Ingersoll-Rand PD30X-X User's Manual
Contents
1. 1 94028 A 135 Valve Block PD30A 1 94032 A Center Body 0205 1 9n fissi Valve Block 5 1 94318 185 103 Bushing 1 9092 D 136 Piston Plug 1 94033 m 107 Inlet Plug 1 s4034 cy 146 0 Ring gez x1 ne oa 1 325 118 109 Piston 1 9201 ID 147 0 Ring ve x 12 oa 2 Y325 202 B 110 lt u Cup 1 3 8 o d Also Item 144 1 Y186 51 B 166 Track Gasket e 1 94026 B 11 Spool ppsoA 1 92005 A 4 167 Pilot Piston includes 168 and 169 1 67164 D Spool ppsos 1 s3047 C 168 0 Ring az x 5 8 o a 2 933 112 Washer 1 556 o a 92877 169 U Cup oe xme o a 1 vzs 9 mB 7113 0 Ring mam x1 14 0 4 5 Y325 214 B 170 Piston Sleeve 1 94081 Br 7114 0 Ring garge 332 1 916 7 Y325 126 B v 171 O Ring gz x i i od 1 325 119 8 D115 Spacer 92876 z 7172 0 Ring ane xii od 1 Y325 22 mB 116 Spacer 94027 IA v 173 0 Ring ane x 1 370 o a 25 26 IB 118 Actuator Pin 250 22167 2 94083 185 Xo7174 0 Ring tx 12 o a 25 202 8 121 Sleeve 2 94084 D 4 176 Diaphragm check valve 2 941022. 93 Dimensional Data See page 8 Mounting Dimensions 12 x 13 1 2 304 8 mm x 342 9 mm Noise Level 70 psi 50 83 0 db A O Tested with 94085 muffler assembly installed The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound Level to meet the intent of ANSI S1 13 1971 CAGI PNEUROP 5 1 using four microphone locations NOTICE All possible options are shown in the chart however certain com binations may not be recommended consulta representative or the facto ry if you have questions concerning availability GENERAL DESCRIPTION The ARO Diaphragm Pump offers high volume delivery even at low air pressure and a broad range of material compatibility options available Refer to the model and option chart ARO pumps feature stall resistant design modular air motor fluid sections Air operated double diaphragm pumps utilize a pressure differential in the air chambers to alternately create suction and positive fluid pressure in the fluid chambers ball checks insure a positive flow of fluid Pump cycling will begin as air pressure is applied and it will continue to pump and keep up with the demand It will build and maintain line pres sure and will stop cycling once maximum line pressure is reached dis pensing device closed and will resume pumping as needed INGERSOLL RAND COMPANY LTD 209 NORTH MAIN STREET BRYAN OHIO 43506 8
3. Clean and lubricate parts not being replaced from service kit Install new 171 172 O rings replace 170 sleeve Install new 168 O rings 169 seal Note the lip direction Lubri cate and replace 167 Reassemble remaining parts replace 173 and 174 O rings Used on Stainless Steel models PD30S only Used on Aluminum models PD30A only MATERIAL CODE Cl Cast Iron SS Stainless Steel D Acetal U Polyurethane SP Santoprene Zinc Aluminum Buna Br Brass C Carbon Steel MAJOR VALVE DISASSEMBLY 1 Remove 135 valve block exposing gaskets 166 132 and 176 checks 2 Remove 177 snap ring and 107 inlet plug 3 On the side opposite the air inlet push on the inner diameter 111 spool This will force the 136 piston plug and 109 piston out Continue pushing the 111 spool and remove Check for scratches or gouges 4 Remove the Major Valve parts 112 116 MAJOR VALVE REASSEMBLY 1 Replace 112 washer 114 ring 113 ring onto 115 spacer and insert etc Continue this routine to build the major valve stack NOTE Be careful to orient spacer legs away from blocking inter nal ports 2 Replace 111 spool on 136 plug 110 seal on 109 piston and replace 109 136 plug and 177 snap ring Smart Parts Keep these items on hand in addition to the Service Kits for fast rep
4. result in severe personal injury death or substantial property damage Hazards or unsafe practices which could result in minor personal injury product or property damage Important installation operation or maintenance information PAGE 20F 8 PD30X X AIR AND LUBE REQUIREMENTS AWARNING EXCESSIVE AIR PRESSURE Can cause pump damage personal injury or property damage e filter capable of filtering out particles larger than 50 microns should be used on the air supply In most applications there is no lubrication required other than the O ring lubricant which is ap plied during assembly or repair e When lubricated air is necessary supply the