Ingersoll-Rand PD10E-X-X User's Manual
Contents
1. 132 176x 101 181 Insert screwdriver here to remove 233 adapter plate c TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS ALL FASTENERS ARE METRIC Torque 105 and 134 screw to 35 40 in Ibs 4 0 4 5 Nm LUBRICATION SEALANTS Apply Lubriplate FML 2 grease to O rings U Cups amp mating parts 55 Apply anti seize compound to threads at assembly A 637395 7 replacement Major Valve Service Assembly is available separately which includes the following 105 4 107 2 111 132 135 136 137 138 139 140 141 166 176 2 200 233 and 236 4 PD10E X X en Page 7 of 8 TROUBLE SHOOTING Product discharged from exhaust outlet e Check for diaphragm rupture Low output volume erratic flow or no flow Check air supply e Check tightness of 6 diaphragm screw e Check for plugged outlet hose e Check for kinked restrictive outlet material hose Air bubbles in product discharge e Check for kinked restrictive or collapsed inlet e Check connections of suction plumbing material hose e Check O rings between intake manifold and inlet side e Check for pump cavitation suction pipe should be fluid caps sized at least as large as the inlet thread diameter of e Check tightness of 6 diaphragm screw the pump for proper flow if high viscosity fluids are being pumped Suction hose must be a non collaps Motor blows air or stalls i2. 1159 Page 8 of 8 PD10E X X en
3. 4 M DIAPHRAGM OPTIONS PD10E FES XXX SERVICE KIT x 7 48 19 ASS XX Ball O Ring O Ring XX Diaphragm Diaphragm Qty Mtl Diaphragm Qty Mtl 1 8 x2 1 8 0 d Qty Mtl 1 8 x1 5 8 0d Qty Mtl axa ss7s96xa _ osara a isei oo a foo Ja eel acesse ___ oeaor c a wi roras w i roam wo w_ rag 6373066 lozers a wi rosas w vor frasz w ool ert 6573067 orse a rm osrasa isr osz w mm fos w mi rao ss7ae6av os a _ raras w i veo w w_ COMMON PARTS item Description size ty Pareno mmen tem peseription szei aty PartNo men apea ffs a orl ouetmanitoa m fos19e3 1601 5 Beckupwasher osso iss C celare f n fosroes oer ofpiaphragmsaew osos e C eolaire n forore 1601 isfra a fosa ice aolo f a oseas T issi 25 serewexiasenxsomm 16 95880 issi _131 screwmexias coximmm e 96716 ie 27 serewiessas coxsonm 2a sores iss ea urupa e vias i C 2e washeresnmiay wm e627 issi 47 175 OrRingosrwaneoa e yazsa coi 29 Fangenewexsas cn a 96220 issi a 710 oning asmmammoan 96252 SSI ia round tug ceems 93008 cor 195 Her Fange nutwaxras om a 95679 SS C eo imermanioa m 961953 ieri V Air Section Service Kit parts see page 6 Page
4. 4 of 8 PD10E X X en PARTS LIST PD10E X X FLUID SECTION Torque Sequence COLOR CODE FOR TH E DIAPHRAGM BALL O AIR MOTOR SECTION MATERIAL COLOR COLOR SEE PAGES 6 amp 7 Hytrel Cream Cream 0 Q Nitrile Black Red e In Santoprene Tan Tan 26 w Santoprene Green N A C Backup 61 T F E Teflon White White Viton Yellow Yellow e O Dash Dot 68 A gt 131wA 70x T gt pi 144x 70x 69 278 144x 175x 175x 180x 195 26 60 Figure 2 c TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS ALL FASTENERS ARE METRIC 6 Diaphragm washer 25 30 ft Ibs 33 9 40 7 Nm lubri cate face with Lubriplate grease and apply Loctite 271 to threads 26 Screws 10 12 ft Ibs 13 6 16 3 Nm VIEW OF TWO PIECE TEFLON DIAPHRAGM AUXILIARY VIEW A A 29 Nuts 10 12 ft Ibs 13 6 16 3 Nm 131 Screws tighten to 11 14 ft Ibs 14 9 19 0 Nm LUBRICATION SEALANTS Xx Apply Lubriplate FML 2 grease to all O rings U cups amp mating parts Apply Loctite 242 to threads at assembly 5E Apply anti seize compound to threads and bolt and nut flange heads which contact pump case when using stainless steel fasteners Santoprene 8 7 Teflon Lubriplate FML 2 is a white food grade petroleum grease PD10E X X en Page 5 of 8 PARTS LIST PD10E X X
