SERVICE BULLETIN SB1118 - Westech Equipment...Process temperature range:-20 C to +80 C for models rated as category 1 equipment-20 C to +100 C for models rated as category 2 equipment

Model 1120-030S Design Level 1

Balcrank Corporation115 Reems Creek Road, Weaverville, NC 28787

Telephone 800.747.5300Fax 800.763.0840

WWW.BALCRANK.Com

SERVICE BULLETIN SB1118Original Instructions

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bc1120-030Smdl1sm-rev0412

www.balcrank.commodel 1120-030S metallic

IMPORTANT

Read the safety warnings and instructions in this manual before pump installation and start-up. Failure to comply with the recommendations stated in this manual could damage the pump and void factory warranty.

When used for toxic or aggressive fluids, the pump should always be flushed clean prior to disassembly.

Airborne particles and loud noise hazards. Wear eye and ear protection.

Before maintenance or repair, shut off the compressed air line, bleed the pressure, and disconnect the air line from the pump. Be certain that approved eye protection and protective clothing are worn at all times. Failure to follow these recommendations may result in serious injury or death.

When the pump is used for materials that tend to settle out or solidify, the pump should be flushed after each use to prevent damage. In freezing temperatures the pump should be completely drained between uses.

Before pump operation, inspect all fasteners for loosening caused by gasket creep. Retighten loose fasteners to prevent leakage. Follow recommended torques stated in this manual.

CAUTION

WARNING

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.

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 that is hazardous or toxic, the air exhaust must be piped to an appropriate area for safe containment.

This pump is pressurized internally with air pressure during operation. Make certain that all fasteners are in good condition and are reinstalled properly during reassembly.

Take action to prevent static sparking. Fire or explosion can result, especially when handling flammable liquids. The pump, piping, valves, containers and other miscellaneous equipment must be properly grounded.

Safety Information

UNIVERSAL ALL AODD

bc1120-030Smdl1sm-rev0412

www.balcrank.com model 1120-030S metallic

Table of Contents

SECTION 1: PumP SPECIfICaTIONS ................1 •Performance •Materials •DimensionalDrawings

SECTION 2: INSTallaTION & OPEraTION ......6 •PrincipleofPumpOperation •RecommendedInstallationGuide •TroubleshootingGuide

SECTION 3: ExPlOdEd VIEw ...........................9 •CompositeRepairPartsDrawing •CompositeRepairPartsList

SECTION 4: aIr ENd .......................................11 •AirDistributionValveAssembly •PilotValveAssembly •IntermediateAssembly

SECTION 5: wET ENd .....................................14 •DiaphragmDrawings •DiaphragmServicing

SECTION 6: warraNTy & CErTIfICaTES ....16 •Warranty

MODEL SPECIFIC

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4 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412

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Performance1120-030S mETallIC

SUCTIoN/DISChARgE PoRT SIzE•2"NPT(internal)

CAPACITY•0to150gallonsperminute(0to567litersperminute)

AIR DISTRIBUTIoN VALVE•No-lube,no-stalldesign

SoLIDS-hANDLINg•Upto.25in.(6mm)

hEADS UP To•125psior289ft.ofwater(8.6Kg/cm2or86meters)

DISPLACEmENT/STRoKE•.42Gallon/.1.59liter

mAXImUm oPERATINg PRESSURE•125psi(8.6bar)

ShIPPINg WEIghT•Aluminum69lbs.(31kg)

0 20 40 60 80 100 120 140 160

20 (34)

40 (68)

60 (102)

80 (136)

100 (170)

600500400300200100

100

90

80

70

60

50

40

30

20

10

0

1

2

3

4

5

6

7

0

30

2025

1015

5

9.1

67.6

34.5

1.5

CAPACITY

U.S. Gallons per minute

Liters per minute

BAR

PSI

HEA

D

NPS

HR

MET

ERS

FEET

40 PSI (2.72 Bar)

20 PSI (1.36 Bar)Air Inlet Pressure

60 PSI (4.08 Bar)

80 PSI (5.44 Bar)

100 PSI (6.8 Bar)

MODEL S20 Metallic Performance CurvePerformance 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%.