air lubricator with a good grade of SAE 90 wt non detergent oil and set the lubricator to a rate not to exceed one drop per minute OPERATING INSTRUCTIONS e Always flush the pump with a solvent compatible with the material being pumped if the material being pumped is subject to setting up when not in use for a period of time Disconnect the air supply from the pump if it is to be inactive for a few hours The outlet material volume is governed not only by the air supply but also by the material supply available at the inlet The material supply tubing should not be too small or restrictive Be sure not to use hose which might collapse e When the diaphragm pump is used in a forced feed flooded inlet situation it is recommended that a Check V
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6. XXX PD30X XAX PD30X XCX PD30X XHX PD30X XSX ITEM DESCRIPTION QTY PART NO MTL PART NO MTL PART NO MTL PART NO MTL 6 Diaphragm Screw 94096 EH 94094 155 94690 94094 155 15 Fluid Cap 2 94024 tal oatos ic 94693 iHa 55 60 Outlet Manifold 9419 IA 94105 s ICI 94692 s Ha 94116 18 ISS 61 Inlet Manifold t 94218 5 A 94305 s CI 94691 5 Ha 94216 s SS 88 For NPT models PD30X AXX XXX use 1 For BSP models PD30X BXX XXxX use 2 EXTERNAL HARDWARE OPTION PD30X XXX PD30X XXP PART NO MTL PD30X XXS PART NO MTL ITEM DESCRIPTION SIZE IN INCHES QTY 26 Screw M12 1 75 6g x 45 mm 28 COMMON PARTS ITEM DESCRIPTION Size in Inches QTY PART NO MTL ITEM DESCRIPTION Size In Inches QTY PART NO MTL 1 Rod 1 94093 C 131 Screw m10 x 1 5 6g x 120 mm 4 94531 C 43 Ground Lug 1 93004 Co 144 U Cup 3 16 x 1 3 8 o d 2 Y186 51 B T0 Gasket 2 94100 B 180 Gasket 406 i d x 031 thick 4 94098 Co Smart Parts keep these items on hand in addition to the Service Kits for fast repair and reduction of down time PAGE 4 8 PD30X X PARTS LIST PD30X X FLUID SECTION FOR THE C AIR MOTOR SECTION COLOR CODE
7. 00 495 0276 FAX 800 892 6276 2010 www ingersollrandproducts com 3 DIAPHRAGM PUMP PD30X XXX XXX C Ww TS 5A e SS A 0 L4 ae 0005 MODEL DESCRIPTION CHART PD30X X X X X X X CENTER SECTION MATERIAL A Aluminum S Stainless Steel THREAD A NPT B BSP FLUID CAPS amp MANIFOLD MATERIAL A Aluminum H Hastelloy C Castlron S Stainless Steel HARDWARE MATERIAL P Plated Steel S Stainless Steel SEAT MATERIAL A Santoprene K PVDF Kynar G Geolast S 316 Stainless Steel H Hard 440 Stainless Steel BALL MATERIAL A Santoprene G Geolast T PTFE DIAPHRAGM MATERIAL A Santoprene G Geolast T PTFE FLUID SECTION SERVICE KIT SELECTION PD30X XXX X X X EXAMPLE MODEL PD30A ACS SAA 637303 XIX FLUID SECTION SERVICE KIT 637303 AA BALL DIAPHRAGM A RO dm Ingersoll Rand Industrial Technologies OPERATING AND SAFETY PRECAUTIONS READ UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE EXCESSIVE AIR PRESSURE STATIC SPARK HAZARDOUS MATERIALS HAZARDOUS PRESSURE al injury pump damage or property damage Do not exceed the maximum inlet air pressure as stated on the pump model plate Be sure material hoses and othe
8. 4621 K K Y328 350 4 SG GXx PEE IG Ses ES X s ISS Y325 350 8 HGX 9414 SH 325 350 IB SAX sm3 ssi 9415 9 HAX eaa SH 94115 9 94113 SS Y328 350 8 HTX 9414 pH Y328 350 8 m ME BALL OPTIONS DIAPHRAGM OPTIONS ETT gt Aluminum Carbon Steel PD30X XXX XXX PD30X XXX XXX C n 22 3 25 dia coma eQ Co Copper x SERVICE KIT x 8 Cast x EE E M E Geolast XXX BALL 4 MTL XXX XX Diaphragm DIAPHRAGM 2 MTL Ha Hastelloy C K PVDF XAX 94103 A SP XXA 637303 94091 A SP Hard S Steel Santoprene S Stainless Steel PTFE 9103 6 637303 6 94091 G 0 XTX 94103 T XXT 637303 XT 94090 T 94110 A T SP CENTER SECTION PART OPTIONS PD30X PD30A PD30S ITEM DESCRIPTION SIZE IN INCHES QTY PART NO MTL PART NO MTL 5 Backup Washer o 66167 r 66167 155 32 94101 1 94101 2 ISS 68 Air Cap 1 94030 1 A 94031 1 iss 69 Air Cap 1 94030 2 94031 2 iss X 175 Ring 3 32 x 01 o d O1 1 16 o d 2 325 1170 B 325 1180 B MANIFOLD THREAD FLUID CAP MATERIAL OPTIONS PD30X
