Model X40 Metallic Design Level 1 Applied for CE · SERVICE & OPERATING MANUAL Model X40 Metallic Design Level 1 Table of Contents U.S. Patent # 5,996,627; 6,241,487 Other U.S. Patents

Blagdon Pump • A Unit of IDEX Corporation • R79 Shannon Industrial Estate • Shannon, Co Clare, Ireland • Tel: +353 (0) 61 471933 Fax: +353 (0) 61 475046 www.blagdonpump.com • E-mail: [email protected]

Engineering Data and Temperature Limitations .................................................. 1

Typical Code ......................................................................................................... 2

Performance Curve ............................................................................................... 3

Dimensions (Side Porting) ................................................................................... 4

Dimensions (Center Porting) ................................................................................ 5

Principle of Pump Operation ................................................................................ 6

Installation and Start-Up ....................................................................................... 6

Air Supply ............................................................................................................. 6

Air Valve Lubrication ............................................................................................. 6

Air Line Moisture .................................................................................................. 6

Air Inlet and Priming ............................................................................................. 6

Between Uses ...................................................................................................... 6

Installation Guide .................................................................................................. 7

Troubleshooting .................................................................................................... 8

Warranty ............................................................................................................... 8

Recycling .............................................................................................................. 9

Important Safety Information ................................................................................ 9

Material Codes ...................................................................................................10

Composite Repair Parts Drawing ......................................................................12

Available Service and Conversion Kits ..............................................................12

Composite Repair Parts List ..............................................................................13

Air Valve Assembly Drawing, Servicing & Parts List ..........................................14

Diaphragm Service Drawing, with Overlay ........................................................15

Diaphragm Service Drawing, Non-Overlay .......................................................15

Diaphragm Servicing ..........................................................................................16

Overlay Diaphragm Servicing ............................................................................16

Pilot Valve Servicing, Assembly Drawing & Parts List .......................................17

Actuator Plunger Servicing .................................................................................18

Check Valve Servicing ........................................................................................19

Check Valve Drawing .........................................................................................19

Pumping Hazardous Liquids ..............................................................................20

Converting Pump for Piping Exhaust Air ............................................................20

Converted Exhaust Illustration ...........................................................................20

Grounding the Pump ..........................................................................................21

SERVICE & OPERATING MANUAL

Model X40 Metallic Design Level 1Model X40 Metallic Design Level 1Model X40 Metallic Design Level 1Model X40 Metallic Design Level 1Model X40 Metallic Design Level 1

Table of Contents

U.S. Patent #5,996,627; 6,241,487Other U.S. PatentsApplied for CE

I M2 c/b T5II 2GD b T5

®

Blagdon Pump • Lambert Road, Armstrong, Washington Tyne & Wear NE37 1QP ENGLAND • Tel: (0191) 4177475 Fax: (0191) 4175435 • www.blagdonpump.com

Material Codes ...................................................................................................10Composite Repair Parts Drawing .......................................................................12Available Service and Conversion Kits ...............................................................12Composite Repair Parts List ...............................................................................13Air Valve Assembly Drawing, Servicing & Parts List ...........................................14Diaphragm Service Drawing, with Overlay .........................................................15Diaphragm Service Drawing, Non-Overlay.........................................................15Diaphragm Servicing ..........................................................................................16Overlay Diaphragm Servicing .............................................................................16Pilot Valve Servicing, Assembly Drawing & Parts List ........................................17Actuator Plunger Servicing .................................................................................18Check Valve Servicing ........................................................................................19Check Valve Drawing .........................................................................................19Pumping Hazardous Liquids ..............................................................................20Converting Pump for Piping Exhaust Air ............................................................20Converted Exhaust Illustration ...........................................................................20Grounding the Pump ..........................................................................................21EC Declaration of Conformity - Machinery .........................................................22EC Declaration of Conformity - ATEX 95a ..........................................................23

See pages 2 & 23 for ATEX markings.


Page 1 Air Operated Double Diaphragm Pump 8/05 Page 1

Buna N purpose, oil-resistant. Shows good solvent, oil, water and hydraulic fluid resistance.Should not be used with highly polar solvents like acetone and MEK, ozone, chlorinated 190°F -10°Fhydrocarbons and nitro hyrdrocarbons. 88°C -23°C

EPDM Shows very good water and chemical resistance. Has poor resistance to oil and solvents, 280°F -40°Fbut is fair in ketones and alcohols. 138°C -40°C

Neoprene All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals,fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, 200°F -10°Festers, nitro hydrocarbons and chlorinated aromatic hydrocarbons. 93°C -23°C

Santoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex 275°F -40°Flife. Excellent abrasion resistance. 135°C -40°C

Virgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically withPTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 220°F -35°Fchlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 104°C -37°C

Viton® Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromaticand halogenated hydrocarbons, acids, animal and vegetable oils. Hot water or hot aqueous solutions 350°F -40°F(over 70°F) will attack Viton. 177°C -40°C

Polypropylene 180°F 32°F82°C 0°C

Materials Maximum MinimumOperating Temperatures

INTAKE/DISCHARGE PIPE SIZE3" BSPT (tapered) or

3" BSP Parallel (internal)

CAPACITY0 to 196 UK gallons per minute

(0 to 889 liters per minute)

AIR VALVENo-lube, no-stall

design

SOLIDS-HANDLINGUp to .25 in. (6mm)

HEADS UP TO125 psi or 289 ft. of water(8.6 Kg/cm2 or 86 meters)

DISPLACEMENT/STROKE.78 UK Gallons / 3.56 liters

CAUTION! Operating temperature limitations are as follows:

X40X40X40X40X40 MetallicMetallicMetallicMetallicMetallicDesign Level 1Design Level 1Design Level 1Design Level 1Design Level 1Ball VBall VBall VBall VBall ValvealvealvealvealveAir-PoweredDouble-Diaphragm Pump

ENGINEERING, PERFORMANCE& CONSTRUCTION DATA

Nitrile

Conductive HDPE

Air Operated Double Diaphragm Pump 8/05 Page 1














design





















design








Page 2


TYPICAL CODE=

Model - X40

Design Level

Wetted ComponentsA: AluminumC: Cast IronS: Stainless Steel

Non-Wetted ComponentsA: AluminumC: Cast IronS: Stainless Steel

Check Valve TypeB: Solid BallW: Weighted Ball

Suction OrientationB: Bottom

X40. 01. A A. B B.

