Dimensions: M30 Non-Metallic with Spill Containment ....................................................................... 6
Metric Dimensions: M30 Non-Metallic with Spill Containment ........................................................... 7
Principle of Pump Operation............................................................................................................... 8
Installation and Start-up...................................................................................................................... 8
Air Supply ........................................................................................................................................... 8
Air Valve Lubrication ........................................................................................................................... 8
Air Line Moisture................................................................................................................................. 8
Air Inlet and Priming ........................................................................................................................... 8
Between Uses .................................................................................................................................... 8
CAUTION! Maximum Operating Temperature Limit is 180°F for Polypropylene and 250°F for PVDF Models.
Temperature Limits
Materials Maximum Minimum
®:
Santoprene
resistance. 88°C -40°C
Virgin 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 triuoride or oxygen diuoride which readily liberate free 350°F -35°F
uorine at elevated temperatures. 177°C -37°C
Polypropylene 180°F 32°F
82°C 0°C
PVDF 250°F 0°F
121°C -18°C
For specic applications, always consult “Chemical Resistance Chart” Technical Bulletin
CAUTION: Nonmetallic pumps and plastic components are not UV stabilized. Ultraviolet radiation can damage these parts and negatively affect material properties.
Do not expose to UV light for extended periods of time.
MARATHON® pumps are designed to be powered only by compressed air.
Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life. Excellent abrasion 275°F -40°F
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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 1
Explanation of Pump Nomenclature
M30 Non-Metallic · Design Level 2· 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)
M30B2P1PQAS000. S 30 B 2 P 1 P Q A S 0 00. 231 (105)
M30B2P2PQAS000. S 30 B 2 P 2 P Q A S 0 00. 231 (105)
M30B2K1KQAS000. S 30 B 2 K 1 K Q A S 0 00. 315 (143)
M30B2K2KQAS000. S 30 B 2 K 2 K Q A S 0 00. 315 (143)
M30B2P4PQAV000. S 30 B 2 P 4 P Q A V 0 00. 270 (122)
M30B2K4KQAV000. S 30 B 2 K 4 K Q A V 0 00. 354 (161)
Pump Style
D= Spill Containment with
Electronic Leak Detection (110V)
E= Spill Containment with
Electronic Leak Detection (220V)
M=Spill Containment with
Mechanical Leak Detection
S= Standard
V= Spill Containment with
Visual Leak Detection
Pump Options
0= None
1= Sound Dampening Mufer
2= Mesh Mufer
3= High temperature Air
Valve w/Integral Mufer
4= High temperature
Air Valve with Sound
Dampening Mufer
5= High temperature
Air Valve w/Mesh Mufer
Kit Options
00.= None
P0.= 10-30VDC Pulse Output Kit
P1.= Intrinsically-Safe 5-30VDC,110/120VAC,
220/240VAC 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 with12VDC
Explosion-Proof Coil
E4.= Solenoid Kit with 110VAC Coil
E5.= Solenoid Kit with 110VAC,
60 Hz Explosion-Proof Coil
E6.= Solenoid Kit with 220VAC Coil
E7.= Solenoid Kit with 220VAC,
60 Hz 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
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 2
MODEL S30 Non-Metallic Performance Curve
Performance Curve, Model M30 Non-Metallic Design Level 2
Performance based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
60 (102)
80 (136)
100 (170)
120 (204)
140 (238)
BAR
100
7
90
6
80
5
70
60
4
50
HEAD
3
40
20 (34)
PSI
40 (68)
100 PSI
80 PSI (5.44 Bar)
60 PSI (4.08 Bar)
40 PSI (2.72 Bar)
(6.8 Bar)
NPSHR
METERS
FEET
30
2
20
1
20 PSI (1.36 Bar)
Air Inlet Pressure
10
0
0
30
25
20
15
10
9.1
7.6
6
4.5
3
1.5
5
020406080100120140160180200220
U.S. Gallons per minute
85075065055045035025015050
Liters per minute
CAPACITY
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 3
DISCHARGE PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
MANIFOLD CAN
ROTATE ±90º
FROM VERTICAL
CENTERLINE
BOLT PATTERN IS
SYMMETRICAL ABOUT
CENTERLINES
AIR INLET
3/4” NPT
BOTTOM VIEW
SIDE VIEW
FRONT VIEW
SUCTION PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
STANDARD INTEGRAL MUFFLER:
1” NPT EXHAUST PORT
FOR OPTIONAL MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS
Dimensions: M30 Non-Metallic
Dimensions in Inches
Dimensional tolerance: ±1/8"
Note: Dimensions "A" is from
the vertical center line to the end
of the mufer.
Dimension
Standard Pump
Pulse Output Kit
Sound Dampening Mufer
Mesh Mufer
Note: Porting Flanges are also available with
PN10 80mm DIN bolting conguration.
