VERSAMATIC E3 (01) PDF MANUAL

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 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.

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.

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

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

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.

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

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.

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.

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

Use safe practices when lifting.

Pump not designed, tested or certified to be powered by compressed natural gas. Powering the pump with natural gas will void the warranty.

The use of non-OEM replacement parts will void (or negate) agency certifications, including CE, ATEX, CSA, 3A and EC1935 compliance (Food Contact Materials). Warren Rupp, Inc. cannot ensure nor warrant non-OEM parts to meet the stringent requirements of the certifying agencies.

1. Ambient temperature range is as specified in the material profile tables.

2. ATEX compliant pumps are suitable for use in explosive atmospheres when the equipment is properly grounded in accordance with local electrical codes.

3. Conductive Polypropylene, conductive Acetal or conductive PVDF pumps are not to be installed in applications where the pumps may be subjected to oil, greases and hydraulic liquids.

4. When operating pumps equipped with non-conductive diaphragms that exceed the maximum permissible projected area, as defined in EN ISO 80079-36: 2016 section 6.7.5 table 8, the following protection methods must be applied:

– Equipment is always used to transfer electrically conductive fluids or

– Explosive environment is prevented from entering the internal portions of the pump, i.e. dry running.

The pump model number is a code that specifies the pump’s configuration. It is read from left to right.

Model Number Structure:

Model – Pump Size – Wetted Parts – Non-Wetted Parts – Diaphragm Material – Diaphragm Series – Valve Ball Material – Valve Seat Material/Valve Seat O-Ring Material – Construction Design – Design Level – Options (if applicable)

Model Codes:

E: Elima-Matic

U: Ultra-Matic

V: V-Series

Pump Size Codes:

6: 1/4″

8: 3/8″

5: 1/2″

7: 3/4″

1: 1″

4: 1-1/4″ or 1-1/2″

2: 2″

3: 3″

Wetted Parts Codes:

A: Aluminum

C: Cast Iron

S: Stainless Steel

H: Alloy C

P: Polypropylene

K: Kynar

G: Groundable Acetal

B: Aluminum (screen mount)

Non-Wetted Parts Codes:

A: Aluminum

S: Stainless Steel

P: Polypropylene

G: Groundable Acetal

Z: PTFE-coated Aluminum

J: Nickel-plated Aluminum

C: Cast Iron

Q: Epoxy-Coated Aluminum

Diaphragm Material Codes:

1: Neoprene

2: Nitrile (Nitrile)

3: FKM (Fluorocarbon)

4: EPDM

5: PTFE

6: Santoprene XL

7: Hytrel

Y: FDA Santoprene

Diaphragm Series Codes:

R: Rugged

D: Dome

X: Thermo-Matic

T: Tef-Matic (2-piece)

B: Versa-Tuff (1-piece)

F: FUSION (one-piece integrated plate)

Valve Ball Material Codes:

1: Neoprene

2: Nitrile

3: (FKM) Fluorocarbon

4: EPDM

5: PTFE

6: Santoprene XL

7: Hytrel

8: Polyurethane

A: Acetal

S: Stainless Steel

Y: FDA Santoprene

Valve Seat/Valve Seat O-Ring Material Codes:

1: Neoprene

2: Nitrile

3: (FKM) Fluorocarbon

4: EPDM

5: PTFE

6: Santoprene XL

7: Hytrel

8: Polyurethane

A: Aluminum w/ PTFE O-Rings

S: Stainless Steel w/ PTFE O-Rings

C: Carbon Steel w/ PTFE O-Rings

H: Alloy C w/ PTFE O-Rings

T: PTFE Encapsulated Silicone O-Rings

Y: FDA Santoprene

Construction Design Codes:

9: Bolted

0: Clamped

Design Level Codes:

A

C

Miscellaneous Options Codes:

B: BSP Tapered Thread

CP: Center Port

ATEX: ATEX Compliant

FP: Food Processing

SP: Sanitary Pump

HP: High Pressure

OE: Original Elima-Matic

F: Flap Valve

HD: Horizontal Discharge

3A: 3-A Certified

UL: UL Listed

OB: Oil Bottle

CAUTION! Operating temperature limitations are as follows: 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.