5. 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 dif ferential 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 pressure and will stop cycling once maxi mum line pressure is reached dispensing device closed and will resume pumping as needed AIR AND LUBE REQUIREMENTS AMARNING EXCESSIVE AIR PRESSURE Can cause pump damage personal injury or property damage e A filter capable of filtering out particles larger than 50 microns should be used on the air supply There is no lu brication required other than the O ring lubricant which is applied during assembly or repair If lubricated air is present make sure that it is compatible with the O rings and seals in the air motor section of the pump INSTALLATION e Verify correct model configuration prior to installation e Retorque all external fasteners per specifications prior to start up e Pumps are tested in water at assembly Flush pump with compatible fluid prior to installation e When the diaphragm pump is used in a forced feed flooded inlet situatio
6. AIR SECTION v Indicates parts included in 637397 Air Section Service Kit shown below and items 70 144 175 and 180 shown on page 4 AIR MOTOR PARTS Mtem Description sze ty PartNo Mt io apioa o 12009 70 Pistonsiewe oer a 4171 O Ringasz xris od m 325 119 B1 0 Ring 1 16 x 1 1 8 o d 1 325 22 B 173 O Ringans xtsis od 2 325 26 BI 7174 O Ringiverxva oa 2 325 202 B1 are Diairagm cater a aston is 181 RollPin si2 ed x12 1ong 4 178 52 S B1 ato coset fen ose Tr Con me or mse _ 233 napere sen 236 Nutmsx1 em a 95924 Iss a7 errr czas oar _ init Grease Paces v0 687308 MATERIAL CODE 1em Description size Taty Pareno IME F101 cemergoay m ossa iori F103 Bushing m 6000 o F105 serew mexicano ia oses Iss Corera ee fa sono iss mjs fs O o Caf actuatoren f foss iss afse a O o mafas fo o o Cis Washerwa i soa 136 Serewixrerxzemm 6 seer Iss Cis vaneso m oers ss isje n foses o arfas fo sone Tasucu n vassa r 7139 ucena n vissa e 140 0 tao 141 1 AO ofern m 7 Pa ener o 95838 Valve Plate 95885 ase assor ningarna a ass w 67 Piot Piston traus samar en s026 181 x Fluid Section Service Kit see page 4 AO Alumina Oxide P Polypropylene B Nitrile S
7. MBLY end cap to 135 valve block securing with 107 end plates and 105 screws 1 Alight tap on 118 should expose the opposite 121 sleeve NOTE Tighten 105 screws to 35 40 in Ibs 4 0 4 5 Nm 167 pilot piston and other parts 4 Install 140 valve insert and 141 valve plate into 135 2 Remove 170 sleeve inspect inner bore of sleeve for damage valve block NOTE Assemble 140 valve insert with SSS In O O e dished side toward 141 valve plate Assemble 141 PILOT VALVE REASSEMBLY valve plate with part number identification toward 140 f f TR Ive insert 1 Clean and lubricate parts not being replaced from service kit Ai 2 Install new 171 and 172 O rings replace 170 sleeve 5 aia gasket and 233 adapter plate to 135 3 Install new 168 O rings and 169 seal Note the lip direc tion Lubricate and replace 167 4 Reassemble remaining parts replace 173 and 174 O rings NOTE Assemble 233 adapter plate with notched side down Assemble 132 and 166 gaskets and 176 checks and to 101 body 7 Assemble 135 valve block and components to 101 body securingwith 134 screws NOTE Tight en 134 screws to 35 40 in lbs 4 0 4 5 Nm Page 6 of 8 PD10E X X en PARTS LIST PD10E X X AIR SECTION 118 173x 140 Figure 3 6 169x 200x sh LIP 168x s PILOT VALVE PART GROUP 173x 118 121 174x
8. OPERATOR S MANUAL PD10E X X INCLUDING OPERATION INSTALLATION amp MAINTENANCE RELEASED 6 15 05 REVISED 5 25 09 REV 03 1 DIAPHRAGM PUMP 1 1 RATIO CONDUCTIVE NON METALLIC T READ THIS MANUAL CAREFULLY BEFORE INSTALLING L OPERATING OR SERVICING THIS EQUIPMENT It is the responsibility of the employer to place this information in the hands of the operator Keep for future reference SERVICE KITS Refer to Model Description Chart to match the pump material options 637397 for air section repair see page 6 637396 XX for fluid section repair see page 4 NOTE This kit also contains several air motor seals which will need to be replaced 637395 7 major air valve assembly see page 7 PUMP DATA Models see Model Description Chart for XXX Pump Type Non Metallic Air Operated Double Diaphragm Material see Model Description Chart Weightsiccsiiesenadsars vevtvsanecs 20 41 Ibs 9 26 kgs Maximum Air Inlet Pressure 120 p s i g 8 3 bar Maximum Material Inlet Pressure 10 p s i g 0 69 bar pe Maximum Outlet Pressure 120 p s i g 8 3 bar FOTOT TESTA Figure 1 Maximum Flow Rate flooded inlet 53 0 g p m 200 6 p m 7 7 RECCDIDTIANI CUADT Displacement Cycle 100 p s i g 0 226 gal 0 86 lit _____ MODEL DESCRIPTION CHART __ Maxim
