with Metallic Center Section E3 3: EXP VIEW 2: INSTAL & OP 1: PUMP SPECS E3 Metallic Pumps • Aluminum 4: WARRANTY Service & Operating Manual Original Instructions Versa-Matic 3" Elima-Matic Bolted Aluminum - ATEX VERSA-MATIC® • Warren Rupp, Inc. • A Unit of IDEX Corporation 800 North Main Street, Mansfield, OH 44902 USA • Phone: (419) 526-7296 • www.versamatic.com © Copyright 2014 Warren Rupp, Inc. All rights reserved Safety Information IMPORTANT WARNING When used for toxic or aggressive fluids, the pump should always be flushed clean prior to disassembly. 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. 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. Airborne particles and loud noise hazards. Wear eye and ear protection. CAUTION 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. 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. 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. 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. 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. WARNING Pump not designed, tested or certified to be powered by compressed natural gas. Powering the pump with natural gas will void the warranty. Use safe practices when lifting kg Grounding the Pump To be fully groundable, the pumps must be ATEX Compliant. Refer to the nomenclature page for ordering information. Optional 8 foot long (244 centimeters) Ground Strap is available for easy ground connection. To reduce the risk of static electrical sparking, this pump must be grounded. Check the local electrical code for detailed grounding instruction and the type of equipment required. Refer to nomenclature page for ordering information. WARNING Take action to prevent static sparking. Fire or explosion can result, especially when handling flammable liquids. The pump, piping, valves, containers or other miscellaneous equipment must be grounded. www . versamatic . com e3mdlCsmATEXAB-rev0514 SECTION 2: INSTALLATION & OPERATION.......6 • Principle of Pump Operation • Typical Installation Guide • Troubleshooting SECTION 3: EXPLODED VIEW............................9 • Composite Drawings • Parts List • Materials Code 4: WARRANTY 3: EXP VIEW SECTION 4: WARRANTY & CERTIFICATES.....13 • Warranty • CE Declaration of Conformity - Directive 2006/42/EC Machinery • CE Declaration of Conformity- Directive 94/9/EC (ATEX) 2: INSTAL & OP SECTION 1: PUMP SPECIFICATIONS.................1 • Nomenclature • Performance • Materials • Dimensional Drawings 1: PUMP SPECS Table of Contents e3mdlCsmATEXAB-rev0514 www . versamatic . com Explanation of Pump Nomenclature Your Serial #: (fill in from pump nameplate)______________________________________ Your Model #: 1: PUMP SPECS (fill in from pump nameplate) __ __________________ ______ Model #: Options (if applicable) Design Level Construction Design Valve Seat Material/Valve Seat O-Ring Material Valve Ball Material Diaphragm Series Diaphragm Material Non-Wetted Parts Wetted Parts Pump Size Model Model Pump Size Wetted Parts Non-Wetted Parts E Elima-Matic 6 1/4" A Aluminum A Aluminum U Ultra-Matic 8 3/8" C Cast Iron S Stainless Steel V V-Series 5 1/2" S Stainless Steel P Polypropylene RE AirVantage 7 3/4" H Alloy C G Groundable Acetal 1 1" P Polypropylene Z PTFE-coated Aluminum 4 1-1/4" or 1-1/2" K Kynar J Nickel-plated Aluminum 2 2" G Groundable Acetal C Cast Iron 3 3" B Aluminum (screen mount) Q Epoxy-Coated Aluminum Diaphragm Material 1 Neoprene 2 Nitrile (Nitrile) 3 FKM (Fluorocarbon) 4 EPDM 5 PTFE 6 Santoprene XL 7 Hytrel 9 Geolast Y FDA Santoprene Diaphragm Series Valve Ball Material Valve Seat/Valve Seat O-Ring Material Construction Design Miscellaneous Options R Rugged 1 Neoprene 1 Neoprene 9 Bolted B BSP Tapered Thread D Dome 2 Nitrile 2 Nitrile 0 Clamped CP Center Port X Thermo-Matic 3 (FKM) Fluorocarbon 3 (FKM) Fluorocarbon ATEX ATEX Compliant T Tef-Matic (2-piece) 4 EPDM 4 EPDM Design Level FP Food Processing B Versa-Tuff (1-piece) 5 PTFE 5 PTFE ASP Sanitary Pump F FUSION (one-piece 6 Santoprene XL 6 Santoprene XL CHP High Pressure integrated plate) 7 Hytrel 7 Hytrel OE Original Elima-Matic 8 Polyurethane 8 Polyurethane F Flap Valve 9 Geolast 9 Geolast HD Horizontal Discharge A Acetal A Aluminum w/ PTFE O-Rings 3A 3-A Certified S Stainless Steel S Stainless Steel w/ PTFE O-Rings UL UL Listed Y FDA Santoprene C Carbon Steel w/ PTFE O-Rings OB Oil Bottle H Alloy C w/ PTFE O-Rings T PTFE Encapsulated Silicone O-Rings Y FDA Santoprene *More than one option may be specified for a particular pump model. 