6 9/16"
6 9/16"
13 3/4"
8 13/16"
A
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 4
Metric Dimensions: M30 Non-Metallic
DISCHARGE PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
MANIFOLD CAN
ROTATE ±90º
FROM VERTICAL
CENTERLINE
BOLT PATTERN IS
SYMMETRICAL ABOUT
CENTERLINES
3/4” TYP.
8 PLACES
BOTTOM VIEW
SIDE VIEW
FRONT VIEW
SUCTION PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
STANDARD INTEGRAL MUFFLER:
1” NPT EXHAUST PORT
FOR OPTIONAL MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS
AIR INLET
3/4” NPT
Dimensions in Millimeters
Dimensional tolerance: ± 3mm
Note: Dimensions "A" is from
the vertical center line to the end
of the mufer.
Dimension
Standard Pump
Pulse Output Kit
Sound Dampening Mufer
Mesh Mufer
A
6 9/16"
6 9/16"
13 3/4"
8 13/16"
Note: Porting Flanges are also available
with PN10 80mm DIN bolting conguration.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 5
Dimensions: M30 Non-Metallic
DISCHARGE PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
MANIFOLD CAN
ROTATE ±90º
FROM VERTICAL
CENTERLINE
BOLT PATTERN IS
SYMMETRICAL ABOUT
CENTERLINES
AIR INLET
3/4” NPT
3/4” TYP.
8 PLACES
BOTTOM VIEW
SIDE VIEW
FRONT VIEW
SUCTION PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
STANDARD INTEGRAL MUFFLER:
1” NPT EXHAUST PORT
FOR OPTIONAL MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS
with Spill Containment
Dimensions in Inches
Dimensional tolerance: ±1/8"
Note: Dimensions "A" is from
the vertical center line to the
end of the mufer.
Note: Dimensions "B" is from
the opposite side of the pump
to the end of the mufer.
Dimension
Standard Pump
Pulse Output Kit
Sound Dampening Mufer
Mesh Mufer
Note: Porting Flanges are also available with
PN10 40mm DIN bolting conguration.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 6
A
6 9/16"
6 9/16"
13 3/4"
8 13/16"
12 11/16"
12 11/16"
22 9/32"
14 15/16"
B
DISCHARGE PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
MANIFOLD CAN
ROTATE ±90º
FROM VERTICAL
CENTERLINE
BOLT PATTERN IS
SYMMETRICAL ABOUT
CENTERLINES
AIR INLET
3/4” NPT
3/4” TYP.
8 PLACES
BOTTOM VIEW
SIDE VIEW
FRONT VIEW
SUCTION PORT
3” STANDARAD 125# FLANGE CONFIGURATION
3/4” DIA., (4) HOLES EQUALLY SPACED
ON A 6” DIA. BOLT CHANGE.
STANDARD INTEGRAL MUFFLER:
1” NPT EXHAUST PORT
FOR OPTIONAL MUFFLER
STYLES OR PIPING EXHAUST
AIR IN SUBMERGED APPLICATIONS
Metric Dimensions: M30 Non-Metallic
with Spill Containment
Dimensions in Millimeters
Dimensional tolerance: ± 3mm
Dimension
Standard Pump
Pulse Output Kit
Sound Dampening Mufer
Mesh Mufer
Note: Porting Flanges are also available with
PN10 80mm DIN bolting conguration.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 7
AB
167mm
167mm
322mm
322mm
349mm579mm
225mm380mm
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 flexible hose
reduces vibration and strain to the
pumping system. A surge suppressor
is recommended to further reduce
pulsation in ow.
AIR SUPPLY
Air supply pressure cannot exceed
100 psi (7 bar). Connect the pump
air inlet to an air supply of sufcient
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 ½"
(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 Warren Rupp)
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 ½ to ¾ 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 efcient 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 8
INSTALLATION GUIDE
Top Discharge Ball Valve Unit
Available from
Warren Rupp
1
Surge Suppressor
020-051-000 Filter/Regulator
2
3
Air Dryer
CAUTION
The air exhaust should be
piped to an area for safe
disposition of the product
being pumped, in the event
of a diaphragm failure.
1
Surge
Suppressor
Limited to
100 psi
3
2
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 9
RECYCLING
Many components of MARATHON® AODD
pumps are made of recyclable materials (see
chart on page 11 for material specications).
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.
installation and start-up
CAUTION
Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep. Retorque 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
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
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 10
WARNING
Airborne particles and
loud noise hazards.
Wear ear and eye
protection.
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
Check Balls/EPDM Seats
661 EPDM/Santoprene
666 FDA Nitrile Diaphragm,
PTFE Overlay, Balls, and Seals
668 PTFE, FDA Santoprene/PTFE
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.
PortaPump, Tranquilizer and
SludgeMaster are registered tradenames
of Warren Rupp, Inc.
®
/EPDM
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 11
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.
What to Check: Undersized suction
line.
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 suppressor.
