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Operating Instructions OIl-free, aIr Operated dOUBle dIapHraGM

1. 25 3 6 4 Maintenance On Air ValVenion riada 26 3 6 5 Dual manifold capability non metallic pumps only sns 26 3 7 Maintenance Model 1 Bolted Version sss tnn 27 3 7 1 Maintenance of Check Valve and O Ring essent tnnnnnns 27 3 7 2 Maintenance of Diaphragm and Pilot Sleeve 5 2 22 2222 27 3 7 3 External fastener torque requirements erret rrr inr reris 28 31 4 Maintenance ot AIF ValV6 screen rto ais 28 3 8 Maintenance Model 1 1 2 and 2 Band Clamp 29 3 8 1 Maintenance of Check Valve and O Ring sess 29 3 8 2 Maintenance of Diaphragm and Pilot Sleeve Assembly sss 29 3 8 3 External fastener torque requirements ainia 30 3 84 Maintenance Ot Air Vale ros etienne Yea Hee Y HERR HY Har ER HL 31 3 9 Maintenance Model 1 1 2 and 2 Bolted Version 32 3 9 1 Maintenance of Check Valve and O Ring E 3 9 2 Maintenance of Diaphragm and Pilot Sleeve Assembly sss 32 3 9 3 External fastener torque requirements essent tnter 33 3 9 4 Maintenance of Air Valve E 3 10 Maintenance Model 3 Bolted Version nnne 35 3 10 1 Maintenance of Check Valve and 0
2. 35 3 10 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 3 10 3 External fastener torque requirements 96 3 10 4 Maintenance of Air Valve 2 37 4 D LM 37 5 Dimensions 51 Moda Eee e t tee ei e m ten eril eate Re ire 38 5 2 Modeli3 8 Band Clamp VerSIOTI seccion teo eet nier ecce he see 39 5 3 Model 1 2 Band Clamp Version 40 5 4 Model 1 2 Bolted Version 241 5 5 Model 1 Band Clamp Version 42 5 6 Model 1 Bolted Version 43 5 7 Model 1 1 2 Band Clamp Version 44 5 8 Model 11 2 Bolted Versiot ia 45 5 9 Model 2 Band Clamp Version i coe cct ier t ie retenti 46 5 10 Model 2 Bolted Version d 5 11 Model 3 Bolted Version 6 Performance curves 6 Model Ain ia n eue Re ts 6 2 Model 3 8 Band Clamp Version sd 6 3 Model 1 2 Band Clamp VES icon a ete nere 6 4 Model 1 2 Bolted Version eiecit itr tice as 6 5 Model 1 Band Clamp Version is 6 6 Model 1 Bolted ct a 6 7 Model 1 1 2 Band Clamp Version 6 8 Model 1 1 2 Bolted Version 6 9 Model 2 Band Clamp Version E 6 10 Mod l 2 BOMBON a 6 11 Model 3 Bolted Version 2 tette te tette decere aiid eat ec etie e 7 Trouble shooting ER D claration ORCOS cebat
3. Air a Outlet w 127 gt 152 4 Approximate Dimensions with Muffler 378 Front View Side View Metallic pumps 495 gt 302 gt Air lt Outlet 324 pa 127 gt 152 4 Front View Side View Dimensions in mm 46 5 10 Model 2 Bolted Version Non metallic pumps lt _ 522 7 Outlet Air Outlet 349 3 Front View Side View Dimensions in mm Metallic pumps Front View Side View Dimensions in mm A B C D E F G J K L M Aluminium 495 665 619 8 338 3 40 4 259 1 304 8 309 9 127 1524 337 1 Stainless steel 495 595 9 561 3 3543 89 304 351 5 309 9 127 1524 358 1 47 5 11 Model 3 Bolted Version Metallic pumps lt 645 2 gt lt 416 with muffler 819 Inlet Outlet y 761 408 le 258 365 2 4 Slots Dia 15 7 284 gt Front View Side View Dimensions in mm 48 6 Performance Curves 6 1 Model 1 4 Working pressure required p bar gt e 3 0 1 5 H m wc Characteristic curve 75 Air consumption in Nm3 h 60 s 45 30 15 0 0 5 10 15 20 Measured v
4. Air consumption in Nm h 80 7 Working pressure required p bar 4 40 4 2 20 0 0 t j 0 200 400 600 800 Measured values 10 determined with water at 20 C and suction lift 0 Q Umin 53 6 11 Model 3 Bolted Version m wc Characteristic curve 10 100 Air consumption in Nm3 h Working pressure required p bar oo 4 2 0 0 200 400 600 800 1000 Measured values 10 determined with water at 20 C and suction lift O Q Umin 54 7 Trouble shooting Air is applied to pump but pump is not starting 1 Clean filters and debris from all fluid lines 2 Make sure all valves on fluid lines are open 3 Inspect diaphragms for rupture 4 Air pressure must not be below 1 4 bar Pump is pumping but not priming 1 Check all suction line connections for leakage 2 Inspect check valves for wear or debris 3 Suction lift specifications may be exceeded 4 If fluid is viscous use larger suction lines Leakage 1 Retorque all fasteners to specified torque requirements 2 Replace o rings 3 Inspect diaphragms for rupture Low Flow rate 1 Confirm air pressure and air capacity at the air valve as required 2 Check for leaks in suction line or obstructions in lines 3 If fluid is viscous use larger suction lines Air in discharge lines 1 Check for leaks in suction lines 2 Ins
5. 47 are separated by o rings 46 Next carefully insert the diaphragm rod assembly 13 15 with pilot sleeve 45 inside the assembly in the bore Reattach retaining plates 49 Do not overtighten self tapping screws 38 Assemble diaphragm 31 and optional Teflon overlay 30 and inner diaphragmm plate 33 onto outer dia phragm plate stud 29 Then screw assembly into diaphragm rod Push diaphragm rod to opposite side of in termediate and add the opposite diaphragm assembly Tighten the outer diaphragm plates to 18 Nm of torque Assemble the outer chamber 28 and band clamps 16 first on the side where the diaphragm is fitted on the intermediate Lightly tighten fasteners at band clamp Push opposite diaphragm towards intermediate and fix second outer chamber When positioning outer diaphragm chambers onto intermediate make sure that witness lines are matching Caution If air valve has been removed proper orientation of air system with fluid chambers must be observed The top of the intermediate has a single vertical air passage slot on the air valve mounting face while the outer chamber check ball cavity should be pointing downward When positioning band clamps use soapy water or a compatible lubricating spray on the inside of band clamps to aid assembly Tap with a mallet on the outside of clamp to help position the clamp while tightening the fasten ers The band clamp fasteners are stainless steel To prevent galling alwa
6. 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the air valve point the bottom of the air valve safely away from people direct compressed air through one of the lower holes in the back of the air valve body and the plug will shoot out Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replacement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly Reinsert air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 If using original valve plate 5 lubricate side of plate that was facing the shuttle 6 or if new valve plate is used lubricate the lapped and polished side of plate and place the lubricated side next to the shuttle in the slot Press the valve plug 1 into air valve body chamfered end first 11 Check that gasket 4 is not cracked If damaged replace 12 After gasket
7. C 93 C 93 C 93 C Maximum air pressure PVDF models 8 0 bar 8 0 bar 8 2 bar 8 2 bar Other models 6 8 bar 8 0 bar 8 0 bar 8 2 bar 8 2 bar 8 5 bar Minimum air pressure 1 2 bar 1 2 bar 1 3 bar 1 3 bar 1 3 bar Dry lift capacity at 6 8 bar 8 0 bar 8 0 bar 8 2 bar 8 2 bar 6 8 bar Models with Teflon balls 50m 3 0m 30m 30m 3 0m 30m Other models 50m 45m 45m 45m 45m 45m Weight PVDF models 3 2 kg 5 4 kg 13 7 kg 29 5 kg 31 kg Other non metallic models 2 8 kg 4 1 kg 9 1 kg 21 kg 22 kg Stainless steel 8 6 kg 20 4 kg 60 kg 60 kg Aluminium 4 5 kg 10 5 kg 27 kg 28 kg 59 kg Maximum solids Max Pass valves Others 1 6 mm 3 1 mm 6 4 mm 6 4 mm 6 4 mm 11 1 mm Air supply Inlet 1 4 NPT female 1 4 NPT female 1 4 NPT female 3 4 NPT female 3 4 NPT female 3 4 NPT female Outlet 1 4 NPT female 3 8 NPT female 3 8 NPT female 3 4 NPT female 3 4 NPT female 3 4 NPT female Fluid inlet discharge Non metallic 1 4 BSP female 1 2 BSP female 1 1 1 2 2 DIN ANSI 3 BSP female models DIN ANSI DIN ANSI Flange Flange Flange Metallic dto dto 1 BSP female dto 2 BSP female dto models Model 3 8 1 2 1 11 2 2 Band clamp Band clamp Band clamp Band clamp Band clamp Version Version Version Version Version Capacity Adjustable Adjustable Adjustable Adjustable Adjustable 0 34 l
8. min 0 53 l min 0 152 l min 0 360 l min 0 569 l min Maximum temperature PVDF models 93 C 93 C 93 C 93 C 93 C PP models 66 C 66 C 66 C 66 C 66 C Metallic models 93 C 93 C 93 C 93 C Maximum air pressure PVDF models 8 2 bar 4 8 bar 4 8 bar 4 8 bar Other models 8 2 bar 6 8 bar 6 8 bar 6 8 bar 6 8 bar Minimum air pressure 1 3 bar 1 3 bar 1 3 bar 1 3 bar 1 3 bar Dry lift capacity at 8 2 bar 6 8 bar 6 8 bar 6 8 bar 6 8 bar Models with Teflon balls 3 0m 3 0m 3 0m 3 0m 30m Other models 52m 45m 45m 45m 45m Weight PVDF models 2 3 kg 4 9 kg 9 9 kg 30 kg 30 kg Other Non metallic models 1 7 kg 3 6 kg 8 6 kg 24 kg 24 kg Stainless steel 7 2 0 19 1 kg 51 kg 59 kg Aluminium 3 8 kg 8 6 kg 28 kg 28 kg Maximum solids Max Pass valves 6 4 mm Others 3 2mm 3 1 mm 6 4 mm 6 4 mm 6 4 mm Air supply Inlet 1 4 NPT female 1 4 NPT female 1 4 NPT female 3 4 NPT female 3 4 NPT female Outlet 3 8 NPT female 3 8 NPT female 3 8 NPT female 3 4 NPT female 3 4 NPT female Fluid inlet discharge Non metallic models 3 8 BSP female 1 2 BSP female 1 BSP female 1 1 2 3 4 BSP male DIN ANSI DIN ANSI Flange Flange Metallic models dto dto dto dto 1 3 2 Operation in hazardous location or pumping flammable liquids Pump may only be used at atmospheric conditions of 0 8 bar up to 1 1 bar normal air moisture conditions and within a tempera