Valve SeatsA: AluminumC: Carbon SteelS: Stainless SteelT: PTFEU: UHMW Polyethylene

Check ValvesT: PTFEB: Buna NN: NeopreneE: EPDMS: Santoprene

DiaphragmsT: PTFEB: Buna NR: Santoprene®

V: Viton®

E: EPDMN: Neoprene

B B B

Maximum delivery: 401 ltrs/minMax. working pressure: 8.6 barMax. solid particle size: 6mmAir inlet: 3/4" BSP (Parallel, Internal)Temperature limits: Determined by elastomersFluid inlet/outlet: 1½" BSP (Parallel, Internal)

Installation: Surface mountedAccessories included: Exhaust air silencerShipping weights withAluminum mid sections: A: 52kg

C: 98kg S: 87kg

Shipping dimensions: 560x430x690mm

II 2GD T5II 1G c T5II 3/1 G c T5II 1D c T100°CI M1 cI M2 c

II 2G c T5II 3/2 G c T5II 2D c T100°C

Models equipped with Wetted Options C or S , Non-Wetted Options C or S.Note: See page 23 EC-Type Certificate.

Models equipped with Wetted Options A, C or S, Non-Wetted Options A, C or S.Note: See page 23 Type Examination Certificate.

Nitrile

FKM

Nitrile

R

- C C: Center Ported*

*Available with Stainless Steel equipped models ONLY.



Performance Curve

10 (17) 20 (34)

70 80 90605040302010

0

Capacity

Litres per minute

U.K. Gallons per minute

400375350325300275250225200175150125100755025

0

100

90

80

70

60

50

40

30

20

10

0

BA

R

PS

I

Hea

d

1

2

3

4

5

6

7

0

100 PSI (6.8 Bar)

80 PSI (5.44 Bar)

60 PSI (4.08 Bar)

40 PSI (2.72 Bar)

20 PSI (1.36 Bar)Air Inlet Pressure

30 (51)

40 (68)

50 (85)

X40

Displacement Per Stroke: 1.55 litres (.34 UK gallons) Fluid Flowrate: 0 to 401 litres per minute (0 to 88.26 UK gallons per minute)



Dimensions (Side Porting):

Dimensions in MillimetersDimensional Tolerance:± 3mm

Air Inlet3/4" BSPT (Tapered)

Suction Port1½" BSP (Parallel)

Discharge Port1½" BSP (Parallel)

1" NPT Exhaust PortFor Optional Piping ExhaustAir Submerged Applications



Dimensions (Center Porting):Stainless Steel Only

Dimensions in MillimetersDimensional Tolerance:± 3mm

547

288

8155

310423

Suction Port 1½" BSPT (Tapered)

48

54

4

339

54

141

518

Discharge Port1½" BSPT (Tapered)

203

124

13

251125

90178

Air Inlet¾" NPT

Encapsulated Muffler1" NPT Exhaust Port

For Optional MufflerStyles Or Piping Exhaust

Air In SubmergedApplications



PRINCIPLE OF PUMP OPERATIONThis ball type check valve pump is

powered by compressed air and is a 1:1ratio design. The inner side of onediaphragm chamber is alternatelypressurized while simultaneouslyexhausting the other inner chamber. Thiscauses the diaphragms, which areconnected by a common rod securedby plates to the centers of thediaphragms, to move in a reciprocatingaction. (As one diaphragm performs thedischarge stroke the other diaphragmis pulled to perform the suction strokein the opposite chamber.) Air pressureis applied over the entire inner surfaceof the diaphragm while liquid isdischarged from the opposite side of thediaphragm. The diaphragm operates ina balanced condition during thedischarge stroke which allows the pumpto be operated at discharge heads over200 feet (61 meters) of water.

For maximum diaphragm life, keepthe pump as close to the liquid beingpumped as possible. Positive suctionhead in excess of 10 feet of liquid (3.048meters) may require a back pressureregulating device to maximizediaphragm life.

Alternate pressurizing andexhausting of the diaphragm chamberis performed by an externally mounted,pilot operated, four way spool type airdistribution valve. When the spool shiftsto one end of the valve body, inletpressure is applied to one diaphragmchamber and the other diaphragmchamber exhausts. When the spool

shifts to the opposite end of the valvebody, the pressure to the chambers isreversed. The air distribution valve spoolis moved by a internal pilot valve whichalternately pressurizes one end of theair distribution valve spool whileexhausting the other end. The pilot valveis shifted at each end of the diaphragmstroke when a actuator plunger iscontacted by the diaphragm plate. Thisactuator plunger then pushes the end ofthe pilot valve spool into position toactivate the air distribution valve.

The chambers are connected withmanifolds with a suction and dischargecheck valve for each chamber,maintaining flow in one direction throughthe pump.

INSTALLATION AND START-UPLocate the pump as close to the

product being pumped as possible. Keepthe suction line length and number offittings to a minimum. Do not reduce thesuction line diameter.

For installations of rigid piping, shortsections of flexible hose should beinstalled between the pump and thepiping. The flexible hose reducesvibration and strain to the pumpingsystem. A surge suppressor isrecommended to fur ther reducepulsation in flow.

AIR SUPPLYAir supply pressure cannot exceed

125 psi (8.6 bar). Connect the pump airinlet to an air supply of sufficientcapacity and pressure required fordesired performance. When the air

supply line is solid piping, use a shortlength of flexible hose not less than1/2" (13mm) in diameter between thepump and the piping to reduce strain tothe piping. The weight of the air supplyline, regulators and filters must besupported by some means other thanthe air inlet cap. Failure to providesupport for the piping may result indamage to the pump. A pressureregulating valve should be installed toinsure air supply pressure does notexceed recommended limits.