What to Check: Blocked air exhaust
mufer.
Corrective Action: Remove mufer
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 mufer.
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 Warren Rupp Technical Services
Department 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 Warren Rupp Distributor or factory
Technical Services Group for a service
evaluation.
WARRANTY
Refer to the enclosed Warren Rupp
Warranty Certicate.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 12
**MUFFLER OPTION
*OVERLAY OPTION
Composite Repair Parts Drawing
AVAILABLE SERVICE AND CONVERSION KITS
476-176-000 AIR END KIT
Seals, O-rings, Gaskets, Retaining Rings, Air Valve Sleeve
& Spool Set and Pilot Valve Assembly.
476-177-000* AIR END KIT (for Stroke Indicator Option)
Seals, O-rings, Gaskets, Retaining Rings, Air Valve Sleeve
& Spool Set and Pilot Valve Assembly.
476-140-354 WETTED END KITSantoprene Diaphragms, Santoprene Balls and TFE Seals.
476-140-654 WETTED END KITSantoprene Diaphragms, PTFE Overlay Diaphragms, TFE
Balls and TFE Seals.
476-143-354 WETTED END KIT (for Polypropylene Spill Containment)Santoprene Diaphragms, PTFE Overlay Diaphragms, PTFE
Pumping Diaphragms, PTFE Balls and PTFE Seals.
Spill Containment Option for Virgin PTFE
Equipped Pumps Drawing
Discharge
Manifold
Suction
Manifold
M30 SPILL CONTAINMENT REPAIR PARTS LIST FOR
VIRGIN PTFE EQUIPPED PUMPS
ITEM PART NUMBER DESCRIPTION QTY
1 031-146-000 Air Valve Assembly 1
(replaces 031-140-000)
031-147-000 Air Valve Assembly 1
(replaces 031-141-000)
43 170-113-115 Capscrew, Hex HD 5/8-11 x 6.00 16
170-113-308 Capscrew, Hex HD 5/8-11 x 6.00 16
44 170-115-115 Capscrew, Hex HD 5/8-11 x 4.00 4
170-115-308 Capscrew, Hex HD 5/8-11 x 4.00 4
45 196-156-552 Chamber, Spill Containment 2
196-156-600 Chamber, Spill Containment 2
46 286-079-600 Diaphragm, Pumping 2
47 518-135-520 Manifold 2
518-135-520E Manifold, 80mm DIN 2
518-135-552 Manifold 2
518-135-552E Manifold, 80mm DIN 2
48 538-022-110 Nipple, Pipe 4
538-022-308 Nipple, Pipe 4
49 560-078-611 O-Ring 8
50 618-003-110 Plug, Pipe 4
618-003-308 Plug, Pipe 4
51 618-025-110 Plug, Boss 4
618-025-308 Plug, Boss 4
52 618-031-110 Plug, Boss 4
618-031-308 Plug, Boss 4
53 770-061-600 Spacer, Manifold 4
770-061-552 Spacer, Manifold 4
54 835-005-110 Tee, Pipe 4
835-005-308 Tee, Pipe 4
55 860-057-606 Tube, Sight 2
56 866-060-110 Connector, Tube 4
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 15
SPILL CONTAINMENT FOR PTFE
EQUIPPED PUMPS CONCEPT
The Spill Containment option
prevents the air end components from
being contaminated or damaged when
a pumping diaphragm ruptures while
pumping caustic or toxic materials. It
also helps to protect the environment.
With the installation of optional leak
detectors (either mechanical or
electronic) the diaphragm rupture can
be detected. The pump can then be
shut down and repaired before any
caustic or toxic materials can enter
the air end and be exhausted into the
surrounding environment.
SPILL CONTAINMENT OPTION
DIAPHRAGM SERVICING
To service the diaphragms first
shut off the suction, then shut off the
discharge lines to the pump. Next shut
off the compressed air supply, bleed
the pressure from the pump, and
disconnect the air supply line from the
pump. Drain any remaining pumped
liquid from the pump. Remove the pump
before servicing.
Next, drain the uid from the Spill
Containment chambers. This can be
done by removing the bottom plug
(item 50) from each Spill Containment
chamber.
After the fluid from the Spill
Containment chambers has been
drained, the wet end components
can now be removed. See diaphragm
servicing section for detailed
instructions. The Spill Containment
option has two additional virgin PTFE
pumping diaphragms (item 46).
FILLING SPILL CONTAINMENT
CHAMBERS WITH LIQUID
THE CHAMBERS ARE FILLED
WITH WATER AT THE FACTORY.
If you prefer to substitute another
liquid, to prevent system contamination
consult the factory rst to determine
compatibility of the substitute with
pump construction.
Follow the steps listed here to
replace the liquid in the pump after
disassembly or liquid loss:
1. Drain the fluid in the Spill
Containment chambers by removing
the bottom two boss plugs (items 50).
