Ingersoll-Rand PD05P-XXX-XXX-B User's Manual
Contents
1. Dimensions shown are for reference only they are displayed in inches and millimeters mm T Air Inlet U Material Outlet U Material Outlet wt A jaa E j F i K S ry ry B T N G i Lo vy ami M l H al m L J U Material Inlet U Material Inlet DIMENSIONS A 10 1 32 254 8 mm F 6 1 32 153 1 mm L 1 15 16 48 9 mm R 3 3 32 78 5 mm B 10 3 32 256 1 mm G 10 29 32 276 8 mm M 3 8 9 6 mm S 1 9 16 39 7 mm C 6 3 16 157 1 mm H 4 29 32 124 2 mm N 6 11 32 160 5 mm T 1 4 18 PT F SAE Short D 2 51 0 mm J 5 17 32 140 2 mm P 8 29 32 225 9 mm U see below E 6 3 4 171 0 mm K 5 16 8 0 mm Q 5 1 32 127 4 mm Pump Model U Material Inlet Outlet PDO5P AXS XXX B 1 2 14 N PT F 1 Figure 5 PDOS5P BXS XXX B Rp 1 2 1 2 14 BSP parallel ARO am Ingersoll Rand Industrial Technologies PN 97999 1164 Page 8 of 8 PDO5P XXX XXX B en2. LLI ELI TETI S TTTTTTTTT EEEF FLA ITTO TT fs Figure 2 e Hytrel Teflon and Viton are registered trademarks of the DuPont Company Kynar is a registered trademark of Arkema Inc ARO is a registered trademark of Ingersoll Rand Company e e Santoprene is a registered trademark of Monsanto Company licensed to Advanced Elastomer Systems L P e Loctite and 242 are registered trademarks of Henkel Loctite Corporation e Lubriplate is a registered trademark of Lubriplate Division Fiske Brothers Refining Company PDO5SP XXX XXX B en Page 3 of 8 PARTS LIST PDOSP XXX XXX B FLUID SECTION 637427 XX Fluid section service kit includes Balls see Ball Option refer to XX in chart below Diaphragms see Diaphragm Option refer to XX in chart below and item 19 listed below plus items 144 174 and 94276 Lubriplate FML 2 grease pages 6 SEAT OPTIONS BALL OPTIONS PD05P XXX XXX B PD05P XXX XXX B 94 22 3 4 diameter XXX Seat ty oxa sesr2 101 ror 365723 va Foc oes salos ist Ex MATERIAL CODE A Alumi O Service Kit B ia XX Ball a a XX Diaphragm GA Groundable Acetal 637427 XA 93465 93763 GFN Glass filled Nylon H Hytrel 637427 XC 93465 9 325 122 KI Kynar PVDF P Polypropylene XXG 637427 XG 193465 G 325 122 spi Santopiene SS Stainless Steel XXT 63
3. 1410 Sa MAJOR VALVE 0 e Figure 4 200 637438 optional 232 130 129 201 optional 101 118 121 1740 1730 PILOT VALVE PARTS 123 screw 4 6 in Ibs 0 45 0 68 Nm 134 bolt torque to 15 20 in Ibs 1 7 2 3 Nm wait 10 minutes Apply Lubriplate FML 2 grease to all O rings U cups and mat ASSEMBLY TORQUE REQUIREMENTS NOTE DO NOT OVERTIGHTEN FASTENERS then re torque to 15 20 in Ibs 1 7 2 3 Nm LUBRICATION SEALANTS ing parts i MAJOR VALVE REASSEMBLY Assemble new 139 and 138 U cups on 111 spool LIPS MUST FACE EACH OTHER Assemble 137 O rings to 136 large plug Assemble 137 and 166 O rings to 107 small plug Insert 111 spool into 136 large plug then insert 136 large plug into 135 valve block being sure the 111 spool is rotated to accept 140 valve insert Assemble 107 small plug into 135 valve block Assemble 140 valve insert and 141 valve plate to 135 valve block NOTE Assemble 140 valve insert with dished side toward 141 valve plate Assemble 141 valve plate with iden tification dot toward 132 gasket Assemble 132 and 200 gaskets 135 valve block and 129 muffler assembly to 101 center body securing with 134 bolts NOTE Tighten 134 bolts to 15 20 in Ibs 1 7 2 3 Nm PDO5SP XXX X
4. prene diaphragm behind the Teflon diaphragm AIR MOTOR SECTION SERVICE Service is divided into two parts 1 Pilot Valve 2 Major Valve e Air Motor Section service is continued from Fluid Section repair PILOT VALVE DISASSEMBLY 1 Remove 123 screws releasing 103 covers 121 washers 118 actuator pins and 167 pilot piston 2 Remove 170 spool bushing and inspect inner bore of bushing for damage PILOT VALVE REASSEMBLY 1 Clean and lubricate parts not being replaced from service kit 2 Assemble 171 O rings to 170 bushing and assemble bush ing into 101 center body 3 Lubricate and assemble 167 pilot piston assembly into 170 bushing 4 Assemble 173 and 174 O rings and 121 washers to 103 covers then insert 118 actuator pins through assembly 5 Assemble 144 U cups note the lip direction and 103 cov ers to 101 center body securing with 123 screws NOTE tighten 123 screws to 4 6 in Ibs 0 45 0 68 Nm MAJOR VALVE DISASSEMBLY Unthread 134 bolts releasing 129 muffler assembly 2 Pull 135 valve block and components from 101 center body 3 Remove 132 gasket 141 valve plate and 140 valve insert from 135 valve block 4 Remove 134 bolts releasing 107 and 136 plugs and 111 spool Page 6 of 8 PDO5P XXX XXX B en PARTS LIST PDOSP XXX XXX B AIR MOTOR SECTION daa VALVE PARTS A 144 118 1690 1680 1710