9. possible to close the suction line by means of e g a ball valve Running out of the container can be effectively avoided in case a damage occurs at the piping system or at the pump Danger Do not clean or service pump hoses or dispensing valves when the system is pressurized serious injury may result Disconnect air supply line and relieve pressure from the system prior to disassembly Warning Maximum temperatures are based on mechanical stress only Certain chemicals will significantly reduce maximum safe operating temperature Consult engineering guides for chemical compatibility and temperature limits Always use minimum air pressure when pumping at elevated temperatures Warning Excessive air pressure can cause pump damage personal injury or property damage Warning Excessive positive suction pressure can cause pump damage The maximum positive suction pressure must not exceed 0 6 bar Warning Pump must be reassembled properly after maintenance Caution Do not use the pump for the structural support of the piping system Be certain the system components are supported to prevent stress on the pump parts The pump must be installed free of tension Flexible connections will avoid damage to piping due to vibration Caution The characteristic feature of double diaphragm pumps is a pulsating volume flow For reduction use a pulsation dampener if necessary In addition please note for model 1 4 Caution Foll
10. service also Remove the nuts 24 and washers 25 from the four long pumping cap screws 35 Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat and manifold o rings 22 Replace if necessary Discharge check valves are located inside of the bottom of the discharge elbows 21 metallic 32 non metallic Non metallic pumps only To inspect the manifold o rings 22 remove the band clamps 20 on either side of the manifold 21 evaluate and replace if necessary Then reassemble the manifold assemblies Lightly tighten fasteners Align the single parts of the complete pump and tighten the screws in turn with the admissible torque requirement The check ball should fit into the curved portion of the valve seat and be facing upward when rein serted into the valve seat location Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump PVDF pumps need additional gaskets 34 These gaskets are adhesive backed Remove paper backing and apply to upper surface of valve seats as shown 3 6 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 24 To inspect diaphragms remove the band clamps 16 from the outer pumping chambers 28 If replacement is necessary due to abrasion or rupture unscrew the
11. sint airo cea ning nis Notice the operating instructions figures are mentioned in brackets These refer to the item specifications in the spare parts list of the respective model The single steps in the operating instructions refer to the non metallic and metallic version If the item number of the operating instructions is not included in the spare parts list the instruction must not be considered for this pump version 1 Safety 1 1 Danger associated with this machine The air operated double diaphragm pumps are tested prior to delivery In case of maloperation or improper use there is danger for life and health of the user the pump and other material assets of the user the efficiency of the machine All persons who are dealing with the installation assembly starting operation servicing and maintenance of the machine have to be accordingly qualified to exactly follow these operating instructions It is your safety 1 2 Safety information and tips In these operating instructions the following explanations are used Danger Refers to a direct danger Non observance of the precaution will cause death or extremely serious injury Warning Defines a possibly dangerous situation Non observance of the precaution can cause death or extremely serious injury AN Caution Defines a possibly harmful situation The product or something in its environment may be damaged if this instruction is not observed 1
12. the shuttle in the slot Press the valve plug 1 into air valve body chamfered end first 13 Check the gaskets 3 4 are not cracked If damaged replace 14 After gaskets 3 4 are pressed back into position align air valve onto intermedaite and reinsert the four cap screws 11 with lock washer 25 and flat washers 10 Apply 7 Nm of torque to fasteners Caution 1 2 double diaphragm pumps non metallic models only are supplied in addition with a dual manifold capability This makes it possible to pump two different fluids at the same time but seperately Manifold dual suction port and single discharge port enable the pump to mix two different fluids 20 Maintenance Model 1 2 Bolted Version 3 5 Maintenance Model 1 2 Bolted Version 3 5 1 Maintenance of Check Valve and O Ring jn 2 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory service also Remove nuts 18 from bolts 16 in both the discharge and suctions manifolds Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat and manifold o rings 19 38 Replace if necessary Discharge check valves are located inside of the bottom of the discharge elbows 32 When re assem
13. turn with the admissible torque requirement The check ball should fit into the curved portion of the valve seat and be facing upward when reinserted into the valve seat location Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 4 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 To inspect diaphragms remove the band clamps 16 from the outer pumping chambers 28 If replacement is necessary due to abrasion or rupture unscrew the outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump When changing diaphragms it is recommended to replace always both Pumps without PTFE will contain only the back up diaphragms 31 5 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the com plete air system should be inspected After removing diaphragms and inner diaphragm plate 33 the pilot sleeve assembly 14 40 42 45 47 and diaphragm rod assembly 13 15 may be removed by removing the retaining plates 41 and push the entire unit out through the bore in the intermediate 34 Diaphragm rod assembly must be unscrewed to remove pilot sleeve Caution To aid in reassembly use a non synthetic petroleum based lubricating grease without EP additives 18 Maintena
14. 10 Notice Re torque fasteners prior to use See respective chapter in this maintenance manual Danger Danger of fire and explosion due to inflammable compressed gases within the air supply system Combustion hazard Blast wave Flying parts can kill you Do not operate the pump with compressed flammable gases 1 Alube free clean dry compressed air source is recommended Use a filter that is capable of filtering out par ticles larger than 50 microns 2 All pumps should be mounted in an upright position 3 When particles exceed the maximum particle specification of the pump or are sharp enough to cut elastomers install a particle fluid filter on the fluid suction line 4 Fluid suction lines and air exhaust lines should never be smaller than the specified pipe size of pump 5 Apply Teflon tape to threads upon assembly to prevent leakage 6 Never use pipe dope on air line connections 7 Never use collapsible tube on fluid inlet 8 Do not exceed 14 Nm of torque on plastic pipe threads 9 For installation with connection flanges tighten fasteners to 25 Nm of torque 10 If changing to a different application reconfirm compatibility of fluid 2 1 Submerged Applications 1 Fluid must be compatible with fasteners and with intermediate material 2 Pipe exhaust above the level of the fluid 2 2 High Viscosity Applications 1 Position the pump close to or below the level of the fluid source 2 Suction lines should be incre
15. 12 When re assembling the max pass pump the sleeve 15 should be assembled into the valve cavity first fol lowed by the max pass valve 13 the valve back up 14 and finally the o ring 12 For pumps with ball valves the cage 27 should be assembled into the valve cavity first followed by the ball 29 valve seat 28 and finally the o ring 12 Lightly tighten all external fasteners when assembling torquing them to their requirements after pump is com pletely assembled Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 3 2 Maintenance of Diaphragms 4 To inspect diaphragms remove the nuts 7 from the carriage bolts 8 on the band clamps 6 surrounding the outer pump chambers 16 If replacement is necessary due to abrasion or rupture unscrew the outer diaphragm plates 17 Only models that have PTFE elastomers will have both a PTFE overlay 18 that faces the outer pump chamber and an o ring 25 on the air side of pump Note Pumps that do not contain PTFE will not have o ring 25 they are built with diaphragms 19 only To inspect the diaphragm rod s lip seals 26 remove diaphragm rod 5 Before remove the air valve assembly 2 by unscrewing the screws 9 Replace if necessary Be sure to reinsert the lip seals with open cup facing the inside of the pump Make sure that the rod guide is facing the air valve assem
16. 13 3 2 3 Maintenance of Air Valve and Diaphram 13 3 3 Maintenance Model 3 8 Band Clamp Version 3 3 1 Maintenance of Max Pass or check valve 15 3 3 2 Maintenance of DIaphIragimis eiii 3 3 3 Air Valve Assembly Inspection 3 3 4 Fastener Torque Requirements 3 4 Maintenance Model 1 2 Band Clamp Version ooooooconicncnoncccnococncncncncncncocnconononononorocnnnrnnnrncncnnncnnn 3 4 1 Maintenance of Check Valve and O Ring sess 3 42 Maintenance of Diaphragm and Pilot Sleeve Assembly 3 4 3 External fastener torque requirements sess 3 4 4 Maintenance OT Al prete rri prede rer rrr pre i ge Hee 3 5 Maintenance Model 1 2 Bolted Version 3 5 1 Maintenance of Check Valve and O Ring 3 5 2 Maintenance of Diaphragm and Pilot Sleeve Assembly sss 3 5 9 External fastener torque requirermieitts encre retenir reor 22 RERO MM IEEE ROT ARCET PTS 23 3 6 Maintenance Model 1 Band Clamp Version 24 3 6 1 Maintenance of Check Valve and O Ring sess 24 3 6 2 Maintenance of Diaphragm and Pilot Sleeve Assembly sss 24 3 6 3 External fastener torque requirement
