How it Works
SANDPIPER
Loading...
M05
User Manual
40 pgs6.12 Mb0
User Manual
35 pgs6.38 Mb0
User Manual
26 pgs4.21 Mb0

SANDPIPER M05 User Manual

Download
Page 1
SERVICE & OPERATING MANUAL
See page 2 for ATEX ratings.
Original Instructions
Model M05 Metallic Design Level 1
Table of Contents
Engineering Data and Temperature Limitations .......................................................1
Explanation of Pump Nomenclature .........................................................................2
Metric Dimensions ( Stainless Steel and Alloy C Models) ........................................7
Principle of Pump Operation.....................................................................................8
Air Supply .................................................................................................................8
Air Valve Lubrication .................................................................................................8
Air Line Moisture.......................................................................................................8
Troubleshooting .....................................................................................................10
Warranty .................................................................................................................10
Available Service and Conversion Kits ...................................................................14
Composite Repair Parts List ...................................................................................15
Air Distribution Valve Assembly Drawing and Parts List .........................................16
Air Distribution Valve Servicing ...............................................................................17
Air Distribution Valve Assembly Drawing and Parts List Polypropylene Centers ...18
Air Distribution Valve Servicing Polypropylene Centers .........................................19
Air Valve with Stroke Indicator Assembly Drawing and Part List ............................20
Air Distribution Valve with Stroke Indicator Option Servicing .................................21
See pages 2, 37 and 38 for ATEX ratings.
Diaphragm Service Drawing, with Overlay .............................................................24
Pilot Valve Servicing, Assembly Drawing & Parts List ............................................26
Intermediate Assembly and Actuator Plunger Servicing ......................................... 27
Check Valve Drawing .............................................................................................28
Optional Mufer Conguration Drawing..................................................................29
Dual Porting Suction and Discharge (Aluminum Model) ........................................31
Single Porting Suction and Dual Porting Discharge (Aluminum Model) ................. 31
Dual Porting Suction and Single Porting Discharge (Aluminum Model) ................. 31
Pumping Hazardous Liquids...................................................................................33
Converted Exhaust Illustration................................................................................33
Pulse Output Kit Drawing .......................................................................................34
Grounding the Pump ..............................................................................................35
CE Declaration of Conformity Machinery ...............................................................36
CE Declaration of Conformity ATEX .......................................................................37
m05mdl1sm-rev0711
Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA
Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com
©Copyright 2010 Warren Rupp, Inc. All rights reserved.
Page 2
Page 3
Aluminum
See page 2 for ATEX ratings.
Model
See pages 2, 37 and 38 for ATEX ratings.
Quality System
ISO9001 Certied
Air Exhaust Side View
Air Inlet Side View
M05 Metallic
Design Level 1
Environmental
Management System
ISO14001 Certied
Stainless Steel
and Alloy C
Models
Ball Valve
Air-Operated Double Diaphragm Pump
ENGINEERING, PERFORMANCE
Air Exhaust Side View Air Inlet Side View
INTAKE/DISCHARGE PIPE SIZE
½" NPT or ½" BSP (Tapered)
1" NPT or 1" BSP (Tapered)
CAPACITY
0 to 15 gallons per minute
(0 to 56 liters per minute)
CAUTION! Operating temperature limitations are as follows:
AIR VALVE
No-lube, no-stall
design
SOLIDS-HANDLING
Up to .125 in. (3mm)
& CONSTRUCTION DATA
HEADS UP TO
125 psi or 289 ft. of water
(8.6 bar or 86 meters)
Operating Temperatures
DISPLACEMENT/STROKE
.026 Gallon / .098 liter
Materials Maximum Minimum
Nitrile General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic uid resistance. Should not be used with highly polar solvents
like acetone and MEK, ozone, chlorinated hydrocarbons and nitro hydrocarbons.
EPDM Shows very good water and chemical resistance. Has poor resistance to oil and solvents, but is fair in ketones and alcohols.
NEOPRENE All purpose. Resistant to vegetable oils. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally
attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons.
PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically with PTFE: molten alkali metals, turbulent liquid or gas­eous uorine and a few uoro-chemicals such as chlorine triuoride or oxygen diuoride which readily liberate free uorine at elevated temperatures.
FKM (Fluorocarbon) shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons, acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.
®
Santoprene
Polypropylene A thermoplastic polymer. Moderate tensile and ex strenght. Resists strong acids and alkalie. Attacked by chlorine, fuming nitric acid and
other strong oxidizing agents.
Conductive HDPE
UHMW PE A thermoplastic polymer that is highly resistant to a broad range of chemicals. Exhibits
outstanding abrasion and impact resistance, along with environmental stress-cracking resistance.
Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life. Excellent abrasion resistance.
190°F -10°F 88°C -23°C
280°F -40°F 138°C -40°C
200°F -10°F 93°C -23°C
220°F -35°F 104°C -37°C
350°F -40°F 177°C -40°C
275°F -40°F 135°C -40°C
180°F 32°F 82°C 0°C
180°F -35°F 82°C -37°C
180°F -35°F 82°C -37°C
For specic applications, always consult “Chemical Resistance Chart" Technical Bulletin
Maximum and Minimum Temperatures are the limits for which these materials can be operated. Temperatures coupled with pressure affect the longevity of diaphragm pump components. Maximum life should not be expected at the extreme limits of the temperature ranges.
m05mdl1sm-rev0711 Model M05 Metallic Page 1
Page 4
Explanation of Pump Nomenclature
II 2GD T5
II 2G EEx m c T5 II 2D c IP65 T100°C
II 2GD T5
II 2G Ex ia c IIC T5 II 2D c iaD 20 IP67 T100˚C
M05 Metallic · Design Level 1· Ball Valve
Check Diaphragm/ Check Non-Wetted Shipping MODEL Pump Pump Valve Design Wetted Check Valve Valve Material Porting Pump Pump Kit Weight Brand Size Type Level Material Materials Seat Options Options Style Options Options lbs. (kg)
M05B1ABWANS000. M 05 B 1 A B W A N S 0 00. 15 (7) M05B1ACTANS000. M 05 B 1 A C T A N S 0 00. 15 (7) M05B1ANWANS000. M 05 B 1 A N W A N S 0 00. 15 (7) M05B1A1WANS000. M 05 B 1 A 1 W A N S 0 00. 15 (7) M05B1A2TANS000. M 05 B 1 A 2 T A N S 0 00. 15 (7) M05B1SCTANS000. M 05 B 1 S C T A N S 0 00. 21 (10) M05B1SNWANS000. M 05 B 1 S N W A N S 0 00. 21 (10) M05B1S1WANS000. M 05 B 1 S 1 W A N S 0 00. 21 (10)
Note: Models listed in the table are for reference only. See nomenclature below for other models.
Pump Brand
M= MARATHON
Pump Size
05= ½"
Check Valve Type
B= Ball
Design Level
1= Design Level
Wetted Material
A= Aluminum S= Stainless Steel H= Alloy C
Diaphragm/Check Ball Material
B= Nitrile/Nitrile C= FKM/PTFE N= Neoprene/Neoprene E= EPDM/EPDM
† Note: Pumps equipped with non-wetted options C or P are limited to a maximum operating pressure of 100 psi or 7 bar.
®
Diaphragm/Check Ball Material Cont.
1= Santoprene/Santoprene 2= PTFE-Santoprene/PTFE Z= One Piece PTFE-Nitrile/PTFE
Valve Seat
A= Aluminum C= Cast Iron H= Alloy C S= Stainless Steel T= PTFE W= UHMW Polyethylene
Non-Wetted Material
A= Aluminum Y= Aluminum With Stainless Steel hardware
†
C= Conductive Polypropylene With Stainless Steel hardware†
†
P= Polypropylene With Stainless Steel hardware
Porting Options
N= NPT Threads B= BSP (Tapered) Threads 1= Dual Porting (NPT) 2= Top Dual Porting (NPT)
Porting Options Cont.
3= Bottom Dual Porting NPT 4= Dual Porting BSP (Tapered) 5= Top Dual Porting BSP (Tapered) 6= Bottom Dual Porting BSP (Tapered)
Pump Style
S= Standard
Pump Options
0= Integral Mufer 1= Sound Dampening Mufer 2= Mesh Mufer 6= Metal Mufer 7= Metal Mufer with grounding cable
Kit Options
00.= None P0.= 10-30VDC Pulse Output Kit P1.= Intrinsically-Safe 5-30VDC, 110/120VAC 220/240 VAC Pulse Output Kit P2.= 110/120 or 220/240VAC Pulse Output Kit E0.= Solenoid Kit with 24VDC Coil E1.= Solenoid Kit with 24VDC Explosion-Proof Coil
E2.= Solenoid Kit with 24VAC/12VDC Coil E3.= Solenoid Kit with 12VDC Explosion-Proof Coil E4.= Solenoid Kit with 110VAC Coil E5.= Solenoid Kit with 110VAC Explosion-Proof Coil E6.= Solenoid Kit with 220VAC Coil
Kit Options continued
E7.= Solenoid Kit with 220VAC Explosion-Proof Coil E8.= Solenoid Kit with 110VAC, 50 Hz Explosion-Proof Coil E9.= Solenoid Kit with 230VAC, 50 Hz Explosion-Proof Coil SP.= Stroke Indicator Pins
A1.= Solenoid Kit with 12 VDC ATEX Compliant Coil A2.= Solenoid Kit with 24 VDC ATEX Compliant Coil A3.= Solenoid Kit with 110/120 VAC 50/60 Hz ATEX Compliant Coil A4.= Solenoid Kit with 220/240 VAC 50/60 Hz ATEX Compliant Coil
(1)
II 1G c T5 II 3/1 G c T5 II 1D c T100°C I M1 c I M2 c
II 2G c T5 II 3/2 G c T5 II 2D c T100°C
Models equipped with Wetted Options S or H, Non-Wetted Option C, Pump
(2)
Options 6 or 7, and Kit Option 0. NOTE: See page 37 for ATEX Explanation of
EC-Type Certicate
Models equipped with Wetted Options A,S or H, Non-Wetted Options A or Y, Pump Options 6 or 7, and Kit Option 0. NOTE: See page 37 for ATEX
Explanation of Type Examination Certicate
II 2G Ex ia c IIC T5 II 3/2 G Ex ia c IIC T5 II 2D Ex c ia 20 IP67 T100°C
Note: Pumps ordered with the options listed in (1) to the left are ATEX compliant when ordered with kit option P1.