Material	Max. Temp.	Min. Temp.	Description
Conductive Acetal	190°F / 88°C	-20°F / -29°C	Tough, impact resistant, ductile. Good abrasion resistance and low friction surface. Generally inert, with good chemical resistance except for strong acids and oxidizing agents.
EPDM	280°F / 138°C	-40°F / -40°C	Shows very good water and chemical resistance. Has poor resistance to oils and solvents, but is fair in ketones and alcohols.
FKM (Fluorocarbon)	350°F / 177°C	-40°F / -40°C	Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons, acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.
Hytrel®	220°F / 104°C	-20°F / -29°C	Good on acids, bases, amines and glycols at room temperatures only.
Neoprene	200°F / 93°C	-10°F / -23°C	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.
Nitrile	190°F / 88°C	-10°F / -23°C	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.
Nylon	180°F / 82°C	32°F / 0°C	6/6 High strength and toughness over a wide temperature range. Moderate to good resistance to fuels, oils and chemicals.
Polypropylene	180°F / 82°C	32°F / 0°C	A thermoplastic polymer. Moderate tensile and flex strength. Resists strong acids and alkali. Attacked by chlorine, fuming nitric acid and other strong oxidizing agents.
PVDF (Polyvinylidene Fluoride)	250°F / 121°C	0°F / -18°C	A durable fluoroplastic with excellent chemical resistance. Excellent for UV applications. High tensile strength and impact resistance.
Santoprene®	275°F / 135°C	-40°F / -40°C	Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex life. Excellent abrasion resistance.
UHMW PE	180°F / 82°C	-35°F / -37°C	A thermoplastic that is highly resistant to a broad range of chemicals. Exhibits outstanding abrasion and impact resistance, along with environmental stress-cracking resistance.
Urethane	150°F / 66°C	32°F / 0°C	Shows good resistance to abrasives. Has poor resistance to most solvents and oils.
Virgin PTFE (PFA/TFE)	220°F / 104°C	-35°F / -37°C	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.
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 applications. Commonly referred to as 316 Stainless Steel in the pump industry.

Flow Rate: Adjustable to 0 to 280 GPM (1060 LPM)

Port Size:

– Suction: 3″ ANSI Style Flange(DIN 80)

– Discharge: 3″ ANSI Style Flange(DIN 80)

Air Inlet: 3/4″ NPT

Air Exhaust: 1″ NPT

Suction Lift:

– Dry: 20′ (6.1 m)

– Wet: 25′ (7.6 m)

Max Solid Size (Diameter): 0.71″ (18 mm)

Max Noise Level: 96 dB(A)

Shipping Weights:

– Polypropylene: 208 lbs (94 kg)

– PVDF: 271 lbs (123 kg)

Displacement Per Stroke: 1.0 Gal. (3.78L)

Note: Performance based on the following: elastomeric 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%.

Dimensions are in Inches [in Millimeters]. Dimensional tolerance: +/- 1/8″ [+/- 3mm].

Overall Dimensions:

– Height: 40.66 [1033]

– Width (across manifolds): 32.31 [821]

– Depth: 16.19 [411]

Port Information:

– Discharge Port: 3″ Standard 125# Flange Configuration. Ø.75 [4] holes equally spaced on a Ø 6.00 [152] bolt circle.

– Suction Port: 3″ Standard 125# Flange Configuration. Ø.75 [4] holes equally spaced on a Ø 6.00 [152] bolt circle.

– Air Inlet: 3/4 NPT

– Exhaust Port: 1″ NPT exhaust port for optional muffler styles or piping exhaust air in submerged applications.

Mounting Dimensions:

– Bottom mounting holes (width): 2X 11.00 [279]

– Bottom mounting holes (depth): 2X 6.51 [165]

– Bottom mounting holes (diameter): 4X Ø.75 [19]

– Side mounting holes (height): 2X 15.00 [381]

AODD pumps are powered by compressed air or nitrogen.

1. 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). Simultaneously, exhausting air (3) from behind the opposite diaphragm is directed through the air valve assembly to an exhaust port (4).

2. As inner chamber pressure (P1) exceeds liquid chamber pressure (P2), the rod (5) connected diaphragms shift together. This creates discharge on one side and suction on the opposite side. The direction of the discharged and primed liquid is controlled by the check valves (6).

3. The pump primes as a result of the suction stroke. The suction stroke lowers the chamber pressure (P3) and increases the chamber volume. This pressure differential allows atmospheric pressure (P4) to push fluid through the suction piping, across the suction side check valve, and into the outer fluid chamber (7).

4. The suction stroke also initiates the reciprocating (cycling) action. The suction diaphragm’s movement is mechanically pulled through its stroke, making contact with an actuator plunger that shifts the pilot signaling valve. The pilot valve then sends a pressure signal to the main air valve, redirecting compressed air to the opposite inner chamber to repeat the cycle.

The 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. A 1″ diameter air exhaust piping is recommended.

When 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.

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.

Note: Surge Suppressor and Piping, including the air line, must be supported after the flexible connections.

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 ensure air supply pressure does not exceed recommended limits.

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.

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.

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 the 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.

Potential Cause(s)	Recommendation(s)
Deadhead (system pressure meets or exceeds air supply pressure).	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).
Air valve or intermediate gaskets installed incorrectly.	Install gaskets with holes properly aligned.
Bent or missing actuator plunger.	Remove pilot valve and inspect actuator plungers.