17. 3 Proper use The air operated double diaphragm pumps are suitable for pumping pure turbid flammable and non flammable aggressive and non aggressive liquids Following regulations however must be observed Please note the following chapters No liability whatsoever can be assumed for failure of the pump or parts of the pump for personal injury or other claims if the pump is used for other purposes For safety reasons the pump must not be converted or modified in any way without authorization Model 1 4 Pump has wear parts in the air flow system A continuous operation therefore is limited Danger Dangerous liquids can damage your health and the environment When handling dangerous or toxic liquids you have to waer goggles and protective clothing Before starting the pump check that the medium being pumped is compatible Changes of temperature concentrations or combinations of chemicals may vary resistance of material Always consult Material Safety Data Sheets and Engineering Resistance Tables for chemical compatibility If a diaphragm ruptures the pumped liquid can enter the air side of the pump and exit through the air exhaust muffler If a diaphragm rupture occurs immediately stop the pump close suction and discharge lines and have pump repaired When the fluid source is at a higher level than the pump flooded suction the exhaust should be piped to a higher level than the fluid source After operation of pump it should be
18. 4 is pressed back into position align air valve onto intermediate and reinsert the six cap screws 34 11 with lock washer 10 and flat washers 8 Apply 4 5 Nm of torque to fasteners Maintenance Model 3 Bolted Version 3 10 Maintenance Model 3 Bolted Version 3 10 1 Maintenance of Check Valve and O Ring 1 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory service also 2 Remove the suction and discharge manifolds fasteners 18 The check valve seats 26 and check balls 27 are located inside the bottom of the outer chamber 28 or inside the discharge manifold 22 Remove the seat and balls and inspect for excessive wear pitting or other signs of degradation On models using nylon check valve seats 25 and o rings 24 check the seats balls for excessive wear pitting or other signs of degradation Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 10 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 3 To inspect the diaphragms remove the eight fasteners 33 from the outer chamber If replacement is necessary due to abrasion or rupture remove the outer diaphragm plates 52 by turning counter clockwise Models that are built with PTFE elastomers will have a PTFE overlay 30 that fac
19. Bolted Version H m wc Characteristic curve e o 100 hir consumption in NmS h e o Working pressure required p bar 4 0 2 0 0 40 80 120 160 Measured values 10 determined with water at 20 C and suction lift 0 Q I min 51 6 7 Model 1 1 2 Band Clamp Version m wc Characteristic curve 7 5 75 Air consumption in Nm3 h 6 0 60 4 5 45 Working pressure required p bar 3 0 30 1 5 15 0 0 0 100 200 300 400 Measured values 10 determined with water at 20 C and suction lift 0 Q l min 6 8 Model 1 1 2 Bolted Version H m wc Characteristic curve 10 100 Air consumption Nm h Working pressure required p bar 4 2 t 0 0 100 200 300 400 500 Measured values 10 determined with water at 20 C and suction lift O Q l min 52 6 9 Model 2 Band Clamp Version m wc Characteristic curve 7 5 75 Air consumption in Nmi h gt on 45 Working pressure required p bar 3 0 30 j 0 150 300 450 600 Measured values 10 determined with water at 20 C and suction lift 0 Q l min 6 10 Model 2 Bolted Version m wc Characteristic curve 10 100
20. Operating Instructions OIL FREE AIR OPERATED DOUBLE DIAPHRAGM PUMPS in non metallic and metallic version Model 1 4 3 8 1 2 1 11 2 24 84 Read this operating instructions before start To be retained for future reference Lutz The Fluid Managers E CE at Table of Contents DI 1 1 Danger associated with this machine usd 1 2 Safety information and tips ueri cree ttt ens eee 1 9 1 351 Specifications eniin eec tette 1 3 2 Operation in hazardous location or pumping flammable liquids 1 3 2 1 Traceability 1 3 2 2 Year of construction 2 Installation 21 Submerged Applicat ONS 5er peccet erre eee 11 22 High VISCOSITY AppliCatiOrI8 x ecco neo rre 11 2 3 Low Temperature and UV EXDOSUEe cero erect sii 11 A 12 31 General Maififenarice icai etm tr tdi 12 3 2 Maintenance Model 1 4 2 2 e ra KEET 12 3 2 1 Maintenance of Check Valve Gasket and O Ring sss 12 3 22 Maintenance or s eoe rte vy EYE EY rev
21. View Metallic pumps 276 lt 203 gt with muffler 138 lt 1046 gt T Air 212 Inlet 198 6 132 Y 40 137 Front View Inlet 28 6 i x a 112 Side View Dimensions in mm 5 4 Model 1 2 Bolted Version Non metallic pumps lt 305 8 gt LA Inlet 3 to 257 bd s UM Ni k 1667 4 Slots Dia 8 0 Outlet Inlet va yl Approximate Dimensions with Muffler 187 2 Front View Side View Metallic pumps 187 2 276 138 Outlet 238 8 225 6 Air Inle 144 8 105 Air 4 Slots Dia 7 0 Front View Side View Outlet 7 133 5 l SE Approximate Dimensions with Muffler 187 2 Dimensions in mm 41 5 5 Model 1 Band Clamp Version Non metallic pumps 305 Outlet 276 2 with muffler gt Air gn Outlet 210 8 Front View Side View Metallic pumps 253 gt Front View 42 X 299 Inlet 322 181 Y a Y y Air Outlet Approximate Dimensions with Muffler 293 9 Side View Dimensions in mm 5 6 Model 1 Bolted Ver
22. a lt lt lt a lt lt Applicable EC Directive on machines 2006 42 E0 e eee e O EC Directives EC directives ATEX 94 9 EC e e e e e e Registered Epsilon Compliance Drury Lane number Drury Buckley CH7 3DU UK Epsilon 03ATEX1239 e hs Certification Ex 11 2 G c T4 Applicable EN 150 12100 1 harmonized EN 150 12100 2 standards EN 1127 EN 13463 1 13463 5 Person authorised to compile the technical file Mr Volker Fertig Lutz Pumpen GmbH ErlenstraBe 5 7 D 97877 Wertheim Wertheim 29 12 2009 J rgen Lutz Managing Director Lutz The Fluid Managers Luiz Pumpen GmbH ErlenstraBe 5 7 D 97877 Wertheim Phone 93 42 8 79 0 Fax 93 42 87 94 04 e mail infoOlutz pumpen de http www lutz pumpen de Subject to technical changes 07 10 Best Nr 5999 801 Printed in Germany Sch 1 000 08 10
23. air valve Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replacement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly 12 Reinsert air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 Lubricate side of plate 5 that faces the shuttle 6 and reposition valve plate over shuttle Press the valve plug 1 into air valve body chamfered end first 13 Check that gasket 4 is not cracked If damaged replace 14 After gasket 4 is pressed back into position align air valve onto intermediate and reinsert the four cap screws 11 with lock washer 25 and flat washers 10 Apply 4 5 Nm of torque to fasteners 23 Maintenance Model 1 Band Clamp Version 3 6 Maintenance Model 1 Band Clamp Version 3 6 1 Maintenance of Check Valve and O Ring 2 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory
24. air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 Lubricate side of plate 5 that faces the shuttle 6 and reposition valve plate over shuttle Press the valve plug 1 into air valve body chamfered end first 13 Check that gasket 4 is not cracked If damaged replace 14 After gasket 4 is pressed back into position align air valve onto intermediate and reinsert the four cap screws 11 with lock washer 25 and flat washers 10 Apply 4 5 Nm of torque to fasteners 28 Maintenance Model 1 1 2 and 2 Band Clamp Version 3 8 Maintenance Model 1 1 2 and 2 Band Clamp Version 3 8 1 Maintenance of Check Valve and O Ring 1 2a 2b Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any maintenance This procedure should always be followed when returning pumps for factory service also Non metallic pumps Remove the elbow to outer pumping chamber 28 band clamps 35 Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat and manifold o rings 24 Replace if necessary Discharge check valves are located inside of the bottom of the discharge elbows 32 Metallic pumps To inspect the check valves remove the nuts 17 from
25. als 40 is facing outward toward the diaphragms Also make sure that the end pilot spacers 14 are at the end on either side of the pilot sleeve assembly and all inner spacers 47 are separated by o rings 46 Next carefully insert the diaphragm rod assembly 13 15 with pilot sleeve 45 inside the assembly in the bore Reattach retaining plates 41 Do not over tighten self tapping screws 24 Take one diaphragm 31 with the curved side of the inner diaphragm plate 33 facing the diaphragm assemble onto outer diaphragm plate stud 29 and then screw assembly into diaphragm rod Push diaphragm rod to opposite side of intermediate and add the opposite diaphragm assembly Apply 18 5 Nm of torque to outer dia phragm plates When positioning outer diaphragm chambers onto intermediate make sure that witness lines are matching 27 Maintenance Model 1 Bolted Version Caution If air valve has been removed proper orientation of air system with fluid chambers must be observed The bottom of the intermediate has the smaller hook shaped air passage slot on the air valve mounting face and the outer chamber check ball cavity should be pointing downward 9 Replace all external fasteners and tighten to final torque requirement after pump is completely assembled 10 Position the manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the manifold o rings do not shift from their
26. alues 10 determined with water at 20 C and suction lift 0 Q l min 6 2 Model 3 8 Band Clamp Version Working pressure required p bar o m wc Characteristic curve 100 Air consumption in NmY h 80 7 60 E 40 20 0 0 10 20 30 40 Measured values 10 determined with water at 20 C and suction lift 0 Q l min 49 6 3 Model 1 2 Band Clamp Version wc 23 a 75 gt ul Working pressure required p bar D o 3 0 Characteristic curve Air consumption in NmY h Measured values 10 determined with water at 20 C and suction lift 0 1 1 15 30 45 60 Q l min 6 4 Model 1 2 Bolted Version 50 wc zd t 75 S t Working pressure required p bar 30 Characteristic curve lt Air consumption in Measured values 10 determined with water at 20 C and suction lift 0 Q I min 6 5 Model 1 Band Clamp Version wc Characteristic curve 7 5 75 Air consumption in Nm h 6 0 4 5 Working pressure required p bar 3 0 1 5 120 Measured values 10 determined with water at 20 C and suction lift 0 Q I min 6 6 Model 1
