Ingersoll-Rand ARO PRO Series User manual

OPERATOR’S MANUAL 67168
INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE
RELEASED: 11-26-97
REVISED: 11-27-21
(REV: J)
67169, 67391
67390, 67392
67393
CYCLE COUNTER KITS
(CLOSED ELECTRICAL CONTACT TYPE)
FOR DIAPHRAGM PUMPS
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.
INGERSOLL RAND COMPANY INC
209 NORTH MAIN STREET – BRYAN, OHIO 43506
[phone] FAX [phone] © 2021 CCN 99733487
arozone.com
CYCLE COUNTER KITS
PRO
Series
Port Size
Metallic Fluid Section Non - Metallic
Fluid Section
and
Center Body
Non - Metallic
Center Body
Metallic
Center Body
1/2” N/A N/A 67168
3/4” and 1” 67169 67169 N/A
1-1/2” 67169 67169 N/A
2” 67169 67169 N/A
EXP
Series
Port Size
Metallic Fluid Section Non - Metallic
Fluid Section
and
Center Body
Non - Metallic
Center Body
Metallic
Center Body
1” 67390 67392 67390
1-1/2” 67390 67392 67390
2” 67391 67393 67391
3” 67391 67393 67391
GENERAL DESCRIPTION
The ARO® diaphragm pump cycle counter kits provide a
closed contact output each time the pump completes a cy-
cle. This signal may be used to record cycles for maintenance
purposes or batching if the discharge volume of each com-
plete cycle is known.
Some parts of the pump must be replaced with those includ-
ed in the kits to enable the activation of the switch.
OPERATION
Maximum Operating Voltage ........... 200 VDC
Switching Current ...................... 0.5 Amps
Once the kit is installed in the pump, it may be interfaced
with a control device in the following ways:
Maximum sensor wire length is 25 ft (7.5 meters).
As a SOURCING switch (see gure 1) for use with PLC’s.
As a SINKING switch (see gure 2) for use with PLC’s.
As a closed contact switch (see gure 3) for use with meters.
INPUT
INPUT
INPUTS
Figure 1
Figure 2
Figure 3
+V
Sourcing Switch
Sinking Switch
Closed Contact Switch

Page 2 of 8 67168 (en)
67168 COUNTER INSTALLATION
1/2” DIAPHRAGM PUMP
Kit Models
67168
66605X-XXX, PD05P-XXX-XXX and
PM05P-CSS-XXX-A02.
Refer to gure 4. NOTE: Apply Lubriplate FML-2 grease 94276
to all “O” rings, “U”cups and mating parts.
1. Remove (134) bolts from the major valve and remove (135)
valve block.
2. Remove (141) valve plate and (140) valve insert from the
valve block.
3. Remove (136) plug and (111) spool and replace with
67157 spool assembly and 67158 sensor assembly from
kit as shown.
4. Replace (140) valve insert and (141) valve plate in valve
block.
NOTE: Assemble (140) valve insert with “dished” side
toward (141) valve plate.
5. Attach (135) valve block to (101) motor body, using (133)
washers and (134) bolts.
NOTE: Torque to 15 - 20 in. lbs (1.7 - 2.3 Nm).
132141k140
135
133
.
134
Identicationdot
this side.
kAssemblewith2identication dots toward (132)
gasket.
.Torque to 15 -20in. lbs(1.7-2.3 Nm).
gAvailablein67168 kitonly.
111
136
67157 g
94654 g
Included butnot shown:
Lubriplate FML-2 grease 94276
Y325-- 125g95276 g
Figure 4

67168 (en) Page 3 of 8
67169 COUNTER INSTALLATION
3/4”, 1”, 1-1/2”AND 2” (66607X-XXX-A, 66608X-XXX-A, 6661XX-XXX-C / 6662XX-XXX-C)
DIAPHRAGM PUMPS
Kit Models
67169
66607X-XXX-A, 66608X-XXX-A, 6661XX-XXX-C and
6662XX-XXX-C.
Refer to gure 5. NOTE: Lubriplate FML-2 grease 94276 to all
“U” cups and mating parts.
1. Remove (105) bolts from both ends of (101) motor body
and remove (107) legs / plates, (117) gasket and (108) gas-
ket.
2. Apply force to (111) spool from the end opposite the air
supply port to force (109) piston out.
3. Replace (109) piston with 94646 piston assembly from kit
as shown.
4. Replace (117) gasket, (107) leg / plate and (105) bolts on
the end opposite the air supply port. NOTE: Torque bolts
to 40 - 50 in. lbs (4.5 - 5.6 Nm).
5. Install 94648 gasket from kit, 94647 sensor assembly from
kit, (108) gasket, (107) leg / plate and Y6-46-T bolts with
Y14-416-T washers from kit as shown. NOTE: Torque bolts
to 40 - 50 in. lbs (4.5 - 5.6 Nm).
Y6-46-T(4)
Y14-416-T (4)
94647
94646
105
106
107
117
107
108
109
111
Included but not shown:
Lubriplate FML-2 grease 94276
Sensor this side.
107
107
94648
~
.
~
~g
g~
,
Torque to 40 -50in. lbs(4.5-5.6 Nm).
Supplied with 67169kit.
Availablein67169kit only.
.
~
g
~
Figure 5