MaterialsMaterial Profile: operating

Temperatures:max. min.

Nitrile: Generalpurpose,oil-resistant.Showsgoodsolvent,oil,waterandhydraulicfluidresistance.ShouldnotbeusedwithhighlypolarsolventslikeacetoneandMEK,ozone,chlorinatedhydrocarbonsandnitrohydrocarbons.

190°F88°C

-10°F-23°C

Virgin PTFE:(PFA/TFE)Chemicallyinert,virtuallyimpervious.VeryfewchemicalsareknowntochemicallyreactwithPTFE;moltenalkalimetals,turbulentliquidorgaseousfluorineandafewfluoro-chemicalssuchaschlorinetrifluorideoroxygendifluoridewhichreadilyliberatefreefluorineatelevated temperatures.

220°F104°C

-35°F-37°C

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.

CAUTION! Operating temperature limitations are as follows:

Ambient temperature range: -20°Cto+40°CProcess temperature range: -20°Cto+80°Cformodelsratedascategory1equipment -20°Cto+100°Cformodelsratedascategory2equipmentInaddition,theambienttemperaturerangeandtheprocesstemperaturerangedonotexceedtheoperatingtemperaturerangeoftheappliednon-metallicpartsaslistedinthemanualsofthepumps.

MODEL SPECIFIC UNIVERSAL ALL AODD

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Model 1120-030S Metallic • 5bc1120-030Smdl1sm-rev0412

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DimensionsinInches.DimensionalTolerance:±1/8"

DimensionsinMillimeters.DimensionalTolerance:±3mm.

dimensional drawings

Both Suction AndDischarge Ports AreAvailable With2" BSP Connection

Discharge Port2" NPT

Suction Port2" NPT

Integral Muffler1" NPT Exhaust PortFor Optional Muffler

Styles or Piping ExhaustAir In Submerged

Applications

26 3/16

13 11/16

5/16

12 19/32

1 7/8

24 5/8

5 13/162 1/4

2 1/4

6 7/32

12 7/16

16 7/8

2 3/8

4 7/8

5 1/3210 1/16

1/2

4 1/29

1/2

510

Air Inlet3/4" NPT

SIDE VIEW

BOTTOM VIEW

FRONT VIEW

Both Suction andDischarge Ports AreAvailable With2" BSP Tapered Connection

Discharge Port2" NPT

Suction Port2" NPT

Air Inlet3/4" NPT

665

348

60

158

316

42847

57256

128

124

12

229

114

127254

625

14857

320

8

Integral Muffler1" NPT Exhaust PortFor Optional Muffler

Styles or Piping ExhaustAir In Submerged

Applications.

SIDE VIEW

BOTTOM VIEW

FRONT VIEW

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Air-OperatedDoubleDiaphragm(AODD)pumpsarepoweredbycompressedair,nitrogenornaturalgas.

Themaindirectional(air)controlvalve① distributescompressedairtoanairchamber,exertinguniformpressureovertheinnersurfaceofthediaphragm②.Atthesametime,theexhaustingair③ frombehindtheoppositediaphragm isdirectedthroughtheairvalveassembly(s)toanexhaust port④.

Asinnerchamberpressure(P1)exceedsliquidchamberpressure(P2),therod⑤connecteddiaphragmsshifttogethercreatingdischargeononesideandsuctionontheoppositeside.Thedischargedandprimedliquid’sdirectionsarecontrolledbythecheckvalves(ballorflap)⑥ orientation.

Thepumpprimesasaresultofthesuctionstroke.Thesuctionstrokelowersthechamberpressure(P3)increasingthechambervolume.Thisresultsinapressuredifferentialnecessaryforatmosphericpressure(P4)topushthefluidthroughthesuctionpipingandacrossthesuctionsidecheckvalveandintotheouterfluidchamber⑦.