AIR VALVE LUBRICATIONThe air distribution valve and the pilot

valve are designed to operate WITHOUTlubrication. This is the preferred modeof operation. There may be instances ofpersonal preference or poor quality airsupplies when lubrication of thecompressed air supply is required. Thepump air system will operate withproperly lubricated compressed airsupply. Proper lubrication requires theuse of an air line lubricator set to deliverone drop of SAE 10 non-detergent oilfor every 20 SCFM (9.4 liters/sec.) ofair the pump consumes at the point ofoperation. Consult the pump’s publishedPerformance Curve to determine this.

AIR LINE MOISTUREWater in the compressed air supply

can create problems such as icing orfreezing of the exhaust air, causing thepump to cycle erratically or stopoperating. Water in the air supply can bereduced by using a point-of-use air dryerto supplement the user’s air drying

equipment. This device removes waterfrom the compressed air supply andalleviates the icing or freezing problems.

AIR INLET AND PRIMINGTo start the pump, open the air valve

approximately 1/2" to 3/4" turn. After thepump primes, the air valve can beopened to increase air flow as desired.If opening the valve increases cyclingrate, but does not increase the rate offlow, cavitation has occurred. The valveshould be closed slightly to obtain themost efficient air flow to pump flow ratio.

BETWEEN USESWhen the pump is used for materials

that tend to settle out or solidify whennot in motion, the pump should be flushedafter each use to prevent damage.(Product remaining in the pump betweenuses could dry out or settle out. This couldcause problems with the diaphragms andcheck valves at restart.) In freezingtemperatures the pump must becompletely drained between uses in allcases.



1

2 3

4

1

2

3

4

PD75M Pulsation Dampener

020-052-000 Filter/Regulator

020-052-001 Lubricator

020-048-008 Air Dryer

Available from Blagdon Pump

CAUTIONThe air exhaust should be piped to an area for safe disposition of the product being pumped, in the event of a diaphragm failure.

INSTALLATION GUIDETop Discharge Ball Unit

PulsationDampener Limited to 125 psi



TROUBLESHOOTINGPossible Symptoms:• Pump will not cycle.• Pump cycles, but produces no flow.• Pump cycles, but flow rate is

unsatisfactory.• Pump cycle seems unbalanced.• Pump cycle seems to produce

excessive vibration.

What to Check: Excessive suction liftin system.Corrective Action: For lifts exceeding20 feet (6 meters), filling the pumpingchambers with liquid will prime the pumpin most cases.

What to Check: Excessive floodedsuction in system.Corrective Action: For floodedconditions exceeding 10 feet (3 meters)of liquid, install a back pressure device.

What to Check: System head exceedsair supply pressure.Corrective Action: Increase the inlet airpressure to the pump. Most diaphragmpumps are designed for 1:1 pressureratio at zero flow.

What to Check: Air supply pressure orvolume exceeds system head.Corrective Action: Decrease inlet airpressure and volume to the pump ascalculated on the publishedPERFORMANCE CURVE. Pump iscavitating the fluid by fast cycling.

What to Check: Undersized suction line.Corrective Action: Meet or exceedpump connection recommendationsshown on the DIMENSIONALDRAWING.

What to Check: Restricted or undersizedair line.Corrective Action: Install a larger air lineand connection. Refer to air inletrecommendations shown in your pump’sSERVICE MANUAL.

What to Check: Check ESADS, theExternally Serviceable Air DistributionSystem of the pump.Corrective Action: Disassemble andinspect the main air distribution valve,pilot valve and pilot valve actuators.Refer to the parts drawing and air valvesection of the SERVICE MANUAL.Check for clogged discharge or closedvalve before reassembly.

What to Check: Rigid pipe connectionsto pump.Corrective Action: Install flexibleconnectors and a surge suppressor.

What to Check: Blocked air exhaustmuffler.Corrective Action: Remove mufflerscreen, clean or de-ice and reinstall.Refer to the Air Exhaust section of yourpump SERVICE MANUAL.

What to Check: Pumped fluid in airexhaust muffler.

Corrective Action: Disassemble pumpchambers. Inspect for diaphragm ruptureor loose diaphragm plate assembly. Referto the Diaphragm Replacement sectionof your pump SERVICE MANUAL.

What to Check: Suction side air leakageor air in product.Corrective Action: Visually inspect allsuction side gaskets and pipeconnections.

What to Check: Obstructed checkvalve.Corrective Action: Disassemble the wetend of the pump and manually dislodgeobstruction in the check valve pocket.Refer to the Check Valve section of thepump SERVICE MANUAL fordisassembly instructions.

What to Check: Worn or misalignedcheck valve or check valve seat.Corrective Action: Inspect check valvesand seats for wear and proper seating.Replace if necessary. Refer to CheckValve section of the pump SERVICEMANUAL for disassembly instructions.

What to Check: Blocked suction line.Corrective Action: Remove or flushobstruction. Check and clear all suctionscreens and strainers.What to Check: Blocked discharge line.Corrective Action: Check for obstructionor closed discharge line valves.

What to Check: Blocked pumpingchamber.Corrective Action: Disassemble andinspect the wetted chambers of thepump. Remove or flush any obstructions.Refer to the pump SERVICE MANUALfor disassembly instructions.

What to Check: Entrained air or vaporlock in one or both pumping chambers.Corrective Action: Purge chambersthrough tapped chamber vent plugs.PURGING THE CHAMBERS OF AIRCAN BE DANGEROUS! Contact theTechnical Services Group beforeperforming this procedure. Any modelwith top-ported discharge will reduce oreliminate problems with entrained air.

If your pump continues to performbelow your expectations, contact yourlocal Distributor or factory TechnicalServices Group for a service evaluation.