27. alve has been removed proper orientation of air system with fluid chambers must be observed The top of the intermediate has a single vertical air passage slot on the air valve mounting face while the outer chamber check ball cavity should be pointing downward 9 When positioning band clamps use soapy water or a compatible lubricating spray on the inside of band clamps to aid assembly Tap with a mallet on the outside of clamp to help position the clamp while tightening the fasten ers The band clamp fasteners are stainless steel To prevent galling always apply anti seize compound to the thread Tighten all external fasteners to final torque requirement after pump is completely assembled 10 Position the reassembled manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the valve seat o rings do not shift from their grooves during reassembly Flat washers should be placed under the head of each cap screw and nut Tighten all external fasteners to final torque requirement after pump is completely assembled 3 4 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Band clamps 18 Nm Manifold bolts and outer chamber cap screws 2 3 Nm Air valve cap screws 7 Nm 19 Maintenance Model 1 2 Band Clamp Version 3 4 4 Mai
28. always replace with new PTFE o rings since the original o rings may not reseal the pump 3 7 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 To inspect diaphragms remove nuts 18 and washers 12 9 from bolts 16 from the outer pumping chambers 28 If replacement is necessary due to abrasion or rupture unscrew the outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump Pumps without PTFE will contain only the back up dia phragms 31 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the com plete air system should be inspected After removing diaphragms and inner diaphragm plate 33 the pilot sleeve assembly 14 40 42 45 47 and diaphragm rod assembly 13 15 may be removed by removing the retaining plates 41 and push the entire unit out through the bore in the intermediate 34 Diaphragm rod assembly must be unscrewed to remove pilot sleeve Caution To aid in reassembly use a non synthetic petroleum based lubricating grease without EP additives Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 47 o rings 42 and lip seals 40 within bore of intermediate Make sure that the open side of the lip se
29. ard stop Shifting the mechanism past its operating position can cause the spring to pop free and many small components to come loose Use caution when shifting the mechanism manually When manually shifting the mechanism firmly hold the spring top shown to avoid the spring coming loose Caution Past this point the spring and mechanism parts will come free 10 If there has been a diaphragm rupture and fluid has entered the air side of the pump the complete air system should be inspected Remove the air valve assembly 2 by unscrewing the screws 9 Clean or replace the air valve assembly if there is excessive wear dirt build up or chemical attack Inspect for proper shifting of the spring mechanism by manually pushing the metal spring retainer from one side to the other 1 12 To reassemble the air valve first shift the spring mechanism to the side with the hard stop Next prop the spring retainer into a more neutral position by inserting a 3 mm hex key as shown between the hard stop and the spring retainer 13 With the rod guide 1 positioned such that the opened end is facing the air valve assembly opening slide the air valve assembly in place so that the forks slide into the rod guide Once the fork of the spring retainer is in the rod guide pull the hex key free and push the air valve assembly fully into place Finally reinsert and tighten the air valve assembly screws to the torqu
30. ased in size up to three times the size of the inlet manifold The use of dual manifolds may increase flow rate only possible with 1 2 models 3 Start the pump slowly using a valve on the air line 2 3 Low Temperature and UV Exposure 1 Polypropylene tends to embrittle at freezing temperature Pump must be insulated or heated otherwise use pumps with different materials of construction 2 If excessive icing occurs at the pump exhaust air source must be dried using mechanical means or through the introduction of ethyl alcohol in the air line note explosion protection 3 UV rays will damage polypropylene pumps Either shroud the pumps from UV rays or use pumps with UV sta bilized materials 11 Maintenance Model 1 4 3 Maintenance 3 1 General Maintenance a 2 3 4A Check periodically for product or air leakage Tighten any joint where leakage is occuring When pumping hazardous or toxic liquids diaphragms should be replaced at regularly scheduled intervals based upon pump usage When pumping highly abrasive fluids reduce discharge flow rate to prolong life of diaphragm valve balls valve seats etc or optionally use a larger pump which can be operated at a lower stroke frequency If you are pumping a fluid that will settle or compact the pump must be flushed before shut down In freezing temperatures the pump must be completely drained when idle 3 2 Maintenance Model 1 4 3 2 1 Maintenance of Che
31. bling the check ball should fit within the ball cavity of the chamber and discharge manifold Press fit the valve seats into position with the curved portion facing the ball Lightly tighten fasteners Tighten all external fasteners to final torque requirement after pump is completely assembled Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 5 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 6 To inspect diaphragms remove nuts 18 from bolts 16 from the outer pumping chambers 28 If replacement is necessary due to abrasion or rupture unscrew the outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump Pumps without PTFE will contain only the back up diaphragms 31 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the com plete air system should be inspected After removing diaphragms and inner diaphragm plate 33 the pilot sleeve assembly 14 40 42 45 47 and diaphragm rod assembly 13 15 may be removed by removing the retaining plates 41 and push the entire unit out through the bore in the intermediate 34 Diaphragm rod assembly must be unscrewed to remove pilot sleeve Caution To aid in reassembly use a non synthetic petrol
32. bly and slide the diaphragm rod back into the intermediate Take one diaphragm and with the curved side of the inner diaphragm plate facing the diaphragm assemble onto the outer diaphragm plate stud 17 Screw the assembly into the end of the diaphragm rod Repeat for the other side Tighten the outer diaphragm plates to 4 5 Nm of torque Position outer diaphragm chambers onto the intermediate making sure that the witness line of the intermediate matches with the parting line of the chamber When positioning band clamps use soapy water or a compatible lubricating spray on the inside of band clamps to aid assembly Tap with a mallet on the outside of clamp to help position the clamp while tightening the fasteners The band clamp fasteners are stainless steel To prevent galling always apply anti seize compound to the thread Tighten all external fasteners to final torque requirement after pump is completely assembled Position the reassembled manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the valve seat o rings do not shift from their grooves during reassembly Flat washers should be placed under the head of each cap screw and nut Tighten all external fasteners to final torque requirement after pump is completely assembled 15 Maintenance Model 3 8 Band Clamp Version 3 3 3 Air Valve Assembly Inspection Caution Only one side of the mechanism has a h
33. ck Valve Gasket and O Ring f 2 3 4 5 12 Flush the pump to be certain all corrosive or hazardous materials are removed Remove suction discharge and air supply lines Remove the nuts 28 and slide the six cap screws 27 that hold the pump together out of the pump Remove the eight screws 5 and two screws 5A from the left and right manifold plates 1 19 and inspect the gaskets 2 The suction or lower check valves are an integral part of the left and right chambers and should not be dis mantled If replacement of the valve seats is necessary items 6 and 18 which contain the valves must be replaced The upper discharge valve disks 3 are not sealed into the chambers and may be inspected for wear Caution Due to the distortion of gaskets under pressure gaskets may need to be replaced after pump has been disas sembled to assure a positive seal To inspect manifold tube o rings 17 remove right chamber 18 Both diaphragms 9 can be inspected after removing the right and left chamber 6 18 If diaphragms appear worn or ruptured go to step 7 If diaphragms do not need replacing proceed with steps 5 and 6 To reassemble Insert the discharge valve disks 3 into place Press gaskets 2 into groove in chambers 6 18 6 Align left and right manifolds 1 19 on the bosses of the chambers 6 18 Secure to each chamber with the eight screws 5 and two screws 5A Slide left chamber tubes 6 through inte