Replace the bottom two boss plugs
after the uid is drained.
2. Remove the eight capscrews
(item 11) fastening the discharge
manifold and elbows to the outer
chambers (items 15). The discharge
manifolds and elbows can now be
removed.
3. Remove the top two boss plugs
(items 50). The Spill Containment
chambers are filled through the
exposed ports.
4. Apply air pressure to the air
distribution valve. Install safety clip
(item 1-F) into the smaller unthreaded
hole in one end cap. This locks the
valve spool to one side, keeping the
pump from shifting.
5. Face the side of the pump with
the installed safety clip. If the safety
clip is installed in the top end cap, ll
the left spill containment chamber. If
the safety clip is installed on the bottom
end cap, ll the right Spill Containment
chamber. The volume of uid is 3770
ml (127.5 . oz.). It is important that
the exact amount of uid is used. Too
little or too much uid causes premature
diaphragm failure and erratic pumping.
6. Loosely reinstall one boss plug
to the lled Spill Containment chamber.
7. Shut off air supply. Remove safety
clip. Adjust the air line regulator so that
air pressure slowly lls the pump. The
diaphragm expands, forcing the uid
in the chamber to be slowly displaced.
When the pump shifts to the opposite
side, quickly install the safety clip.
8. Loosen the top boss plug on the
lled chambers. This allows uid in the
chamber to purge trapped air from the
chamber. This can be seen by watching
the column of uid in the sight tube.
When uid appears at the top of the
port, quickly tighten the boss plug. Fluid
loss of 1 to 2ml is acceptable.
9. Tilt the pump so the uppermost
pipe tee (item 53) is in the vertical
position. Loosen the pipe plug (item
49). This will allow trapped air to
purge through the pipe tee. When uid
appears at the tee opening, reinstall
the pipe plug.
NOTE: If all air is not purged using
this procedure, remove the check valve
components from the top port of the
outer chamber (item 15). Apply manual
pressure to the pumping diaphragm by
inserting a blunt instrument into the top
port of the outer chamber and applying
pressure to the diaphragm. Loosen the
pipe plug (item 49) allowing the uid
to purge any remaining trapped air.
Reinstall the plug.
10. Repeat steps 5 through 9 to ll
opposite Spill Containment chamber.
11. Reinstall the check valve
components, discharge manifold and
elbows 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 16
Spill Containment Option for TPE
Equipped Pumps Drawing
Suction
Manifold
Discharge
Manifold
M30 SPILL CONTAINMENT FOR TPE EQUIPPED PUMPS
REPAIR PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-146-000 Air Valve Assembly 1
(replaces 031-140-000)
031-147-000 Air Valve Assembly 1
(replaces 031-141-000)
43 170-113-115 Capscrew, Hex HD 5/8-11 x 6.00 16
170-113-308 Capscrew, Hex HD 5/8-11 x 6.00 16
44 170-115-115 Capscrew, Hex HD 5/8-11 x 4.00 4
170-115-308 Capscrew, Hex HD 5/8-11 x 4.00 4
45 196-156-552 Chamber, Spill Containment 2
196-156-600 Chamber, Spill Containment 2
46 286-080-354 Diaphragm, Pumping 2
47 518-135-520 Manifold, Spill Containment 2
518-135-520E Manifold, 80mm DIN 2
518-135-552 Manifold, Spill Containment 2
518-135-552E Manifold, 80mm DIN 2
48 538-022-110 Pipe, Nipple 4
538-022-308 Pipe, Nipple 4
49 560-078-611 O-ring 8
50 618-003-110 Plug, Pipe 4
618-003-308 Plug, Pipe 4
51 618-025-110 Plug, Boss 4
618-025-308 Plug, Boss 4
52 618-031-110 Plug, Boss 4
618-031-308 Plug, Boss 4
53 770-061-600 Spacer, Manifold 4
770-061-552 Spacer, Manifold 4
54 835-005-110 Tee, Pipe 4
835-005-308 Tee, Pipe 4
55 860-057-606 Tube, Sight 2
56 866-060-110 Connector, Tube 4
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 17
SPILL CONTAINMENT FOR TPE
EQUIPPED PUMPS CONCEPT
The Spill Containment option
prevents the air end components from
being contaminated or damaged when
a pumping diaphragm ruptures while
pumping caustic or toxic materials. It
also helps to protect the environment.
With the installation of optional leak
detectors (either mechanical or
electronic) the diaphragm rupture can
be detected. The pump can then be
shut down and repaired before any
caustic or toxic materials can enter
the air end and be exhausted into the
surrounding environment.
SPILL CONTAINMENT OPTION
DIAPHRAGM SERVICING
To service the diaphragms first
shut off the suction, then shut off the
discharge lines to the pump. Next shut
off the compressed air supply, bleed
the pressure from the pump, and
disconnect the air supply line from the
pump. Drain any remaining pumped
liquid from the pump. Remove the pump
before servicing.