WARRANTYRefer to the enclosed Warranty

Certificate.



RECYCLINGMany components of Metallic AODD

pumps are made of recyclable materials(see chart on page 10 for materialspecifications). We encourage pumpusers to recycle worn out parts andpumps whenever possible, after anyhazardous pumped fluids are thoroughlyflushed.

This pump is pressurizedinternally with air pressureduring operation. Alwaysmake certain that all boltingis in good condition and that

all of the correct bolting is reinstalled duringassembly.

WARNING

Before pump operation,inspect all gasketedfasteners for loosenesscaused by gasket creep.Re-torque loose fasteners

to prevent leakage. Follow recommendedtorques stated in this manual.

CAUTION

When used for toxic oraggressive fluids, the pumpshould always be flushedclean prior to disassembly.

WARNING

Before maintenance orrepair, shut off the com-pressed air line, bleed thepressure, and disconnectthe air line from the pump.

The discharge line may be pressurized andmust be bled of its pressure.

WARNING

Take action to prevent staticsparking. Fire or explosioncan result, especially whenhandling flammable liquids.The pump, piping, valves,

containers or other miscellaneous equipment mustbe grounded. (See page 28)

WARNING

IMPORTANTRead these safety warningsand instructions in thismanual completely, beforeinstallation and start-upof the pump. It is the

responsibility of the purchaser to retain thismanual for reference. Failure to comply withthe recommendations stated in this manual willdamage the pump, and void factory warranty.

WARNINGAirborne particles and loudnoise hazards.

Wear ear and eye protection.

Before doing any main-tenance on the pump, becertain all pressure iscompletely vented from thepump, suction, discharge,

piping, and all other openings and connections.Be certain the air supply is locked out or madenon-operational, so that it cannot be started whilework is being done on the pump. Be certain thatapproved eye protection and protective clothingare worn all times in the vicinity of the pump.Failure to follow these recommendations mayresult in serious injury or death.

WARNING

WARNINGIn the event of diaphragmrupture, pumped materialmay enter the air end of thepump, and be dischargedinto the atmosphere. If

pumping a product which is hazardous or toxic,the air exhaust must be piped to an appropriatearea for safe disposition.

IMPORTANT SAFETYINFORMATION

CE

Pump complies with EN809 PumpingDirective and Directive 98/37/EC Safety ofMachinery, and ATEX 100a Directive94/9/EC Equipment for use in PotentiallyExplosive Environments.

I M2 c/b T5II 2GD b T5I M2 c T5II 2GD T5

Pump complies with EN809 pumps and pumping systems and Directive 2006/42/ECMachinery, and ATEX 95a Directive94/9/EC Equipment for use in PotentiallyExplosive Environments.

(See page 21)


Page 10

000 .....Assembly, sub-assembly; and some purchased items010 ..... Cast Iron012 .....Powered Metal015 .....Ductile Iron020 .....Ferritic Malleable Iron025 .....Music Wire080 .....Carbon Steel, AISI B-1112100 .....Alloy 20110 .....Alloy Type 316 Stainless Steel111 .....Alloy Type 316 Stainless Steel (Electro Polished)112 .....Alloy “C” (Hastelloy equivalent) 113 .....Alloy Type 316 Stainless Steel (Hand Polished)114 .....303 Stainless Steel115 .....302/304 Stainless Steel117 .....440-C Stainless Steel (Martensitic)120 .....416 Stainless Steel (Wrought Martensitic)123 .....410 Stainless Steel (Wrought Martensitic)148 .....Hardcoat Anodized Aluminum149 .....2024-T4 Aluminum150 .....6061-T6 Aluminum151 .....6063-T6 Aluminum152 .....2024-T4 Aluminum (2023-T351)154 .....Almag 35 Aluminum155 .....356-T6 Aluminum156 .....356-T6 Aluminum157 .....Die Cast Aluminum Alloy #380158 .....Aluminum Alloy SR-319159 .....Anodized Aluminum162 .....Brass, Yellow, Screw Machine Stock165 .....Cast Bronze, 85-5-5-5166 .....Bronze, SAE 660170 .....Bronze, Bearing Type, Oil Impregnated

MATERIAL CODESThe Last 3 Digits of Part Number

175 ..... Die Cast Zinc180 ..... Copper Alloy305 ..... Carbon Steel, Black Epoxy Coated306 ..... Carbon Steel, Black PTFE Coated307 ..... Aluminum, Black Epoxy Coated308 ..... Stainless Steel, Black PTFE Coated309 ..... Aluminum, Black PTFE Coated310 ..... Kynar® Coated330 ..... Zinc Plated Steel331 ..... Chrome Plated Steel332 ..... Aluminum, Electroless Nickel Plated333 ..... Carbon Steel, Electroless Nickel Plated335 ..... Galvanized Steel336 ..... Zinc Plated Yellow Brass337 ..... Silver Plated Steel340 ..... Nickel Plated342 ..... Filled Nylon353 ..... Geolast; Color: Black354 ..... Injection Molded #203-40 Santoprene- Duro 40D +/-5; Color: RED355 ..... Thermal Plastic356 ..... Hytrel357 ..... Injection Molded Polyurethane358 ..... Urethane Rubber (Some Applications) (Compression Mold)359 ..... Urethane Rubber360 ..... Nitrile Rubber. Color coded: RED361 ..... Nitrile363 ..... FKM (Flurorel). Color coded: YELLOW364 ..... E.P.D.M. Rubber. Color coded: BLUE365 ..... Neoprene Rubber. Color coded: GREEN366 ..... Food Grade Nitrile368 ..... Food Grade EPDM370 ..... Butyl Rubber. Color coded: BROWN371 ..... Philthane (Tuftane)