Suction(side)strokingalsoinitiatesthereciprocating(shifting,strokingorcycling)actionofthepump.Thesuctiondiaphragm’smovementismechanicallypulledthroughitsstroke.Thediaphragm’sinnerplatemakescontactwithanactuatorplungeralignedtoshiftthepilotsignalingvalve.Onceactuated,thepilotvalvesendsapressuresignaltotheoppositeendofthemaindirectionalairvalve,redirectingthecompressedairtotheoppositeinnerchamber.

Principle of Pump Operation

Air Line

Discharged Fluid

DischargeStroke Suction

Stroke

PrimedFluid

SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING



MUFFLER

LIQUIDLEVEL

SUCTIONLINE

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

MUFFLER

SUBMERGED ILLUSTRATION

Pumpcanbesubmergedifthepumpmaterialsofconstructionarecompatiblewiththeliquidbeingpumped.Theairexhaustmustbepipedabovetheliquidlevel.Whenthepumpedproductsourceisatahigherlevelthanthepump(floodedsuctioncondition),pipetheexhausthigherthantheproductsourcetopreventsiphoningspills.

UNIVERSAL ALL AODD

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Principle of Pump Operation

SUBMERGED ILLUSTRATION

Installation And Start-Up Locatethepumpasclosetotheproductbeingpumpedaspossible.Keepthesuctionlinelengthandnumberoffittingstoaminimum.Donotreducethesuctionlinediameter.

Air Supply Connectthepumpairinlettoanairsupplywithsufficientcapacityandpressuretoachievedesiredperformance.Apressureregulatingvalveshouldbeinstalledtoinsureairsupplypressuredoesnotexceedrecommendedlimits.

Air Valve Lubrication TheairdistributionsystemisdesignedtooperateWITHOUTlubrication.Thisisthestandardmodeofoperation.Iflubricationisdesired,installanairlinelubricatorsettodeliveronedropofSAE10non-detergentoilforevery20SCFM(9.4liters/sec.)ofairthepumpconsumes.ConsultthePerformanceCurvetodetermineairconsumption.

Air Line moisture Waterinthecompressedairsupplymaycauseicingorfreezingoftheexhaustair,causingthepumptocycleerraticallyorstopoperating.Waterintheairsupplycanbereducedbyusingapoint-of-useairdryer.

Air Inlet And Priming Tostartthepump,slightlyopentheairshut-offvalve.Afterthepumpprimes,theairvalvecanbeopenedtoincreaseairflowasdesired.Ifopeningthevalveincreasescyclingrate,butdoesnotincreasetherateofflow,cavitationhasoccurred.Thevalveshouldbeclosedslightlytoobtainthemostefficientairflowtopumpflowratio.

Surge Suppressor

Shut-Off Valve

Pressure Gauge

Drain PortShut-OffValve

CheckValve

Air Inlet

Discharge

Unregulated AirSupply to Surge

Suppressor

Pipe Connection(Style Optional)

Flexible Connector

Flexible Connector

VacuumGauge

Suction

Shut-Off Valve

Drain Port

Air Dryer

Filter Regulator

Muffler(Optional Piped Exhaust)

recommended Installation Guide

Available Accessories: 1. Surge Suppressor 2. Filter/Regulator 3. Air Dryer

1

2

3

Note: SurgeSuppressorandPipingmustbesupportedaftertheflexibleconnection

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

UNIVERSAL ALL AODD, EXCEPT FLAP

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Troubleshooting GuideSymptom: Potential Cause(s): Recommendation(s):Pump Cycles once Deadhead(systempressuremeetsorexceedsair

supplypressure).Increasetheinletairpressuretothepump.Pumpisdesignedfor1:1pressureratioatzeroflow. (Doesnotapplytohighpressure2:1units).