5. 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 dispensing device is clean and in proper working condition ZAWARNING STATIC SPARK Can cause explosion resulting in severe injury or death Ground pump and pumping system PDO5P XDS XXX B and PDO5P XES XXX B Groundable Ac etal pumps Use the pump ground lug provided Connect to a 12 ga minimum wire kit is included to a good earth ground source e Sparks can ignite flammable material and vapors e The pumping system and object being sprayed must be grounded when it is pumping flushing recirculating or spraying flammable materials such as paints solvents lac quers etc or used in a location where surrounding atmo sphere is conducive to spontaneous combustion Ground the dispensing valve or device containers hoses 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 spe cific grounding requirements After grounding periodically verify continuity of electrical path to ground Test with an ohmmeter from each compo nent e g hoses pump clamps container spray gun etc to ground to insure continuity Ohmmeter should show 0 1 ohms or less S
6. 039 gal 0 15 lit Maximum Particle Size 3 32 dia 2 4 mm Maximum Temperature Limits diaphragm ball seat material Acetal osue 10 to 180 F 12 to 82 C HYtre lcs sccttesmessimes eencnaae 20 to 150 F 29 to 66 C Kynar PVDF eeee eee 10 to 200 F 12 to 93 C Nitrile s iaccrre ne iniii aac 10 to 180 F 12 to 82 C Polypropylene 0065 35 to 175 F 2 to 79 C Polyurethane 00005 10 to 150 F 12 to 66 C Santoprene 0085 40 to 225 F 40 to 107 C Teflon PITRE cresernerecarerniss 40 to 225 F 4 to 107 C VION iae deseercnnmbbnees deans 40 to 350 F 40 to 177 C Groundable Models PD05P XDS XXX B PDO5P XES XXX B Dimensional Data see page 8 Noise Level 70 p s i 60 c p m 75 0 db A The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound Level Laeq to meet the intent of ANSI 1 13 1971 CAGI PNEUROP S5 1 using four microphone locations NOTICE All possible options are shown in the chart however certain combinations may not be recommended consult a representative or the factory if you have questions concerning availability INGERSOLL RAND COMPANY LTD P O BOX 151 e ONE ARO CENTER BRYAN OHIO 43506 0151 800 276 4658 e FAX 800 266 7016 2009 CCN 15250376 fluids ingersoll
7. 7427 XT 93111 T Teflon PTFE V Viton Item Description size Diaphragm Nut 5 16 18 15 Fluid Cap 43 Ground Strap Ground Kit Assembly not shown 1 Inlet Manifold N P T F m Outlet Manifold N P T F he Pipe Plug 1 2 14 N P T x 9 16 R 1 2 1 2 14 BSP taper COMMON PARTS Description size Qty Part No Item Description size Qty Part No Connecting Rod 1 96379 93095 Diaphragm Washer 94645 29 Hex Flange Nut 5 16 18 20 93886 Flange Bolt 5 16 18 x 7 8 a 96176 Logo Plate 2 DUAL INLET DUAL OUTLET KITS 637440 X Polypropylene Kynar PVDF Groundable Acetal 637440 1 N P T 637440 4 BSP 637440 3 N P T 637440 6 BSP 637440 2 N P T 637440 5 BSP Item Description size Qty Part No Part No F 17 uatiniet manitola 989141 1 95914 i 95914 3 ii 05914 6 1i 95914 2 roa sspr65 roa 18 pualinietmanitoa a 98915 1 1P 959154 Smart Parts keep these items on hand in addition to the service kits for fast repair and reduction of down time Page 4 of 8 PDO5P XXX XXX B en PARTS LIST PDOSP XXX XXX B FLUID SECTION FOR THE AIR MOTOR SEC ASSEMBLY TORQUE REQUIREMENTS TION SEE PAGES 6 AND 7 NOTE DO NOT OVERTIGHTEN FASTENERS 6 diaphragm nut 95 105 in Ibs 10 7 11 9 Nm 26 bolt and 29 nut 50 60 in Ibs 5 6 6 8 Nm alternately and evenly then re torque after initial run i