(3*)
II 2G EEx m c II T5 II 3/2 2G EEx m c II T5 II 2D c IP65 T100°C
Note: Pumps ordered with the options listed in (1) to the left are ATEX com­pliant when ordered with kit option A1, A2, A3, or A4. Compressed Air Temperature Range: Maximum Ambi­ent Temperature to plus 50°C.
*Note: See page 21 for Special Conditions For Safe Use.
(4)
IEC EEX m T4
Note: Pump models equipped with these explosion-proof solenoid kit options E1,
E3, E5, E7, E8 or E9, are certied and
approved by the above agencies. They are NOT ATEX compliant.
m05mdl1sm-rev0711 Model M05 Metallic Page 2
Page 5
MODEL S05 Metallic Performance Curve
Performance based on the following: elastomer tted pump, ooded suction, water at ambient conditions.
Performance Curve, M05 Metallic, Design Level 1
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
BAR
7
6
5
4
HEAD
3
2 (3.5)
PSI
100
100 PSI (6.8 Bar)
80
80 PSI (5.44 Bar)
60
60 PSI (4.08 Bar)
40
40 PSI (2.72 Bar)
4 (7)
6 (10)
8 (13.5)
SCFM (M /hr)
10 (17)
12 (20)
14 (24)
16 (27)
18 (30)
20 (33.75)
NPSHR
FEET
METERS
2
20
20 PSI (1.36 Bar)
1
0
0
Air Inlet Pressure
20
4 6 8 10 12 14 16
30 25 20
15 10
9.1
7.6 6
4.5 3
1.5
5
U.S. Gallons per minute
0
10 20 30 40 50 60
Liters per minute
CAPACITY
m05mdl1sm-rev0711 Model M05 Metallic Page 3
Page 6
Dimensions: M05 Metallic (Aluminum Model)
Dimensions in Inches Dimensional tolerance: ±1/8"
ENCAPSULATED MUFFLER:
3/8” NPT EXHAUST PORT
FOR OPTIONAL PIPING MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS.
DISCHARGE PORT 1/2” NPT (INTERNAL) 1” NPT (EXTERNAL)
AIR INLET 1/4” NPT
FRONT VIEW
BOTH SUCTION AND DISCHARGE
1/2” BSP TAPERED (INTERNAL)
1” BSP TAPERED (EXTERNAL)
BOTTOM VIEW
SIDE VIEW
SUCTION PORT
1/2” NPT (INTERNAL)
1” NPT (EXTERNAL)
PORTS ARE AVAILABLE IN
DIMENSION A B
Integral Mufer 4 5/16" 7 5/16"
Pulse Output Kit 4 5/16" 7 5/16"
Mesh Mufer 6" 9"
Sound Dampening Mufer 6" 9"
Metal Mufer 5 5/8" 8 5/8"
m05mdl1sm-rev0711 Model M05 Metallic Page 4
Page 7
Metric Dimensions: M05 Metallic (Aluminum Model)
Dimensions in millimeters Dimensional tolerance: ±3mm
ENCAPSULATED MUFFLER:
3/8” NPT EXHAUST PORT
FOR OPTIONAL PIPING MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS.
DISCHARGE PORT 1/2” NPT (INTERNAL) 1” NPT (EXTERNAL)
AIR INLET 1/4” NPT
FRONT VIEW
BOTTOM VIEW
SUCTION PORT
1/2” NPT (INTERNAL)
1” NPT (EXTERNAL)
BOTH SUCTION AND DISCHARGE
PORTS ARE AVAILABLE IN
1/2” BSP TAPERED (INTERNAL)
1” BSP TAPERED (EXTERNAL)
SIDE VIEW
DIMENSION A B
Integral Mufer 109mm 186mm
Pulse Output Kit 109mm 186mm
Mesh Mufer 152mm 229mm
Sound Dampening Mufer 152mm 229mm
Metal Mufer 143 mm 219 mm
m05mdl1sm-rev0711 Model M05 Metallic Page 5
Page 8
Dimensions: M05 Metallic (Stainless Steel & Alloy C Models)
Dimensions in Inches Dimensional tolerance: ±
1
/8"
DISCHARGE PORT 1/2” NPT (INTERNAL) 1” NPT (EXTERNAL)
ENCAPSULATED MUFFLER:
3/8” NPT EXHAUST PORT
FOR OPTIONAL PIPING MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS.
AIR INLET 1/4” NPT
FRONT VIEW
SIDE VIEW
SUCTION PORT
1/2” NPT (INTERNAL)
1” NPT (EXTERNAL)
BOTH SUCTION AND DISCHARGE
PORTS ARE AVAILABLE IN
1/2” BSP TAPERED (INTERNAL)
1” BSP TAPERED (EXTERNAL)
DIMENSION A B Integral Mufer 4 5/16" 7 5/16"
BOTTOM VIEW
Pulse Output Kit 4 5/16" 7 5/16" Mesh Mufer 6" 9" Sound Dampening Mufer 6" 9" Metal Mufer 5 5/8" 8 5/8"
m05mdl1sm-rev0711 Model M05 Metallic Page 6
Page 9
Metric Dimensions: M05 Metallic (Stainless Steel & Alloy C Models)
Dimensions in millimeters Dimensional tolerance: ±3mm
ENCAPSULATED MUFFLER:
3/8” NPT EXHAUST PORT
FOR OPTIONAL PIPING MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS.
FRONT VIEW
SUCTION PORT
1/2” NPT (INTERNAL)
1” NPT (EXTERNAL)
DISCHARGE PORT 1/2” NPT (INTERNAL) 1” NPT (EXTERNAL)
AIR INLET 1/4” NPT
SIDE VIEW
BOTH SUCTION AND DISCHARGE
PORTS ARE AVAILABLE IN
1/2” BSP TAPERED (INTERNAL)
1” BSP TAPERED (EXTERNAL)
DIMENSION A B Integral Mufer 109mm 186mm
Pulse Output Kit 109mm 186mm Mesh Mufer 152mm 229mm
BOTTOM VIEW
Sound Dampening Mufer 152mm 229mm Metal Mufer 143mm 219mm
m05mdl1sm-rev0711 Model M05 Metallic Page 7
Page 10
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump is powered by compressed air and is a 1:1 ratio design. The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber. This causes the diaphragms, which are connected by a common rod secured by plates to the centers of the diaphragms, to move in a reciprocating action. (As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber.) Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm. The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet (61 meters) of water.
For maximum diaphragm life, keep the pump as close to the liquid being pumped as possible. Positive suction head in excess of 10 feet of liquid (3.048 meters) may require a back pressure regulating device to maximize diaphragm life.
Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally mounted, pilot operated, four way spool type air distribution valve. When the spool shifts to one end of the valve body, inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts. When the spool shifts to the opposite end of the valve body, the pressure to the chambers
is reversed. The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end. The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate. This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve.
The chambers are connected with manifolds with a suction and discharge check valve for each chamber, maintaining flow in one direction through the pump.
INSTALLATION AND START-UP
Locate the pump as close to the product being pumped as possible. Keep the suction line length and number of ttings to a minimum. Do not reduce the suction line diameter.
For installations of rigid piping, short sections of exible hose should be installed between the pump and the piping. The exible hose reduces vibration and strain to the pumping system. A DA05 Surge Dampener is recommended to further reduce pulsation in ow.
AIR SUPPLY
Air supply pressure cannot exceed 125 psi (8.6 bar). Connect the pump air inlet to an air supply of sufcient capacity and pressure required for desired performance. When the air supply line is solid piping, use a short length of exible hose not less than 1/2" (13mm) in diameter between the pump and the piping to reduce
strain to the piping. The weight of the air supply line, regulators and lters must be supported by some means other than the air inlet cap. Failure to provide support for the piping may result in damage to the pump. A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended limits.
AIR VALVE LUBRICATION
The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication. This is the preferred mode of operation. There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required. The pump air system will operate with properly lubricated compressed air supply. Proper lubrication requires the use of an air line lubricator (available from MARATHON) set to deliver one drop of SAE 10 non­detergent oil for every 20 SCFM (9.4 liters/sec.) of air the pump consumes at the point of operation. Consult the pump’s published Performance Curve to determine this.
AIR LINE MOISTURE
Water in the compressed air supply can create problems such as icing or freezing of the exhaust air, causing the pump to cycle erratically or stop operating. Water in the air supply can be reduced by using a point-of-use air dryer to supplement the user’s air drying equipment. This device removes water from the compressed air supply and alleviates the icing or freezing problems.
AIR INLET AND PRIMING
To start the pump, open the air valve approximately 1/2" to 3/4" turn. After the pump primes, the air valve can be opened to increase air ow as desired. If opening the valve increases cycling rate, but does not increase the rate of ow, cavitation has occurred. The valve should be closed slightly to obtain the most efcient air ow to pump ow ratio.
BETWEEN USES
When the pump is used for materials that tend to settle out or solidify when not in motion, the pump should be flushed after each use to prevent damage. (Product remaining in the pump between uses could dry out or settle out. This could cause problems with the diaphragms and check valves at restart.) In freezing temperatures the pump must be completely drained between uses in all cases.
m05mdl1sm-rev0711 Model M05 Metallic Page 8
Page 11
CAUTION
The ai r exhau st sho ul d be pip ed t o an area f or saf e disposition of the product bei ng pumped , in t he event of a diaphr agm failu re.
TYPICAL INSTALLATION GUIDE
For Metallic Pumps
Air Inlet
Line
Available from MARATHON
m05mdl1sm-rev0711 Model M05 Metallic Page 9
Page 12
TROUBLESHOOTING Possible Symptoms:
• Pump will not cycle.
• Pump cycles, but produces no ow.
• Pump cycles, but ow rate is
unsatisfactory.
• Pump cycle seems unbalanced.
• Pump cycle seems to produce
excessive vibration.