Airvalveorintermediategasketsinstalledincorrectly. Installgasketswithholesproperlyaligned.Bentormissingactuatorplunger. Removepilotvalveandinspectactuatorplungers.

Pump Will Not operate / Cycle

Pumpisoverlubricated. Setlubricatoronlowestpossiblesettingorremove.Unitsaredesignedforlubefreeoperation.Lackofair(linesize,PSI,CFM). Checktheairlinesizeandlength,compressorcapacity(HPvs.CFMrequired).Checkairdistributionsystem. Disassembleandinspectmainairdistributionvalve,pilotvalveandpilotvalveactuators.Dischargelineisblockedorcloggedmanifolds. Checkforinadvertentlycloseddischargelinevalves.Cleandischargemanifolds/piping.Deadhead(systempressuremeetsorexceedsairsupplypressure).

Increasetheinletairpressuretothepump.Pumpisdesignedfor1:1pressureratioatzeroflow. (Doesnotapplytohighpressure2:1units).

Blockedairexhaustmuffler. Removemufflerscreen,cleanorde-ice,andre-install.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Pumpchamberisblocked. Disassembleandinspectwettedchambers.Removeorflushanyobstructions.

Pump Cycles and Will Not Prime or No Flow

Cavitationonsuctionside. Checksuctioncondition(movepumpclosertoproduct).Checkvalveobstructed.Valveball(s)notseatingproperlyorsticking.

Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket. Cleanoutaroundvalveballcageandvalveseatarea.Replacevalveballorvalveseatifdamaged. Useheaviervalveballmaterial.

Valveball(s)missing(pushedintochamberormanifold).

Wornvalveballorvalveseat.Wornfingersinvalveballcage(replacepart).CheckChemical ResistanceGuideforcompatibility.

Valveball(s)/seat(s)damagedorattackedbyproduct. CheckChemicalResistanceGuideforcompatibility.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Suctionlineisblocked. Removeorflushobstruction.Checkandclearallsuctionscreensorstrainers.Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.

Pump Cycles Running Sluggish / Stalling, Flow Unsatisfactory

Overlubrication. Setlubricatoronlowestpossiblesettingorremove.Unitsaredesignedforlubefreeoperation.Icing. Removemufflerscreen,de-ice,andre-install.Installapointofuseairdrier.Cloggedmanifolds. Cleanmanifoldstoallowproperairflow.Deadhead(systempressuremeetsorexceedsairsupplypressure).


Cavitationonsuctionside. Checksuction(movepumpclosertoproduct).Lackofair(linesize,PSI,CFM). Checktheairlinesize,length,compressorcapacity.Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Airsupplypressureorvolumeexceedssystemhd. Decreaseinletair(press.andvol.)tothepump.Pumpiscavitatingthefluidbyfastcycling.Undersizedsuctionline. Meetorexceedpumpconnections.Restrictiveorundersizedairline. Installalargerairlineandconnection.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Suctionlineisblocked. Removeorflushobstruction.Checkandclearallsuctionscreensorstrainers.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Checkvalveobstructed. Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Entrainedairorvaporlockinchamber(s). Purgechambersthroughtappedchamberventplugs.Purgingthechambersofaircanbedangerous.

Product Leaking Through Exhaust

Diaphragmfailure,ordiaphragmplatesloose. Replacediaphragms,checkfordamageandensurediaphragmplatesaretight.Diaphragmstretchedaroundcenterholeorboltholes. Checkforexcessiveinletpressureorairpressure.ConsultChemicalResistanceChartforcompatibility

withproducts,cleaners,temperaturelimitationsandlubrication.Premature Diaphragm Failure

Cavitation. Enlargepipediameteronsuctionsideofpump.Excessivefloodedsuctionpressure. Movepumpclosertoproduct.Raisepump/placepumpontopoftanktoreduceinletpressure.