9. P Santoprene Br Brass SS Stainless Steel D Acetal U Polyurethane GP Groundable Polypropylene AIR MOTOR SECTION SERVICE MAJOR VALVE DISASSEMBLY Service is divided into two parts 1 Pilot Valve 1 Remove 135 valve block and 233 adapter plate expos 2 Major Valve GENERAL REASSEMBLY NOTES ing 132 and 166 gaskets and 176 checks e Air Motor Section Service is continued from Fluid Section repair 2 Insert a small flat blade screwdriver into the notch e Inspect and replace old parts with new parts as necessary Look in the side of 135 valve block and push in on tab for deep scratches on surfaces and nicks or cuts in O rings to remove 233 adapter plate releasing 140 valve e Take precautions to prevent cutting O rings upon installa insert 141 valve plate and 200 gasket tion 3 Remove 136 end cap and 137 O ring releasing 111 e Lubricate O rings with Lubriplate FML 2 grease spool e Do not over tighten fasteners refer to torque specification MAJOR VALVE REASSEMBLY block on view a O e Re torque fasteners following restart 1 Install new 138 and 139 U cups on 111 spool e SERVICE TOOLS To aid in the installation of 168 O rings onto LIPS MUST FACE EACH OTHER the 167 pilot piston use tool 204130 T available from ARO Insert 111 spool into 135 valve block 3 Install 137 gasket on 136 end cap and assemble Y PILOT VALVE DISASSE
10. agm INGERSOLL RAND COMPANY LTD TX P O BOX 151 e ONE ARO CENTER BRYAN OHIO 43506 0151 ARO GR Ingersoll Rand 800 276 4658 FAX 800 266 7016 2009 CCN 15244940 a OPERATING AND SAFETY PRECAUTIONS READ UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE e Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions AMARNING EXPLOSION HAZARD Models contain HAZARDOUS MATERIALS HAZARDOUS PRESSURE Eog EXCESSIVE AIR PRESSURE 4 STATIC SPARK fe ZNWARNING EXCESSIVE AIR PRESSURE Can cause per sonal 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 other components are able to withstand fluid pressures developed by this pump Check all hoses for damage or wear Be certain dispens ing device is clean and in proper working condition ZAWARNINGS STATIC SPARK Can cause explosion resulting in severe injury or death Ground pump and pumping system Sparks can ignite flammable material and vapors The pumping system and object being sprayed must be grounded when it is pumping flushing recirculating or spraying flammable materials such as paints solvents lacquers etc or used in a location where surrounding atmosphere is conducive to spontaneous combustion Ground the dispensing valve or device
11. containers hos es and any object to which material is being pumped 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 con tainer spray gun etc to ground to insure continuity Ohmmeter should show 0 1 ohms or less Submerse the outlet hose end dispensing valve or device in the material being dispensed if possible Avoid free streaming 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 location when pumping hazardous or inflammable materials Use a grounded 3 8 minimum i d hose between the pump and the muffler ZNWARNING 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 system by opening dispensing valv