1 • Model E3 Bolted Aluminum www . versamatic . com e3mdlCsmATEXAB-rev0514 Material Profile: Operating Temperatures: CAUTION! Operating temperature limitations are as follows: Max. Min. Conductive Acetal: Tough, impact resistant, ductile. Good abrasion resistance and low friction surface. Generally inert, with good chemical resistance except for strong acids and oxidizing agents. 190°F 88°C -20°F -29°C EPDM: Shows very good water and chemical resistance. Has poor resistance to oils and solvents, but is fair in ketones and alcohols. 280°F 138°C -40°F -40°C FKM: (Fluorocarbon) Shows good resistance to a wide range of oils and sovents; especially all aliphatic, aromatic and halogenated hydrocarbons, acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM. 350°F 177°C -40°F -40°C Hytrel®: Good on acids, bases, amines and glycols at room temperatures only. 220°F 104°C -20°F -29°C Neoprene: All purpose. Resistance to vegetable oils. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, esters and nitro hydrocarbons and chlorinated aromatic hydrocarbons. 200°F 93°C -10°F -23°C Nitrile: General 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 hydrocarbons and nitro hydrocarbons. 190°F 88°C -10°F -23°C Nylon: 6/6 High strength and toughness over a wide temperature range. Moderate to good resistance to fuels, oils and chemicals. 180°F 82°C 32°F 0°C Polypropylene: A thermoplastic polymer. Moderate tensile and flex strength. Resists stong acids and alkali. Attacked by chlorine, fuming nitric acid and other strong oxidizing agents. 180°F 82°C 32°F 0°C PVDF: (Polyvinylidene Fluoride) A durable fluoroplastic with excellent chemical resistance. Excellent for UV applications. High tensile strength and impact resistance. 250°F 121°C 0°F -18°C Santoprene®: Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex life. Excellent abrasion resistance. 275°F 135°C -40°F -40°C UHMW PE: A thermoplastic that is highly resistant to a broad range of chemicals. Exhibits outstanding abrasion and impact resistance, along with environmental stress-cracking resistance. 180°F 82°C -35°F -37°C Urethane: Shows good resistance to abrasives. Has poor resistance to most solvents and oils. 150°F 66°C 32°F 0°C Virgin PTFE: (PFA/TFE) Chemically inert, virtually impervious. Very few chemicals are known to chemically react with PTFE; molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 220°F 104°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. Metals: Alloy C: Equal to ASTM494 CW-12M-1 specification for nickel and nickel alloy. Stainless Steel: Equal to or exceeding ASTM specification A743 CF-8M for corrosion resistant iron chromium, iron chromium nickel and nickel based alloy castings for general applicaitons. Commonly referred to as 316 Stainless Steel in the pump industry. For specific applications, always consult the Chemical Resistance Chart. AFTERMARKET PARTS RIGHT PART, RIGHT NOW Pumper Parts is your single source for parts that fit Air-Operated Double Diaphragm (AODD) pumps • Wilden® • ARO® • Yamada® Designed to perform equal to or greater than original equipment manufacture. Phone: (419) 526-7296 info@pumperparts.com www.pumperparts.com Pumper Parts and its products are not affiliated with any of the original equipment manufacturers referenced herein. All original equipment manufacturers’ names, colors, pictures, descriptions and part numbers are used for identification ® ® purposes only. Pumper Parts is a registered trade name of IDEX Corporation. All other trademarks, registered trademarks and product names are the property of their respective owners. Yamada is a registered trademark of Yamada Corporation. ARO® is a registered trade name of Ingersoll-Rand Company. Wilden® is a registered trade name of Wilden Pump and Engineering Company, a Dover Resources Company. e3mdlCsmATEXAB-rev0514 www . versamatic . com Model E3 Bolted Aluminum • 2 1: PUMP SPECS Materials Performance E3 3" Bolted Aluminum Rubber and TPE Fitted - Domed Flow Rate Adjustable to . . . . . . . . 0-252 gpm (954 lpm) Port Size Suction . . . . 3" ANSI 150 lbs. Class (DIN80) Discharge . . . . . . . . . 3" ANSI 150 lbs. Class Air Inlet . . . . . . . . . . . . . . . . . . . . . 1/2" NPT Air Exhaust . . . . . . . . . . . . . . . . . . . 1" NPT Suction Lift Dry . . . . . . . . . . . . . . . . . . . . . . . . 17' (5.2 m) Wet . . . . . . . . . . . . . . . . . . . . . . . 32' (9.8 m) Max Solid Size (Diameter) . . . . . . . . . . . . . . . . . . . . . . . . 3/8" (9.5 mm) Max Noise Level . . . . . . . . . . . . 