What to Check: Excessive suction lift in system. Corrective Action: For lifts exceeding 20 feet (6 meters), lling the pumping chambers with liquid will prime the pump in most cases.
What to Check: Excessive flooded suction in system. Corrective Action: For flooded conditions exceeding 10 feet (3 meters) of liquid, install a back pressure device.
What to Check: System head exceeds air supply pressure. Corrective Action: Increase the inlet air pressure to the pump. Most diaphragm pumps are designed for 1:1 pressure ratio at zero ow.
What to Check: Air supply pressure or volume exceeds system head. Corrective Action: Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE. Pump is cavitating the uid by fast cycling.
Corrective Action: Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING.
What to Check: Restricted or undersized air line. Corrective Action: Install a larger air line and connection. Refer to air inlet recommendations shown in your pump’s SERVICE MANUAL.
What to Check: Check ESADS+Plus, the Externally Serviceable Air Distribution System of the pump. Corrective Action: Disassemble and inspect the main air distribution valve, pilot valve and pilot valve actuators. Refer to the parts drawing and air valve section of the SERVICE MANUAL. Check for clogged discharge or closed valve before reassembly.
What to Check: Rigid pipe connections to pump. Corrective Action: Install flexible connectors and a surge dampener.
What to Check: Blocked air exhaust mufer. Corrective Action: Remove mufer screen, clean or de-ice and reinstall. Refer to the Air Exhaust section of your pump SERVICE MANUAL.
What to Check: Pumped uid in air exhaust mufer. Corrective Action: Disassemble
pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly. Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL.
What to Check: Suction side air leakage or air in product. Corrective Action: Visually inspect all suction side gaskets and pipe connections.
What to Check: Obstructed check valve. Corrective Action: Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket. Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions.
What to Check: Worn or misaligned check valve or check valve seat. Corrective Action: Inspect check valves and seats for wear and proper seating. Replace if necessary. Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions.
What to Check: Blocked suction line. Corrective Action: Remove or ush
obstruction. Check and clear all suction screens and strainers.
What to Check: Blocked discharge line. Corrective Action: Check for
obstruction or closed discharge line valves.
What to Check: Blocked pumping chamber. Corrective Action: Disassemble and inspect the wetted chambers of the pump. Remove or flush any obstructions. Refer to the pump SERVICE MANUAL for disassembly instructions.
What to Check: Entrained air or vapor lock in one or both pumping chambers. Corrective Action: Purge chambers through tapped chamber vent plugs. PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS! Contact the MARATHON Technical Services Group before performing this procedure. A model with top-ported discharge will reduce or eliminate problems with entrained air.
If your pump continues to perform below your expectations, contact your local MARATHON Distributor or factory Technical Services Group for a service evaluation.
WARRANTY
Refer to the enclosed MARATHON Warranty Card.
What to Check: Undersized suction line.
m05mdl1sm-rev0711 Model M05 Metallic Page 10
Page 13
RECYCLING
Many components of MARATHON® AODD
pumps are made of recyclable materials (see
chart on page 12 for material specications). We
encourage pump users to recycle worn out parts and pumps whenever possible, after any hazardous
pumped uids are thoroughly ushed.
IMPORTANT SAFETY
INFORMATION
IMPORTANT
Read these safety warnings
Read these safety warnings and instructions in this
and instructions in this
manual completely, before
manual completely, before
installation and start-up
of the pump. It is the responsibility of the
of the pump. It is the responsibility of the purchaser to retain this manual for reference.
purchaser to retain this manual for reference. Failure to comply with the recommendations
Failure to comply with the recommendations stated in this manual will damage the pump,
stated in this manual will damage the pump, and void factory warranty.
and void factory warranty.
prevent leakage. Follow recommended torques stated in this manual.
line may be pressurized and must be bled of its pressure.
pumping a product which is hazardous or toxic, the air exhaust must be piped to an appropriate area for safe disposition.
installation and start-up
CAUTION
Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep. Re-
torque loose fasteners to
WARNING
Before maintenance or repair, shut off the
compressed air line, bleed the pressure, and disconnect the air line from the pump. The discharge
WARNING
In the event of diaphragm rupture, pumped material may enter the air end of the pump, and be discharged into the atmosphere. If
WARNING
Take action to prevent static
sparking. Fire or explosion
can result, especially when
handling ammable liquids.
containers or other miscellaneous equipment
must be grounded. (See page 35)
The pump, piping, valves,
WARNING
This pump is pressurized
internally with air pressure
during operation. Always
make certain that all bolting
is in good condition and
bolting is reinstalled during assembly.
that all of the correct
WARNING
When used for toxic or aggressive uids, the pump should always be ushed clean prior to disassembly.
WARNING
Before doing any
maintenance on the pump, be certain all pressure is
completely vented from the pump, suction, discharge,
openings and connections. Be certain the air supply is locked out or made non-operational, so that it cannot be started while work is being done on the pump. Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump. Failure to follow these recommendations may result in serious injury or death.
piping, and all other
WARNING
Airborne particles and loud noise hazards.
Wear ear and eye protection.
m05mdl1sm-rev0711 Model M05 Metallic Page 11
Page 14
Material Codes
The Last 3 Digits of Part Number
000 Assembly, sub-assembly;
and some purchased items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable Iron 025 Music Wire 080 Carbon Steel, AISI B-1112 100 Alloy 20 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel
(Electro Polished) 112 Alloy C 113 Alloy Type 316 Stainless Steel
(Hand Polished) 114 303 Stainless Steel 115 302/304 Stainless Steel 117 440-C Stainless Steel (Martensitic) 120 416 Stainless Steel
(Wrought Martensitic) 123 410 Stainless Steel
(Wrought Martensitic) 148 Hardcoat Anodized Aluminum 149 2024-T4 Aluminum 150 6061-T6 Aluminum 151 6063-T6 Aluminum 152 2024-T4 Aluminum (2023-T351) 154 Almag 35 Aluminum 155 356-T6 Aluminum 156 356-T6 Aluminum 157 Die Cast Aluminum Alloy #380 158 Aluminum Alloy SR-319 159 Anodized Aluminum 162 Brass, Yellow, Screw Machine Stock 165 Cast Bronze, 85-5-5-5 166 Bronze, SAE 660 170 Bronze, Bearing Type,
Oil Impregnated 175 Die Cast Zinc
180 Copper Alloy 305 Carbon Steel, Black Epoxy Coated 306 Carbon Steel, Black PTFE Coated 307 Aluminum, Black Epoxy Coated 308 Stainless Steel, Black PTFE Coated 309 Aluminum, Black PTFE Coated 310 PVDF Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminum, Electroless Nickel Plated 333 Carbon Steel, Electroless
Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 353 Geolast; Color: Black 354 Injection Molded #203-40 Santoprene-
Duro 40D +/-5; Color: RED 355 Thermal Plastic 356 Hytrel 357 Injection Molded Polyurethane 358 Urethane Rubber
(Some Applications) (Compression Mold) 359 Urethane Rubber 360 Nitrile Rubber. Color coded: RED 361 FDA Accepted Nitrile 363 FKM (Fluorocarbon).
Color coded: YELLOW 364 E.P.D.M. Rubber. Color coded: BLUE 365 Neoprene Rubber.
Color coded: GREEN 366 Food Grade Nitrile 368 Food Grade EPDM 370 Butyl Rubber. Color coded: BROWN 371 Philthane (Tuftane) 374 Carboxylated Nitrile 375 Fluorinated Nitrile
378 High Density Polypropylene 379 Conductive Nitrile 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 502 Conductive Acetal, ESD-800 503 Conductive Acetal, Glass-Filled 505 Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF Natural color 521 Conductive PVDF 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene 551 Glass Filled Polypropylene 552 Unlled Polypropylene 553 Unlled Polypropylene 555 Polyvinyl Chloride 556 Black Vinyl 557 Conductive Polypropylene 558 Conductive HDPE 559 Glass-Filled Conductive Polypropylene 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G-S 592 Nylatron NSB 600 PTFE (virgin material)
Tetrauorocarbon (TFE) 601 PTFE (Bronze and moly lled) 602 Filled PTFE 603 Blue Gylon
604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Integral Silicon 611 PTFE Integral FKM 632 Neoprene/Hytrel 633 FKM (Fluorocarbon)/PTFE 634 EPDM/PTFE 635 Neoprene/PTFE 637 PTFE, FKM (Fluorocarbon)/PTFE 638 PTFE, Hytrel/PTFE 639 Nitrile/TFE 643 Santoprene/EPDM 644 Santoprene/PTFE 650 Bonded Santoprene and PTFE 654 Santoprene Diaphragm, PTFE Overlay
Balls and seals
656 Santoprene Diaphragm and
Check Balls/EPDM Seats
661 EPDM/Santoprene
Delrin and Hytrel are registered tradenames of E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of Polymer Corp.
Santoprene is a registered tradename of Exxon Mobil Corp.
Rulon II is a registered tradename of Dixion Industries Corp.
Ryton is a registered tradename of Phillips Chemical Co.
Valox is a registered tradename of General Electric Co.
MARATHON, Portapump and SludgeMaser are registered tradenames of Warren Rupp, Inc.
m05mdl1sm-rev0711 Model M05 Metallic Page 12
Page 15
m05mdl1sm-rev0711 Model M05 Metallic Page 13
Page 16
14
37
27
37
30
8
20
3
22
18
23
25
13
10
10
37
9
29
9
10
37
37
27
2
29
36
29
10
21
1
26
12
10
37
35
32
28
7
33
34
6
31
19
15
2
29
29
36
29
23
27
37
29
9
37
5
11
10
24
37
9
37
9
10
15
16
30
4
18
17
10 10a
9a
9
38
*OVERLAY OPTION
Alum Center
Poly Center
Alum Center
Poly Center
Torque: 70 in/lbs
Torque: 50 in/lbs Aluminum ONLY
Torque: 120 in/lbs
Torque: 50 in/lbs Aluminum ONLY
Composite Repair Parts Drawing
Available Service and Conversion Kits
PART NO. DESCRIPTION
476-219-000 AIR END KIT (Polypropylene)
Seals, O-ring, Gaskets, Retaining Rings, Air Valve Assembly and Pilot Valve Assembly
476-239-000 AIR END KIT
Seals, O-rings, Gaskets, Bumpers, Retainers, Air Valve Assembly and Pilot Valve Assembly.