8. N HAZARD Models containing alu minum parts cannot be used with 1 1 1 trichloroethane methylene chloride or other halogenated 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 sol vents of this type ZAWARNING MISAPPLICATION HAZARD Do not use models containing aluminum wetted parts with food products for human consumption Plated parts can contain trace amounts of lead ZX CAUTION Verify the chemical compatibility of the pump wetted parts and the substance being pumped flushed or recirculated Chemical compatibility may change with tem perature and concentration of the chemical s within the substances being pumped flushed or circulated For spe cific fluid compatibility consult the chemical manufacturer Maximum temperatures are based on mechani cal stress only Certain chemicals will significantly reduce maximum safe operating temperature Consult the chemi cal manufacturer for chemical compatibility and tempera ture limits Refer to PUMP DATA on page 1 of this manual ZX CAUTION Be certain all operators of this equipment have been trained for safe working practices understand it s limitations and wear safety goggles equipment when re quired 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
9. OPERATOR S MANUAL PDO5P XXX XXX B INCLUDING OPERATION INSTALLATION amp MAINTENANCE 1 2 DIAPHRAGM PUMP RELEASED 8 27 08 REVISED 10 16 09 REV 04 1 1 RATIO NON METALLIC LL READ THIS MANUAL CAREFULLY BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT It is the responsibility of the employer to place this information in the hands of the operator Keep for future reference SERVICE KITS Refer to Model Description Chart to match the pump material op tions 637427 XX for fluid section repair see page 4 637428 for air section repair see page 6 PUMP DATA Models see Model Description Chart for XXX Pump Type Non Metallic Air Operated Double Diaphragm Material see Model Description Chart Weight PDOSP XDS XXX B 6 28 Ibs 2 85 kgs PDO5SP XES XXX B 05 6 67 lbs 3 03 kgs PDO5P XKS XXX B 055 6 78 lbs 3 08 kgs PDO5SP XLS XXX B 005 7 24 lbs 3 28 kgs PDO5P XPS XXX B 055 5 21 lbs 2 36 kgs PDO5P XRS XXX B 2000 5 44 Ibs 2 47 kgs Maximum Air Inlet Pressure 100 p s i g 6 9 bar Maximum Material Inlet Pressure 10 p s i g 0 69 bar Maximum Outlet Pressure 100 p s i g 6 9 bar Air Consumption 40 p si 1 cfm gallon approx Maximum Flow Rate flooded inlet 14 4 g p m 54 5 l p m Displacement Cycle 100 p s i g 0
10. XX B en Page 7 of 8 TROUBLE SHOOTING Product discharged from exhaust outlet Low output volume e Check for diaphragm rupture e Check air supply e Check tightness of 6 diaphragm nut e Check for plugged outlet hose Air bubbles in product discharge e Check connections of suction plumbing e Check O rings between intake manifold and fluid caps e Check tightness of 6 diaphragm nut Motor blows air out main exhaust when stalled on either stroke e Check U cups on 111 spool in major valve e Check 141 valve plate and 140 insert for wear e Check 169 U cup on 167 pilot piston For the pump to prime itself it must be mounted in the vertical position so that the balls will check by gravity 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 collapsing type capable of pulling a high volume Check all joints on the inlet manifolds and suction connections These must be air tight Inspect the pump for solid objects lodged in the diaphragm chamber or the seat area DIMENSIONAL DATA
11. n LUBRICATION SEALANTS Apply Lubriplate FML 2 grease to all O rings U cups and mating parts Apply pipe sealant to threads Apply anti seize compound to threads and bolt and nut flange heads which contact pump case when using stainless steel fasteners Apply Loctite 242 to threads Note Lubriplate FML 2 is a white food grade petroleum grease 61 PDO5P XDS XXX B PDO5P XKS XXX B PDOS5P XPS XXX B 26 61 PDO5SP XES XXX B PDO5P XLS XXX B PDOS5P XRS XXX B 190 27 60 PD05P XES XXX B 21 PDOSP XLS XXX B PDOSP XRS XXX B 190 Figure 3 63 View for PDO5P XXS XXT B Teflon 60 PDOSP XDS XXXB diaphragm configuration only PDOSP XKS XXX B Fluid side Teflon white 7 j PD05P XPS XXX B 18 COLOR CODE Diaphragm Ball Material Color Color Hytrel Cream Black Nitrile Black Red Polyurethane Clear Red Santoprene Tan Tan Teflon PTFE White White Viton Yellow Yellow Dot 8 Air side Santoprene tan PDO5P XXX XXX B en Page 5 of 8 PARTS LIST PDOSP XXX XXX B AIR MOTOR SECTION Indicates parts included in 637428 air section service kit AIR MOTOR PARTS LIST ttem Description tee Qty PartNo me or centersoy n faa rrai osr cover vons fn osor 101 rost coveroensea fo fosst fior 107 Pug sma fo fos fior mm majorvavespo fon f
