Rings Gaskets Retaining Rings Air Valve Assembly and Pilot Valve Assembly Wet End Kit 832974 Nitrile Diaphragms Nitrile Check Balls and PTFE Check
12. e and ozone chlorinated hydrocarbons and nitro hydrocarbons Neoprene All purpose Resistant to vegetable oil Generally not affected by moderate chemicals fats greases and many oils and solvents Generally attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocarbons Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures Polypropylene Polyethylene These pumps are designed to be powered only by compressed air Balcrank Model 1120 0155 Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA HEADS UP TO DISPLACEMENT STROKE 100 psi or 230 7 ft of water 11 Gallon 42 liter 7 Kg cm or 70 meters Operating Temperatures Maximum Minimum 190 F 10 F 88 C 23 C 170 F 10 F 77 C 23 C 212 F 35 F 100 C 37 C 150 F 40 F 65 C 40 C 180 F 40 F 82 C 40 C bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 1 Explanation of Pump Nomenclature Model 1120 0155 is UL79 listed for pumping Diesel Fuel No 4 Fuel Oils or lighter Motor Oil Kerosene Aviation Fuel and Water AWARNING In the event of diaphragm rupture pumped material may enter the
13. e joints tight Hn LT DISCHARGE Pump shall be installed in accordance to Flammable bell U E and Combustible Liquids Code NFPA 30 or the Automotive N and Marine Service Station Code NFPA 30A as appropriate Ban Bos to the intended use of the pump Flexible A CAUTION 5 The air exhaust should be Connection Air Shut Off piped to an area for safe Pipe Connection Valve disposition of the product Style Optional TOP being pumped in the event Air Exhaust T Air Dryer of a diaphragm failure DISCHARGE DIAPHRAGM Shut Off PUMP Valve AWARNING AIR INLET T intai ductivity 1 D T rone painted use a conductive SUCTION Imo NT Connection O paint or coating HHI i Drain Port The pump must be rigidly mounted with fasteners to a conductive base or natural ground bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 7 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory Pump cycle seems unbalanced Pump cycle seems to produce excessive vibration What to Check 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
14. es Use a 7 8 wrench or six point socket to remove the outer diaphragm plate assemblies item 24 diaphragms item 14 and inner diaphragm plates item 23 from the diaphragm rod item 28 by turning counterclockwise In spect the diaphragm for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEALS bc1020 015Sdl1sm rev0312 Step 4 Assembling the diaphragm and diaphragm plates to the diaphragm rod Push the threaded stud of one outer diaphragm plate assembly through the center of one diaphragm and through one inner diaphragm plate Install the diaphragm with the natural bulge facing away from the diaphragm rod and make sure the radius on the inner diaphragm plate is towards the diaphragm as indicated on the diaphragm servicing illustration Thread the assembly onto the diaphragm rod leaving loose Step 5 Installing the diaphragm and rod assembly to the pump Make sure the bumper item 6 is installed over the diaphragm rod Insert rod into pump On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the second bumper is installed over the diaphragm rod Push the threaded stud of the other outer diaphragm plate assembly through the center of the other diaphragm and through the other inner diaphragm plate Make sure the radius on the inner diaphragm plate
15. et creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual 44 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 AWARNING In the event of diaphragm rupture pumped material AWARNING 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 44 WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the 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 AWARNING Airborne particles and loud noise hazards Underwriters Laboratories C US Inc an Internationally LISTED recognized independent organization for testin 1TA3 3 2 may enter the air end of th
16. hat 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 ofthe pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both pumping chambers Corrective Action Pu
17. he air supply line is solid piping use a short length of flexible conductive hose not less than 1 2 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 Failure to 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 AIR VALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the preferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication ofthe 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 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 supplement the user s air drying equipment This device removes wa
18. 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 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 Remove the muffler item 21 The air distribution valve item 1 has 1 NPT threads for piped exhaust bc1020 015Sdl1sm rev0312 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded threads of the 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 conductive and physically supported Failure to support these connections could also result in damage to the air distribution valve body Air Valve Assembly The pump comes equipped with a standard metal muffler CONVERTED EXHAU
19. is towards the diaphragm Thread the assembly onto the diaphragm rod Use a 7 8 wrench or socket to hold one outer diaphragm plate Then use a torque wrench to tighten the other outer diaphragm plate to the diaphragm rod to 350 in Ibs 39 5 Newton meters Align one diaphragm with the intermediate and install the outer chamber to the pump using the 8 capscrews Tighten the opposite diaphragm plate until the holes in the diaphragm align with the holes in the intermediate Then install the other outer chamber using the 8 capscrews Step 6 Reinstall the manifolds to the pump using the 16 capscrews The pump is now ready to be reinstalled connected and returned to operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model 1120 0155 Page 15 ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 1 2 wrench or socket remove the four capscrews items 11 Remove the air inlet cap item 8 and air inlet gasket item 18 The pilot valve assembly item 4 can now be removed Step 2 Inspect the actuator
20. lve components 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 check valve components remove the manifold item 20 or item 19 not shown Use a 1 2 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 30 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled bc1020 015Sdl1sm rev0312 Check Valve Drawing Model 1120 0155 Page 17 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
21. rge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact your 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 factory Technical Services Group for a service evaluation Model 1120 0155 Page 8 IMPORTANT SAFETY INFORMATION RECYCLING Many components of Balcrank Metallic AODD pumps are made of recyclable materials We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are 44 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 44 IMPORTANT Read these safety warnings thoroughly flushed 44 WARNING Do not smoke near the pump or use the pump near an open flame Fire or explosion could result 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 CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gask
22. spect the inner diameter of the Sleeve part of item 1 A for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings item 1 D and fasten with four hex capscrews items 1 F to the valve body items 1 A Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 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 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 rings and fasten with the remaining hex capscrews Fasten the air valve assembly item 1 and gasket item 16 to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up Itis 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
23. sure 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 chambers is bc1020 015Sdl1sm rev0312 reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the 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 product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible conductive hose should be installed between the pump and the piping The flexible conductive hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When t
24. ter from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 1 2 to 3 4 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 BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model 1120 0155 Page 6 INSTALLATION GUIDE Top Discharge Ball Valve Pump Air Inlet Air Exhaust Surge Suppressor Pipe Connection Limited to le Optional 125 psi Style Optional A CAUTION il Flexible Shut Off Valve Use a gasoline resistant pipe Connection aS compound to make pip
25. y 115 Reems Creek Road Weaverville NC 28787 800 747 5300 800 763 0840 Fax www balcrank com SERVICE BULLETIN SB1113 Revised 11 11 bc1020 015Sdl1sm rev0312 Model 1120 0155 Page 20
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