34. e and reinstall the shuttle valve 6 and valve plate 5 Place the gasket 4 with the words This side up facing the valve plate Reas semble to the intermediate using cap screws 11 and washers 8 10 Flat washers should be touching the plastic air valve body Tighten the screws to 4 5 Nm 4 Repairs Repairs should only be made by the manufacturer or authorized Lutz dealers Only use genuine Lutz spare parts Before sending back the appliance following must be observed Residuals in the appliance can cause danger to the environment and human health The appliance must be completely emptied rinsed and cleaned Please advise which liquid has been pumped A respective safety data sheet must be attached to the return consignment 37 5 Dimensions 5 1 Model 1 4 95 25 4 Air Outlet Rear View Side View F 190 5 E mer EL Air Inlet 135 73 2 ES gt EN NE 9 6 Front View Mounting Positions Dimensions in mm 38 5 2 Model 3 8 5 3 Model 1 2 Band Clamp Version Non metallic pumps lt 248 gt lt 203 with muffler Outlet pi A 273 Air Inlet Air Inlet 157 2 d mig T 35 c x 4 Slots Dia 8 0 170 2 Front View Side
35. e listed below 16 Maintenance Model 3 8 Band Clamp Version 3 3 4 Fastener Torque Requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Air valve assembly screws 1 35 Nm Band clamps 18 8 Nm Manifold bolts 1 13 Nm Outer diaphragm plates 4 5 Nm 17 Maintenance Model 1 2 Band Clamp Version 3 4 Maintenance Model 1 2 Band Clamp Version 3 4 1 Maintenance of Check Valve and O Ring 1 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory service also 2 Remove the nuts 8 and washers 10 from the four long pumping cap screws 35 Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat and manifold o rings 38 Replace if necessary Discharge check valves are located inside of the bottom of the discharge elbows 32 3 To inspect the manifold o rings 22 remove the eight sets of nuts washers and bolts 10 19 20 from each manifold assembly and replace if necessary Then reassemble lightly tighten fasteners Align the single parts of the complete pump and tighten the screws in
36. elbow manifold sections 21 23 and screws 19 Repeat procedure as described under point 2a There are no manifold o rings in the metallic pumps To inspect the manifold o rings 22 remove the manifold band clamps 20 from each manifold assembly Inspect and replace o rings 22 if necessary Then reassemble lightly tighten fasteners Align the single parts of the complete pump and tighten the screws in turn with the admissible torque requirement The check ball should fit into the curved portion of the valve seat and be facing upward when reinserted into the valve seat location Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 8 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 To inspect diaphragms remove the band clamps 16 from the outer pumping chambers 28 If replacement is necessary due to abrasion or rupture unscrew the outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump When changing diaphragms it is recommended to replace always both Pumps without PTFE will contain only the back up diaphragms 31 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the complete air system should be inspected After removing diaphragms and inner diaphragm
37. ement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly 10 Reinsert air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 If using original valve plate 5 lubricate side of plate that was facing the shuttle 6 or if new valve plate is used lubricate the lapped and polished side of plate and place the lubricated side next to the shuttle in the slot Press the valve plug 1 into air valve body chamfered end first 11 Check the gaskets 3 4 are not cracked If damaged replace 12 After gaskets 3 4 are pressed back into position align air valve onto intermedaite and reinsert the four cap screws 11 with lock washer 10 and flat washers 8 Apply 7 Nm of torque to fasteners 31 Maintenance Model 1 1 2 and 2 Bolted Version 3 9 Maintenance Model 1 1 2 and 2 Bolted Version 3 9 1 Maintenance of Check Valve and O Ring 1 2a 2b Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any maintenance This procedure should always be followed when returning pumps for factory service also Non metallic pumps Remove the elbow to
38. es the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump Pumps without PTFE will contain only the back up diaphragms 31 4 If diaphragm replacement is required remove the inner diaphragm plate by removing fasteners 56 55 5 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the com plete air system should be inspected 6 After removing the diaphragm plate assemblies bumpers 3 amp flat washers 47 the pilot sleeve assembly 13 14 15 42 45 amp 48 and diaphragm rod assembly 34 49 may be removed after removing the retaining plate 46 fasteners 38 and pushing the entire unit out through the bore in the intermediate 41 The diaphragm rod assembly must be unscrewed to remove the pilot sleeve 13 Caution To aid in reassembly apply a non synthetic petroleum based lubricating grease without EP additives on all the o rings and the intermediate bore 7 Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 45 o rings 42 and lip seals 14 within bore of intermediate Make sure that the open side of the lip seals 14 is facing outward toward the diaphragms Also make sure that the end pilot spacers 45 are at the end on either side of the pilot sleeve assembly and all inner spacers 48 are separated by o rings 42 Next careful
39. eum based lubricating grease without EP additives Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 47 o rings 42 and lip seals 40 within bore of intermediate Make sure that the open side of the lip seals 40 is facing outward toward the diaphragms Also make sure that the end pilot spacers 14 are at the end on either side of the pilot sleeve assembly and all inner spacers 47 are separated by o rings 46 Next carefully insert the diaphragm rod assembly 13 15 with pilot sleeve 45 inside the assembly in the bore Reattach retaining plates 41 Do not over tighten self tapping screws 24 21 Maintenance Model 1 2 Bolted Version 7 Take one diaphragm and invert reverse the natural bow of the material and with the curved side of the inner diaphragm plate 33 facing the diaphragm assemble onto outer diaphragm plate stud 29 and then screw assembly into diaphragm rod Push diaphragm rod to opposite side of intermediate and add the opposite dia phragm assembly Tighten the outer diaphragm plates to 8 Nm of torque After tightening reverse the inverted diaphragm back to its original state allowing the outer bead to seat in the groove of the intermediate Caution Inverting the first diaphragm aids reassembly 8 When positioning outer diaphragm chambers onto intermediate make sure that witness lines are matc
40. ew the outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump Pumps without PTFE will contain only the back up diaphragms 31 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the complete air system should be inspected After removing diaphragms and inner diaphragm plate 33 and flat washer 47 the pilot sleeve assembly 13 14 15 42 45 48 and diaphragm rod assembly 34 49 may be removed by removing the retaining plates 46 you may only need to remove one retaining plate and pushing the entire unit out through the bore in the intermediate 41 Diaphragm rod assembly must be unscrewed to remove pilot sleeve Caution To aid in reassembly use a non synthetic petroleum based lubricating grease without EP additives Maintenance Model 1 1 2 and 2 Bolted Version 6 Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 45 48 o rings 42 and lip seals 14 within bore of intermediate Make sure that the open side of the lip seals 14 is facing outward toward the diaphragms Also make sure that the end pilot spacers 45 are at the end on either side of the pilot sleeve assembly and all inner spacers 48 are separated by o rin
41. grooves during reassembly Tighten all external fasteners to final torque requirement after pump is completely assembled 3 7 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Air valve cap screws 4 5 Nm Manifold bolts 11 3 12 5 Nm Outer chamber cap screws 8 5 9 5 Nm Caution Always torque the chamber bolts prior to the manifold bolts 3 7 4 Maintenance of Air Valve 11 To evaluate air valve components remove the four cap screws 11 washers 25 10 and nuts 17 from the air valve body 7 The shuttle plate 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the air valve Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replacement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly 12 Reinsert
42. gs 42 Next carefully insert the diaphragm rod assembly 34 49 with pilot sleeve assembly 13 14 15 42 45 48 inside the bore Reattach retaining plates 46 Do not overtighten self tapping screws 38 7 With the curved side of the inner diaphragm plate 33 facing the diaphragm assemble onto outer diaphragm plate stud 29 and then screw assembly into diaphragm rod Push diaphragm rod to opposite side of inter mediate and add the opposite diaphragm assembly Tighten the outer diaphragm plates to 42 Nm of torque Assemble the outer chamber 28 reinforcement brackets 25 and bolts first on the side where the diapragm has been inverted Next reach under the opposite diaphragm assembly and pull diaphragm rod to opposite side a large flat screwdriver may be used as an aid in this process and assemble remaining outer chamber reinforcement brackets and cap screws When positioning outer diaphragm chambers onto intermediate make sure that witness lines are matching Caution If air valve has been removed proper orientation of air system with fluid chambers must be observed The top of the intermediate has a single vertical air passage slot on the air valve mounting face while the outer chamber check ball cavity should be pointing downward Caution Non metallic pumps When positioning band clamps 35 20 use soapy water or a compatible lubricating spray on the inside of band clamps to aid assembly Tap with a mallet on the outside of cla