9. OPERATOR S MANUAL INCLUDING OPERATION INSTALLATION amp MAINTENANCE 3 DIAPHRAGM PUMP PD30X X RELEASED 9 18 95 REVISED 6 22 10 REV J 1 1 RATIO METALLIC LI READ THIS MANUAL CAREFULLY BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT It is the responsibility of the employer to place this information in the hands of the operator Keep for future reference SERVICE KITS Refer to Model Chart to match the pump material options 637303 XX for Fluid Section Repair see page 4 Note This kit also contains several air motor seals which will need to be replaced 637302 for Air Section Repair see page 6 PUMP DATA Models See Model Description Chart for XXX Pump Type Metallic Air Operated Double Diaphragm Material See Model Description Chart Weight Aluminum wet end 102 Ibs 46 3 kgs Cast Iron wet end 192 5 Ibs 87 3 kgs Hastelloy wet end 193 Ibs 87 5 kgs Stainless Steel wet end 193 Ibs 87 5 kgs add 36 Ibs 16 3 kg for stainless steel air motor section Maximum Air Inlet Pressure 120 p s i g 8 3 bar Maximum Material Inlet Pressure 10 p s i g 69 bar Maximum Outlet Pressure 120 p s i g 8 3 bar Maximum Flow Rate flooded inlet 275 g p m 1041 l p m Displacement Cycle 100 p s i g 2 8 gal 10 6 1 Maximum Particle Size 3 8 dia 9 5 mm Maximum Temperature Limits 200
10. SEE PAGES 6 amp 7 MATERIAL T ad EOLAST BLACK BLACK BLACK UN G 26 PVDF NIA BLACK SANTOPRENE GREEN NIA BACKUP gt PTFE WHITE WHITE N A FIGURE 1 VIEW OF TWO PIECE PTFE DIAPHRAGM 8 gt TORQUE REQUIREMENTS nee NOTE DO NOT OVERTIGHTEN FASTENERS ALL FASTENERS ARE METRIC 6 Diaphragm Screw 60 70 ft Ibs 81 4 94 9 Nm 26 Fluid Caps Manifold Screw 60 70 ft Ibs 81 4 94 9 Nm Es Do not exceed 90 ft Ibs 122 Nm on 5 stud and apply Loctite 271 to threads Apply anti seize compound to threads when using SS fasteners and stainless steel wet ends LUBRICATION SEALANTS Apply Lubriplate FML 2 Grease to all 0 rings U Cups amp mating parts USED WITH HXX amp SXX ONLY USED WITH HXX amp SXX ONLY Apply Loctite 242 to threads at assembly D006 Lubriplate FML 2 is a white food grade petroleum grease PD30X X PAGE 5 OF 8 PARTS LIST PD30X X AIR SECTION Indicates parts included in 637302 Air Section Service Kit shown below and items 70 144 175 and 180 shown on page 4 AIR MOTOR PARTS ITEM DESCRIPTION Size in Inches QTY PART NO PART NO 101 Center Body PD30A
11. U 4 132 Gasket valve Body 1 94099 B w 177 Retaining Ring 1 804 dia 1 Y147 16 C C 133 Lockwasher 14 PD30A Yrz ae c c 181 Roll Pin s os xsmniong 4 Y178 56 S SS Lockwasher 1 4 PD30S 3 Y14 416 T SS Lubriplate FML 2 Grease 1 94276 134 Screw m6 x 1 0 16 mm PD30A 4 96721030 C Lubriplate Grease Packets 10 637308 Screw Me x 1 0 x 16 mm PD30S 4 96720081 SS AIR MOTOR SECTION SERVICE Service is divided into two parts 1 Pilot Valve 2 Major Valve GENERALREASSEMBLY NOTES Air Motor Section Service is continued from Fluid Section repair Inspect and replace old parts with new parts as necessary Look for deep scratches on metallic surfaces and nicks or cuts in O rings Take precautions to prevent cutting O rings upon installation Lubricate rings with Lubriplate FML 2 Grease Do not over tighten fasteners refer to torque specification block on view Re torque fasteners following restart SERVICE TOOLS To aid in the installation of 168 rings onto the 167 pilot piston use Tool 204130 T available from Aro PILOT VALVE DISASSEMBLY A light tap on 118 should expose the opposite 121 sleeve 167 pilot piston and other parts Remove 170 sleeve inspect inner bore of sleeve for damage PILOT VALVE REASSEMBLY
12. air and reduction of down time PAGE 6 OF 8 PD30X X PARTS LIST PD30X X AIR SECTION MAJOR VALVE CROSS SECTION DETAIL 109 110 112 114x 1134 115 111 116 PILOT VALVE PART GROUP Substitute these 0 rings for 166 on models PD30S 111 147 x 146 X FIGURE 2 181 Pp3os only N Optional 94117 Muffler MAJOR VALVE See cross section detail figure 3 above IMPORTANT BE CERTAIN TO ORIENT 115 SPACER LEGS AWAY FROM BLOCKING INTERNAL PORTS WHEN REASSEMBLING AIR SECTION gt TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS 107 ALL FASTENERS ARE METRIC Torque 134 Screw to 40 50 in Ibs 4 5 5 6 Nm LUBRICATION SEALANTS Apply Lubriplate FML 2 Grease to O rings U Cups amp mating parts A Major Valve Service Asm is available separately which includes the following Valve Asm Pump Models Items Included 67089 1 PD30A 107 116 132 135 136 166 176 177 67089 2 0305 107 116 132 135 136 146 147 176 177 PD30X X PAGE 7 OF 8 TROUBLE Product discharged from exhaust outlet e Check for diaphragm rupture e Check tightness of diaphragm nut Air bubbles in product discharge e Check connections of suction plumbing e Check rings between intake manifold and fluid caps Check tightness of diaphragm nut Motor