94 dB(A) Shipping Weights Aluminum . . . . . . . . . . . . . 146 lbs. (66.2 kg) E3 3" Bolted Aluminum PTFE Fitted Flow Rate Adjustable to . . . . . . . . 0-186 gpm (704 lpm) Port Size Suction . . . . 3" ANSI 150 lbs. Class (DIN80) Discharge . . . . . . . . . 3" ANSI 150 lbs. Class Air Inlet . . . . . . . . . . . . . . . . . . . . . 1/2" NPT Air Exhaust . . . . . . . . . . . . . . . . . . . 1" NPT Suction Lift Dry . . . . . . . . . . . . . . . . . . . . . . . . 13' (5.2 m) Wet . . . . . . . . . . . . . . . . . . . . . . . 31' (9.8 m) Max Solid Size (Diameter) . . . . . . . . . . . . . . . . . . . . . . . . 3/8" (9.5 mm) Max Noise Level . . . . . . . . . . . . 92 dB(A) Shipping Weights Aluminum . . . . . . . . . . . . . 146 lbs. (66.2 kg) 3 • Model E3 Bolted Aluminum 80 70 280 240 9 8 7 60 200 6 50 160 5 40 30 20 10 0 Meters 120 80 40 4 3 140 Displacement Per Stroke, 1.45 Gal. (5.5 L) 20 40 120 60 80 100 AIR CONSUMPTION IN SCFM AIR PRESSURE IN PSI 120 2 SCFM M3/HR 20 34 40 68 60 102 80 136 100 170 120 204 140 238 160 272 180 306 140 100 Discharge Head in PSI 90 10 160 180 80 60 40 20 1 0 0 Feet BAR 0 0 20 0 40 60 120 80 240 100 120 140 160 180 200 220 240 Capacity in U.S. Gallons Per Minute 360 480 600 720 Capacity in Liters Per Minute 840 260 280 960 NOTE: Performance based on the following: PTFE 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%. 320 90 80 70 280 240 10 9 8 7 60 200 6 50 160 5 40 30 20 10 0 Meters 120 80 40 4 3 140 Capacity Per Stroke, 1.26 Gal. (4.8 L) 20 40 120 60 80 100 AIR CONSUMPTION IN SCFM AIR PRESSURE IN PSI 120 140 100 Discharge Head in PSI Flow Rate Adjustable to . . . . . . 0-273 gpm (1,033 lpm) Port Size Suction . . . . 3" ANSI 150 lbs. Class (DIN80) Discharge . . . . . . . . . 3" ANSI 150 lbs. Class Air Inlet . . . . . . . . . . . . . . . . . . . . . 1/2" NPT Air Exhaust . . . . . . . . . . . . . . . . . . . 1" NPT Suction Lift Dry . . . . . . . . . . . . . . . . . . . . . . . . 16' (4.9 m) Wet . . . . . . . . . . . . . . . . . . . . . . . 31' (9.4 m) Max Solid Size (Diameter) . . . . . . . . . . . . . . . . . . . . . . . . 3/8" (9.5 mm) Max Noise Level . . . . . . . . . . . . 93 dB(A) Shipping Weights Aluminum . . . . . . . . . . . . . 146 lbs. (66.2 kg) 320 2 SCFM M3/HR 20 34 40 68 60 102 80 136 100 170 120 204 140 238 160 272 180 306 160 180 80 60 40 20 1 0 0 Feet BAR 0 0 20 40 60 120 0 240 80 100 120 140 160 180 200 Capacity in U.S. Gallons Per Minute 360 480 600 Capacity in Liters Per Minute 720 220 240 840 260 960 NOTE: Performance based on the following: PTFE 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%. 320 90 80 70 280 240 10 9 8 7 60 200 6 50 160 5 40 30 20 10 0 Meters 120 80 40 4 3 2 1 0 0 Feet BAR 140 120 Capacity Per Stroke, 0.91 Gal. (3.4 L) 20 40 60 80 100 AIR CONSUMPTION IN SCFM AIR PRESSURE IN PSI 120 140 100 Discharge Head in PSI 1: PUMP SPECS E3 3" Bolted Aluminum Rubber and TPE Fitted - Rugged 160 SCFM M3/HR 20 34 40 68 60 102 80 136 100 170 120 204 140 238 160 272 180 306 180 80 60 40 20 0 0 0 20 90 40 60 80 100 120 140 Capacity in U.S. Gallons Per Minute 180 270 360 450 Capacity in Liters Per Minute 160 540 180 630 200 720 NOTE: Performance based on the following: PTFE 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%. www . versamatic . com e3mdlCsmATEXAB-rev0514 Dimensional Drawings E3 Aluminum Bolted - ANSI Flange Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). 25.12 638.05 3" 150# ANSI / DIN DISCHARGE FLANGE 1: PUMP SPECS 16.11 409.23 7.00 177.80 1/2" NPT AIR INLET R.3 7.6 32.38 822.33 36.31 922.34 11.00 279.40 25.20 640.18 15.17 385.32 1" NPT AIR EXHAUST 0 80 4.38 111.13 3" 150# ANSI / DIN SUCTION FLANGE .44 11.18 14.00 355.60 R.30 7.62 36.31 922.34 10.00 254.00 11.00 279.40 2.00 50.80 16.00 406.40 BOTTOM VIEW .44 11.18 e3mdlCsmATEXAB-rev0514 www . versamatic . com Model E3 Bolted Aluminum • 4 E3 Aluminum Bolted - NPT / BSP Dimensionally Interchangeable with Versa-Matic and Wilden Clamped Pumps Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). 6 1: PUMP SPECS 12 .05 Dimensional Drawings 7 4 6 5 3 2 16.08 408.43 25.12 638.05 3" NPT/BSP TAPERED DISCHARGE PORT PT LET 4 3 5 16 408 3.30 83.82 3.30 83.82 1/2" NPT AIR INLET 32.10 815.34 29.90 759.46 29.90 759.46 22.13 562.08 " NPT 12.10 IR EXHAUST307.21 22.13 562.08 1" NPT AIR EXHAUST 2.40 60.96 3" NPT/BSP TAPERED SUCTION PORT 12.04 05.69 .51 12.95 .51 12.95 3" NPT/BSP TAPERED SUCTION PORT 3.30 83.82 3.30 83.82 12.04 305.69 11.10 281.94 10.00 254 14.39 365.54 10.00 254 14.39 365.54 WA MADE FROM PART NUMBER E3AAxxxx9C-DV-ATEX PART NUMBER UNLESS OTHERWISE SPECIFIED E3AAxxxx9C-DV-ATEX N/A TOLERANCES MATERIALTHIS IS A PROP MATERIAL N/A LY. ONATHIS CERTIFIED DRAWING ARE FOR REFERENCE ONLY. A CERTIFIED EQUESTED EDED. IF PHYSICAL DIMENSIONS ARE NEEDED. 