Next, drain the uid from the Spill
Containment chambers. This can be
done by removing the bottom plug
(item 50) from each Spill Containment
chamber.
After the fluid from the Spill
Containment chambers has been
drained, the wet end components
can now be removed. See diaphragm
servicing section for detailed
instructions. The Spill Containment
option has two additional TPE pumping
diaphragms (item 46).
FILLING SPILL CONTAINMENT
CHAMBERS WITH LIQUID
THE CHAMBERS ARE FILLED
WITH WATER AT THE FACTORY.
If you prefer to substitute another
liquid, to prevent system contamination
consult the factory rst to determine
compatibility of the substitute with
pump construction.
Follow the steps listed here to
replace the liquid in the pump after
disassembly or liquid loss:
1. Drain the fluid in the Spill
Containment chambers by removing
the bottom two boss plugs (items 50).
Replace the bottom two boss plugs
after the uid is drained.
2. Remove the eight capscrews
(item 11) fastening the discharge
manifold and elbows to the outer
chambers (items 15). The discharge
manifolds and elbows can now be
removed.
3. Remove the top two boss plugs
(items 50). The Spill Containment
chambers are filled through the
exposed ports.
4. Apply air pressure to the air
distribution valve. Install safety clip
(item 1-F) into the smaller unthreaded
hole in one end cap. This locks the
valve spool to one side, keeping the
pump from shifting.
5. Face the side of the pump with
the installed safety clip. If the safety
clip is installed in the top end cap, ll
the left Spill Containment chamber. If
the safety clip is installed on the bottom
end cap, ll the right Spill Containment
chamber. The volume of uid is 3770
ml (127.5 . oz.). It is important that the
exact amount of uid is used. Too little
or too much uid causes premature
diaphragm failure and erratic pumping.
6. Loosely reinstall one boss plug to
the lled Spill Containment chamber.
7. Shut off air supply. Remove safety
clip. Adjust the air line regulator so that
air pressure slowly lls the pump. The
diaphragm expands, forcing the uid
in the chamber to be slowly displaced.
When the pump shifts to the opposite
side, quickly install the safety clip.
8. Loosen the top boss plug on the
lled chambers. This allows uid in the
chamber to purge trapped air from the
chamber. This can be seen by watching
the column of uid in the sight tube.
When uid appears at the top of the
port, quickly tighten the boss plug. Fluid
loss of 1 to 2ml is acceptable.
9. Tilt the pump so the uppermost
pipe tee (item 53) is in the vertical
position. Loosen the pipe plug (item
49). This will allow trapped air to
purge through the pipe tee. When uid
appears at the tee opening, reinstall
the pipe plug.
NOTE: If all air is not purged using
this procedure, remove the check valve
components from the top port of the
outer chamber (item 15). Apply manual
pressure to the pumping diaphragm by
inserting a blunt instrument into the top
port of the outer chamber and applying
pressure to the diaphragm. Loosen the
pipe plug (item 49) allowing the uid
to purge any remaining trapped air.
Reinstall the plug.
10. Repeat steps 5 through 9 to ll
opposite Spill Containment chamber.
11. Reinstall the check valve
components, discharge manifold and
elbows to the pump. The pump is now
ready for operation.
IMPORTANT
Read these instructions
completely, before
installation and startup. 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 18
Air Distribution Valve Assembly Drawing
1-J
1-D
1-F
1-G
1-H
1-G
1-E
1-C
1-A
1-A
1-B
1-C
1-E
1-G
1-H
NOTE: CHECK GAP AFTER ASSEMBLY
TO INSURE COMPLETE
INSTALLATION OF RETAINING RING
M30 Design Level 2
MAIN AIR VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-140-000 Main Air Valve Assembly 1
1-A 031-139-000 Spool Assembly 1
1-B 095-094-551 Body, Air Valve 1
1-C 132-029-552 Bumper 2
1 031-140-002 Air Valve Assembly 1
(Includes all items used on 031-140-000 except:)
1-J 710-015-308 Screw Self tapping 4
1-H 675-044-308 Ring, Retaining 2
For pumps equipped with PTFE coated hardware option:
1 031-141-000 Air Valve Assembly 1
(Includes all items used on 031-140-000 minus
items 1-D, 1-F & 1-J)
For pumps with alternate Mesh or Sound Dampening mufers
or piped exhaust:
1 031-041-002 Air Valve Assembly 1
(Includes all items used on 031-141-000 except:)
1-H 675-044-308 Ring, Retaining 2
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 19
AIR DISTRIBUTION VALVE
SERVICING
To service the air valve rst shut off
the compressed air, bleed the pressure
from the pump, and disconnect the air
supply line from the pump.
STEP #1: See Composite Repair
and Parts Drawing.
Using a 5/16" Allen wrench, remove
the four hex socket capscrews (item 14)
and four at washers (item 41). Remove
the air valve assembly from the pump.