InstallBackpressuredevice(Techbulletin41r).Addaccumulationtankorpulsationdampener.Misapplication(chemical/physicalincompatibility). ConsultChemicalResistanceChartforcompatibilitywithproducts,cleaners,temperaturelimitations

andlubrication.Incorrectdiaphragmplatesorplatesonbackwards,installedincorrectlyorworn.

CheckOperatingManualtocheckforcorrectpartandinstallation.Ensureouterplateshavenotbeenworntoasharpedge.

Unbalanced Cycling Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Undersizedsuctionline. Meetorexceedpumpconnections.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Checkvalveobstructed. Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Entrainedairorvaporlockinchamber(s). Purgechambersthroughtappedchamberventplugs.

UNIVERSAL ALL SANDPIPER, EXCEPT FLAP

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Troubleshooting GuideSymptom: Potential Cause(s): Recommendation(s):Pump Cycles once Deadhead(systempressuremeetsorexceedsair

supplypressure).Increasetheinletairpressuretothepump.Pumpisdesignedfor1:1pressureratioatzeroflow. (Doesnotapplytohighpressure2:1units).

Airvalveorintermediategasketsinstalledincorrectly. Installgasketswithholesproperlyaligned.Bentormissingactuatorplunger. Removepilotvalveandinspectactuatorplungers.

Pump Will Not operate / Cycle

Pumpisoverlubricated. Setlubricatoronlowestpossiblesettingorremove.Unitsaredesignedforlubefreeoperation.Lackofair(linesize,PSI,CFM). Checktheairlinesizeandlength,compressorcapacity(HPvs.CFMrequired).Checkairdistributionsystem. Disassembleandinspectmainairdistributionvalve,pilotvalveandpilotvalveactuators.Dischargelineisblockedorcloggedmanifolds. Checkforinadvertentlycloseddischargelinevalves.Cleandischargemanifolds/piping.Deadhead(systempressuremeetsorexceedsairsupplypressure).


Blockedairexhaustmuffler. Removemufflerscreen,cleanorde-ice,andre-install.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Pumpchamberisblocked. Disassembleandinspectwettedchambers.Removeorflushanyobstructions.

Pump Cycles and Will Not Prime or No Flow

Cavitationonsuctionside. Checksuctioncondition(movepumpclosertoproduct).Checkvalveobstructed.Valveball(s)notseatingproperlyorsticking.

Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket. Cleanoutaroundvalveballcageandvalveseatarea.Replacevalveballorvalveseatifdamaged. Useheaviervalveballmaterial.

Valveball(s)missing(pushedintochamberormanifold).

Wornvalveballorvalveseat.Wornfingersinvalveballcage(replacepart).CheckChemical ResistanceGuideforcompatibility.

Valveball(s)/seat(s)damagedorattackedbyproduct. CheckChemicalResistanceGuideforcompatibility.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Suctionlineisblocked. Removeorflushobstruction.Checkandclearallsuctionscreensorstrainers.Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.

Pump Cycles Running Sluggish / Stalling, Flow Unsatisfactory

Overlubrication. Setlubricatoronlowestpossiblesettingorremove.Unitsaredesignedforlubefreeoperation.Icing. Removemufflerscreen,de-ice,andre-install.Installapointofuseairdrier.Cloggedmanifolds. Cleanmanifoldstoallowproperairflow.Deadhead(systempressuremeetsorexceedsairsupplypressure).


Cavitationonsuctionside. Checksuction(movepumpclosertoproduct).Lackofair(linesize,PSI,CFM). Checktheairlinesize,length,compressorcapacity.Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Airsupplypressureorvolumeexceedssystemhd. Decreaseinletair(press.andvol.)tothepump.Pumpiscavitatingthefluidbyfastcycling.Undersizedsuctionline. Meetorexceedpumpconnections.Restrictiveorundersizedairline. Installalargerairlineandconnection.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Suctionlineisblocked. Removeorflushobstruction.Checkandclearallsuctionscreensorstrainers.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Checkvalveobstructed. Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Entrainedairorvaporlockinchamber(s). Purgechambersthroughtappedchamberventplugs.Purgingthechambersofaircanbedangerous.