374 .....Carboxylated Nitrile375 .....Fluorinated Nitrile378 .....High Density Polypropylene379 .....Conductive Nitrile405 .....Cellulose Fibre408 .....Cork and Neoprene425 .....Compressed Fibre426 .....Blue Gard440 .....Vegetable Fibre465 .....Fibre500 .....Delrin 500501 .....Delrin 570502 .....Conductive Acetal, ESD-800503 .....Conductive Acetal, Glass-Filled505 .....Acrylic Resin Plastic506 .....Delrin 150520 .....Injection Molded PVDF Natural color540 .....Nylon541 .....Nylon542 .....Nylon544 .....Nylon Injection Molded550 .....Polyethylene551 .....Glass Filled Polypropylene552 .....Unfilled Polypropylene553 .....Unfilled Polypropylene555 .....Polyvinyl Chloride556 .....Black Vinyl558 .....Conductive HDPE570 .....Rulon II580 .....Ryton590 .....Valox591 .....Nylatron G-S592 .....Nylatron NSB600 .....PTFE (virgin material) Tetrafluorocarbon (TFE)601 .....PTFE (Bronze and moly filled)602 .....Filled PTFE

603 .....Blue Gylon604 .....PTFE606 .....PTFE607 .....Envelon608 .....Conductive PTFE610 .....PTFE Encapsulated Silicon611 .....PTFE Encapsulated FKM632 .....Neoprene/Hytrel633 .....FKM/PTFE634 .....EPDM/PTFE635 .....Neoprene/PTFE637 .....PTFE , FKM/PTFE638 .....PTFE , Hytrel/PTFE639 .....Nitrile/TFE643 .....Santoprene®/EPDM644 .....Santoprene®/PTFE656 .....Santoprene Diaphragm and Check Balls/EPDM Seats

Delrin, FKM and Hytrel areregistered tradenames of E.I. DuPont.Gylon is a registered tradename of Garlock, Inc.Nylatron is a registered tradename ofPolymer Corp.Santoprene is a registered tradename ofExxon Mobil Corp.Rulon II is a registered tradename ofDixion Industries Corp.Ryton is a registered tradename ofPhillips Chemical Co.Valox is a registered tradename ofGeneral Electric Co.





PTFE FittedPump Configuration

Viton FittedPump Configuration

Composite Repair Parts Drawing

B476-227-000 AIR END KITSeals, O-ring, Gaskets, Retaining Rings, Air ValveSleeve and Spool Set, and Pilot Valve Assembly

B476-196-360 WET END KITBuna Diaphragms, Balls, and Seats.

B476-196-656 WET END KITSantoprene Diaphragms, Balls and EPDM Seats.

B476-196-365 WET END KITNeoprene Diaphragms, Balls, and Seats.

476-196-635 WET END KITNeoprene Diaphragms, PTFE Overlay,PTFE Balls and PTFE Seats.

HARDWARE KITS475-200-330 Zinc Plated Capscrews, Washers, and Hex Nuts

AVAILABLE SERVICE AND CONVERSION KITS

Nitrile

FKM

B476-196-635

B475-200-330



Composite Repair Parts List

1 B031-183-000 Air Valve Assembly 1B031-179-000 Air Valve Assembly 1

2 B050-005-354 Ball, Check 4B050-005-360 Ball, Check 4B050-005-363 Ball, Check 4B050-005-364 Ball, Check 4B050-005-365 Ball, Check 4B050-010-600 Ball, Check 4

3 B070-006-170 Bushing 24 B095-096-000 Pilot Valve Assembly 15 B114-024-157 Intermediate, Bracket 1

B114-024-010 Intermediate, Bracket 1B114-024-110 Internediate, Bracket 1

6 B132-035-360 Bumper, Diaphragm 27 B135-034-506 Bushing, Plunger 28 B165-118-157E Cap, Air Inlet Assembly 3/4" NPT 1

B165-118-010E Cap, Air Inlet Assembly 3/4" BSP (Parallel) 1B165-118-110 Cap, Air Inlet Assembly 3/4" NPT 1

9 B170-060-115 Capscrew, Hex Hd 7/16-14 X 2.00 16B170-060-330 Capscrew, Hex Hd 7/16-14 X 2.00 16




13 B171-059-115 Capscrew, Soc Hd 7/16-14 X 1.25 8B171-059-330 Capscrew, Soc Hd 7/16-14 X 1.25 8B171.011.110 Capscrew, Soc Hd 1/2-13 X 1.25 8

(Stainless Steel Only)14 B196-169-156 Chamber, Outer 2

B196-169-010 Chamber, Outer 2B196-169-110 Chamber, Outer 2

15 B196-170-156 Chamber, Inner 2B196-170-010 Chamber, Inner 2B196-170-110 Chamber, Inner 2

16 B286-103-354 Diaphragm 2B286-103-360 Diaphragm 2B286-103-364 Diaphragm 2B286-103-365 Diaphragm 2

17 B286-103-600 Diaphragm, Overlay 2

ITEM PART NO. DESCRIPTION QTY18 B360-093-360 Gasket, Air Valve 119 B360-103-360 Gasket, Pilot Valve 120 B360-104-379 Gasket, Air Inlet 121 B360-105-360 Gasket, Inner Chamber 222 B518-161-010E Manifold, Suction 1½" BSP (Parallel) 1

B518-151-110E Manifold, Suction 1½" BSP 1Center Ported (Tapered)

B518-161-156E Manifold, Suction 1½" BSP (Parallel) 123 B518-162-010E Manifold, Discharge 1½" BSP (Parallel) 1

B518-152-110E Manifold, Discharge 1½" BSP 1Center Ported (Tapered)

B518-162-156E Manifold, Discharge 1½" BSP (Parallel) 124 B530-033-000 Silencer 125 B545-005-115 Nut, Hex 3/8-16 16

B545-005-330 Nut, Hex 3/8-16 1626 B545-007-115 Nut, Hex 7/16-14 16

B545-007-330 Nut, Hex 7/16-14 1627 B560-001-360 O-Ring 228 B560-084-360 Seal (O-Ring) (see item 34) 8

B560-084-363 Seal (O-Ring) (see item 34) 8B560-084-364 Seal (O-Ring) (see item 34) 8B720-061-600 Seal (see item 34) 8