6 7 A INITIAL RELEASE REV REVISION 5 • Model E3 Bolted Aluminum 6 VOLUME: A JLL REV CHG 6/11/13 DATE INITIAL RELEASE 3300 APP DATE REVISIONECN PUMP REFERENCE 3 in JLL www . versamatic . com lbs PROJECT 6/11/13 DATE N/A .010 .005 ANGULAR 1/2 DESCRIPTIO E3 VM 63 EST WT: CHG .XX .XXX APP SURFACE FINSHVOLUME: DRAWING NU E3A PUMP REFERENCE 3300 DO NOT SCALE DRAWING DIMENSIONS DATE ECNARE INCHES e3mdlCsmATEXAB-rev0514 Principle of Pump Operation Air-Operated Double Diaphragm (AODD) pumps are powered by compressed air or nitrogen. The main directional (air) control valve ① distributes compressed air to an air chamber, exerting uniform pressure over the inner surface of the diaphragm ②. At the same time, the exhausting air ③ from behind the opposite diaphragm is directed through the air valve assembly(s) to an exhaust port ④. The pump primes as a result of the suction stroke. The suction stroke lowers the chamber pressure (P3) increasing the chamber volume. This results in a pressure differential necessary for atmospheric pressure (P4) to push the fluid through the suction piping and across the suction side check valve and into the outer fluid chamber ⑦. PUMP INSTALLATION AREA SAFE AIR Suction (side) stroking also initiates the reciprocating EXHAUST (shifting, stroking or cycling) action of the pump.DISPOSAL The suction AREA its diaphragm’s movement is mechanically pulled through stroke. 1" DIAMETER AIR The diaphragm’s inner plate makes contact with an EXHAUST PIPING actuator plunger aligned to shift the pilot signaling valve. Once actuated, the pilot valve sends a pressureMUFFLER signal to the opposite end of the main directional air valve, redirecting the compressed air to the opposite inner chamber. SUBMERGED ILLUSTRATION MUFFLER LIQUID LEVEL 1" DIAMETER AIR EXHAUST PIPING SUCTION LINE 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. When the MUFFLER 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. LIQUID LEVEL 1" DIAMETER AIR EXHAUST PIPING SUCTION LINE e3mdlCsmATEXAB-rev0514 www . versamatic . com Model E3 Bolted Aluminum • 6 2: INSTAL & OP As inner chamber pressure (P1) exceeds liquid chamber pressure (P2), the rod ⑤ connected diaphragms shift together creating discharge on one side and suction on the opposite side. The discharged and primed liquid’s directions are controlled by the check valves (ball or flap)⑥ orientation. Recommended Installation Guide Available Accessories: 1. Surge Suppressor 2. Filter/Regulator 3. Air Dryer Unregulated Air Supply to Surge Suppressor 1 Surge Suppressor Pressure Gauge Shut-Off Valve Note: Surge Suppressor and Piping must be supported after the flexible connection. Pipe Connection (Style Optional) Flexible Connector Discharge 2: INSTAL & OP Check Valve Muffler (Optional Piped Exhaust) Shut-Off Valve Drain Port 2 Flexible Connector Vacuum Gauge Air Inlet 3 Filter Regulator P/N: 020.V107.000 Air Dryer Suction CAUTION Shut-Off Valve The air exhaust should be p iped to an area for safe d isposition of the product b eing pumped, in the event of a diaphragm failure. Drain Port Installation And Start-Up Locate the pump as close to the product being pumped as possible. Keep the suction line length and number of fittings to a minimum. Do not reduce the suction line diameter. Air Supply Connect the pump air inlet to an air supply with sufficient capacity and pressure to achieve desired performance. A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended limits. Air Valve Lubrication The air distribution system is designed to operate WITHOUT lubrication. This is the standard mode of operation. If lubrication is desired, install an air line lubricator set to deliver one drop of SAE 10 non-detergent oil for every 20 SCFM (9.4 liters/sec.) of air the pump consumes. Consult the Performance Curve to determine air consumption. Air Line Moisture Water in the compressed air supply may cause 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. Air Inlet And Priming To start the pump, slightly open the air shut-off valve. After the pump primes, the air valve can be opened to increase air flow as desired. If opening the valve increases cycling rate, but does not increase the rate of flow, cavitation has occurred. The valve should be closed slightly to obtain the most efficient air flow to pump flow ratio. 