Potential Cause(s)	Recommendation(s)
Pump is over lubricated.	Set lubricator on lowest possible setting or remove. Units are designed for lube free operation.
Lack of air (line size, PSI, CFM).	Check the air line size and length, compressor capacity (HP vs. cfm required).
Check air distribution system.	Disassemble and inspect main air distribution valve, pilot valve and pilot valve actuators.
Discharge line is blocked or clogged manifolds.	Check for inadvertently closed discharge line valves. Clean discharge manifolds/piping.
Deadhead (system pressure meets or exceeds air supply pressure).	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).
Blocked air exhaust muffler.	Remove muffler screen, clean or de-ice, and re-install.
Pumped fluid in air exhaust muffler.	Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.
Pump chamber is blocked.	Disassemble and inspect wetted chambers. Remove or flush any obstructions.

Potential Cause(s)	Recommendation(s)
Cavitation on suction side.	Check suction condition (move pump closer to product).
Check valve obstructed. Valve ball(s) not seating properly or sticking.	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.
Valve ball(s) missing (pushed into chamber or manifold).	Worn valve ball or valve seat. Worn fingers in valve ball cage (replace part). Check Chemical Resistance Guide for compatibility.
Valve ball(s)/seat(s) damaged or attacked by product.	Check Chemical Resistance Guide for compatibility.
Check valve and/or seat is worn or needs adjusting.	Inspect check valves and seats for wear and proper setting. Replace if necessary.
Suction line is blocked.	Remove or flush obstruction. Check and clear all suction screens or strainers.
Excessive suction lift.	For lifts exceeding 20′ of liquid, filling the chambers with liquid will prime the pump in most cases.
Suction side air leakage or air in product.	Visually inspect all suction-side gaskets and pipe connections.
Pumped fluid in air exhaust muffler.	Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.

Potential Cause(s)	Recommendation(s)
Over lubrication.	Set lubricator on lowest possible setting or remove. Units are designed for lube free operation.
Icing.	Remove muffler screen, de-ice, and re-install. Install a point of use air drier.
Clogged manifolds.	Clean manifolds to allow proper air flow.
Deadhead (system pressure meets or exceeds air supply pressure).	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).
Cavitation on suction side.	Check suction (move pump closer to product).
Lack of air (line size, PSI, CFM).	Check the air line size, length, compressor capacity.
Excessive suction lift.	For lifts exceeding 20′ of liquid, filling the chambers with liquid will prime the pump in most cases.
Air supply pressure or volume exceeds system hd.	Decrease inlet air (press. and vol.) to the pump. Pump is cavitating the fluid by fast cycling.
Undersized suction line.	Meet or exceed pump connections.
Restrictive or undersized air line.	Install a larger air line and connection.
Suction side air leakage or air in product.	Visually inspect all suction-side gaskets and pipe connections.
Suction line is blocked.	Remove or flush obstruction. Check and clear all suction screens or strainers.
Pumped fluid in air exhaust muffler.	Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.
Check valve obstructed.	Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket.
Check valve and/or seat is worn or needs adjusting.	Inspect check valves and seats for wear and proper setting. Replace if necessary.
Entrained air or vapor lock in chamber(s).	Purge chambers through tapped chamber vent plugs. Purging the chambers of air can be dangerous.

Potential Cause(s)	Recommendation(s)
Diaphragm failure, or diaphragm plates loose.	Replace diaphragms, check for damage and ensure diaphragm plates are tight.
Diaphragm stretched around center hole or bolt holes.	Check for excessive inlet pressure or air pressure. Consult Chemical Resistance Chart for compatibility with products, cleaners, temperature limitations and lubrication.

Potential Cause(s)	Recommendation(s)
Cavitation.	Enlarge pipe diameter on suction side of pump.
Excessive flooded suction pressure.	Move pump closer to product. Raise pump/place pump on top of tank to reduce inlet pressure. Install Back pressure device. Add accumulation tank or pulsation dampener.
Misapplication (chemical/physical incompatibility).	Consult Chemical Resistance Chart for compatibility with products, cleaners, temperature limitations and lubrication.
Incorrect diaphragm plates or plates on backwards, installed incorrectly or worn.	Check Operating Manual to check for correct part and installation. Ensure outer plates have not been worn to a sharp edge.

Potential Cause(s)	Recommendation(s)
Excessive suction lift.	For lifts exceeding 20′ of liquid, filling the chambers with liquid will prime the pump in most cases.
Undersized suction line.	Meet or exceed pump connections.
Pumped fluid in air exhaust muffler.	Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.
Suction side air leakage or air in product.	Visually inspect all suction-side gaskets and pipe connections.
Check valve obstructed.	Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket.
Check valve and/or seat is worn or needs adjusting.	Inspect check valves and seats for wear and proper setting. Replace if necessary.
Entrained air or vapor lock in chamber(s).	Purge chambers through tapped chamber vent plugs.