43. he air valve body and the plug will shoot out Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replacement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly 12 Reinsert air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 If using original valve plate 5 lubricate side of plate that was facing the shuttle 6 or if new valve plate is used lubricate the lapped and polished side of plate and place the lubricated side next to the shuttle in the slot Press the valve plug 1 into air valve body chamfered end first 13 Check the gaskets 3 4 are not cracked If damaged replace 14 After gaskets 3 4 are pressed back into position align air valve onto intermedaite and reinsert the four cap screws 11 with lock washer 10 and flat washers 8 Apply 7 Nm of torque to fasteners 3 6 5 Dual manifold capability non metallic pumps only 1 Release the four screws 35 and the band clamps 20 2 Remove existing manifolds 21 depending on func
44. hing Caution If air valve has been removed proper orientation of air system with fluid chambers must be observed The bottom of the intermediate has the smaller hook shaped air passage slot on the air valve mounting face and the outer chamber check ball cavity should be pointing downward 9 Tighten all external fasteners to final torque requirement after pump is completely assembled 10 Position the manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the manifold o rings do not shift from their grooves during reassembly Tighten all external fasteners to final torque requirement after pump is completely assembled 3 5 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Air valve cap screws 4 5 Nm Manifold bolts 10 0 11 3 Nm Outer chamber cap screws 8 5 9 5 Nm 22 Maintenance Model 1 2 Bolted Version 3 5 4 Maintenance of Air Valve 11 To evaluate air valve components remove the four cap screws 11 washers 25 10 and nuts 17 from the air valve body 7 The shuttle plate 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the
45. lds Chamber 50 Nm Air Valve Body 4 5 Nm 36 Maintenance Model 3 Bolted Version 3 10 4 Maintenance of Air Valve 11 To evaluate the air valve components remove the eight cap screws 11 washers 8 10 from the air body 7 Inspect the gasket 4 valve plate 5 and shuttle 6 for scratches surface irregularities and excessive wear Replace if necessary Remove one of the end plugs 1 by inserting two of the cap screws 11 back into one end of the air valve body point the other end of the air valve body safely away from people and apply compressed air through one of the holes located on the gasket surface of the air valve body and the end plug will shoot out Remove the two cap screws and push the air valve spool 2 toward the remaining end plug until both the end plug and air valve spool are removed being careful not to damage the machined bore in the air valve body Gently reach in and pull the lip seal 43 and o rings 44 out of inside bore of the air valve body Check the air valve spool lip seal and o rings for cracks splitting scratches and wear Replace and or clean items as neces sary 12 Lubricate lip seals 43 and o rings 44 Reinstall the o rings and lip seals making sure that the lips of the seals are facing each other Lubricate and insert the air valve spool 2 with the chamfered end entering the air valve body s inside bore through the end that has the spool image Press the end plugs into position Lubricat
46. ll external fasteners to final torque requirement after pump is completely assembled 8a Metallic pumps Position manifold elbow sections making sure that the valve seat o rings do not shift from their grooves Tighten fasteners on bolts loosely 3 8 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Band clamps outer chamber all versions 28 Nm Band clamps manifolds and elbow 9 Nm Metallic pumps elbow and chamber bolts 50 Nm 30 Maintenance Model 1 1 2 and 2 Band Clamp Version 3 8 4 Maintenance of Air Valve 9 To evaluate air valve components remove the four cap screws 11 washers 8 10 and nuts 40 from the air valve body 7 The valve plate 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the air valve point the bottom of the air valve safely away from people direct compressed air through one of the lower holes in the back of the air valve body and the plug will shoot out Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replac
47. ly insert the diaphragm rod assembly 34 49 with pilot sleeve 13 inside the assembly in the bore Reattach retaining plates 46 Do not over tighten self tapping screws 38 Caution To aid in reassembly of the diaphragms apply a non synthetic petroleum based lubricating grease without EP additives to the diaphragm s outside diameter sealing bead 8 Reassemble the diaphragms 31 by placing the liquid side on the outer diaphragm plate 52 place the in ner diaphragm plate on the opposite side of the diaphragm insert fasteners 56 with washers 55 and tighten fasteners to 17 0 Nm of torque 35 Maintenance Model 3 Bolted Version 10 Caution For models with Teflon overlays 30 position the overlay between the outer diaphragm plate 52 and the diaphragm 31 before attaching the inner diaphragm plate 51 Screw stud 35 into the end of the diaphragm rod place washer 47 onto stud 35 and bumper 3 onto diaphragm rod Screw the diaphragm assembly to one end of the diaphragm rod and tighten to 10 ft Ibs 13 56 Nm Position the outer chamber 28 and lightly tighten fasteners 16 17 18 33 Insert a pry bar into the chamber s suction opening until it touches the hex boss of the outer diaphragm plate 52 Move the diaphragm rod toward the open chamber Wedge a block of wood between the pry bar and the side of the suction opening to hold the diaphragm rod in position Invert the second diaphragm assembly place washe
48. mber which allows them to be traced This number provides the year of construction and the design of the equipment This product is an appliance for potentially explosive atmospheres In this regard and in compliance with the EC ATEX 94 9 Directive provisions must be made to ensure ascending and descending traceability Our ATEX notified quality system ensures this traceability up to the initial point of delivery Except as otherwise agreed in writing anyone that guarantees to redeliver said equipment undertakes to put in place a system that allows for equipment that is not conform to be recalled if necessary 1 3 2 2 Year of construction The year of construction of the appliance can be seen on the field for the serial number Here are attached to the serial number the both last digits of the year of construction e g 10 for the year 2010 2 Installation Only Model 1 4 Valve optional Regulator Filter i tional Union optiona Valve optional mm Air Outlet Flexible Connection C Flexible Caution Do not use air line lubrication Connactina Air supply should be clean and dry Flexible Connection All other models Muffler Air Outlet Discharge Flexible Connection Valve Flexible a Air Inlet Connection Maintenance unit Suction must be supported Air flow control valve Notice Suction and discharge ports may be repositioned to suit the application
49. mp to help posi tion the clamp while tightening the fasteners The band clamp fasteners and cap screws are stainless steel To prevent galling always apply an anti seize compound to the thread Tighten all external fasteners to final torque requirement after pump is completely assembled 8 Position the reassembled manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the valve seat o rings do not shift from their grooves during reassembly Flat washers should be placed under the head of each cap screw and nut Tighten all external fasteners to final torque requirement after pump is completely assembled 8a Metallic pumps Also make sure that the valve seat o rings do not shift from their grooves during reassembly Tighten fasteners on bolts loosely 3 9 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Chamber Bolts Outer Chamber all versions 20 5 Nm Band clamps manifolds and elbow 9 Nm Metallic pumps elbow and chamber bolts 50 Nm Air valve cap screws 4 5 Nm 33 Maintenance Model 1 1 2 and 2 Bolted Version 3 9 4 Maintenance of Air Valve 9 10 To evaluate air valve components remove the six cap screws 11 washers 8 10 and nuts 40 from the air valve body 7 The shuttle plate
50. nce Model 1 2 Band Clamp Version 6 Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 14 o rings 42 and lip seals 40 within bore of intermediate Make sure that the open side of the lip seals 40 is facing outward toward the diaphragms Also make sure that the end pilot spacers 14 are at the end on either side of the pilot sleeve assembly and all inner spacers 47 are separated by o rings 46 Next carefully insert the diaphragm rod assembly 13 15 with pilot sleeve 45 inside the assembly in the bore Reattach retaining plates 41 Do not overtighten self tapping screws 24 7 Take one diaphragm and invert reverse the natural bow of the material and with the curved side of the inner diaphragm plate 33 facing the diaphragm assemble onto outer diaphragm plate stud 29 and then screw assembly into diaphragm rod Push diaphragm rod to opposite side of intermediate and add the opposite dia phragm assembly Tighten the outer diaphragm plates to 8 Nm of torque 8 Assemble the outer chamber 28 and band clamps 16 first on the side where the diaphragm is fitted on the intermediate Lightly tighten fasteners at band clamp Push opposite diaphragm towards intermediate and fix second outer chamber When positioning outer diaphragm chambers onto intermediate make sure that witness lines are matching Caution If air v