Remove and inspect gasket (item
23) for cracks or damage. Replace
gasket if needed.
STEP #2: Disassembly of the air
valve.
To access the internal air valve
components rst remove the two retaining
rings (item 1-H) from each end of the air
valve assembly using clip ring pliers.
Next remove the two end caps (item
1-E). Inspect the o-rings (item 1-G) for
cuts or wear. Replace the o-rings if
necessary.
Remove the two bumpers (item
1-C). Inspect the bumpers for cuts, wear
or abrasion. Replace if necessary.
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 contaminates.
Remove the sleeve if needed and
replace both the sleeve and spool with
a new sleeve and spool set (item 1-A).
STEP #3: Reassembly of the air
valve.
Install one end cap (item 1-E) with
an o-ring (item 1-G) and one bumper
(item 1-C) into one end of the air valve
body (item 1-B). Install one retaining
ring (item 1-H) into the groove on the
same end.
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-G)
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. Push the
spool in until it touches the bumper on
the opposite end.
Install the remaining bumper, end
cap with o-ring, and retaining ring.
Fasten the air valve assembly (item
1) and gasket (item 23) 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 20
Air Valve Assembly Drawing with Stroke Indicator Option
NOTE: CHECK GAP AFTER ASSEMBLY
TO INSURE COMPLETE
INSTALLATION OF RETAINING RING
M30 Design Level 2
Note: Stroke Indicator is standard on Spill Containment models
PILOT VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-146-000 Air Valve Assembly 1
1-A 031-143-000 Sleeve and Spool Set w/Pins 1
1-B 095-094-551 Body, Air Valve 1
1-C 132-029-552 Bumper 2
1 031-146-002 Air Valve Assembly 1
1-J 710-015-308 Screw, Self Tapping 4
1-H 675-044-308 Ring, Retaining 2
(includes all other items on 031-146-000 above.)
For Pumps with Alternate Mesh, Sound Dampening Mufers
or Piped Exhaust:
1 031-147-000 Air Valve Assembly 1
(includes all items on 031-146-000 minus 1-D, 1-F, &1-J)
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 21
AIR DISTRIBUTION VALVE WITH
STROKE INDICATOR OPTION
SERVICING
To service the air valve rst shut off
the compressed air, bleed the pressure
from the pump, and disconnect the air
supply line from the pump.
STEP #1: See Composite Repair
and Parts Drawing.
Using a 5/16" Allen wrench, remove
the four hex socket capscrews (item 14)
and four at washers (item 41). Remove
the air valve assembly from the pump.
Remove and inspect gasket (item
23) for cracks or damage. Replace
gasket if needed.
STEP #2: Disassembly of the air
valve.
To access the internal air valve
components rst remove the two retaining
rings (item 1-H) from each end of the air
valve assembly using clip ring pliers.
Next remove the two end caps (item
1-E). Inspect the o-rings (item 1-G) for
cuts or wear. Replace the o-rings if
necessary.
Remove the two bumpers (item
1-C). Inspect the bumper for cuts, wear
or abrasions. Replace if necessary.
Remove the spool (part of item
1-C) 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 contaminates.
Remove the sleeve if needed and
replace both the sleeve and spool 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-E) with an o-ring
(item 1-G) into one end of the air valve
body (item 1-B). Install one retaining
ring (item 1-H) into the groove on the
same end. Insert the safety clip (item
1-K) through the small unthreaded hole
in the end cap.
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-G)
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. Push the spool
in until the pin touches the safety clip
on the opposite end.
Install the remaining bumper, end
cap with o-ring, and retaining ring.
Fasten the air valve assembly (item
1) and gasket (item 23) 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 startup. 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 22
Solenoid Shifted Air Valve Drawing
SOLENOID SHIFTED AIR VALVE PARTS LIST
(Includes all items used on Composite Repair Parts List except as shown)
Warren Rupp’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)
BEFORE INSTALLATION
Before wiring the solenoid, make
certain it is compatible with your system
voltage.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 24
Pilot Valve Assembly Drawing
PILOT VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
2 095-089-000 Pilot Valve Assembly 1
2-A 095-081-551 Body, Pilot Valve 1
2-B 135-033-506 Bushing 2
2-C 675-055-115 Ring, Retaining 2
2-D 770-049-175 Spacer 5
2-E 917-001-374 Wiper 6
2-F 775-033-506 Spool, Pilot 1
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 25
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. Insert the safety clip (item 1-F
from Air Distribution Valve assembly
drawing) into the smaller unthreaded
holes in the end cap (item 1-E from air
distribution valve assembly drawing).
Step #1: See PUMP ASSEMBLY
DRAWING.
Using a 9/16" wrench or socket,
remove the four capscrews (items
10) and four at washers (items 41).