Product Leaking Through Exhaust

Diaphragmfailure,ordiaphragmplatesloose. Replacediaphragms,checkfordamageandensurediaphragmplatesaretight.Diaphragmstretchedaroundcenterholeorboltholes. Checkforexcessiveinletpressureorairpressure.ConsultChemicalResistanceChartforcompatibility

withproducts,cleaners,temperaturelimitationsandlubrication.Premature Diaphragm Failure

Cavitation. Enlargepipediameteronsuctionsideofpump.Excessivefloodedsuctionpressure. Movepumpclosertoproduct.Raisepump/placepumpontopoftanktoreduceinletpressure.

InstallBackpressuredevice(Techbulletin41r).Addaccumulationtankorpulsationdampener.Misapplication(chemical/physicalincompatibility). ConsultChemicalResistanceChartforcompatibilitywithproducts,cleaners,temperaturelimitations

andlubrication.Incorrectdiaphragmplatesorplatesonbackwards,installedincorrectlyorworn.

CheckOperatingManualtocheckforcorrectpartandinstallation.Ensureouterplateshavenotbeenworntoasharpedge.

Unbalanced Cycling Excessivesuctionlift. Forliftsexceeding20’ofliquid,fillingthechamberswithliquidwillprimethepumpinmostcases.Undersizedsuctionline. Meetorexceedpumpconnections.Pumpedfluidinairexhaustmuffler. Disassemblepumpchambers.Inspectfordiaphragmruptureorloosediaphragmplateassembly.Suctionsideairleakageorairinproduct. Visuallyinspectallsuction-sidegasketsandpipeconnections.Checkvalveobstructed. Disassemblethewetendofthepumpandmanuallydislodgeobstructioninthecheckvalvepocket.Checkvalveand/orseatiswornorneedsadjusting. Inspectcheckvalvesandseatsforwearandpropersetting.Replaceifnecessary.Entrainedairorvaporlockinchamber(s). Purgechambersthroughtappedchamberventplugs.

833174 Air End Kit Seals,O-Ring,Gaskets,RetainingRings,Air ValveSleeveandSpoolSetandPilotValve Assembly.833175 Air Seal Kit Seals,O-Ring,Gaskets,RetainingRings,Bumpers833173 Wet End Kit NitrileDiaphragms,Balls,andSeats.

Torque:90 in. lbs.

Torque:90 in. lbs.

Torque:Plate to Rod 360 in. lbs.

Torque:Plate to Plate 480 in. lbs.

Torque:360 in. lbs. Aluminum

Composite repair Parts drawing

Service & Repair Kits

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Item Description Qty 1 AirValveAssemblyw/Integralmuffler (Cast Iron Centers Only) 1 2 Ball, Check 4 3 Bushing 2 4 Pilot Valve Assembly 1 5 Intermediate Bracket 1 6 Bumper, Diaphragm 2 7 Bushing, Plunger 2 8 Cap, Air Inlet Assembly 1 9 Capscrew, Hex Hd 3/8-16 X 2.25 16 10 Capscrew, Hex Hd 7/16-14 X 2.00 16 11 Capscrew, Hex Hd 5/16-18 X 1.75 4 12 Capscrew, Hex HD 3/8-16 X 1.00 4 13 Capscrew, Soc Hd 7/16-14 X 1.25 8 14 Chamber, Outer 2 15 Chamber, Inner 2 18 Diaphragm 2 19 Gasket, Air Valve 1 20 Gasket, Pilot Valve 1 21 Gasket, Air Inlet 1 22 Gasket, Inner Chamber 2 23 Manifold, Suction 1 24 Manifold, Discharge 1 25 Nut, Hex 3/8-16 16 26 Nut, Hex 7/16-14 16 27 O-Ring 2 28 Plate, Inner Diaphragm 2 29 Plate, Outer Diaphragm Assembly 2 30 Plate, Inner Diaphragm (used with 286-020-604) 2 32 Plunger, Actuator 2 33 Ring, Retaining 2 34 Rod, Diaphragm 1 35 Seal, Diaphragm Rod 2 36 Seat, Check Ball 4 37 Washer, Lock 16 38 Washer, Flat 5/16 4