12. e or device and or carefully and slowly loosening and removing out let hose or piping from pump ZNWARNING 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 ing aluminum wetted parts cannot be used with IIl Trichloroethane Methylene Chloride or other Halo genated Hydrocarbon solvents which may react and explode e Check pump motor section fluid caps manifolds and all wetted parts to assure compatibility before using with solvents of this type AMARNING MISAPPLICATION HAZARD Do not use models containing aluminum wetted parts with food products for human consumption Plated parts can contain trace amounts of lead A CAUTION Verify the chemical compatibility of the pump wetted parts and the substance being pumped flushed or recirculated Chemical compatibility may change with temperature and concentration of the chemical s within the substances being pumped flushed or circulated For specific fluid compatibility consult the chemical manufacturer Maximum temperatures are based on mechanical stress only Certain chemicals will significantly reduce maximum safe operating temperature Consult the chemical manufacturer for chemical compatibility and temperature limits Refer to PUMP DATA on page 1 of this ma
13. for fast repair and reduction of down time e Service kits are divided to service two separate diaphragm pump functions 1 AIR SECTION 2 FLUID SECTION The Fluid Section is divided further to match typical part Material Options MAINTENANCE e Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during service disassembly and reassembly e Keep good records of service activity and include pump in preventive maintenance program e Before disassembling empty captured material in the outlet manifold by turning the pump upside down to drain material from the pump FLUID SECTION DISASSEMBLY 1 Remove 60 outlet manifold 61 inlet manifold 2 Remove 22 balls 19 and 33 O rings and 21 seats 3 Remove 15 fluid caps NOTE Only Teflon diaphragm models use a primary diaphragm 7 and a backup diaphragm 8 Refer to the auxiliary view in the Fluid Section illustration 4 Remove the 6 diaphragm washer 7 or 7 8 diaphragms and 5 backup washer NOTE Do not scratch or mar the surface of 1 diaphragm rod FLUID SECTION REASSEMBLY e Reassemble in reverse order Refer to the torque requirements on page 5 e Clean and inspect all parts Replace worn or damaged parts with new parts as required e Lubricate 1 diaphragm rod and 144 U cup with Lubri plate FML 2 grease 94276 grease packet is included in ser vice kit e For models
14. n it is recommended that a check valve be installed at the air inlet e Material supply tubing should be at least the same diam eter as the pump inlet manifold connection e Material supply hose must be reinforced non collapsible type compatible with the material being pumped e Piping must be adequately supported Do not use the pump to support the piping e Use flexible connections such as hose at the suction and discharge These connections should not be rigid piped and must be compatible with the material being pumped e Secure the diaphragm pump legs to a suitable surface level and flat to insure against damage by vibration e Pumps that need to be submersed must have both wet and non wet components compatible with the material being pumped e Submersed pumps must have exhaust pipe above liquid level Exhaust hose must be conductive and grounded e Flooded suction inlet pressure must not exceed 10 p s i g 0 69 bar 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 PARTS AND SERVICE KITS 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
15. ng type capable of pulling a high vacuum e Check 176 check valve for damage or wear e Check all joints on the inlet manifolds and suction e Check for restrictions in valve exhaust connections These must be air tight e Inspect the pump for solid objects lodged in the dia phragm chamber or the seat area DIMENSIONAL DATA ____ 4 1 8 358 5 mm be 8 5 16 211 1 mm Dimensions shown are for reference only they are displayed in inches and millimeters mm 1 A N S I DIN Flange e 16 1 32 407 0 mm k 6 31 32 176 6 mm a n i GP hngepsal can ni Outlet E g 16 1 32 407 0 mm g q D i 13 25 32 i gl 349 8 mm 5 d p a J A Inlet 8 1 32 203 4 mm D T 2 2 11 32 i 59 4 i CI E i 1 m 5 1 32 E 1 2 12 7 mm 7 16 11 1 mm 127 6 mm 6 9 32 4 1 16 10 1 16 255 3 mm 159 6 mm 103 0 mm H 16 1 32 407 3 mm Figure 4 Air Inlet 1 4 18 N PT am Ingersoll Rand Industrial Technologies ARO PN 97999