476-240-000 AIR END KIT for pumps equipped with Stroke Indicator
(same components as above, except Air Valve Assembly with pins replaces Air Valve Standard).
476-199-354 WETTED END KIT
476-199-356 WETTED END KIT
Santoprene Diaphragm, Santoprene Check Balls, UHMW Seats, Nitrile Spacer Gasket.
Hytrel Diaphragm, Hytrel Check Balls, UHMW Seats.
476-199-360 WETTED END KIT
Nitrile Diaphragm, Nitrile Check Balls, UHMW Seats.
476-199-661 WETTED END KIT
EPDM Diaphragm, Santoprene Check Balls, UHMW Seats.
476-199-365 WETTED END KIT
476-199-633 WETTED END KIT
476-199-650 WETTED END KIT
Neoprene Diaphragm, Neoprene Check Balls, UHMW Seats.
FKM Diaphragm, PTFE Check Balls, PTFE Seats.
PTFE and Santoprene Diaphragm, PTFE Check Balls, PTFE Seats.
476-199-654 WETTED END KIT
Santoprene Diaphragm, PTFE Overlay Diaphragm, PTFE Check Balls, PTFE Seats.
476-199-659 WETTED END KIT
One-PIece Bonded PTFE/Nitrile Diaphragm, PTFE Balls, PTFE Seats.
m05mdl1sm-rev0711 Model M05 Metallic Page 14
Page 17
Composite Repair Parts List
ITEM PART NUMBER DESCRIPTION QTY
1 031-191-000 Air Valve Assembly (Integral Mufer) 1 031-166-000 Air Valve Assembly 031-168-000 Air Valve Assembly 031-168-002 Air Valve Assembly (Conductive Polypropylene Center ONLY) 1 031-167-000 Air Valve Assembly (w/ stroke Indicator Pins) 1 031-186-000 Air Valve Assembly 1 031-169-000 Air Valve Assembly (Stroke Indicator & Optional Mufers) 1 031-186-003 Air Valve Assembly w/ Stainless Steel hardware 1 031-186-002 Air Valve (High Temperature) 1 031-191-002 Air Valve (High Temperature With Integral Mufers) 1 031-191-003 Air Valve Assembly (Stainless Steel Hardware) 1 2 050-022-600 Ball, Check 4 050-027-354 Ball, Check 4 050-027-356 Ball, Check 4 050-027-360 Ball, Check 4 050-027-364 Ball, Check 4 050-027-365 Ball, Check 4 3 095-091-000 Pilot Valve Assembly (Polypropylene Center ONLY) 1 095-091-001 Pilot Valve Assembly (Conductive Polypropylene Center ONLY) 1 095-116-000 Pilot Valve Assembly 1 4 114-023-157 Bracket, Intermediate 1 114-023-551 Bracket, Intermediate (Polypropylene Center) 1 114-023-559 Bracket, Intermediate (Conductive Polypropylene Center ONLY) 1 5 115-152-151 Bracket, Mounting (Aluminum) 2 6 132-034-360 Bumper, Diaphragm 2 7 135-036-506 Bushing, Plunger 2 8 165-110-157 Cap, Air Inlet 1
165.110.551 Cap, Air Inlet (Polypropylene Center ONLY) 1
165.110.559 Cap, Air Inlet (Conductive Polypropylene Center ONLY) 1 9 170-044-115 Capscrew, Hex 5/16-18 X 1.00 12 170-044-115 Capscrew, Hex 5/16-18 X 1.00 (Poly Center ONLY) 8 170-044-330 Capscrew, Hex 5/16-18 X 1.00 12 9A 171-062-115 Capscrew, Flanged 5/16-18 x 1.00 (Poly Center ONLY) 4 10 170-045-115 Capscrew, Hex 5/16-18 X 1.25 (alum 40 170-045-330 Capscrew, Hex 5/16-18 X 1.25 (alum) 40 170-045-115 Capscrew, Hex 5/16-18 x 1.25 (ss) 24 170-045-330 Capscrew, Hex 5/16-18 x 1.25 (ss) 24 170-045-115 Capscrew, Hex 5/16-18 x 1.25 (Polypropylene Centers ONLY) 8 10A 170-029-115 Capscrew, Hex 5/16-18 x 1.50 (Polypropylene Centers ONLY) 12 11 171-017-115 Capscrew, Flat Socket Head 1/4-20 x .50 (alum) 4 171-017-330 Capscrew, Flat Socket Head 1/4-20 x .50 (alum) 4 12 171-076-115 Capscrew, Flanged 1/4- 20 x 75 4 171-076-330 Capscrew, Flanged 1/4-20 x 75 4 171-066-115 Capscrew, Flanged 1/4-20 x 1.25 (Poly Centers ONLY) 4 13 171-077-115 Capscrew, Flanged 1/4-20 x 1.50 4 171-077-330 Capscrew, Flanged 1/4-20 x 1.50 4 171-066-115 Capscrew, Flanged 1/4-20 x 1.25 (Poly Centers ONLY) 4 14 196-171-110 Chamber, Outer 2 196-171-112 Chamber, Outer 2 196-171-157 Chamber, Outer 2 15 286-095-354 Diaphragm 2 286-095-356 Diaphragm 2 286-095-360 Diaphragm 2 286-095-363 Diaphragm 2 286-095-364 Diaphragm 2 15 286-095-365 Diaphragm 2 286-116-000 Diaphragm, One-Piece Bonded 2 16 286-096-600 Diaphragm, Overlay 2
(Polypropylene Center w/Integral Mufer) 1 (Polypropylene Center w/External Mufer Options)
1
ITEM PART NUMBER DESCRIPTION QTY
17 312-110-157 Elbow, Suction 2 18 312-111-157 Elbow, Discharge 2 19 360-099-360 Gasket, Spacer (used TPE Diaphragms only) 2 20 360-100-379 Gasket, Air Inlet 1 21 360-102-360 Gasket, Air Valve 1 22 360-108-360 Gasket, Pilot Valve 1 360-101-360 Gasket, Pilot Valve (Polypropylene Centers ONLY) 1 23 518-157-157 Manifold (see item 29) 2 518-157-157E Manifold BSP Tapered (see item 29) 2 24 518-158-110 Manifold, Suction 1 518-158-110E Manifold, Suction BSP Tapered 1 518-158-112 Manifold, Suction 1 518-158-112E Manifold, Suction BSP Tapered 1 25 518-159-110 Manifold, Discharge 1 518-159-110E Manifold, Discharge BSP Tapered 1 518-159-112 Manifold, Discharge 1 518-159-112E Manifold, Discharge BSP Tapered 1 26 530-035-000 Metal Mufer 1 27 545-004-115 Nut, Hex 5/16-18 (Aluminum) 24 545-004-330 Nut, Hex 5/16-18 (Aluminum) 24 545-004-115 Nut, Hex 5/16-18 (Stainless Steel) 8 545-004-330 Nut, Hex 5/16-18 (Stainless Steel) 8 28 560-001-360 O-ring 2 29 560-083-360 O-ring (Aluminum Manifold) 4 560-083-363 O-ring (Aluminum Manifold) 4 560-083-364 O-ring (Aluminum Manifold) 4 560-083-365 O-ring (Aluminum Manifold) 4 720-064-600 Seal (Aluminum Manifold) 4 560-083-360 O-ring (metallic seats only) 8 560-083-363 O-ring (metallic seats only) 8 560-083-364 O-ring (metallic seats only) 8 560-083-365 O-ring (metallic seats only) 8 560-083-611 O-ring (metallic seats only) 8 30 612-091-110 Plate, Outer Diaphragm 2 612-091-112 Plate, Outer Diaphragm 2 612-091-157 Plate, Outer Diaphragm 2 31 612-177-330 Plate, Inner Diaphragm 2 612-221-330 Plate, Inner Diaphragm (One-Piece Bonded Only) 2 32 620-019-115 Plunger, Actuator 2 33 675-042-115 Ring, Retainer 1 34 685-056-120 Rod, Diaphragm 2 35 720-012-360 Seal, U-Cup Shaft 4 36 722-094-080 Seat, Check Valve (item 29 required) 4 722-094-110 Seat, Check Valve (item 29 required) 4 722-094-150 Seat, Check Valve (item 29 required) 4 722-094-550 Seat, Check Valve 4 722-094-600 Seat, Check Valve 4 37 900-004-115 5/16 Lock Washer (Aluminum) 48 900-004-330 5/16 Lock Washer (Aluminum) 48 900-004-115 5/16 Lock Washer (Stainless Steel) 32 900-004-330 5/16 Lock Washer (Stainless Steel) 32 900-004-115 5/16 Lock Washer (Stainless Steel 38 544-005-115 Nut, Flanged 5/16-18 (Poly Centers ONLY) 12
NOTE: See Pages 16, 17 and 19 For Full Explanation of Air Valve Options.
(Poly Center ONLY) 28
Note: Atex Compliant
m05mdl1sm-rev0711 Model M05 Metallic Page 15
Page 18
Distribution Valve Assembly Drawing
1-I
1-H
1-F
1-F
MAIN AIR VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-191-000 Valve Assembly 1
1-A 031-132-000 Sleeve and Spool Set 1
*
1-B 095-106-157 Valve Body 1 1-C 132-038-357 Bumper 2 1-D 165-128-157 End Cap 2 1-E 171-076-330 Hex Flange Capscrew 1/4-20 x .75 8 1-F 560-101-360 O-ring 4 1-G 530-031-550 Mufer 1 1-H 165-109-551 Mufer Cap 1 1-I 706-027-330 Machine Screw 4
ITEM PART NUMBER DESCRIPTION QTY
1 031-191-003 Valve Assembly 1
(same as above 031-191-003 except items 1-E, and 1-I)
*
1-E 171-076-115 Hex Flange Capscrew 1/4-20 x .75 8 1-I 706-027-115 Machine Screw 4
1-E
1-D
1-C
1-A
1-B
1-F
1-G
1-C
1-F
Note: Atex Compliant
1-D
1-E
MAIN AIR VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-186-000 Valve Assembly 1
(Same as above 031-191-000 minus items 1-G, 1-H, and 1-I)
ITEM PART NUMBER DESCRIPTION QTY
1 031-186-003 Valve Assembly 1
(Same as above 031-186-003 except item 1-E) 1-E 171-076-115 Hex Flange Capscrew 1/4-20 x .75 8
NOTE: Pumps equipped with integral mufers are not ATEX compliant.