29 B612-039-157 Plate, Outer Diaphragm 2B612-039-010 Plate, Outer Diaphragm 2B612-097-110 Plate, Outer Diaphragm 2

30 B612-195-157 Plate, Inner Diaphragm 2B612-195-082 Plate, Inner Diaphragm 2

31 B620-020-115 Plunger, Actuator 232 B675-042-115 Ring, Retaining 233 B685-059-120 Rod, Diaphragm 134 B720-004-360 Seal, Diaphragm Rod 235 B722-091-550 Seat, Check Ball 4

B722-091-080 Seat, Check Ball 4B722-091-110 Seat, Check Ball 4B722-091-150 Seat, Check Ball 4B722-091-600 Seat, Check Ball 4

36 B901-038-115 5/16 Flat Washer 4B901-038-330 5/16 Flat Washer 4

37 B901-038-115 3/8 Flat Washer 4B901-048-330 3/8 Flat Washer 4

38 B570-009-363 Pad, Wear (Use With 286-099-363) 2

ITEM PART NO. DESCRIPTION QTY

Center-Ported Stainless Steel ONLY.

Center-Ported Stainless Steel ONLY.

Tapered

Tapered



Read these instructionscompletely, before in-stallation and start-up. Itis the responsibility ofthe purchaser to retain

this manual for reference. Failure tocomply with the recommendations statedin this manual will damage the pump, andvoid factory warranty.

IMPORTANT

Air Valve Servicing, Assembly Drawing & Parts List

Air Valve Assembly Parts List (Use w/Aluminum centers only)Item Part Number Description Qty1 031-183-000 Air Valve Assembly 11-A 095-109-157 Body, Air Valve 11-B 031-139-000 Sleeve and Spool Set 11-C 132-029-357 Bumper 21-D 560-020-360 O-Ring 101-E 165-127-157 Cap, End 21-F 170-032-330 Hex Head Capscrew 1/4-20 x .75 8

Air Valve Assembly Parts List (Use w/Cast Iron centers only)Item Part Number Description Qty1 031-179-000 Air Valve Assembly 11-A 095-109-110 Body, Air Valve 11-B 031-139-000 Sleeve and Spool Set 11-C 132-029-357 Bumper 21-D 560-020-379 O-Ring 101-E 165-127-110 Cap, End 21-F 170-032-115 Hex Head Capscrew 1/4-20 x .75 8

1-E

1-F

1-D

1-C

1-A

1-B

1-B

1-C

1-D

1-E

1-F

1-D

I M2 c/b T5II 2GD b T5

Air Distribution Valve ServicingTo service the air valve first shut off the

compressed air, bleed pressure from thepump, and disconnect the air supply linefrom the pump.

Step #1: See COMPOSITE REPAIR PARTSDRAWING.

Using a 9/16" wrench or socket, removethe four hex capscrews (items 12). Removethe air valve assembly from the pump.

Remove and inspect gasket (item 18)for cracks or damage. Replace gasket ifneeded.

Step #2: Disassembly of the air valve.Using a 7/16" wrench or socket, remove

the eight hex capscrews (items 1-F) that

fasten the end caps to the valve body. Nextremove the two end caps (items 1-E).Inspect the two o-rings (items 1-D) on eachend cap for damage or wear. Replace thebumpers 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-B) fromthe sleeve. Be careful not to scratch ordamage the outer diameter of the spool.Wipe spool with a soft cloth and inspect forscratches or wear.

Inspect the inner diameter of the sleeve(part of item 1-B) for dirt, scratches, or othercontaminants. Remove the sleeve if neededand replace with a new sleeve and spoolset (item 1-B).

Step #3: Reassembly of the air valve.Install one bumper (item 1-C) and one

end cap (item 1-E), with two o-rings (items1-D), and fasten with four hex capscrews(items 1-F) to the valve body (item 1-A).

Remove the new sleeve an spool set(item 1-B) from the plastic bag. Carefullyremove the spool from the sleeve. Installthe six o-rings (item 1-D) into the six grooveson the sleeve. Apply a light coating ofgrease to the o-rings before installing thesleeve into the valve body (item 1-A), alignthe slots in the sleeve with the slots in thevalve body. Insert the spool into the sleeve.Be careful not to scratch or damage thespool during installation. Carefully insert thesleeve into the bumper and end cap

(with o-rings) and fasten with the remaininghex capscrews.

Fasten the air valve assembly (item 1)and gasket to the pump.Connect thecompressed air line to the pump. The pumpis now ready for operation.

I M2 c T5II 2GD T5



Diaphragm Service Drawing,Non-Overlay

Diaphragm Service Drawing,with Overlay

32

25

15

13

6

28

17

16

29

9

1424

24

32

25

15

13

6

28

17

29

9

1424

24



DIAPHRAGM SERVICINGTo service the diaphragms first shut

off the suction, then shut off thedischarge lines to the pump. Shut off thecompressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump. Drainany remaining liquid from the pump.

Step #1: See the pump assemblydrawing, and the diaphragm servicingillustration.

Using a 9/16" wrench or socket,remove the 16 capscrews (item 10), andhex nuts that fasten the manifolds (items22 & 23) to the outer chambers (item 14).

Step #2: Removing the outerchambers.

Using a 11/16" and a 5/8" wrench orsocket, remove the 16 capscrews (items9), and hex nuts that fasten the outerchambers, diaphragms, and innerchambers (items 15) together.

Step #3: Removing the diaphragmassemblies.

Use a 11/16" (27mm) wrench or sixpointed socket to remove the diaphragmassemblies (outer plate, diaphragm, andinner plate) from the diaphragm rod(item 32) by turning counterclockwise.

NOTE: To uninstall the diaphragmplates from the diaphragm, hold the innerdiaphragm plate using one of twomethods:

Preferred Method: Place theassembled plates and diaphragm in alarge vise, gripping on the exterior castdiameter of the inner diaphragm plate(see the drawing at far right).

