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
1: P
UmP
SPEC
S2:
INST
AL &
oP
3: E
XP V
IEW
4: A
IR E
ND5:
WET
END
6: W
ARRA
NTY
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
1: P
UMP
SPEC
S2:
INST
AL &
OP
3: E
XP V
IEW
4: A
IR E
ND5:
WET
END
6: W
ARRA
NTY
4 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
1: P
UMP
SPEC
S
Model 1120-030S Metallic • 5bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
MODEL SPECIFIC
1: P
UMP
SPEC
S
6 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
1" DIAMETER AIREXHAUST PIPING
1" DIAMETER AIREXHAUST PIPING
MUFFLER
LIQUIDLEVEL
SUCTIONLINE
LIQUIDLEVEL
SUCTIONLINE
MUFFLER
MUFFLER
SUBMERGED ILLUSTRATION
Pumpcanbesubmergedifthepumpmaterialsofconstructionarecompatiblewiththeliquidbeingpumped.Theairexhaustmustbepipedabovetheliquidlevel.Whenthepumpedproductsourceisatahigherlevelthanthepump(floodedsuctioncondition),pipetheexhausthigherthantheproductsourcetopreventsiphoningspills.
UNIVERSAL ALL AODD
2: IN
STAL
& O
P
Model 1120-030S Metallic • 7bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
2: IN
STAL
& O
P
8 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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).
Increasetheinletairpressuretothepump.Pumpisdesignedfor1:1pressureratioatzeroflow. (Doesnotapplytohighpressure2:1units).
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
2: IN
STAL
& O
P
Model 1120-030S Metallic • 9bc1120-030Smdl1sm-rev0412
www.balcrank.com
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).
Increasetheinletairpressuretothepump.Pumpisdesignedfor1:1pressureratioatzeroflow. (Doesnotapplytohighpressure2:1units).
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
MODEL SPECIFIC
3: E
XP V
IEW
10 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
MODEL SPECIFIC
3: E
XP V
IEW
Model 1120-030S Metallic • 11bc1120-030Smdl1sm-rev0412
www.balcrank.com
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.
MODEL SPECIFIC
4: A
IR E
ND
12 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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.
MODEL SPECIFIC
4: A
IR E
ND
Model 1120-030S Metallic • 13bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
MODEL SPECIFIC
4: A
IR E
ND
14 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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.
MODEL SPECIFIC
5: W
ET E
ND
Model 1120-030S Metallic • 15bc1120-030Smdl1sm-rev0412
www.balcrank.com
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.
5: W
ET E
ND
16 • Model 1120-030S Metallic bc1120-030Smdl1sm-rev0412
www.balcrank.com
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
6: W
ARRA
NTY