12. nut 7 or 7 8 diaphragms and 5 washer 7 Remove 1 connecting rod from air motor 8 Carefully remove remaining 6 diaphragm nut 7 or 7 8 dia phragms and 5 washer from 1 connecting rod Do not mar surface of connecting rod FLUID SECTION REASSEMBLY e Reassemble in reverse order e Lubricate 1 connecting rod with Lubriplate or equivalent O ring lubricant e Connecting rod 1 should be installed using 96571 bullet in cluded in service kit item Description sas Qty Pareno mea 0 vavemnser m 9276 fico vai vaere fofos f U Cup Packing 3 16 x 1 o d 2 Y187 48 BI O Ring 1 16 x 1 1 4 o d 1 Y325 24 BI C6 167 Piot Piston nausrioomaresr 67582 0T 168 O Ring 1 16 x 7 16 o d 2 96459 ul 169 U Cup Packing 1 8 x 5 8 o d 96384 ti 170 peotBushing fo foso0 101 Com onnsa vs2517 m O Ring G7 718 od Fa v325 175 81 O Ring 3 32 x 11 32 o d 2 325 105 B1 0200 Porting Gasket on oessa ier C aon Mutter orion fn fastto Mia O Ring 1 16 x 3 8 o d optional 4 325 10 BI Ported Exhaust Kit includes items 637438 ooo 129 130 and 232 optional oo Lubriplate FML 2 grease 94276 Lubriplate Grease Packets 10 637308 e Install 5 washers with i d chamfer toward diaphragm e When replacing Teflon diaphragms install the 93465 Santo
13. oss Tir C nefaeuoren fafon _ ss Com wmer fefee To l m sewa f fosos ss 128 muther assembiy on e7367 lirai T0 129 Exhaust Cover ouran 67366 Pa Co 130 Gasteren fon fosto 159 0132 ir manitoid Gaskets o 962141 134 Flange Bolt 1 4 20 x 5 3 4 4 94871 issi iss vavesoa fn os204 frai 136 Plug tare fon foess2 ior O Ring 1 16 x 1 5 8 o d 3 Y325 23 BI U Cup Packing 1 8 x 1 o d a 94395 tu 139 U Cup Packing 1 8 x 1 7 16 o d 1 96383 ul Items included in fluid section service kit see page 4 MATERIAL CODE B Nitrile PPG Glass filled Polypropylene C Carbon Steel SS Stainless Steel Ck Ceramic Sy Syn Seal D Acetal U Polyurethane DIAPHRAGM PUMP SERVICE GENERAL SERVICE NOTES e Inspect and replace old parts with new parts as necessary Look for deep scratches on metallic surfaces and nicks or cuts in O rings e Tools needed to complete disassembly and repair e 7 8 socket or wrench 1 2 socket or wrench 3 8 socket or wrench 3 8 Allen wrench T 10 Torx screwdriver torque wrench measuring inch pounds O ring pick FLUID SECTION DISASSEMBLY 1 Remove 61 top manifold 2 Remove 19 O rings 21 seats and 22 balls 3 Remove 60 bottom manifold 4 Remove 19 O rings 21 seats and 22 balls 5 Remove 15 fluid caps 6 Remove 6 diaphragm
14. parts e Suction and discharge connections should be flexible con nections 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 as sure compatible pressure rating and longest service life NOTICE Install the pump in the vertical position The pump may not prime properly if the balls do not check by gravity upon start up NOTICE _ Re torque all fasteners before operation Creep of housing and gasket materials may cause fasteners to loosen Re torque all fasteners to insure against fluid or air leakage NOTICE Replacement warning labels are available upon request Static Spark pn 93616 1 Diaphragm Rupture pn 93122 ZAWARNING Hazards or unsafe practices which could result in severe personal injury death or substantial property damage ZX CAUTION Hazards or unsafe practices which could result in minor personal injury product or property damage NOTICE Important installation operation or maintenance information Page 2 of 8 PDO5P XXX XXX B en GENERAL DESCRIPTION The ARO diaphragm pump offers high volume delivery even at low air pressure and a broad range of material com