Alternate Method: When a larger viseis not available, insert a 1/4 - 20UNChex capscrew or setscrew (standardhardware) into the tapped hole in the innerdiaphragm plate. Insert the assembledplates and diaphragm into a vise withthe stud from the outer plate and the1/4 - 20 fastener loosely between thejaws of the vise (see illustration at right).

Use a 11/16" wrench or socket toremove the outer diaphragm plate (item29) by turning counterclockwise. Inspectthe diaphragm (item 17) for cuts,punctures, abrasive wear or chemicalattack. Replace the diaphragms ifnecessary.

Step #4: Installing the diaphragms.Push the threaded stud of the outer

diaphragm plate through the center holeof the diaphragm. Thread the inner plateclockwise onto the stud. Use one of thetwo methods for holding the innerdiaphragm plate that was described inprior note in step #3. Use a torque wrenchto tighten the diaphragm assemblytogether to 50 ft. lbs. (67.79 Newtonmeters). Allow a minimum of 15 minutesto elapse after torquing, then re-torquethe assembly to compensate for stressrelaxation in the clamped assembly.

Step #5: Installing the diaphragmassemblies to the pump.

Make sure the bumper (item 6) isinstalled over the diaphragm rod.

Thread the stud of the one diaphragmassembly clockwise into the tapped holeat the end of the diaphragm rod (item32) until the inner diaphragm plate is flushto the end of the rod. Insert rod intopump.

Align the bolt holes in the diaphragmwith the bolt pattern in the inner chamber(item 15).

Fasten the outer chamber (item 14)to the pump, using the capscrews (items9), and hex nuts.

On the opposite side of the pump,pull the diaphragm rod out as far aspossible. Make sure the bumper (item6) is installed over the diaphragm rod.

Thread the stud of the remainingdiaphragm assembly clockwise into thetapped hole at the end of the diaphragmrod (item 32) as far as possible and stillallow for alignment of the bolt holes inthe diaphragm with the bolt pattern inthe inner chamber (item 15).

Fasten the remaining outer chamber(item 14) to the pump, using thecapscrews (items 9), and hex nuts.

Step #6: Re-install the manifolds tothe pump, using the capscrews (items10), hex nuts and flat washers.



IMPORTANT

The pump is now ready to bere-installed, connected and returned tooperation.

OVERLAY DIAPHRAGM SERVICINGThe overlay diaphragm (item 16)

is designed to fit over the exterior of thestandard TPE diaphragm (item 17).

The molded directional arrows on theoverlay diaphragm must point vertically.

Follow the same proceduresdescribed for the standard diaphragm forremoval and installation.

Alternate Method:Install 1/4 - 20UNC fastener

into tapped hole.

Preferred Method:Grip this exteriorcast diameter.



PILOT VALVE SERVICINGTo service the pilot valve first shut

off the compressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump.

STEP #1: See pump assemblydrawing.

Using a 1/2" wrench or socket,remove the four capscrews (item 11).Remove the air inlet cap (item 8) and airinlet gasket (item 21). The pilot valveassembly (item 4) can now be removedfor inspection and service.

STEP #2: Disassembly of the pilotvalve.

Remove the pilot valve spool (item4-D). Wipe clean and inspect spool ando-rings for dirt, cuts or wear. Replace theo-rings and spool if necessary.

Remove the retaining ring (item 4-F)from the end of the sleeve (item 4-B)and remove the sleeve from the valvebody (item 4-A). Wipe clean and inspectsleeve and o-rings for dirt, cuts or wear.Replace the o-rings and sleeve ifnecessary.

STEP #3: Re-assembly of the pilotvalve.

Generously lubricate outsidediameter of the sleeve and o-rings. Thencarefully insert sleeve into valve body.Take CAUTION when inserting sleeve,not to shear any o-rings. Install retainingring to sleeve. Generously lubricateoutside 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 valveassembly into the intermediate.

Be careful to align the ends of thepilot valve stem between the plungerpins when inserting the pilot valve intothe cavity of the intermediate.

Re-install the gasket, air inlet capand capscrews. Connect the air supplyto the pump. The pump is now ready foroperation.

Pilot Valve Servicing, Assembly Drawing & Parts ListPILOT VALVE ASSEMBLY PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY4 095-110-000 Pilot Valve Assembly 14-A 095-095-157 Valve Body 14-B 755-051-000 Sleeve (With O-rings) 14-C 560-033-379 O-ring (Sleeve) 64-D 775-055-000 Spool (With O-rings) 14-E 560-023-379 O-ring (Spool) 34-F 675-037-080 Retaining Ring 1

FOR PUMPS WITH CAST IRON CENTER SECTION

ITEM PART NUMBER DESCRIPTION QTY4 095-110-558 Pilot Valve Assembly 14-A 095-095-558 Valve Body 1(includes all other items used on 095-110-000)

FOR PUMPS WITH STAINLESS STEEL CENTER SECTION

ITEM PART NUMBER DESCRIPTION QTY4 095-110-110 Pilot Valve Assembly 14-A 095-095-110 Valve Body 1(includes all other items used on 095-110-000)



ACTUATOR PLUNGER SERVICINGTo service the actuator plunger first

shut off the compressed air supply,bleed the pressure from the pump, anddisconnect the air supply line from thepump.

Step #1: See PUMP ASSEMBLYDRAWING.

Using a 1/2" wrench or socket,remove the four capscrews (items 11).Remove the air inlet cap (item 8) andair inlet gasket (item 20). The pilot valveassembly (item 4) can now be removed.

Step #2: Inspect the actuatorplungers.

See ILLUSTRATION AT RIGHT.The actuator plungers (items 30) can

be reached through the pilot valve cavityin the intermediate assembly (item 5).

Remove the plungers (item 30) fromthe bushings (item 7) in each end ofthe cavity. Inspect the installed o-ring(items 26) for cuts and/or wear. Replacethe o-rings if necessary. Apply a lightcoating of grease to each o-ring andre-install the plungers in to the bushings.Push the plungers in as far as they willgo.