Composite repair Parts list

lEGENd:=ItemscontainedwithinAirEndKits=ItemscontianedwithinWetEndKits=ItemscontianedwithinAirSealKits

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air distribution Valve assembly

Air Valve Assembly Parts List Item Description Qty1 Air Valve Assembly 11-A Body, Air Valve 11-B Sleeve and Spool Set 11-C Bumper 21-D O-Ring 101-E Cap, End 21-F Hex Head Capscrew 1/4-20 x .75 81-G Muffler 11-H MufflerCap 11-J Machine Screw 4

IMPORTANTRead 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.

Air Distribution Valve ServicingSeerepairpartsdrawing,removescrews.Step 1:RemoveHexHeadCapScrews(1-F).Step 2: Removeendcap(1-E).Step 3: Removespoolpartof(1-B)(caution:donotscratch).Step 4: Presssleeve(1-B)frombody(1-A).Step 5:InspectO-Ring(1-D)andreplaceifnecessary.Step 6:LightlylubricateO-Rings(1-D)onsleeve(1-B).Step 7: Presssleeve(1-B)intobody(1-A).Step 8: Reassembleinreverseorder,startingwithstep3.

Note: Sleeveandspool(1-B)setismatchgroundtoaspecifiedclearancesleeveandspools(1-B)cannotbeinterchanged.

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Pilot Valve assembly

Pilot Valve Assembly Parts List

Item Description Qty4 Pilot Valve Assembly 14-A Valve Body 14-B Sleeve (With O-Rings) 14-C O-Ring (Sleeve) 64-D Spool (With O-Rings) 14-E O-Ring (Spool) 34-F Retaining Ring 1

Pilot Valve ServicingWithPilotValveremovedfrompump.Step 1:Removesnapring(4-F).Step 2:Removesleeve(4-B),inspectO-Rings(4-C), replaceifrequired.Step 3: Removespool(4-D)fromsleeve(4-B), inspectO-Rings(4E),replaceifrequired.Step 4: LightlylubricateO-Rings(4-C)and(4-E). Reassembleinreverseorder.

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Pilot Valve assembly

Pilot Valve Assembly Parts List

Item Description Qty4 Pilot Valve Assembly 14-A Valve Body 14-B Sleeve (With O-Rings) 14-C O-Ring (Sleeve) 64-D Spool (With O-Rings) 14-E O-Ring (Spool) 34-F Retaining Ring 1

Intermediate assembly drawing

INTERMEDIATE REPAIR PARTS LISTItem Description Qty5 Bracket,Intermediate 17 Bushing,Plunger 227 O-Ring 232 Plunger,Actuator 233 Ring,Retaining* 235 Seal,DiaphragmRod 2

*Note: Itisrecommendedthatwhenplungercomponents areserviced,newretainingringsbeinstalled.

Intermediate Assembly DrawingStep 1: Removeplunger,actuator(32)fromcenterof intermediatepilotvalvecavity.Step 2: RemoveRing,Retaining(33),discard.Step 3: Removebushing,plunger(7),inspectforwear andreplaceifnecessarywithgenuineparts.Step 4: RemoveO-Ring(27),inspectforwearand replaceifnecessarywithgenuineparts.Step 5: LightlylubricateO-Ring(27)andinsertinto intermediate.Step 6: Reassembleinreverseorder.Step 7: RemoveSeal,DiaphragmRod(35).Step 8: Cleansealarea,lightlylubricateandinstallnewSeal, DiaphragmRod(35).