*
NOTE: Pumps equipped with this valve assembly are ATEX compliant when a metal
mufer is used.
m05mdl1sm-rev0711 Model M05 Metallic Page 16
Page 19
AIR DISTRIBUTION VALVE SERVICING
To service the air valve rst shut off the compressed air, bleed pressure from the pump, and disconnect the air supply line from the pump.
Step #1: See COMPOSITE REPAIR PARTS DRAWING.
Using a 3/8" wrench or socket, remove the four hex capscrews (items
12). Remove the air valve assembly from the pump.
Remove and inspect gasket (item
21) for cracks or damage. Replace gasket if needed.
Step #2: Disassembly of the air valve.
Using a 3/8" wrench or socket, remove the eight hex capscrews (items 1-E) that fasten the end caps to the valve body. Next remove the two end caps (items 1-D). Inspect the two o-rings (items 1-F) on each end cap for damage or wear. Replace the o-rings as needed.
Remove the bumpers (items 1-C). Inspect the bumpers for damage or wear. Replace the bumpers as needed.
Remove the spool (part of item 1-A) from the sleeve. Be careful not to scratch or damage the outer diameter of the spool. Wipe spool with a soft cloth and inspect for scratches or wear.
Inspect the inner diameter of the sleeve (part of item 1-A) for dirt,
scratches, or other contaminants. Remove the sleeve if needed and replace with a new sleeve and spool set (item 1-A).
Step #3: Reassembly of the air valve.
Install one bumper (item 1-C) and one end cap (item 1-D), with two o-rings (items 1-F), and fasten with four hex capscrews (items 1-E) to the valve body (item 1-B). Align hole in end cap with roll pin on valve body.
Remove the new sleeve an spool set (item 1-A) from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings (item 1-F) into the six grooves on the sleeve. Apply a light coating of grease to the o-rings before installing the sleeve into the valve body (item 1-B), align the slots in the sleeve with the slots in the valve body. Insert the spool into the sleeve. Be careful not to scratch or damage the spool during installation. Install the remaining bumper and end cap (with o-rings), and fasten with the remaining hex capscrews. Align hole in end cap with roll pin on valve body.
Fasten the air valve assembly (item
1) and gasket to the pump. Connect the compressed air line to the pump. The pump is now ready for operation.
IMPORTANT
Read these instructions
completely, before
installation and start-up.
It is the responsibility of the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
m05mdl1sm-rev0711 Model M05 Metallic Page 17
Page 20
Air Distribution Valve Assembly Drawing for Polypropylene Center Sections
MAIN AIR VALVE ASSEMBLY PARTS LIST
Item Part Number Description Qty
1 031-166-000 Air Valve Assembly 1 1-A 095-106-551 Body, Air Valve 1 1-B 031-132-000 Sleeve and Spool Set 1 1-C 560-101-360 O-Ring 8 1-E 165-122-551 End Cap 2 1-F 560-026-360 O-Ring 2 1-G 675-062-115 End Cap Retainer 2 1-H 530-031-550 Mufer 1 1-I 165-109-551 Mufer Cap 1 1-J 710-011-115 Self-Tapping Screw 4
For Pumps with Virgin PTFE coated hardware:
1 031-166-002 Air Valve Assembly 1 1-G 675-062-308 End Cap Retainer 2 1-J 710-011-308 Self Tapping Screw 4 (Includes all other items used on 031-166-000 above)
For Pumps with alternate Mesh or Sound Dampening Mufers or Piped Exhaust:
1 031-168-000 Air Valve Assembly 1 (Includes all items used on 031-166-000 above minus 1-H, 1-I and 1-J)
MAIN AIR VALVE ASSEMBLY PARTS LIST (For conductive ploypropylene center only)
Item Part Number Description Qty
1 031-168-002 Air Valve Assembly 1 1-A 095-106-559 Body, Air Valve 1 1-B 031-132-000 Sleeve and Spool Set 1 1-C 560-101-360 O-Ring 8 1-E 165-122-558 End Cap 2 1-F 560-026-360 O-Ring 2 1-G 675-062-115 End Cap Retainer 2
ATEX Compliant
m05mdl1sm-rev0711 Model M05 Metallic Page 18
Page 21
AIR DISTRIBUTION VALVE SERVICING
To service the air valve rst shut off the compressed air, bleed pressure from the pump, and disconnect the air supply line from the pump.
STEP #1: See COMPOSITE REPAIR PARTS DRAWING.
Using a 3/8" wrench or socket, remove the four hex anged capscrews (item 12). Remove the air valve assembly from the pump.
STEP #2: Disassembly of the air valve.
To access the internal air valve components rst remove the two end cap retainers (item 1-G) by inserting a small at screwdriver into the two slotted grooves on the valve body and gently lifting the retainers out.
Next remove the two end caps (item 1-E) by grasping the pull tab with nger and thumb or pliers and tugging. Inspect the two o-rings (items 1-C and 1-F) on each end cap for wear or cuts. Replace the o-rings if necessary.
Remove the spool (part of item 1-B) from the sleeve. Be careful not to scratch or damage the outer diameter of the spool. Wipe spool with a soft clean cloth and inspect for scratches or abrasive wear.
Inspect the inner diameter of the sleeve (part of item 1-B) for dirt, scratches, or other contaminants. Remove the sleeve if needed and replace with a new sleeve and spool set (item 1-B). Note: The sleeve and spool set is match-ground to a specied clearance. Sleeves and spools cannot be interchanged.
STEP #3: Reassembly of the air distribution valve.
Install one end cap with o-rings (items 1-E, 1-C, and 1-F) into one end of the air valve body (item 1-A). Insert one end cap retainer (item 1-G) into the two smaller holes, align with groove in the end cap, and push until the closed end of the retainer is below the at surface of the valve body.
Remove the new sleeve and spool set (item 1-B) from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings (item 1-C) into the six grooves on the sleeve. Apply a light coating of grease to the o-rings before installing the sleeve into the valve body. Align the slots in the sleeve with the slots in the valve body. Insert the spool into the sleeve. Be careful not to scratch or damage the spool during installation. Push the spool in until the pin touches the end cap on the opposite end.
Install the remaining end cap with
o-rings and retainer.
Fasten the air valve assembly (item
1) and gasket (item 23) to the pump, using the four hex anged capscrews (item 12).
Connect the compressed air line to the pump. The pump is now ready for operation.
IMPORTANT
Read these instructions completely, before in­stallation and start-up.
It is the responsibility of the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
m05mdl1sm-rev0711 Model M05 Metallic Page 19
Page 22
Air Valve with Stroke Indicator Assembly Drawing, Parts List
MAIN AIR VALVE ASSEMBLY PARTS LIST
Item Part Number Description Qty
1 031-167-000 Air Valve Assembly 1 1-A 095-106-559 Body, Air Valve 1 1-B 031-134-000 Sleeve and Spool Set 1 1-C 560-101-360 O-Ring 8 1-D 132.030.552 Bumper 2 1-E 165-123-147 End Cap 2 1-F 560-029-360 O-Ring 2 1-G 675-062-115 End Cap Retainer 2 1-H 210-008-330 Safety Clip 1 1-I 530-031-550 Mufer 1 1-J 165-109-559 Mufer Cap 1 1-K 710-011-115 Self-Tapping Screw 4
For Pumps with Virgin PTFE coated hardware:
1 031-167-002 Air Valve Assembly 1 1-G 675-062-308 End Cap Retainer 2 1-J 710-011-308 Self Tapping Screw 4 (Includes all other items used on 031-166-000 above)
For Pumps with alternate Mesh Mufer or Piped Exhaust:
1 031-169-000 Air Valve Assembly 1 (Includes all items used on 031-167-000 above minus 1-H, 1-I and 1-J)
1-F
1-J
1-D
1-C
1-K
1-I
1-B
1-B
1-H
1-D
1-F
1-C
1-E
1-A
Note: Atex Compliant
1-E
m05mdl1sm-rev0711 Model M05 Metallic Page 20
1-G
Page 23
AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING
To service the air valve rst shut off the compressed air, bleed pressure from the pump, and disconnect the air supply line from the pump.
STEP #1: See COMPOSITE REPAIR PARTS DRAWING.
Using a 3/8" wrench or socket, remove the four hex anged capscrews (item 12). Remove the air valve assembly from the pump.
STEP #2: Disassembly of the air valve.
To access the internal air valve components rst remove the two end cap retainers (item 1-G) by inserting a small at screwdriver into the two slotted grooves on the valve body and gently lifting the retainers out.
Next remove the two end caps (item 1-E) by grasping the pull tab with nger and thumb or pliers and tugging. Inspect the two o-rings (items 1-C and 1-F) on each end cap for wear or cuts. Replace the o-rings if necessary.
Remove the spool (part of item 1-B) from the sleeve. Be careful not to scratch or damage the outer diameter of the spool. Wipe spool with a soft clean cloth and inspect for scratches or abrasive wear.
Inspect the inner diameter of the sleeve (part of item 1-B) for dirt, scratches, or other contaminants. Remove the sleeve if needed and replace with a new sleeve and spool set (item 1-B). Note: The sleeve and spool set is match-ground to a specied clearance. Sleeves and spools cannot be interchanged.
STEP #3: Reassembly of the air distribution valve.
Install one end cap with o-rings (items 1-E, 1-C, and 1-F) into one end of the air valve body (item 1-A). Insert one end cap retainer (item 1-G) into the two smaller holes, align with groove in the end cap, and push until the closed end of the retainer is below the at surface of the valve body.
Remove the new sleeve and spool set (item 1-B) from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings (item 1-C) into the six grooves on the sleeve. Apply a light coating of grease to the o-rings before installing the sleeve into the valve body. Align the slots in the sleeve with the slots in the valve body. Insert the spool into the sleeve. Be careful not to scratch or damage the spool during installation. Push the spool in until the pin touches the end cap on the opposite end.