Remove the air inlet cap (item 8) and
air inlet gasket (item 20). The pilot
valve assembly (item 2) can now be
removed for inspection or service.
Step #2: Disassembly of the pilot
valve.
Remove the pilot valve spool (item
2-F). Wipe clean, and inspect for dirt,
scratches or wear. Replace the spool
if necessary.
Remove the two retaining rings
(items 2-C) from each end of the pilot
valve body using clip ring pliers.
Remove the two pilot valve bushings
(items 2-B), ve spacers (items 2-D),
and six spool wipers (items 2-E) by
pushing gently from other end of the
pilot valve body. Inspect the wipers for
cuts and/or wear. Replace any wipers
as necessary.
Step #3: Re-assembly of the pilot
valve.
First install a spiral retaining ring to
one end of the pilot valve body. Install
one bushing making sure the step
side faces toward the wiper. Apply a
light coating of grease to the outside
diameter of each wiper. Next, gently
push in the wipers and spacers until
they are against the installed retaining
ring in the opposite end of the pilot valve
body. Install the remaining bushing
making sure the step side faces the
wiper. Install the remaining retaining
ring using clip ring pliers.
Apply a light coating of grease to
the inner diameter of each wiper. Also
apply a light coating of grease to the
outer diameter of the pilot valve spool
and gently push the spool through each
wiper.
Step #4: Inspect the actuator
plungers.
See PUMP ASSEMBLY DRAWING.
The actuator plungers (items 31)
can be reached through the stem cavity
of the pilot valve in the intermediate
assembly (item 4).
Remove the plungers (items 31) from
the bushings (item 7) in each end of the
cavity. Inspect the installed o-ring (items
28) for cuts and/or wear. Replace the
o-rings if necessary. 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 #5: 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), capscrews and
washers (items 10 and 39).
Connect the air supply to the pump.
Remove the safety clip (item 1-F) from
the end cap (item 1-E). The pump is
now ready for operation.
IMPORTANT
Read these instructions
completely, before
installation and startup. 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 26
Diaphragm Service Drawing,
Diaphragm Service Drawing,
Non-Overlay
32
25
with Overlay
15
13
6
28
17
32
15
13
6
28
17
25
16
9
29
14
29
24
24
24
9
14
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 27
24
DIAPHRAGM SERVICING
To service the diaphragms 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 9/16" wrench or socket,
remove the 16 capscrews (items 11),
hex nuts and washers that fasten the
elbows (items 19) to the outer chambers
(items 15). Remove the elbows with the
manifolds and spacers attached.
Step #2: Removing the outer
chambers.
Using a 9/16" wrench or socket,
remove the 20 capscrews (items 9 &
12), hex nuts and washers that fasten
the outer chambers, diaphragms, and
inner chambers (items 16) together.
Step #3: Removing the diaphragm
assemblies.
Use a 13/8" (35mm) wrench or
six pointed socket to remove the
diaphragm assemblies (outer plate,
diaphragm, and inner plate) from the
diaphragm rod (item 33) by turning
counterclockwise.
Insert a 1/4-20 capscrew or set
screw into the smaller tapped hole in
the inner diaphragm plate (item 30).
Insert the protruding stud and the 1/420 fastener loosely into a vise. Use a
13/8" wrench or socket to remove the
outer diaphragm plate (item 29) by
turning counterclockwise. Inspect the
diaphragm (item 17) 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. Use a
torque wrench to tighten the diaphragm
assembly together to 480 in Lbs. (54.23
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 33) 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 inner chamber
(item 16). Make sure the molded
directional arrows on the diaphragm
point vertically.
Fasten the outer chamber (item 15)
to the pump, using the capscrews (items
9 & 12), hex nuts and at washers.
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 33) as far as possible and still
allow for alignment of the bolt holes
in the diaphragm with the bolt pattern
in the inner chamber. The molded
directional arrows on the diaphragm
must point vertically.
Fasten the remaining outer chamber
(item 15) to the pump, using the
capscrews (items 9 & 12), hex nuts and
at washers.
Step #6: Re-install the elbow/
spacer/manifold assemblies to the
pump, using the capscrews (items 11),
hex nuts and at washers.
The pump is now ready to be
re-installed, connected and returned to
operation.
OVERLAY DIAPHRAGM SERVICING
The PTFE overlay diaphragm (item
18) is designed to t snugly over the
exterior of the standard TPE diaphragm
(item 17).
The molded directional arrows
on the overlay diaphragm must point
vertically.
Follow the same procedures
described for the standard diaphragm
for removal and installation.
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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 28
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" (2.54 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.
NOTE: The manufacturer recommends
installing a 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
physically supported. Failure to support
these connections could also result in
damage to the air distribution valve
body.
Exhaust Conversion Drawing
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
Illustration #2
PIPING THE EXHAUST AIR
The following steps are necessary
to convert the pump to pipe the exhaust
air away from the pump.