IMPORTANTWhen the pumped product source is at a higher level than the pump (flooded suction condition), pipe the exhaust higher than the product source to prevent siphoning spills. In the event of a diaphragm failure a complete rebuild of the center section is recommended.

33

30

5

31

726

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diaphragm Service drawing, Non-Overlay

34

26

26 13

15

630

18

16

31

14

10 37

25

25

37 10

14

37

25

25

37

29

1325

34

26

15

628

18

Torque: Plate to Plate480 in. lbs.600 in. lbs. Santoprene

Torque: Plate to Plate480 in. lbs.

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Step 1: With manifolds and outer chambersremoved, remove diaphragm assemblies fromdiaphragmrod.Do NoTuseapipewrenchorsimilartooltoremoveassemblyfromrod.Flawsintherodsurfacemaydamagebearingsandseal.Soft jawsin a vise are recommended to prevent diaphragmroddamage.

Step 1.A: NoTE: Notall innerdiaphragmplatesarethreaded.Somemodelsutilizeathoughholeinthe inner diaphragmplate. If required to separatediaphragm assembly, place assembly in a vice,gripping on theexterior cast diameter of the innerplate.Turntheouterplateclockwisetoseparatetheassembly.

Always inspect diaphragms for wear cracks orchemicalattack. Inspect innerandouterplates fordeformities,rustscaleandwear.Inspectintermediatebearingsforelongationandwear.Inspectdiaphragmrodforwearormarks.Cleanorrepairifappropriate.Replaceasrequired.

Step 2: Reassembly:TherearetwodifferenttypesofdiaphragmplateassembliesutilizedthroughouttheSandpiperproductline:Outerplatewithathreadedstud,diaphragm,andathreadedinnerplate.

Outer platewith a threaded stud, diaphragm, andan inner platewith throughhole.Secure threadedinnerplateinavice.Ensurethattheplatesarebeinginstalledwiththeouterradiusagainstthediaphragm.

Step 3:Lightlylubricate,withacompatiblematerial,theinnerfacesofbothouterandinnerdiaphragmplateswhenusingonnonOverlaydiaphragms(ForEPDMwater isrecommended).No lubrication isrequired.

Step 4: Push the threaded outer diaphragmplate through the center hole of the diaphragm.Note: Most diaphragms are installed with thenatural bulge out towards the fluid side. S05,S07, and S10 non–metallic units are installedwith the natural bulge in towards the air side.

Step 5: Thread or place, outer plate stud intothe inner plate. For threaded inner plates use atorquewrench to tighten the assembly together.Torquevaluesarecalledoutontheexplodedview.

Repeatprocedureforsecondsideassembly.Allowaminimumof15minutestoelapseaftertorquingthenre-torque the assembly to compensate for stressrelaxationintheclampedassembly. Step 6:Threadoneassemblyontothediaphragmrodwithsealingwasher (whenused)andbumper.

Step 7: Instal l diaphragm rod assemblyinto pump and secure by installing the outerchamber in place and tightening the capscrews.

Step 8: On opposite side of pump thread theremainingassemblyontothediaphragmrod.Usingatorquewrenchtightentheassemblytothediaphragmrod.Aligndiaphragmthroughboltholesalwaysgoingforwardpasttherecommendedtorque.Torquevaluesarecalledoutontheexplodedview.NEVERreverseto align holes, if alignment cannot be achievedwithout damage to diaphragm, loosen completeassemblies rotate diaphragm and reassemble asdescribedabove.

dIaPhraGm SErVICING

IMPORTANTRead 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.

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For Warranty Information Visit:www.balcrank.com

SERVICE BULLETIN SB1118Revised 04/12

Distributed by:Balcrank Corporation115 Reems Creek RoadWeaverville, NC 28787800-747-5300800-763-0840 Faxwww.balcrank.com

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SERVICE BULLETIN SB1118 - Westech Equipment...Process temperature range:-20 C to +80 C for models rated as category 1 equipment-20 C to +100 C for models rated as category 2 equipment

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