13. alve be installed at the air inlet e Secure the diaphragm pump legs to a suitable surface to insure against damage by vibration MAINTENANCE Refer to the part views and descriptions as provided on page 4 through 7 for parts identification and Service Kit information e Certain ARO Smart Parts are indicated which should be available for fast repair and reduction of down time Service kits are divided to service two separate diaphragm pump functions 1 AIR SECTION 2 FLUID SECTION The FLUID SEC TION is divided further to match typical part MATERIAL OPTIONS MAINTENANCE CONT D e Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during ser vice disassembly and reassembly Keep good records of service activity and include pump in preven tive maintenance program Before disassembling empty captured material in the outlet man ifold by turning the pump upside down to drain material from the pump FLUID SECTION DISASSEMBLY 1 Remove top manifold s 2 Remove 22 balls 19 O rings and 21 seats 3 Remove 15 fluid caps NOTE Only PTFE diaphragm models use a primary 7 diaphragm and a backup 8 diaphragm Refer to the auxiliary view Fig 1 4 Remove the 6 nut 7 or 7 8 diaphragms and 5 washer NOTE Do not scratch or mar the surface of 1 diaphragm rod FLUID SECTION REASSEMBLY SERVICE NOTE ARO PN 204214 T Diaphragm A
14. blows air or stalls e Check 176 check valve for damage or wear e Check for restrictions in valve exhaust SHOOTING Low output volume erratic flow or no flow Check air supply Check for plugged outlet hose Check for kinked restrictive outlet material hose Check for kinked restrictive or collapsed inlet material hose Check for pump cavitation suction pipe should be sized at least as large as the inlet thread diameter of the pump for proper flow if high viscosity fluids are being pumped Suction hose must be a non col lapsing type capable of pulling a high vacuum Check all joints on the inlet manifolds and suction connections These must be air tight e Inspect the pump for solid objects logged in the diaphragm cham ber or the seat area DIMENSIONAL DATA 29 144 17 32 SLOT 14 mm D009 Dimensions shown are for reference only they are displayed in inches and millimeters mm 17 11 16 450 mm 15 381 mm 23 594 Dotted lines show optional 94085 Muffler Asm 23 5 8 599 mm 3 NPT PD30X AXX XXX 3 BSP PD30X BXX XXX 3 4 NPT 305 mm 13 1 2 343 mm FIGURE 4 3 13 16 97 mm 1 1 2 NPT Exhaust port MATERIAL INLET 13 1 2 343 mm OPTIONAL ACCESSORY 66109 Airline Connection Kit ARO dm Ingersoll Rand Industrial Technologies PN 97999 639 PAGE 8
15. e substance being pumped flushed or re circulated Chemical compatibility may change with tempera ture and concentration of the chemical s within the substances being pumped flushed or circulated Consult the material manufacturer and ARO Form No 8677 P Fluid Com patibility Guide for information on chemical compatibility Maximum temperatures are based on mechani cal stress only Certain chemicals will significantly reduce maximum safe operating temperature Consult Fluid Compati bility Guide for chemical compatibility and temperature limits Refer to PUMP DATA on page 1 of this manual CAUTION Be certain all operators of this equipment have NOTICE been trained for safe working practices understand it s limita tions and wear safety goggles equipment when required Do not use the pump for the structural support of the piping system Be certain the system components are properly supported to prevent stress on the pump parts Suction and discharge connections should be flexible con nections such as hose not rigid piped and should be com patible with the substance being pumped Prevent unnecessary damage to the pump Do not allow pump to operate when out of material for long peri ods of time Disconnect air line from pump when system sits idle for long periods of time Use only genuine ARO replacement parts to as sure compatible pressure rating and longest service life G Hazards or unsafe practices which could