Install the remaining end cap with
o-rings and retainer.
Fasten the air valve assembly (item
1) and gasket (item 23) to the pump, using the four hex anged capscrews (item 12).
Connect the compressed air line to the pump. The pump is now ready for operation.
IMPORTANT: Remove the safety clip. The pump will not function properly until it is removed. The pump is now ready for operation.
IMPORTANT
Read these instructions
completely, before
installation and start-up.
It is the responsibility of
the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
m05mdl1sm-rev0711 Model M05 Metallic Page 21
Page 24
Solenoid Shifted Air Valve Drawing
13
39
22
4
41
40
33
43
28
33
43
28
20
8
42
II 2G EEx m c T5 II 2D c IP65 T100°C
SOLENOID SHIFTED AIR VALVE PARTS LIST
(Includes all items used on Composite Repair Parts List except as shown)
ITEM PART NUMBER DESCRIPTION QTY
4 114-023-157 Bracket, Intermediate 1 114-023-551 Bracket, Intermediate 1 114-023-559 Bracket, Intermediate 1
(Conductive Polypropylene Midsection ONLY)
38 893-099-000 Solenoid Valve, NEMA4 1 39 219-001-000 Solenoid Coil, 24VDC 1 219-004-000 Solenoid Coil, 24VAC/12VDC 1 219-002-000 Solenoid Coil, 120VAC 1 219-003-000 Solenoid Coil, 240VAC 1 40 241-001-000 Connector, conduit 1 241-003-000 Conduit Connector with 1 Suppression Diode (DC Only) 41 171-065-115 Capscrew, Flanged ¼-20 x 1.00 4 42 618-050-150 Plug (Replaces Item 7) 2
IEC EEX m T4
For Explosion Proof Solenoid Coils used in North America and outside the European Union.
39 219-009-001 Solenoid Coil, 120VAC 60 Hz 1 219-009-002 Solenoid Coil, 240VAC 60 Hz 1 219-009-003 Solenoid Coil, 12VDC 1 219-009-004 Solenoid Coil, 24VDC 1 219-009-005 Solenoid Coil, 110VAC 50 Hz 1 219-009-006 Solenoid Coil, 230VAC 50 Hz 1
Note: Item 40 (Conduit Connector) is not required
For ATEX Compliant Solenoid Coils used in the European Union
*
39 219-011-001 Solenoid Coil, Single mounting 12 VDC, 3.3W / 267mA 1 219-011-002 Solenoid Coil, Single mounting 24 VDC, 3.3W / 136mA 1 219-011-003 Solenoid Coil, Single mounting 110/120 VAC, 3.4W / 29mA 1 219-011-004 Solenoid Coil, Single mounting 220/240 VAC, 3.4W / 15mA 1
Note: Item 37 (Conduit Connector) is not required
Compressed Air Temperature Range: Maximum Ambient Temperature to plus 50°C
II 2G EEx m c II T5 II 3/2 G Ex m c II T5 II 2D c IP65 T100°c
*Special Conditions For Safe Use
A fuse corresponding to its rated current (max. 3*I series to each solenoid as short circuit protection. For very low rated currents of the solenoid the fuse of lowest current value according to the indicated IEC standard will be sufcient. The fuse may be accommodated in the associated supply unit or shall be separately arranged. The rated voltage to the fuse shall be equal to or greater than the stated rated voltage of the magnet coil. The breakage capacity of the fuse-link shall be as high as or higher than the maximum expected short circuit current at the location of the installation (usually 1500 A). A maximum permissible ripple of 20% is valid for all magnets of direct-current design.
m05mdl1sm-rev0711 Model M05 Metallic Page 22
according IEC 60127-2-1) or a motor protecting switch with short-circuit and thermal instantaneous tripping (set to rated current) shall be connected in
rat
Page 25
SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION
MARATHON’s solenoid shifted, air distribution valve option utilizes electrical signals to precisely control your MARATHON’s speed. The solenoid coil is connected to a customer
- supplied control. Compressed air provides the pumping power, while electrical signals control pump speed (pumping rate).
OPERATION
The Solenoid Shifted MARATHON has a solenoid operated, air distribution valve in place of the standard MARATHON’s pilot operated, air distribution valve. Where a pilot valve is normally utilized to cycle the pump’s air distribution valve, an electric solenoid is utilized. As the solenoid is powered, one of the pump’s air chambers is pressurized while the other chamber is exhausted. When electric power is turned off, the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized. By alternately applying and removing power to the solenoid, the pump cycles much like a standard MARATHON pump, with one exception. This option provides a way to precisely control and monitor pump speed.
Solenoid Connector
Before wiring, remove terminal block from conduit connector.
Wiring Diagram
#2 Terminal Neutral (Negative)
3rd Terminal for ground.
#1 Terminal Power (Positive)
To Control
BEFORE INSTALLATION
Before wiring the solenoid, make certain it is compatible with your system voltage.
m05mdl1sm-rev0711 Model M05 Metallic Page 23
Page 26
Diaphragm Service
34
6
31
20
15
30
14
11
27
11
34
6
31
34
6
31
16
17
30
14
11
27
11
15
14
11
27
37
37
37
11
11
37
37
37
14
37
37
11
15
14
30
16
11
15
11
14
30
11
15
11
20
37
*
Use With TPE Diaphragms Only
(286-116-000 only)
Diaphragm Service
Diaphragm Service for
Drawing
Drawing, with Overlay
One-Piece Bonded
m05mdl1sm-rev0711 Model M05 Metallic Page 24
Page 27
DIAPHRAGM SERVICING
To service the diaphragm first shut off the suction, then shut off the discharge lines to the pump. Shut off the compressed air supply, bleed the pressure from the pump, and disconnect the air supply line from the pump. Drain any remaining liquid from the pump.
Step #1: See the pump composite repair parts drawing, and the diaphragm servicing illustration.
Using a 1/2" wrench or socket, remove 8 capscrews (items 9 & 10), washers and nuts that fasten the discharge elbows (item 18) or the discharge manifold (item 25). Remove the elbows and manifold assembly (items 18 & 23) or manifold (item 25). Use the same procedure to remove the suction elbows (item 17) or suction manifold (item 24).
Step #2: Removing the outer chambers. Using a 1/2" wrench or socket, remove the 16 capsrews (item 10), washers that fasten the outer chambers (item 14), diaphragms (items 15 & 16) and intermediate bracket (item
4) together.
Step #3: Removing the diaphragm assemblies.
Use a 3/4" (19mm) wrench or six pointed socket to remove the diaphragm assemblies (outer plate, diaphragm, and inner plate) from the diaphragm rod (item 34) by turning counterclockwise.
Insert a 6-32 set screw into the smaller tapped hole in the inner
diaphragm plate (item 31). Insert the protruding stud and the 6-32 fastener loosely into a vise. Use a 3/4" wrench or socket to remove the outer diaphragm plate (item 30) by turning counterclockwise. Inspect the diaphragm (item 15 & 16) for cuts, punctures, abrasive wear or chemical attack. Replace the diaphragms if necessary.
Step #4: Installing the diaphragms.
Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm. Thread the inner plate clockwise onto the stud. Insert the loose assembly with the above 6-32 fastener back into the vise. Use a torque wrench to tighten the diaphragm assembly together to 7.5 ft. Lbs. (10.17 Newton meters). Allow a minimum of 15 minutes to elapse after torquing, then re-torque the assembly to compensate for stress relaxation in the clamped assembly.
Step #5: Installing the diaphragm assemblies to the pump.
Make sure the bumper (item 6) is installed over the diaphragm rod.
Thread the stud of the one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod (item 34) until the inner diaphragm plate is ush to the end of the rod. Insert rod into pump.
Align the bolt holes in the diaphragm with the bolt pattern in the intermediate (item 4).
Fasten the outer chamber (item
14) to the pump, using the capscrews
On the opposite side of the pump, pull the diaphragm rod out as far as possible. Make sure the bumper (item 6) is installed over the diaphragm rod.
Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod (item 34) as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber. Install diaphragms with convolutions facing towards center of pump. See sectional view on previous page.
Fasten the remaining outer chamber (item 14) to the pump, using the capscrews (item 10) and washers.
Step #6: Re-install the elbow/ manifold assemblies to the pump, using the capscrews (items 9 and 10) washers and nuts.
The pump is now ready to be re-installed, connected and returned to operation.
OVERLAY DIAPHRAGM SERVICING
The overlay diaphragm (item 16) is designed to fit snugly over the exterior of the standard TPE diaphragm (item 15).
ONE-PIECE BONDED DIAPHRAGM SERVICING
The one-piece bonded diaphragm has a threaded stud installed in the integral plate at the factory. The inner diaphragm plate has a through hole instead of a threaded hole.
IMPORTANT
Read these instructions completely, before in­stallation and start-up.
It is the responsibility of the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
Place the inner plate over the diaphragm stud and thread the first diaphragm/inner plate into the diaphragm rod only until the inner plate contacts the rod. Do not tighten. A small amount of grease may be applied between the inner plate and the diaphragm to facilitate assembly.
Inside the rst inner chamber push the pilot plunger pin all the way in, insert the rst diaphragm/rod assembly into the pump and install the rst outer chamber. Attach a regulated air line to the air inlet of the pump with the air pressure turned down to zero. Slowly begin turning up the air pressure until the diaphragm assembly completes one shift, enabling the second outer chamber to be installed.
Turn the pump over and thread the second diaphragm/inner plate onto the diaphragm rod. Turn the diaphragm until the inner plate contacts the rod and hand tighten the assembly. Continue tightening until the bolt holes align with eight inner chamber holes. DO NOT LEAVE THE ASSEMBLY LOOSE. Install the second outer chamber.