7 • Model E3 Bolted Aluminum www . versamatic . com e3mdlCsmATEXAB-rev0514 Troubleshooting Guide Pump Cycles Once Pump Will Not Operate / Cycle Pump Cycles and Will Not Prime or No Flow Potential Cause(s): Deadhead (system pressure meets or exceeds air supply pressure). Air valve or intermediate gaskets installed incorrectly. Bent or missing actuator plunger. Pump is over lubricated. Lack of air (line size, PSI, CFM). Check air distribution system. Discharge line is blocked or clogged manifolds. Deadhead (system pressure meets or exceeds air supply pressure). Blocked air exhaust muffler. Pumped fluid in air exhaust muffler. Pump chamber is blocked. Cavitation on suction side. Check valve obstructed. Valve ball(s) not seating properly or sticking. Product Leaking Through Exhaust Valve ball(s) missing (pushed into chamber or manifold). Valve ball(s)/seat(s) damaged or attacked by product. Check valve and/or seat is worn or needs adjusting. Suction line is blocked. Excessive suction lift. Suction side air leakage or air in product. Pumped fluid in air exhaust muffler. Over lubrication. Icing. Clogged manifolds. Deadhead (system pressure meets or exceeds air supply pressure). Cavitation on suction side. Lack of air (line size, PSI, CFM). Excessive suction lift. Air supply pressure or volume exceeds system hd. Undersized suction line. Restrictive or undersized air line. Suction side air leakage or air in product. Suction line is blocked. Pumped fluid in air exhaust muffler. Check valve obstructed. Check valve and/or seat is worn or needs adjusting. Entrained air or vapor lock in chamber(s). Diaphragm failure, or diaphragm plates loose. Diaphragm stretched around center hole or bolt holes. Premature Diaphragm Failure Cavitation. Excessive flooded suction pressure. Pump Cycles Running Sluggish/Stalling, Flow Unsatisfactory Misapplication (chemical/physical incompatibility). Unbalanced Cycling Incorrect diaphragm plates or plates on backwards, installed incorrectly or worn. Excessive suction lift. Undersized suction line. Pumped fluid in air exhaust muffler. Suction side air leakage or air in product. Check valve obstructed. Check valve and/or seat is worn or needs adjusting. Entrained air or vapor lock in chamber(s). Recommendation(s): Increase the inlet air pressure to the pump. Pump is designed for 1:1 pressure ratio at zero flow. (Does not apply to high pressure 2:1 units). Install gaskets with holes properly aligned. Remove pilot valve and inspect actuator plungers. Set lubricator on lowest possible setting or remove. Units are designed for lube free operation. Check the air line size and length, compressor capacity (HP vs. cfm required). Disassemble and inspect main air distribution valve, pilot valve and pilot valve actuators. Check for inadvertently closed discharge line valves. Clean discharge manifolds/piping. Increase the inlet air pressure to the pump. Pump is designed for 1:1 pressure ratio at zero flow. (Does not apply to high pressure 2:1 units). Remove muffler screen, clean or de-ice, and re-install. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly. Disassemble and inspect wetted chambers. Remove or flush any obstructions. Check suction condition (move pump closer to product). Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket. Clean out around valve ball cage and valve seat area. Replace valve ball or valve seat if damaged. Use heavier valve ball material. Worn valve ball or valve seat. Worn fingers in valve ball cage (replace part). Check Chemical Resistance Guide for compatibility. Check Chemical Resistance Guide for compatibility. Inspect check valves and seats for wear and proper setting. Replace if necessary. Remove or flush obstruction. Check and clear all suction screens or strainers. For lifts exceeding 20’ of liquid, filling the chambers with liquid will prime the pump in most cases. Visually inspect all suction-side gaskets and pipe connections. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly. Set lubricator on lowest possible setting or remove. Units are designed for lube free operation. Remove muffler screen, de-ice, and re-install. Install a point of use air drier. Clean manifolds to allow proper air flow Increase the inlet air pressure to the pump. Pump is designed for 1:1 pressure ratio at zero flow. (Does not apply to high pressure 2:1 units). Check suction (move pump closer to product). Check the air line size, length, compressor capacity. For lifts exceeding 20’ of liquid, filling the chambers with liquid will prime the pump in most cases. Decrease inlet air (press. and vol.) to the pump. Pump is cavitating the fluid by fast cycling. Meet or exceed pump connections. Install a larger air line and connection. Visually inspect all suction-side gaskets and pipe connections. Remove or flush obstruction. Check and clear all suction screens or strainers. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly. Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket. Inspect check valves and seats for wear and proper setting. Replace if necessary. Purge chambers through tapped chamber vent plugs. Purging the chambers of air can be dangerous. Replace diaphragms, check for damage and ensure diaphragm plates are tight. Check for excessive inlet pressure or air pressure. Consult Chemical Resistance Chart for compatibility with products, cleaners, temperature limitations and lubrication. Enlarge pipe diameter on suction side of pump. Move pump closer to product. Raise pump/place pump on top of tank to reduce inlet pressure. Install Back pressure device (Tech bulletin 41r). Add accumulation tank or pulsation dampener. Consult Chemical Resistance Chart for compatibility with products, cleaners, temperature limitations and lubrication. Check Operating Manual to check for correct part and installation. Ensure outer plates have not been worn to a sharp edge. For lifts exceeding 20’ of liquid, filling the chambers with liquid will prime the pump in most cases. Meet or exceed pump connections. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly. Visually inspect all suction-side gaskets and pipe connections. Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket. Inspect check valves and seats for wear and proper setting. Replace if necessary. Purge chambers through tapped chamber vent plugs. For additional troubleshooting tips contact After Sales Support at [email protected] or 419-524-8388 e3mdlCsmATEXAB-rev0514 www . versamatic . com Model E3 Bolted Aluminum • 8 2: INSTAL & OP Symptom: Composite Repair Parts Drawing - Elastomeric and TPE Fitted 43 25 31 38 30 36 42 26 39 24 44 11 2 27 8 42 3 37 36 7 5 41 6 9 4 11 DOME DIAPHRAGM ASSEMBLY DROP IN MANIFOLDS 10 13 25 31 26 30 38 36 22 21 24 25 39 27 8 41 DOME DIAPHRAGM ASSEMBLY 6 4 36 32 25 33 37 42 42 14 27 21 27 18 13 41 36 12 16 37 37 23 42 36 30 24 42 36 29 24 28 36 41 34 42 41 35 42 37 42 37 23 40 40 37 37 42 9 • Model E3 Bolted Aluminum 36 4 10 36 37 42 9 22 21 30 28 7 6 14 29 42 10 40 31 31 36 5 19 20 16 25 37 8 11 17 12 18 26 3: EXP VIEW 15 19 20 22 3 11 36 17 23 36 28 13 15 9 24 DROP IN MANIFOLDS 35 2 30 42 11 41 7 29 DROP IN MANIFOLDS 34 37 5 31 3 37 39 11 2 42 42 18 44 26 36 16 14 32 4427 19 20 42 12 38 17 43 33 37 36 15 43 www . versamatic . com e3mdlCsmATEXAB-rev0514 Composite Repair Parts List - Elastomeric and TPE Fitted Qty. 1 1 1 1 6 1 6 1 2 2 13 Item # 12 13 14 15 16 17 18 19 20 21 22 23 Qty. 1 2 2 2 2 8 1 6 1 1 8 1 Item # Qty. Description 24 25 26 27 28 29 30 31 32 33 1 2 2 2 12 12 2 2 4 4 Main Shaft Diaphragm (See Below Material Chart) Outer Diaphragm Plate Inner Diaphragm Plate Bolt Washer Bumper Washer Back-Up Washer Valve Seat (See Below Material Chart) Valve Ball (See Below Material Chart) Item # 34 35 36 37 38 39 40 41 42 Qty. 2 20 52 52 2 2 2 4 32 1 1 1 1 Description Water Chamber Water Chamber Bolt Nut Washer Manifold Tee Discharge Elbow Suction Elbow O-Ring Elbow Bolt Discharge Drop in Manifold Discharge Drop in Manifold (BSP) Suction Drop in Manifold Suction Drop in Manifold (BSP) 43 44 Description Valve Body (includes items 2-11) Valve Body Valve Body Gasket Valve Sleeve O-ring Valve Spool Assembly (Includes items 7) Glyde Ring Assembly Air Valve Screen End Cap Gasket End Cap Mounting Screws (8 included on item 1) Air Valve Assembly Center Section Assembly Description Center Block Assembly (Includes item 13&14) Bearing Sleeve Main Shaft O-Ring Air Chamber Air Chamber Gasket Bolt Pilot Sleeve Assembly (include item 19) O-ring Retaining Ring Pilot Spool Assembly (Includes item 22) O-ring Muffler Diaphragm Assembly / Elastomers Material Neoprene Nitrile FKM EPDM PTFE Santoprene Hytrel Geolast e3mdlCsmATEXAB-rev0514 Versa-Rugged Part Number 031.V003.156 095.V001.156 P24-202 755.V005.148 560.206.360 775.V001.000 P34-204F P24-210 P24-205 P34-300 S1001 Part Number P34-400DC ASY P34-404 P34-403 196.V008.157 P79-109 P24-110 755.V002.000 560.101.358 675.037.080 775.V006.000 560.023.358 530.033.000 Part Number V305xx V302BDC