16. nual Be certain all operators of this equipment have been trained for safe working practices understand it s limitations 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 connections such as hose not rigid piped and should be compatible with the substance being pumped Prevent unnecessary damage to the pump Do not allow pump to operate when out of material for long periods of time e Disconnect air line from pump when system sits idle for long periods of time Use only genuine ARO replacement parts to assure compatible pressure rating and longest service life NOTICE RE TORQUE ALL FASTENERS BEFORE A CAUTION Hazards or unsafe practices which OPERATION Creep of housing and gasket materials may cause fasteners to loosen Re torque all fasteners to insure against fluid or air leakage Hazards or unsafe practices which could result in severe personal injury death or substantial property damage could result in minor personal injury product or property damage NOTICE Important installation operation or maintenance information Page 2 of 8 PD10E X X en GENERAL DESCRIPTION The ARO diaphragm pump offers high volume delivery even at low air pressure and
17. um Particle Size 1 8 dia 3 2 mm Maximum Temperature Limits diaphragm ball seal material PDIOE FES PXX E PR EPDM 0 60 to 280 F 51 to 138 C Center Section Material Hytrel E E EE 20 to 150 F 29 to 66 C E Conductive Polypropylene Nitrile o 10 to 180 F 12 to 82 C REEE Seton Folypronyine T Bo oe F 2 to 79 c F 1 A N S I DIN Flange End Santoprene sse 40 to 225 F 40 to 107 C E TFE Teflon o i 40 to 225 F 4 to 107 C Fluid Caps amp Manifold Material Viton oiiire 40 to 350 F a0 to 70 C eee ee Dimensional Data 5 see page 8 agarose Mounting Dimension 5 032 x 10 050 127 8 mm x 255 3 mm 2 S otainess otee Noise Level 70 p s i 50 c p m 85 0 db A Seat Material P_ Polypropylene Th d levels published here have been updated to an Equivalent o a a ealbiaiadl 5 1 using four microphone locations A Santoprene T T FE Teflon C Hytrel V Viton NOTICE All possible options are shown in the chart however G Nitrile certain combinations may not be recommended consult a Diaphragm Material representative or the factory if you have questions concerning A Santoprene T TFE Teflon Santoprene availability z ta V Viton Nitrile FLUID SECTION SERVICE KIT SELECTION PD10 FES P X X EXAMPLE Model PD10E FES PAA 637396 X X Fluid Section Service Kit 637396 AA Ball Diaphr
18. with Teflon diaphragms Item 8 Santoprene diaphragm is installed with the side marked AIR SIDE towards the pump center body Install the Teflon diaphragm 7 with the side marked FLUID SIDE towards the 15 fluid cap e Re check torque settings after pump has been re started and run a while eViton Teflon and Hytrel are registered trademarks of the DuPont Company Loctite is a registered trademark of Henkel Loctite Corporation e Santoprene is a registered trademark of Monsanto Company licensed to Advanced Elastomer Systems L P Lubriplate is a registered trademark of Lubriplate Division Fiske Brothers Refining Company e PD10E X X en Page 3 of 8 PARTS LIST PD10E X X FLUID SECTION FLUID SECTION SERVICE KITS 637396 XX x KITS INCLUDE BALLS see Ball Option refer to XX in Service Kit chart below DIAPHRAGMS see Diaphragm Option refer to XX in Service Kit chart below and items 19 33 70 144 175 and 180 listed below plus 174 and 94276 Lubriplate FML 2 grease page 6 SEAT OPTIONS BALL OPTIONS _______MATERIALCODE__ PD10E FES XXX PD10E FES XXX B Nitrile meee es a C Carbon Steel 21 22 2 1 4 dia Co Copper E EPR XXX XXX Ball Qty Mtl GP Groundable Polypropylene z H Hytrel xax fosar a SP i e 93278 c 4 IH SP Santoprene E SS Stainless Steel xGX 93278 2 4 B a ean 93278 4 4 m VI Viton 93278 3
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