To remove the bushings (item 7),first remove the retaining rings (item 31)by using a flat screwdriver.NOTE: It is recommended that newretaining rings be installed.

Step #3: Re-install the pilot valveassembly into the intermediate assembly.

Be careful to align the ends of thestem between the plungers wheninserting the stem of the pilot valve intothe cavity of the intermediate.

Re-install the gasket (item 20), airinlet cap (item 8) and capscrews (item11).

Connect the air supply to the pump.The pump is now ready for operation.

ACTUATOR PLUNGER SERVICING

277

32

31

5



IMPORTANT



Check Valve DrawingCHECK VALVE SERVICINGBefore servicing the check valve

components, first shut off the suctionline and then the discharge line to thepump. Next, shut off the compressed airsupply, bleed air pressure from thepump, and disconnect the air supply linefrom the pump. Drain any remaining fluidfrom the pump. The pump can now beremoved for service.

To access the check valvecomponents, remove the manifold(item 23 or item 22 not shown). Use a9/16" wrench or socket to remove thefasteners. Once the manifold is removed,the check valve components can beseen.

Inspect the check balls (items 2) forwear, abrasion, or cuts on the sphericalsurface. The check valve seats (item 34)should be inspected for cuts, abrasivewear, or embedded material on thesurfaces of both the external and internalchambers. The spherical surface of thecheck balls must seat flush to thesurface of the check valve seats for thepump to operate to peak efficiency.Replace any worn or damaged parts asnecessary.

Re-assemble the check valvecomponents. The seat should fit into thecounter bore of the outer chamber.

The pump can now be reassembled,reconnected and returned to operation.

METALLIC SEATSTwo o-rings (or conductive PTFE

seals) (item 27) are required for metallicseats.

with Non-MetallicSeats

with Metallic Seats



SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING



MUFFLER

LIQUIDLEVEL

SUCTIONLINE

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

MUFFLER

CONVERTED EXHAUST ILLUSTRATION

Illustration #1

Illustration #2

Illustration #3

PUMPING HAZARDOUS LIQUIDSWhen a diaphragm fails, the pumped

liquid or fumes enter the air end of thepump. Fumes are exhausted into thesurrounding environment. When pumpinghazardous or toxic materials, theexhaust air must be piped to anappropriate area for safe disposal. Seeillustration #1 at right.

This pump can be submerged if thepump materials of construction arecompatible with the liquid being pumped.The air exhaust must be piped abovethe liquid level. See illustration #2 atright. Piping used for the air exhaust mustnot be smaller than 1" (2.54 cm)diameter. Reducing the pipe size willrestrict air flow and reduce pumpperformance. When the pumped productsource is at a higher level than the pump(flooded suction condition), pipe theexhaust higher than the product sourceto prevent siphoning spills. Seeillustration #3 at right.

CONVERTING THE PUMP FORPIPING THE EXHAUST AIR

The following steps are necessary toconvert the pump to pipe the exhaustair away from the pump.

Remove the muffler (item 42). Theair distribution valve (item 1) has 1" NPTthreads for piped exhaust.

IMPORTANT INSTALLATIONNOTE: The manufacturer recommendsinstalling a flexible conductive hose orconnection between the pump and anyrigid plumbing. This reduces stresses onthe molded threads of the air exhaustport. Failure to do so may result indamage to the air distribution valve body.

Any piping or hose connected to the pump’s air exhaust port must beconductive and physically supported.Failure to support these connectionscould also result in damage to the airdistribution valve body.

1

On ATEX compliant unitsthe pump comes equippedwith a standard metalmuffler

Air Valve Assembly

42



One eyelet end is fastened to the pump hardware.

One eyelet end is installed to a true earth ground. This 8 foot long (244 centimeters) Ground Strap, partnumber 920-025-000, can be ordered as a service part.

To reduce the risk of static electrical sparking, thispump must be grounded. Check the local electricalcode for detailed grounding instruction and the type ofequipment required.

Grounding The Pump

Take action to prevent staticsparking. Fire or explosion canresult, especially when handlingflammable liquids. The pump,piping, valves, containers or othermiscellaneous equipment must begrounded.

WARNING

Declaration of Conformity

Date of issue

Printed name of authorized person

Revision Level: E

TitleDes Monaghan Production & Tech Manager

October 20, 2005

Date of revisionMay 27, 2010

Manufacturer: IDEX Pump Technologies (Ireland) Ltd., A Unit of IDEX Corporation, R79, Shannon, Co Clare, IRELAND.

Certifies that Air-Operated Double Diaphragm Pump B and X Series, comply with the European Community Directive 2006/42/EC on Machinery, according to Annex VIII.

This product has used Harmonized Standard EN 809, Pumps and Pump Units for Liquids - Common Safety Requirements, to verify conformance.

Signature of authorized person

EC Declaration of ConformityIn accordance with ATEX Directive 94/9/EC,

Equipment intended for use in potentially explosive environments.

Applicable Standard:EN13463-1: 2001,EN13463-5: 2003

DATE/APPROVAL/TITLE:27 MAY 2010

AODD Pumps Equipped with AluminiumType Examination Certificate: KEMA 09ATEX0072 X

AODD (Air-Operated Double Diaphragm) PumpsEC Type Examination Certificate No. Pumps: KEMA 09ATEX0071 XKEMA Quality B.V.Utrechtseweg 3106812 AR Arnhem, The Netherlands

Manufacturer: IDEX Pump Technologies (Ireland) Ltd., A Unit of IDEX Corporation, R79, Shannon, Co Clare, IRELAND.

Production and Technical Manager

Documents

Model X40 Metallic Design Level 1 Applied for CE · SERVICE & OPERATING MANUAL Model X40 Metallic Design Level 1 Table of Contents U.S. Patent # 5,996,627; 6,241,487 Other U.S. Patents