V302CDC V302G V302GA Wet End Assembly V306xx VB307 V307B N/A N/A P34-501 V302E V456xx V455xx Part Number V350FB V387A V387C V387B V358FB V351E-FB V352E-FB V258xx V387D 518.V002.156 518.V002.156 E 518.V003.156 518.V003.156 E Elastomer Material Specifications Versa-Dome Versa-Rugged Diaphragm P/N "Ball P/N" Diaphragm P/N V305N V306N V455N V305BN V306BN V455BN V305VT V306VT V455VT V305ND V306ND V455ND N/A N/A V455TF V305TPEXL N/A V455TPEXL V305TPEFG N/A V455TPEFG V305G N/A N/A www . versamatic . com Versa-Dome P34-103 3: EXP VIEW Item # 1 2 3 4 5 6 7 8 9 10 11 Seat P/N V456N V456BN V456VT V456ND V456TF V456TPEXL V456TPEFG N/A "Manifold Tee O-ring P/N" N/A V258BN V258VT V258ND V258TFS V258XL N/A N/A Model E3 Bolted Aluminum • 10 Composite Repair Parts Drawing - PTFE Fitted 29 42 30 37 41 24 36 38 28 36 40 27 E3 BONDED DIAPHRAGM ASSEMBLY 8 11 43 25 41 5 2 36 7 6 41 3 29 DROP IN MANIFOLDS 30 42 42 37 32 25 43 E3 BONDED DIAPHRAGM ASSEMBLY 11 26 36 25 40 27 36 21 282 5 23 6 9 12 3233 17 34 19 27 3: EXP VIEW 20 25 26 31 25 28 36 21 26 13 21 22 28 12 16 40 41 23 41 18 36 36 29 18 30 13 39 23 29 10 41 14 27 35 11 22 14 36 4 19 20 9 10 35 17 16 41 6 11 15 15 3 7 24 4 30 DROP IN MANIFOLDS 41 5 29 3 8 2 736 18 27 41 DROP IN MANIFOLDS 13 11 40 41 41 36 16 19 8 22 14 36 36 17 20 43 27 31 38 38 10 12 15 41 41 28 4 37 35 24 30 35 24 35 40 35 41 40 33 34 41 39 39 34 36 36 11 • Model E3 Bolted Aluminum www . versamatic . com e3mdlCsmATEXAB-rev0514 Composite Repair Parts List - PTFE Fitted Qty. 1 1 1 1 6 1 6 1 2 2 13 Description Valve Body (includes items 2-11) Valve Body Valve Body Gasket Valve Sleeve O-ring Valve Spool Assembly (Includes items 7) Glyde Ring Assembly Air Valve Screen End Cap Gasket End Cap Mounting Screws (8 included on item 1) Item # 12 13 14 15 16 17 18 19 20 21 22 23 Qty. 1 2 2 2 2 8 1 6 1 1 8 1 Item # Qty. Description 24 25 26 27 28 29 30 31 32 1 2 2 2 2 2 2 4 4 Main Shaft Diaphragm Back-Up Diaphragm Outer Diaphragm Plate Inner Diaphragm Plate Bumper Washer Back-Up Washer Valve Seat (See Below Material Chart) Valve Ball Item # 33 34 35 36 37 38 39 40 41 Qty. 2 20 52 52 2 2 2 4 32 42 1 43 1 Description Water Chamber Water Chamber Bolt Nut Washer Manifold Tee Discharge Elbow Suction Elbow Manifold Seal Elbow Bolt Discharge Drop in Manifold Discharge Drop in Manifold (BSP) Suction Drop in Manifold Suction Drop in Manifold (BSP) Air Valve Assembly Center Section Assembly Description Center Block Assembly (Includes item 13 & 14) Bearing Sleeve Main Shaft O-Ring Air Chamber Air Chamber Gasket Bolt Pilot Sleeve Assembly (include item 19) O-ring Retaining Ring Pilot Spool Assembly (Includes item 22) O-ring Muffler Diaphragm Assembly / Elastomers Material PTFE Stainless Steel (not pictured) Seat P/N V456TF SV456 PTFE Two Piece V305TF-FB V305TFB Wet End Assembly Elastomer Material Specifications Part Number 031.V003.156 095.V001.156 P24-202 755.V005.148 560.206.360 775.V001.000 P34-204F P24-210 P24-205 P34-300 S1001 Part Number P34-400DC ASY P34-404 P34-403 196.V008.157 P79-109 P24-110 755.V002.000 560.101.358 675.037.080 775.V002.000 560.023.358 530.033.000 Part Number P34-103 V302TO V302TI P34-501 V302E V456xx V455TF PTFE Bonded V305TX N/A 3: EXP VIEW Item # 1 2 3 4 5 6 7 8 9 10 11 Part Number V350FB V387A V387C V387B V358FB V351E-FB V352E-FB V258TFS V387D 518.V002.156 518.V002.156 E 518.V003.156 518.V003.156 E Manifold Seat O-Ring P/N N/A See Note 2 Notes: 1.) The outer diaphragm plate material is to match the water chamber material (cast iron uses SV302B or SVB307) 2.) In addition to the stainless valve setas, (8) orings are needed. (4) SV456TES-1 and (4) SV456TES-2 e3mdlCsmATEXAB-rev0514 www . versamatic . com Model E3 Bolted Aluminum • 12 Written Warranty 5 - YEAR Limited Product Warranty Quality System ISO9001 Certified • Environmental Management Systems ISO14001 Certified Versa-Matic warrants to the original end-use purchaser that no product sold by Versa-Matic that bears a Versa-Matic brand shall fail under normal use and service due to a defect in material or workmanship within five years from the date of shipment from Versa-Matic’s factory. ~ See complete warranty at http://www.versamatic.com/pdfs/VM%20Product%20Warranty.pdf ~ DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE • DECLARACION DE CONFORMIDAD • ERKLÄRUNG BEZÜGLICH EINHALTUNG DER VORSCHRIFTEN DICHIARAZIONE DI CONFORMITÀ • CONFORMITEITSVERKLARING • DEKLARATION OM ÖVERENSSTÄMMELSE EF-OVERENSSTEMMELSESERKLÆRING • VAATIMUSTENMUKAISUUSVAKUUTUS • SAMSVARSERKLÄRING DECLARAÇAO DE