15. patibility options are 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 differen tial in the air chambers to alternately create suction and a 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 will continue to pump and keep up with the demand It will build and maintain line pressure and will stop cycling once maximum line pressure is reached dispensing device closed and will resume pumping as needed AIR AND LUBE REQUIREMENTS ZAWARNING EXCESSIVE AIR PRESSURE Can cause pump dam age 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 lubrication re quired other than the O ring lubricant which is applied during assembly or repair e f lubricated air is present make sure that it is compatible with the O rings and seals in the air motor section of the pump OPERATING INSTRUCTIONS e Always flush the pump with a solvent compatible with the ma terial being pumped if the material being pumped is subject to setting up when not in use for a period of time e Disconnect the air supply from the pump if it is to be inactive for a few hours e The outlet material volume is governed not only by the ai
16. r sup ply 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 valve be in stalled at the air inlet e Secure the diaphragm pump legs to a suitable surface to insure against damage by vibration MAINTENANCE e Certain ARO Smart Parts are indicated which should be avail able for fast repair and reduction of down time e Provide a clean work surface to protect sensitive internal mov ing parts from contamination from dirt and foreign matter dur ing service disassembly and reassembly e Keep good records of service activity and include the pump in preventive maintenance program e Service kits are available to service two separate diaphragm pump functions 1 AIR SECTION 2 FLUID SECTION The Fluid Section is divided further to match typical part Material Op tions e Before disassembling empty captured material in the outlet manifold by turning the pump upside down to drain material from the pump TYPICAL CROSS SECTION LEA EE TTT TTT EEE TTT TT TTT TTT rir ELIISA TA ATT T A
17. rand com Figure 1 MODEL DESCRIPTION CHART PDOSP XXS XXX B Center Section Material P Polypropylene Fluid Connection A 1 2 14N PTF 1 B Rp 1 2 1 2 14 BSP parallel luid Cap amp Manifold Material Groundable Acetal single port Groundable Acetal multiple port Kynar PVDF single port Kynar PVDF multiple port Polypropylene single port Polypropylene multiple port Hardware Material S Stainless steel Seat Material D Acetal K Kynar PVDF Polypropylene Stainless steel Ball Material A Santoprene Teflon PTFE C Hytrel Polyurethane G Nitrile Viton S Stainless steel Diaphragm Material A Santoprene T Teflon PTFE Santoprene C Hytrel U Polyurethane G Nitrile V Viton Fluid Section Service Kit Selection PDOSP XXX XXX B Example Model PD05P ARS SAA B 637427 XIX Fluid Section Service Kit 637427 AA Ball Diaphragm ARO aim Ingersoll Rand Industrial Technologies OPERATING AND SAFETY PRECAUTIONS READ UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE pa EXCESSIVE AIR PRESSURE p hfs STATIC SPARK EA RVA _ HAZARDOUS MATERIALS HAZARDOUS PRESSURE ZAWARNING EXCESSIVE AIR PRESSURE Can cause personal injury pump damage or property damage Do not exceed
18. ubmerse the outlet hose end dispensing valve or device in the material being dispensed if possible Avoid free streaming of material being dispensed e Use hoses incorporating a static wire e Use proper ventilation e Keep inflammables away from heat open flames and sparks Keep containers closed when not in use ZNSWARNING 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 ZAWARNING 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 valve or device and or carefully and slowly loosening and removing outlet hose or piping from pump HAZARDOUS MATERIALS Can cause serious in jury 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 e Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions ZAWARNING EXPLOSIO
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