With the pilot valve removed from the pump:

Step 1: Remove snap ring (2-F).

Step 2: Remove sleeve (2-B), inspect O-Rings (2-C), replace if required.

Step 3: Remove spool (2-D) from sleeve (2-B), inspect O-Rings (2E), replace if required.

Step 4: Lightly lubricate O-Rings (2-C) and (2-E).

Reassemble in reverse order.

The required torque is 600 in/lbs.

The last three digits of a part number indicate the material of the component. – – – – – – – – – – – – – – –

Code	Material
000	Assembly, sub-assembly; and some purchased items
010	Cast Iron
015	Ductile Iron
020	Ferritic Malleable Iron
080	Carbon Steel, AISI B-1112
110	Alloy Type 316 Stainless Steel
111	Alloy Type 316 Stainless Steel (Electro Polished)
112	Alloy C
113	Alloy Type 316 Stainless Steel (Hand Polished)
114	303 Stainless Steel
115	302/304 Stainless Steel
117	440-C Stainless Steel (Martensitic)
120	416 Stainless Steel (Wrought Martensitic)
148	Hardcoat Anodized Aluminum
150	6061-T6 Aluminum
152	2024-T4 Aluminum (2023-T351)
155	356-T6 Aluminum
156	356-T6 Aluminum
157	Die Cast Aluminum Alloy #380
158	Aluminum Alloy SR-319
162	Brass, Yellow, Screw Machine Stock
165	Cast Bronze, 85-5-5-5
166	Bronze, SAE 660
170	Bronze, Bearing Type, Oil Impregnated
180	Copper Alloy
305	Carbon Steel, Black Epoxy Coated
306	Carbon Steel, Black PTFE Coated
307	Aluminum, Black Epoxy Coated
308	Stainless Steel, Black PTFE Coated
309	Aluminum, Black PTFE Coated
313	Aluminum, White Epoxy Coated
330	Zinc Plated Steel
332	Aluminum, Electroless Nickel Plated
333	Carbon Steel, Electroless Nickel Plated
335	Galvanized Steel
337	Silver Plated Steel
351	Food Grade Santoprene®
353	Geolast; Color: Black
354	Injection Molded #203-40 Santoprene® Duro 40D +/-5; Color: RED
356	Hytrel®
357	Injection Molded Polyurethane
358	Urethane Rubber (Some Applications) (Compression Mold)
359	Urethane Rubber
360	Nitrile Rubber Color coded: RED
363	FKM (Fluorocarbon) Color coded: YELLOW
364	EPDM Rubber Color coded: BLUE
365	Neoprene Rubber Color coded: GREEN
366	Food Grade Nitrile
368	Food Grade EPDM
371	Philthane (Tuftane)
374	Carboxylated Nitrile
375	Fluorinated Nitrile
378	High Density Polypropylene
379	Conductive Nitrile
408	Cork and Neoprene
425	Compressed Fibre
426	Blue Gard
440	Vegetable Fibre
500	Delrin® 500
502	Conductive Acetal, ESD-800
503	Conductive Acetal, Glass-Filled
506	Delrin® 150
520	Injection Molded PVDF Natural color
540	Nylon
542	Nylon
544	Nylon Injection Molded
550	Polyethylene
551	Glass Filled Polypropylene
552	Unfilled Polypropylene
555	Polyvinyl Chloride
556	Black Vinyl
558	Conductive HDPE
570	Rulon II®
580	Ryton®
600	PTFE (virgin material) Tetrafluorocarbon (TFE)
603	Blue Gylon®
604	PTFE
606	PTFE
607	Envelon
608	Conductive PTFE
610	PTFE Encapsulated Silicon
611	PTFE Encapsulated FKM
632	Neoprene/Hytrel®
633	FKM/PTFE
634	EPDM/PTFE
635	Neoprene/PTFE
637	PTFE, FKM/PTFE
638	PTFE, Hytrel®/PTFE
639	Nitrile/TFE
643	Santoprene®/EPDM
644	Santoprene®/PTFE
656	Santoprene® Diaphragm and Check Balls/EPDM Seats
661	EPDM/Santoprene®
666	FDA Nitrile Diaphragm, PTFE Overlay, Balls, and Seals
668	PTFE, FDA Santoprene®/PTFE

Many components of Versamatic® AODD pumps are made of recyclable materials. We encourage pump users to recycle worn out parts and pumps whenever possible, after any hazardous pumped fluids are thoroughly flushed. Pump users that recycle will gain the satisfaction to know that their discarded part(s) or pump will not end up in a landfill. The recyclability of Versamatic products is a vital part of Warren Rupp’s commitment to environmental stewardship.