51. nd of each half Pull each half out of the pump Inspect for corrosion 11 To inspect diaphragm rod lip seals 14 remove the two self tapping screws 12 from the retaining plates 13 Gently remove lip seals and inspect for damage To reassemble lubricate diaphragm rod lip seals 14 and insert into bore with the u cup portion facing inward 13 Maintenance Model 1 4 12 13 14 15 16 17 18 19 14 To remove spring clip assembly 23 firmly pull air valve plug 25 from pump Inspect spring clip assembly 23 and shuttle 22 for damage Surface of intermediate around air ports and flat surface of shuttle must be smooth no scratches or debris Replace or clean if necessary Attach seal retainer 13 with flat surface toward lip seals 14 Do not over tighten self tapping screws 12 To reinsert diaphragm rod halves drop shuttle 22 into intermediate over ports Groove in should be aligned vertically in pump and should face outward Insert spring side of spring clip assembly into groove in shuttle At this point the assembly is not affixed to anything Press down as shown below to insert long half of diaphragm rod 16 through spring clip assembly and position un der spring ends Apply pressure with finger while inserting and assem bling the diaphragm rods While continuing to apply pressure to spring clip assembly screw short half of diaphragm rod 11 into long half Follow instruction
52. ntenance of Air Valve 11 To evaluate air valve components remove the four cap screws 11 washers 25 10 and nuts 19 from the air valve body 7 The valve plate 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the air valve point the bottom of the air valve safely away from people direct compressed air through one of the lower holes in the back of the air valve body and the plug will shoot out Next push the air valve spool 2 out of the air valve body Gently reach in and pull lip seals 43 out of inside bore of the air valve body Check for cracks splitting or scratches Clean components if replacement is not necessary Inspect plug o ring 44 for any damage and replace if necessary and reinsert in o ring groove Caution Make sure that the open sides of the two lip seals 43 face each other when reassembling air valve Lube all components with suggested maintenance grease as an aid in reassembly 12 Reinsert air valve spool 2 inside of air valve body 7 Place shuttle 6 on middle rib of air valve spool 2 through the square slot in back of air valve 7 If using original valve plate 5 lubricate side of plate that was facing the shuttle 6 or if new valve plate is used lubricate the lapped and polished side of plate and place the lubricated side next to
53. outer diaphragm plates 29 Models that are built with PTFE elastomers will have a PTFE overlay 30 that faces the outer pumping chamber 28 and a back up diaphragm 31 on the air side of pump When changing diaphragms it is recommended to replace always both Pumps without PTFE will contain only the back up diaphragms 31 If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side of the pump the com plete air system should be inspected After removing diaphragms and inner diaphragm plate 33 the pilot sleeve assembly 14 42 45 48 and diaphragm rod assembly 13 15 may be removed by removing the retaining plates 49 you may only need to remove one retaining plate and pushing the entire unit out through the bore in the intermediate 41 Diaphragm rod assembly must be unscrewed to remove pilot sleeve Caution To aid in reassembly use a non synthetic petroleum based lubricating grease without EP additives 10 Maintenance Model 1 Band Clamp Version Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 14 o rings 42 and lip seals 48 within bore of intermediate Make sure that the open side of the lip seals 48 is facing outward toward the diaphragms Also make sure that the end pilot spacers 14 are at the end on either side of the pilot sleeve assembly and all inner spacers
54. outer pumping chamber 28 band clamps 35 Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat o rings 24 Replace if nec essary Discharge check valves are located inside of the bottom of the discharge elbows 32 Repeat procedure for inspection of discharge check valves Metallic pumps To inspect the check valves remove the cap screws 19 from manifold sections 21 23 Repeat procedure as described under point 2a There are no manifold o rings in the metallic pumps Non metallic pumps To inspect the manifold o rings 22 remove the manifold band clamps 20 from each manifold assembly Inspect and replace o rings 22 if necessary Then reassemble lightly tighten fasteners The check ball should fit into the curved portion of the valve seat and be facing upward when reinserted into the valve seat location Tighten all external fasteners to final torque requirement after pump is completely as sembled Caution When using pumps built with PTFE o rings always replace with new PTFE o rings since the original o rings may not reseal the pump 3 9 2 Maintenance of Diaphragm and Pilot Sleeve Assembly 4 32 To inspect diaphragms remove cap screws 16 and reinforcement bracket 25 from the outer pumping cham bers 28 If replacement is necessary due to abrasion or rupture unscr
55. owing operating conditions can cause early damage of the pump by spring breakage e dirty wet or contaminated air supply too small suction pipe diameter or too large particles in the pumped liquid blocked valve seats or viscosity of the liquid exceeding 10 000 mPas high flow rate at a back pressure of more than Ap 1 4 bar safe operating pressure exceeded AN Caution Following conditions cut down the continuous operation of the pump high stroke frequency Flow rate at maximum value resistance at suction side large suction head filter or valve viscous liquid high operating pressure During continuous operation t 2h day operating pressure and flow rate must not exceed more than the half of the maximum admissible operating pressure respectively the maximum possible flow rate high suction prepressure These operating conditions and long running times can wear movable parts after 3 6 months 1 3 1 Specifications Model 1 4 1 2 1 11 2 2 3 Bolted Bolted Bolted Bolted Bolted Version Version Version Version Version Capacity Adjustable Adjustable Adjustable Adjustable Adjustable Adjustable 0 16 l min 0 65 l min 0 156 l min 0 492 l min 0 681 l min 0 965 l min Maximum temperature PVDF models 93 C 93 C 93 C 93 C 93 C PP models 66 C 66 C 66 C 66 C 66 C Metallic models 93 C 93
56. pect diaphragms for rupture Erratic cycling 1 Inspect check valve seats for debris 2 Inspect fluid lines for debris 3 Automatic valves must be properly functioning 4 Viscosity of product may be changing Premature destruction of wetted components 1 If fluid is abrasive slow down pump or increase size of pump 2 Filter fluid for sharp objects 3 Make sure fluid is compatible with wetted materials 55 D 97877 Wertheim Lutz Pumpen GmbH Erlenstra e 5 7 u 2 NENNEN The Fluid Managers Declaration of Conformity Herewith we declare that the below mentioned machine in it s conception and design and in the execu tion marketed by us fully complies with the EC directives This declaration ceases to be valid if the machine is modified in any way without prior consultation with us Type of device Double diaphragm pump Model 14 3 8 1 2 1 112 2 3 Version po N EX c ur EXE E E 5515 a 5 a a ur S SE Biz s ed ed cea ja 8 2 lt 9 gt g 3 o 1 a a TZ ar 1254 a a 2 amp amp ud d E E a E Blelel ae 5 eee z sls cis a 2 al ES E E c3 amp ee E 2 EZ e EIE elel Q 2 a a a 0 0 a a na l es zl al a E pe E a n 2 a E a 3 a a
57. phragm assembly Apply 42 Nm of torque to outer diaphragm plates 29 Assemble the outer chamber 28 and band clamps 16 first on the side where the diaphragm has been inverted Next reach under the opposite diaphragm assembly and pull diaphragm rod to opposite side a large flat screw driver may be used as an aid in this process and assemble remaining outer chamber and band clamp When position ing outer diaphragm chambers onto intermediate make sure that witness lines are matching Caution If air valve has been removed proper orientation of air system with fluid chambers must be observed The top of the intermediate has a single vertical air passage slot on the air valve mounting face while the outer chamber chack ball cavity should be pointing downward Caution When positioning band clamps use soapy water or a compatible lubricating spray on the inside of band clamps to aid assembly Tap with a mallet on the outside of clamp to help position the clamp while tightening the fasteners To prevent galling always apply an anti seize compound to the thread Tighten all external fasteners to final torque requirement after pump is completely assembled 8 Position the reassembled manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the valve seat o rings do not shift from their grooves during reassembly Flat washers should be placed under the head of each cap screw and nut Tighten a
58. plate 33 and flat washer 47 the pilot sleeve assembly 13 14 15 42 45 48 and diaphragm rod assembly 34 49 may be removed by removing the retaining plates 49 you may only need to remove one retaining plate and pushing the entire unit out through the bore in the intermediate 41 The diaphragm rod assembly must be unscrewed to remove the pilot sleeve 13 Caution To aid in reassembly use a non synthetic petroleum based lubricating grease without EP additives 29 Maintenance Model 1 1 2 and 2 Band Clamp Version 6 Clean or replace any components that have excessive wear dirt build up or chemical attack Lube all compo nents prior to reassembling Reassemble pilot sleeve spacers 45 o rings 42 and lip seals 14 within bore of intermediate Make sure that the open side of the lip seals 14 is facing outward toward the diaphragms Also make sure that the end pilot spacers 45 are at the end on either side of the pilot sleeve assembly and all inner spacers 48 are separated by o rings 15 Next carefully insert the diaphragm rod assembly 34 49 with pilot sleeve 13 inside the assembly in the bore Reattach retaining plates 46 Do not overtighten self tapping screws 38 7 With the curved side of the inner diaphragm plate 33 facing the diaphragm assemble onto outer diaphragm plate stud 29 and then screw assembly into diaphragm rod Push diaphragm rod to opposite side of intermedi ate and add the opposite dia