(item 10) washers.
m05mdl1sm-rev0711 Model M05 Metallic Page 25
Page 28
Pilot Valve Servicing, Assembly Drawing & Parts List
PILOT VALVE ASSEMBLY PARTS LIST
For Models Equipped with Aluminum Midsections ITEM PART NUMBER DESCRIPTION QTY
3 095-116-000 Pilot Valve Assembly 1 3-A 095-087-157 Valve Body 1 3-B 755-051-000 Sleeve (With O-rings) 1 3-C 560-033-360 O-ring (Sleeve) 6 3-D 775-055-000 Spool (With O-rings) 1 3-E 560-023-360 O-ring (Spool) 3 3-F 675-037-080 Retaining Ring 1
For Models Equipped with Polypropylene Midsections ITEM PART NUMBER DESCRIPTION QTY
3 095-091-000 Pilot Valve Assembly 1 3-A 095-087-551 Pilot Valve Body 1 3-B 755-051-000 Sleeve (With O-rings) 1 3-C 560-033-360 O-ring (Sleeve) 6 3-D 775-055-000 Spool (With O-rings) 1 3-E 560-023-360 O-ring (Spool) 3 3-F 675-037-080 Retaining Ring 1
For Models Equipped with Conductive Polypropylene Midsections ITEM PART NUMBER DESCRIPTION QTY
3 095-091-001 Pilot Valve Assembly 1 3-A 095-087-558 Pilot Valve Body 1 3-B 755-051-000 Sleeve (With O-rings) 1 3-C 560-033-360 O-ring (Sleeve) 6 3-D 775-055-000 Spool (With O-rings) 1 3-E 560-023-360 O-ring (Spool) 3 3-F 675-037-080 Retaining Ring 1
PILOT VALVE SERVICING
To service the pilot valve rst shut off the compressed air supply, bleed the pressure from the pump, and disconnect the air supply line from the pump.
STEP #1: See pump assembly drawing.
Using a 7/16" wrench or socket, remove the four capscrews (item 13). Remove the air inlet cap (item 8) and air inlet gasket (item 20). The pilot valve assembly (item 3) can now be removed
STEP #2: Disassembly of the pilot
valve.
Remove the pilot valve spool (item 3-D). Wipe clean and inspect spool and o-rings for dirt, cuts or wear. Replace the o-rings and spool if necessary.
Remove the retaining ring (item 3-F) from the end of the sleeve (item 3-B) and remove the sleeve from the valve body (item 3-A). Wipe clean and inspect sleeve and o-rings for dirt, cuts or wear. Replace the o-rings and sleeve if necessary.
STEP #3: Re-assembly of the pilot
valve.
Generously lubricate outside diameter of the sleeve and o-rings. Then carefully insert sleeve into valve body. Take CAUTION when inserting sleeve, not to shear any o-rings. Install retaining ring to sleeve. Generously lubricate outside diameter of spool and o-rings. Then carefully insert spool into sleeve. Take CAUTION when inserting spool, not to shear any o-rings. Use BP-LS-EP-2 multipurpose grease, or equivalent.
STEP #4: Re-install the pilot valve
assembly into the intermediate.
Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate.
Re-install the gasket, air inlet cap and capscrews. Connect the air supply to the pump. The pump is now ready for operation.
for inspection and service.
m05mdl1sm-rev0711 Model M05 Metallic Page 26
Page 29
7
26
21
4
21
7
26
25
25
35
Intermediate Assembly Drawing Intermediate Assembly Servicing
INTERMEDIATE REPAIR PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
4 114-023-157 Bracket, Intermediate 1 114-023-551 Bracket, Intermediate 1 114-023-559 Bracket, Intermediate 1
(Conductive Polypropylene Midsection ONLY)
7 135-036-506 Bushing, Plunger 2 28 560-001-360 O-Ring 2 32 620-019-115 Plunger, Actuator 2 33 675-042-115 Ring, Retaining* 2
*NOTE: It is recommended that when plunger components are serviced, new retaining rings be installed.
ACTUATOR PLUNGER SERVICING
To service the actuator plunger rst shut off the compressed air supply, bleed the pressure from the pump, and disconnect the air supply line from the pump.
Step #1: See PUMP ASSEMBLY DRAWING.
Using a
3/8" wrench or socket,
remove the four capscrews (items 12). Remove the air inlet cap (item 8) and air inlet gasket (item 20). The pilot valve assembly (item 3) can now be removed.
Step #2: Servicing the actuator plungers.
See PUMP ASSEMBLY DRAWING.
The actuator plungers (items 32) can be reached through the stem cavity of the pilot valve in the intermediate bracket (item 4). To service bushings, o-rings and retaining rings, see Intermediate Drawing.
Remove the plungers (items 32) from the bushings (item 7) in each end of the intermediate cavity. Inspect for wear or damage. Replace plunger as needed. Apply a light coating of grease to each o-ring and re-install the plungers in to the bushings. Push the plungers in as far as they will go.
Step #3: Re-install the pilot valve assembly into the intermediate
assembly.
Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate.
Re-install the gasket (item 20), air inlet cap (item 8) and capscrews (items 12).
Connect the air supply to the pump. The pump is now ready for operation.
PLUNGER BUSHING, O-RING, AND RETAINING RING SERVICING
To service the plunger bushing components first remove the two retaining rings (items 33) using a small flat screwdriver. *Note: It is recommended that new retaining rings be installed.
Next remove the two plunger bushings (items 7). Inspect the bushings for wear or scratches. Replace the bushings as necessary.
Inspect the two o-rings (28) for cuts and/or wear.
IMPORTANT
Read these instructions completely, before in­stallation and start-up.
It is the responsibility of
the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
m05mdl1sm-rev0711 Model M05 Metallic Page 27
Page 30
CHECK VALVE SERVICING
37
37
9
10
2
36
27
37
29
36
29
Before servicing the check valve components, rst shut off the suction line and then the discharge line to the pump. Next, shut off the compressed air supply, bleed air pressure from the pump, and disconnect the air supply line from the pump. Drain any remaining uid from the pump. The pump can now be removed for service.
To access the check valve components, remove the manifold/ manifold assembly. Use a 1/2" wrench or socket to remove the fasteners. Once the manifold is removed, the check valve components can be seen.
Inspect the check balls (items 2) for wear, abrasion, or cuts on the spherical surface. The check valve seats (item
36) should be inspected for cuts, abrasive wear, or embedded material on the surfaces of both the external and internal chambers. The spherical surface of the check balls must seat ush to the surface of the check valve seats for the pump to operate to peak efciency. Replace any worn or damaged parts as necessary.
Re-assemble the check valve components. The seat should t into the counter bore of the outer chamber.
The pump can now be reassembled, reconnected and returned to operation.
Check Valve Drawing
METALLIC SEATS
Two o-rings (or conductive PTFE seals) (item 29) are required for metallic seats.
m05mdl1sm-rev0711 Model M05 Metallic Page 28
Page 31
Optional Mufer Congurations, Drawing
OPTION 0
530-031-550 Integral Mufer uses (1) Cap and (4) 706-027-115 Machine Screw to hold it in place.
OPTION 1
530-024-000 Sound Dampening Mufer screws directly into the Air Valve body. This mufer is equipped with a porous plastic element.
OPTION 2
530-023-000 Mesh Mufer screws directly into the Air Valve Body. This mufer is equipped with a metal element.
OPTION 6
530-035-000 Metal Mufer screws directly into the Air Body.
Option 0
Option 6
Option 1 and 2
Note: ATEX compliant
m05mdl1sm-rev0711 Model M05 Metallic Page 29
Page 32
Dual Port Option Drawing (Aluminum Model Only)
1/2” NPT or 1/2” BSP Tapered
INTERNAL (DUAL PORT PARTS ONLY)
1” NPT or 1” BSP Tapered EXTERNAL
1/2” NPT or 1/2” BSP Tapered INTERNAL
(THIS PART REQUIRED FOR SINGLE
PORT SUCTION ONLY)
1” NPT or 1” BSP Tapered EXTERNAL 1/2” NPT or 1/2” BSP Tapered INTERNAL (THIS PART REQUIRED FOR SINGLE PORT SUCTION ONLY)
1/2” NPT or 1/2” BSP Tapered INTERNAL
(DUAL PORT PARTS ONLY)
m05mdl1sm-rev0711 Model M05 Metallic Page 30
Page 33
DUAL PORTING OPTIONS
Several dual porting options are possible. The pump can be converted to a dual port arrangement on both the suction and the discharge ends. The porting can be congured to a single suction and a dual discharge. The porting can be changed to a dual suction and a single discharge.
The above changes are possible because the porting flange of the elbows (items 19) are designed to mate with 1/2" NPT or BSP (Tapered) connection.
DUAL PORTING OF BOTH SUCTION AND DISCHARGE ENDS OF THE PUMP
Converting the pump from the standard single suction and discharge porting conguration to dual porting at each end is easy. Simply remove the manifold seals and manifolds (items 24 and 29 from pump assembly drawing) from the pump.
The discharge elbows and suction elbows can be rotated 90° increments (see arrows and optional positioning in the Dual Port Options Drawing.)
SINGLE PORTING OF THE SUCTION AND DUAL PORTING OF THE PUMP DISCHARGE
To convert the pump from the standard single suction and single discharge porting conguration to a dual discharge porting arrangement remove the only the discharge manifolds and manifold seals. Position the discharge elbows in the desired direction at 90° increments. (See arrows and optional positioning in the Dual Porting Drawing.)
DUAL PORTING OF THE SUCTION AND SINGLE PORTING OF THE PUMP DISCHARGE
To convert the pump from the standard single suction and single discharge porting conguration to a dual suction porting arrangement remove the only the suction (bottom) manifolds and manifold seals.
Position the suction elbows in the desired direction at 90° increments. (See arrows and optional positioning in the Dual Porting Drawing.)
IMPORTANT
Read these instructions completely, before in­stallation and start-up.