CONFORMIDADE MANUFACTURED BY: FABRIQUE PAR: FABRICADA POR: HERGESTELLT VON: FABBRICATO DA: VERVAARDIGD DOOR: TILLVERKAD AV: FABRIKANT: VALMISTAJA: PRODUSENT: FABRICANTE: VERSA-MATIC® Warren Rupp, Inc. A Unit of IDEX Corporation 800 North Main Street P.O. Box 1568 Mansfield, OH 44901-1568 USA Tel: 419-526-7296 Fax: 419-526-7289 PUMP MODEL SERIES: E SERIES, V SERIES, VT SERIES, VSMA3, SPA15, RE SERIES AND U2 SERIES 2006/42/EC This product complies with the following European Community Directives: Ce produit est conforme aux directives de la Communauté européenne suivantes: on Machinery, Este producto cumple con las siguientes Directrices de la Comunidad Europea: to Dieses produkt erfüllt die folgenden Vorschriften der Europäischen Gemeinschaft: Questo prodotto è conforme alle seguenti direttive CEE: Dir produkt voldoet aan de volgende EG-richtlijnen: Denna produkt överensstämmer med följande EU direktiv: Versa-Matic, Inc., erklærer herved som fabrikant, at ovennævnte produkt er i overensstemmelse med bestemmelserne i Direkktive: Tämä tuote täyttää seuraavien EC Direktiivien vaatimukstet: Dette produkt oppfyller kravene til følgende EC Direktiver: Este produto está de acordo com as seguintes Directivas comunitárias: 4: WARRANTY This product has used the following harmonized standards to verify conformance: Ce materiel est fabriqué selon les normes harmonisées suivantes, afin d’ en garantir la conformité: Este producto cumple con las siquientes directrices de la comunidad europa: Dieses produkt ist nach folgenden harmonisierten standards gefertigtworden, die übereinstimmung wird bestätigt: Questo prodotto ha utilizzato i seguenti standards per verificare la conformita´: De volgende geharmoniseerde normen werden gehanteerd om de conformiteit van dit produkt te garanderen: För denna produkt har följande harmoniserande standarder använts för att bekräfta överensstämmelse: Harmoniserede standarder, der er benyttet: Tässä tuotteessa on sovellettu seuraavia yhdenmukaistettuja standardeja: Dette produkt er produsert i overenstemmelse med fløgende harmoniserte standarder: Este produto utilizou os seguintes padrões harmonizados para varificar conformidade: EN809:1998+ A1:2009 DATE: August 10, 2011 AUTHORIZED / APPROVED BY: Approuve par: Aprobado por: Genehmigt von: approvato da: Goedgekeurd door: Underskrift: Valtuutettuna: Bemyndiget av: Autorizado Por: Dave Roseberry Engineering Manager FECHA: DATUM: DATA: DATO: PÄIVÄYS: 04/19/2012 REV 07 13 • Model E3 Bolted Aluminum according Annex VIII VMQR 044FM www . versamatic . com e3mdlCsmATEXAB-rev0514 EC DECLARATION OF CONFORMITY in accordance with ANNEX VIII of Directive 94/9/EC - Equipment for use in Potentially Explosive Atmospheres Date of Issue: 10 May 2014 Technical File No.: 203104000-1410/MER Quality System Registration No: ISO 9001-2000 Directive: 94/9/EC 23 March 1994 Annex VIII Conforming Apparatus: Air-Operated Metal Double Diaphragm Pumps for Use In Potentially Explosive Atmospheres Hazardous Location Applied: 1. II 3/2GD c T5* T5 fluids up to 95° C * When pumping non-conductive fluids the internal surfaces that contact the fluid are restricted to Ex II 3GD c T5. The external surfaces of the pump are still Ex II 2GD c T5. 2. I M2 c fluids up to 95° C Pumps marked with equipment Category II 3/2 G (internal 3 G / external 2 G), 2D, when used with non-conductive fluids. The pumps are Category II 2 G when used for conductive fluids. Manufacture: Warren Rupp, Inc., A Unit of IDEX Corporation 800 North Main Street, P.O. Box 1568 Mansfield, OH 44901-1568 USA. On File With: DEKRA Certification B.V. (0344) Meander 1051 6825 MJ Arnhem The Netherlands Harmonized Standards Applied: EN 13463-1:2009 Non-Electrical Equipment Potentially Explosive Atmospheres-Part 1 Basic Methods and Requirements EN 13463-5:2011 Non-Electrical Equipment for Potentially Explosive Atmospheres-Part 5 Protection by Constructional Safety Equipments: 1. Elima-Matic Series metal pumps for II 3/2GD c T5 2. Elima-Matic Series Cast Iron or Stainless Steel pumps with Stainless Steel air center sections for I M2 c We hereby certify that the equipment described above conforms with the protection requirements of Council Directive 94/9/EC of 23 March 1994 Annex VIII on the approximation of the laws of the Member States Concerning Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres DATE/OF REVISION/TITLE: 29 May 2014 Dave Roseberry Engineering Manager VM_DofC_ATEX_Metallic_V_rev0514
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