16. ion when pumping haz ardous or inflammable materials Use a grounded 1 min i d hose between the pump and the muffler AAWARNING HAZARDOUS PRESSURE Can result in serious injury or property damage Do not service or clean pump hoses or dispensing valve while the system is pressurized Disconnect air supply line and relieve pressure from the sys tem by opening dispensing valve or device and or carefully and slowly loosening and removing outlet hose or piping from pump AWARNING HAZARDOUS MATERIALS Can cause serious injury or property damage Do not attempt to return a pump to the factory or service center that contains hazardous material Safe handling practices must comply with local and national laws and safety code requirements Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions ING EXPLOSION HAZARD Models containing alu minum wetted parts cannot be used with Ill Trichloroethane Methylene Chloride or other Halogenated Hydrocarbon sol vents which may react and explode Check pump motor section fluid caps manifolds and all wetted parts to assure compatibility before using with sol vonis of this type R G MISAPPLICATION HAZARD Do not use models containing aluminum wetted parts with food products for hu man consumption Plated parts can contain trace amounts of lead A CAUTION Verify the chemical compatibility of the pump wetted parts and th
17. r components are able to with stand fluid pressures developed by this pump Check all hoses for damage or wear Be certain dispensing device is clean andi in proper working condition IG STATIC SPARK Can cause explosion resulting in severe injury or death Ground pump and pumping system Use the pump grounding screw terminal provided Use Aro Part No 66885 1 Ground Kit or connect a suitable ground wire 12 ga min to a good earth ground source Secure pump connections and all contact points to avoid vibration and generation of contact or static spark Consult local building codes and electrical codes for specific grounding requirements After grounding periodically verify continuity of electrical path to ground Test with an ohmmeter from each component e g hoses pump clamps container spray gun etc to ground to insure continuity Ohmmeter should show 100 ohms or less Submerse the outlet hose end dispensing valve or device in the material being dispensed if possible Avoid free stream ing of material being dispensed Use hoses incorporating a static wire Use proper ventilation Keep inflammables away from heat open flames and sparks Keep containers closed when not in use Pump exhaust may contain contaminants Can cause severe injury Pipe exhaust away from work area and personnel In the event of a diaphragm rupture material can be forced out of the air exhaust muffler Pipe the exhaust to a safe remote locat
18. ssembly Tool is rec ommended for use when reassembling the pump e Reassemble in reverse order e Clean and inspect all parts Replace worn or damaged parts with new parts as required Lubricate 1 diaphragm rod and 144 U cup with Lubriplate FML 2 Grease 94276 grease packet is included in service kit Be certain the diaphragm assembly bottoms out on the 1 rod back off Teflon Diaphragm assembly far enough to align holes e For models with Teflon diaphragms Item 8 Santoprene dia phragm is installed with the side marked AIR SIDE towards the pump center body Install the 7 PTFE Diaphragm with the side marked FLUID SIDE towards the fluid cap e Re check torque settings after pump has been re started and run a while Kynar is a registered trademark of Penwalt Corp Geolast is a registered trademark of Advanced Elastomer Systems Santoprene is a registered trademark of Monsanto Company licensed to Advanced Elastomer Systems L P PD30X X PAGE 30F8 PARTS LIST PD30X X FLUID SECTION FLUID SECTION SERVICE KITS 637303 XX KITS INCLUDE BALLS See Ball Option refer to XX in chart below DIAPHRAGMS See Diaphragm Option refer to XX in chart below and items 19 70 144 175 listed below plus 174 and 94276 Lubriplate FML 2 grease page 6 SEAT OPTIONS PD30X XXX XXX 917 x 19 21 Xx 19 XXX SEAT m MTL GASKET ux MTL XXX x sm 4 MTL GASKET arv 9
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