It is the responsibility of
the purchaser to retain
this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
NOTE: See Repair Parts Lists on next page.
m05mdl1sm-rev0711 Model M05 Metallic Page 31
Page 34
SINGLE PORT SUCTION REPAIR PARTS LIST ITEM PART NO. DESCRIPTION QTY
10* 170-045-115 Capscrew, Hex 5/16-18 x 1.25 32 170-045-330 Capscrew, Hex 5/16-18 x 1.25 32 18* 312-111-157E Elbow, Discharge BSP (tapered) 2 (repalces 312-111-157) 312-111-157N Elbow, Discharge 1/2" NPT 2 (replaces 312-111-157) 23* 518-157-157 Manifold BSPT (suction position only) 1 518-157-157E Manifold NPT (suction position only) 1 27* 545-004-115 Nut, Hex 5/16-18 28 545-004-330 Nut, Hex 5/16-18 28 29* 560-083-360 O-ring (Alum Manifold) 2 560-083-363 O-ring (Alum Manifold) 2 560-083-364 O-ring (Alum Manifold) 2 560-083-365 O-ring (Alum Manifold) 2 720-064-600 Seal (Alum Manifold) 2 37* 900-004-115 Lock Washer 40 900-004-330 Lock Washer 40
SINGLE PORT DISCHARGE REPAIR PARTS LIST
10* 170-045-115 Capscrew, Hex 5/16-18 X 1.25 32 170-045-330 Capscrew, Hex 5/16-18 X 1.25 32 17* 312-110-157E Elbow, Suction BSP (tapered) 2 (replaces 312-110-157) 312-110-157N Elbow, Suction 1/2" NPT 2 (replaces 312-110-157) 23* 518-157-157 Manifold BSPT (discharge position only) 1 518-157-157E Manifold NPT (discharge position only) 1 27* 545-004-115 Nut, Hex 5/16-18 28 545-004-330 Nut, Hex 5/16-18 28 29* 560-083-360 O-ring (Alum Manifold) 2 560-083-363 O-ring (Alum Manifold) 2 560-083-364 O-ring (Alum Manifold) 2 560-083-365 O-ring (Alum Manifold) 2 720-064-600 Seal (Alum Manifold) 2 37* 900-004-115 Lock Washer 40 900-004-330 Lock Washer 40
DUAL PORT SUCTION AND DISCHARGE REPAIR PARTS LIST
10* 170-045-115 Capscrew, Hex 5/16-18 X 1.25 24 170-045-330 Capscrew, Hex 5/16-18 X 1.25 24 17* 312-110-157E Elbow, Suction BSP (tapered) 2 (replaces 312-110-157) 312-110-157N Elbow, Suction 1/2" NPT 2 (replaces 312-110-157) 18* 312-111-157E Elbow, Discharge BSP (tapered) 2 (replaces 312-111-157) 312-111-157N Elbow, Discharge 1/2" NPT 2 (replaces 312-111-157) 23* 518-157-157 Manifold (not required) 0 27* 545-004-115 Nut, Hex 5/16-18 20 545-004-330 Nut, Hex 5/16-18 20 29* 560-083-360 O-ring (Alum Manifold) (not required) 0 560-083-363 O-ring (Alum Manifold) (not required) 0 560-083-364 O-ring (Alum Manifold) (none required) 0 560-083-365 O-ring (Alum Manifold) (none required) 0 720-064-600 Seal (Alum Manifold) (none required) 0 37* 900-004-115 Lock Washer 32 900-004-330 Lock Washer 32
*Quantities change from Composite Repair Parts List.
m05mdl1sm-rev0711 Model M05 Metallic Page 32
Page 35
PUMPING HAZARDOUS LIQUIDS
When a diaphragm fails, the pumped liquid or fumes enter the air end of the pump. Fumes are exhausted into the surrounding environment. When pumping hazardous or toxic materials, the exhaust air must be piped to an appropriate area for safe disposal. See illustration #1 at right.
This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped. The air exhaust must be piped above the liquid level. See illustration #2 at right. Piping used for the air exhaust must not be smaller than 1/2" (1.27 cm) diameter. Reducing the pipe size will restrict air ow and reduce pump performance. When the pumped product source is at a higher level than the pump (ooded suction condition), pipe the exhaust higher than the product source to prevent siphoning spills. See illustration #3 at right.
IMPORTANT INSTALLATION NOTE:
The manufacturer recommends installing a conductive exible hose or connection between the pump and any rigid plumbing. This reduces stresses on the molded plastic threads of the air exhaust port. Failure to do so may result in damage to the air distribution valve body.
Any piping or hose connected to the pump’s air exhaust port must be conductive and physically supported. Failure to support these connections could also result in damage to the air distribution valve body.
Exhaust Conversion Drawing
Air Valve Assembly
1
CONVERTED EXHAUST ILLUSTRATION
PUMP INSTALLATION AREA
1" DIAMETER AIR
EXHAUST PIPING
Illustration #1
LIQUID LEVEL
SUCTION
LINE
SAFE AIR EXHAUST DISPOSAL AREA
MUFFLER
MUFFLER
1" DIAMETER AIR EXHAUST PIPING
CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR
The following steps are necessary
26
Illustration #2
to convert the pump to pipe the exhaust air away from the pump.
Use a Phillips screwdriver to remove
MUFFLER
the four self-tapping screws (item 1-H).
Remove the mufer cap and mufer (items 1-G and 1-F). The 3/8" NPT molded threads in the air distribution valve body (item 1-A).
On ATEX compliant units the pump comes equipped with a metal mufer
Piping or hose may now be installed.
Illustration #3
m05mdl1sm-rev0711 Model M05 Metallic Page 33
LIQUID LEVEL
SUCTION
LINE
1" DIAMETER AIR EXHAUST PIPING
Page 36
Pulse Output Kit Drawing
PULSE OUTPUT KIT OPTION
This pump can be tted with a Pulse Output Kit. This converts the mechanical strokes of the pump to an electrical signal which interfaces with the Stroke Counter/ Batch Controller or user control devices such as a PLC.
The Pulse Output Kits mount directly onto the Mufer Cap on the Air Distribution Valve Assembly or onto the air valve and senses each stroke of the main spool.
Consult the factory for further information and availability.
Pulse Output Kits
475-244-001 10-30 VDC
475-244-002 110/220 VAC
475-244-003 10-30VDC, 110VAC and 220 VAC
m05mdl1sm-rev0711 Model M05 Metallic Page 34
Page 37
Grounding The Pump
To be fully groundable, the pumps must be ATEX Compliant. Refer to pump data sheet for ordering.
One eyelet is fastened to the pump hardware.
This 8 foot long (244 centimeters) Ground Strap, part number 920-025-000, can be ordered as a service item.
One eyelet is installed to a true earth ground. (Requires a 5/16 or 8mm maximum diameter bolt)
To reduce the risk of static electrical sparking, this pump must be grounded. Check the local electrical code for detailed grounding instruction and the type of equipment required.
WARNING
Take action to prevent static
sparking. Fire or explosion can result, especially when handling flammable liquids. The pump,
piping, valves, containers or other miscellaneous equipment must
be grounded.
m05mdl1sm-rev0711 Model M05 Metallic Page 35
Page 38
Declaration of Conformity
Manufacturer: Warren Rupp, Inc.®, 800 N. Main Street, P.O. Box 1568,
Mansfield, Ohio, 44901-1568 USA
certifies that Air-Operated Double Diaphragm Pump Series: M Non-Metallic, M Metallic, and Surge Suppressors comply
with the European Community Directive 2006/42/EC on Machinery,
according to Annex VIII. This product has used Harmonized Standard
EN809:1998+A1:2009, Pumps and Pump Units for Liquids - Common Safety
Requirements, to verify conformance.
October 20, 2005
Signature of authorized person
Date of issue
David Roseberry Printed name of authorized person
Revision Level: F
Engineering Manager Title
August 23, 2012 Date of revision
Page 39
EC Declaration of Conformity
In accordance with ATEX Directive 94/9/EC,
Equipment intended for use in potentially explosive environments.
Manufacturer: Warren Rupp, Inc.
800 North Main Street, P.O. Box 1568, Mansfield, OH 44901-1568 USA
EN 60079-25: 2004
For pumps equipped with Pulse Output ATEX Option KEMA Quality B.V. (0344)
AODD Pumps and Surge Suppressors
For Type Examination Designations, see page 2 (back)
AODD (Air-Operated Double Diaphragm) Pumps
EC Type Examination Certificate No. Pumps: KEMA 09ATEX0071 X KEMA Quality B.V. Utrechtseweg 310 6812 AR Arnhem, The Netherlands
DATE/APPROVAL/TITLE: 27 MAY 2010
®
, A Unit of IDEX Corportion
Applicable Standard:
EN13463-1: 2001, EN13463-5: 2003
David Roseberry, Engineering Manager
Page 40
EC Declaration of Conformity
ATEX Summary of Markings
Type Marking Listed In
Pump types, M05, M1F, M15, M20 and M30 provided with the pulse output option
Pump types, M05, M1F, M15 M20 and M30 provided with the integral solenoid option
Pump types, MPB1/4, M05, M1F, M15, M20, M30, MSB1, MHDF1, MHDF2 without the above listed options, no aluminum parts
Pump types,
MPB1/4, M05, M1F, M15, M20, M30, MSB1, MHDF1, MHDF2, MHDF3
MT Series Surge Suppressors II 2 G T5
EC Type Certificate No. Pumps: KEMA 09ATEX0071 X Type Certificate No. Pumps: KEMA 09ATEX0072 X Type Certificate No. Suppressors: KEMA 09ATEX0073
II 2 G Ex ia c IIC T5 II 3/2 G Ex ia c IIC T5 II 2 D
Ex c iaD 20 IP67 T100oC
II 2 G EEx m c II T5 II 3/2 G EEx m c II T5 II 2 D c IP65 T100
II 1 G c T5 II 3/1 G c T5 II 1 D c T100 I M1 c I M2 c
II 2 G c T5 II 3/2 G c T5 II 2 D c T100
II 3/2 G T5 II 2 D T100
Non-Conductive
Fluids
KEMA 09ATEX0071 X CE 0344
KEMA 09ATEX0071 X
o
C
o
C
o
C
o
C
CE 0344
KEMA 09ATEX0071 X KEMA 09ATEX0072 X CE 0344
KEMA 09ATEX0072 X CE
KEMA 09ATEX0073 CE
KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X
KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X
KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0072 X
KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X
KEMA 09ATEX0073 KEMA 09ATEX0073 KEMA 09ATEX0073
No Yes Yes
No Yes Yes
No Yes Yes
No Yes
No Yes Yes
No Yes Yes
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use