59. r 47 onto stud 35 and bumper 3 onto diaphragm rod Screw the diaphragm assembly to the end of the diaphragm rod and tighten to 10 ft Ibs 13 56 Nm of torque Roll the outside bead of the diaphragm toward the outer chamber Position the outer chamber 28 and tighten fasteners 16 17 18 33 to 20 ft lbs 27 12 Nm of torque Return to the first outer chamber align the suction opening flanges until they are level and on the same plane tighten fasteners 16 17 18 33 to 20 ft lbs 27 12 Nm of torque Place the check balls 27 and check valve seats 26 in the discharge manifold 22 position on the outer chamber 28 and reassemble using fasteners 16 17 18 Place the check balls 27 and check valve seats 26 in the outer chambers 28 position the suction manifold 23 and reasssemble using fasteners 16 17 18 Torque all manifold fasteners to 50 Nm 10a For models using Teflon elastomers check valve seats 25 and o rings 24 make sure that the o rings 24 are facing the machined flanges of the suction manifold 23 and or discharge manifold 22 Also make sure that the o rings do not shift from their grooves during reassembly 3 10 3 External Fastener Torque Requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Diapraghm Plates 17 Nm Diaphragm Rod 13 5 Nm Chambers 27 Nm Manifo
60. rmediate 15 Position o ring retainers 4 and o rings 17 on the end of the tubes Lubricate o rings and right cham ber holes 18 Slide a flat washer 26 onto each of the six cap screws 27 and insert through the entire assembly Secure with a flat washer 26 and a ten sion washer 29 under each nut Tighten to 7 Nm Apply torque evenly 3 2 2 Maintenance of Diaphragms Maintenance Model 1 4 Valve Disk Suction Valve is part of right and left chambers EN gt JAS aR Disk 7 Remove outer diaphragm plates 7 by holding one diaphragm plate and twisting off the other plate 8 The diaphragm o ring 8 is used only with Teflon diaphragms Replace diaphragms if ruptured or worn Inspect inner diaphragm plates 10 If diaphragm rod needs replacing go to step 10 9 If no further inspection is necessary reassemble inner diaphragm plates and diaphragms onto stud of outer diaphragm plates and screw each assembly into diaphragm rod Make sure optional diaphragm o ring is in posi tion in the o ring groove on either side of the intermediate if using Teflon diaphragms When positioning Teflon diaphragms make sure that the concave side is facing the wet ends of pump Tighten outer diaphragm plates to 4 5 Nm Reassemble pump according to steps 5 and 6 3 2 3 Maintenance of Air Valve and Diaphram Rod 10 To remove the diaphragm rod twist the two rod halves 11 16 apart by using a wrench on the flats at the e
61. s for assembly of diaphragms in step 9 Final tightening of diaphragm rod will occur when outer diaphragm plates 7 are tightened Make sure valve plug o ring 21 is well lubed position o ring and press air valve plug into the intermediate making sure that tab and indentation are aligned If o ring is not well lubricated it will not permit reinsertion Follow procedure for final assembly of pump in step 6 Maintenance Model 3 8 Band Clamp Version 3 3 Maintenance Model 3 8 3 3 1 Maintenance of Max Pass or Check Valve 1 2 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory service also Remove the nuts 3 and washers 4 from the bolts 23 in manifolds Remove the manifolds 20 11 Two of the four max pass valves and back ups 13 14 are located inside of the bottom of the outer chambers 16 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect manifold o ring 12 as well and replace if necessary The other two max pass valves are located inside of the bottom of the discharge manifold 20 Repeat the procedure for inspection of discharge valves back ups and o rings Some pumps such as those built with PTFE have ball valves in place of the max pass valves Repeat the proce dure inspect valve seat 28 balls 29 ball cage 27 and o ring
62. sion Non metallic pumps 228 6 4 Slots Dia 10 0 Outlet Air 414 5 Outlet 216 9 Inlet gt A 66 Y 158 8 Approximate Dimensions with Muffler 272 5 Front View Side View Metallic pumps le 304 8 I amp 225 5 lt 1207 gt 152 4 gt 859 gt Mtr 4 Slots Dia 11 2 198 1 Front View Air 15 3 Outlet 193 182 9 Approximate Dimensions with Muffler 264 Side View Dimensions in mm 43 5 7 Model 1 1 2 Band Clamp Version Non metallic pumps 516 6 gt 4 amp 878 _ gt with muffler Le 1792 gt l 284 4 Slots Dia 14 2 2548 Front View Side View Metallic pumps 495 gt Air Inlet E 283 4 Slots Dia 14 2 Front View Side View Approximate Dimensions with Muffler 378 Dimensions in mm 44 5 8 Model 1 1 2 Bolted Version Non metallic pumps Outlet 518 2 Y Front View Metallic pumps 495 r 311 9 Outlet Air Outlet 152 4 Front View Side View Dimensions in mm 45 5 9 Model 2 Band Clamp Version Non metallic pumps 523 8 302
63. tion Caution There is a female 1 NPT thread inside the elbows 3 Rotate elbows 180 outwards and realign and secure pumping chamber cap screws 35 4 Pump is now ready for dual side suction and discharge through the elbows 26 Maintenance Model 1 Bolted Version 3 7 Maintenance Model 1 Bolted Version 3 7 1 Maintenance of Check Valve and O Ring 1 2 Flush and neutralize the pump to be certain all corrosives or hazardous materials are removed prior to any main tenance This procedure should always be followed when returning pumps for factory service also Remove nuts 18 and washers 12 from bolts 16 in both the discharge and suctions manifolds Suction check valve seats and check balls 26 27 are located inside of the bottom of the outer chamber 28 Gently remove and inspect for excessive wear pitting or other signs of degradation Inspect valve seat and manifold o rings 19 38 Replace if necessary Discharge check valves are located inside of the bottom of the discharge elbows 32 Repeat procedure for inspection of discharge check valves and o rings When re assembling the check ball should fit within the ball cavity of the chamber and discharge manifold Press fit the valve seats into position with the curved portion facing the ball Lightly tighten fasteners Tighten all external fasteners to final torque requirement after pump is completely assembled Caution When using pumps built with PTFE o rings
64. ture range of 20 C up to 40 C Pump must not be used within atmospheres containing inflam mable dust Danger Pumping of flammable liquids may cause a build up of a static charge within the electrically non conductive pumps Static spark can cause explosion resulting in severe injury or death Ground pump and pumping systems when pumping flammable liquids or when used in a location where surrounding atmosphere is conductive to spontaneous combustion The rating plate of the pump must show a respective Ex identification according to the application Use grounding plugs and always connect to a good ground source Actual valid regulations concerning the grounding have to be observed Secure pump connections and all contact points to avoid vibrations and generation of contact or static spark Periodically verify continuity of electrical path to ground with an ohmmeter from each component Resistance of grounding must not exceed 105 ohm Vote local building codes and regulations for explosion protection Use conductive hoses Use proper ventilation Keep flammables away from heat open flames and sparks Keep containers closed when not in use Use only new genuine spare parts for repairs Pumps which are modified by the customer may vary from the EC Declaration of Conformity Observe rating plate 1 3 2 1 Traceability Products manufactured by Lutz Pumpen for potentially explosives atmospheres are identified by an individual batch nu
65. ys apply anti seize compound to the thread Tighten all external fasteners to final torque requirement after pump is completely assembled Position the reassembled manifolds making sure of the proper orientation in relation to the air valve for your application Also make sure that the valve seat o rings do not shift from their grooves during reassembly Flat washers should be placed under the head of each cap screw and nut Concave side of tension washers used in non metalllic pumps only should face each other 3 6 3 External fastener torque requirements Caution When reassembling loosely tighten all external fasteners adjusting and aligning and gradually in an alternat ing fashion tighten to torque requirements listed below Band clamps outer chamber 18 Nm Band clamps manifolds 9 Nm Outer chamber cap screws Non metallic pumps 5Nm Metallic pumps 22 Nm 25 Maintenance Model 1 Band Clamp Version 3 6 4 Maintenance of Air Valve 11 To evaluate air valve components remove the four cap screws 11 washers 8 10 and nuts 40 from the air valve body 7 The valve plate 5 and shuttle 6 may be inspected by removing them from their location in the slot in the back of the air valve Inspect for scratches or surface irregularities Replace if necessary Remove the plug 1 at the bottom of the air valve point the bottom of the air valve safely away from people direct compressed air through one of the lower holes in the back of t

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