Use a #8 Torx or at screwdriver
MUFFLER
to remove the six self-tapping screws
(item 1-J).
Remove the mufer cap and mufer
(items 1-D and 1-F). The 1" NPT
LIQUID
LEVEL
1" DIAMETER AIR
EXHAUST PIPING
molded threads in the air distribution
valve body (item 1-B).
Piping or hose may now be installed.
SUCTION
LINE
IMPORTANT INSTALLATION
Illustration #3
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 29
MODULAR CHECK VALVE
6
SERVICING
Before servicing the check valves,
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 modular check valve,
remove the elbows (items 19 from
pump composite repair parts drawing).
Use a 9/16" wrench or socket to remove
the fasteners. Once the elbows are
removed, the modular check valves
can be seen in the cavities of the outer
chamber (items 15).
Next remove the check valve seal
(item 37). Inspect the seal for cuts
or pinched areas. Replace seal as
needed.
Disassemble the component parts of
each modular check valve. Inspect the
check valve retainer (item 32) for cuts,
abrasive wear, or embedded materials.
Replace as needed.
Inspect the check balls (items 3) for
wear, abrasion, or cuts on the spherical
surface. The check valve seats (items
38) should be inspected for cuts,
abrasive wear, or embedded material
on the surfaces of both the external
and internal chamfers. The spherical
surface of the check balls must seat
ush to the surface of the inner chamfer
on the check valve seats for the pump to
operate to peak efciency. Replace any
worn or damaged parts as necessary.
Remove the remaining check valve
seal (item 37). Inspect the seal for cuts
or pinched areas. Replace seal as
needed.
Re-assemble the modular check
valve. The seat should t snugly into
the retainer.
Place a check valve seal (item 37)
into the cavity of the outer chamber
(item 15). Make sure the chamfer side
of the seal faces out. Insert the modular
check valve into the outer chamber
with the retainer facing up. Install a
check valve seal (item 37). Make sure
the chamfer side of the seal faces the
chamfer on the check valve seat or
retainer.
The pump can now reassembled,
reconnected and returned to operation.
Modular Check Valve Drawing
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 30
Dual Port Option Drawing
3" ANSI STYLE FLANGE CONNECTION
FOUR ø.75 HOLES ON A ø6.00 BOLT CIRCLE
3" ANSI STYLE FLANGE CONNECTION
FOUR ø.75 HOLES ON A ø6.00 BOLT CIRCLE
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 31
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 congured 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 standard 125# ANSI style 4-bolt,
3" pipe anges.
Dual porting of both suction and
discharge ends of the pump
Converting the pump from the
standard single suction and discharge
porting conguration to dual porting at
each end is easy. Simply remove the
manifold seals, spacers, and manifolds
(items 36, 39, and 24 from pump
assembly drawing) from the pump.
The discharge and suction elbows
can be rotated at 90° increments (see
arrows and optional positioning in the
Dual Porting 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 conguration to a dual
discharge porting arrangement remove
the only the discharge manifolds,
spacers, 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 conguration to a dual
suction porting arrangement remove
the only the suction (bottom) manifolds,
spacers, 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 startup. 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.
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 32
Leak Detection Options Drawing
For pumps with
530-028-550
ENCLOSED MUFFLER
LEAK DETECTION OPTION (ELECTRONIC)
Follow instructions found elsewhere in this manual, “Filling the
Spill Containment Chambers” when installing leak detectors.
Electronic Leak Detector Installation
Kit 032-037-000 100VAC 50Hz
or 110-120VAC 50/60Hz
or 220-240VAC 50/60Hz
Kit 032-045-000 12-32VDC
To install electronic leak detectors, remove the bottom ¼" NPT pipe
plug on the visual sight tube (item 52). Insert leak detector into the
¼" pipe tee (item 56).
LEAK DETECTION OPTION (MECHANICAL)
Follow instructions found elsewhere in this manual, “Filling
the Spill Containment Chambers” when installing leak detectors.
Mechanical Leak Detector Installation
Kit 031-023-110
To install mechanical leak detectors, remove the bottom ¼" NPT
pipe plug on the visual sight tube (item 52). Insert leak detector
into the ¼" pipe tee (item 56).
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 33
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 Mufer 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
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 34
Optional Mufer Congurations, Drawing
OPTION 0
530-028-550 Integral Mufer uses (1) Cap
and (4) 710-015-115 Self Tapping Screw to
hold it in place.
OPTION 1
530-027-000 Sound Dampening Mufer
screws directly into the Air Valve body.
This mufer is equipped with a porous
plastic element.
OPTION 2
530-010-000 Mesh Mufer screws
directly into the Air Valve Body. This
mufer is equipped with a metal element.
OPTION 6
530-033-000 Metal Mufer screws
directly into the Air Body.
Option 0
Option 6
m30nmdl2sm-rev0713 Model S30 Non-Metallic Page 35
Option 1 and 2
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
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