Page 4 of 8 67168 (en)
67390 COUNTER INSTALLATION
1” and 1-1/2” DIAPHRAGM PUMP WITH
NON-METALLIC CENTER BODY
Kit Models
67390
Non Metallic Models: PD10E-XXX-XXX, PD10P-XXX-
XXX, PE10P-XXX-XXX, PD15E-XXX-XXX, PD15P-XXX-
XXX and PE15P-XXX-XXX.
Metallic Models: PD10R-XXX-XXX, PE10R-XXX-XXX,
PM10R-CSS-XXX-A02, PD15R-XXX-XXX,
PE15R-XXX-XXX and PM15R-CSS-XXX-A02.
Refer to figure 6. NOTE: Apply Lubriplate FML-2 grease
(94276) to all “O” rings, “U” cups and mating parts upon as-
sembly.
1. Remove (134) screws and remove (135) valve block.
2. Insert a small at blade screwdriver into the notch in the
side of (135) valve block and push in on tab to remove
(233) adapter plate, releasing (140) valve insert, (141)
valve plate and (200) gasket.
3. Remove (236) nuts from the major valve and remove (107)
end plate.
4. Remove (136) end cap and (111) spool and replace with
67394 spool assembly as shown.
5. Place 95276 sensor and 96581 mounting plug thru hole in
(107) end plate.
6. Install (137) gasket on (136) end cap and assemble end
cap and (107) end plate to (135) valve block, securing (105)
screws and (236) nuts. NOTE: Torque (105) screws to 35 -
40 in. lbs (4.0 - 4.5 Nm).
7. Install (140) valve insert and (141) valve plate in (135)
valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with part number identication toward (140)
valve insert.
8. Assemble (200) gasket and (233) adapter plate to (135)
valve block. NOTE: Assemble (233) adapter plate with
notched side down.
9. Attach (135) valve block to (101) motor body, using (133)
washers and (134) bolts. NOTE: Torque to 35 - 40 in. lbs (4.0
- 4.5 Nm).
200141140
135
133
134
Torque to 35 -40in. lbs(4.0-4.5 Nm).
Included in 67390kit.
111
136
67394
Includedbut not shown:
94276 Lubriplate grease
107
236
137
105
233
96581
95276
Notch
k
.
k
.
g
g
.
g
g
Assemblewith part number identication
toward(140) valve insert.
Insert screwdriver here to
remove (233) adapter plate
.
Figure 6
67391 COUNTER INSTALLATION
2” AND 3” DIAPHRAGM PUMP WITH
NON-METALLIC CENTER BODY
Kit Models
67391
Metallic Models: PD20R-XXX-XXX, PD20Y-XXX-XXX,
PD20R-XXX-XXX-B, PE20R-XXX-XXX-B, PD20Y-XXX-
XXX-B, PE20Y-XXX-XXX-B, PF20R-XXX-XXX,
PF20Y-XXX-XXX, PF20R-XXX-XXX-B, PF20Y-XXX-XXX-B,
PM20R-CSS-XXX-A02, PM20R-CSS-XXX-B02, PD30R-
XXX-XXX-B, PD30R-XXX-XXX-C, PE30R-XXX-XXX-C,
PM30R-CSS-XXX-B02 and PM30R-CSS-XXX-C02.
Non Metallic Models: PD20E-XXX-XXX, PE20E-XXX-XXX
PD20P-XXX-XXX, PE20P-XXX-XXX, PD30P-XXX-XXX and
PE30P-XXX-XXX.
Refer to gure 7. NOTE: Apply Lubriplate FML-2 grease (94276)
to all “O” rings, “U”cups and mating parts upon assembly.
1. Remove (134) screws and remove (135) valve block.
2. Remove (233) adapter plate, releasing (140) valve insert,
(141) valve plate and (200) gasket.
3. Remove (236) nuts from the major valve and remove (107)
end plate.
4. Remove (136) end cap and (111) spool and replace with
67395 spool assembly as shown.
5. Place 95276 sensor and 96582 mounting plug thru hole in
(107) end plate.
6. Install (137) “O” ring on (136) end cap and assemble end
cap and (107) end plate to (135) valve block, securing with
(105) screws and (236) nuts. NOTE: Torque (105) screws to
15 - 20 in. lbs (1.7 - 2.3 Nm).
7. Install (140) valve insert and (141) valve plate in (135)
valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with identication dots toward (199 and 200)
gaskets.
8. Assemble (232, 243 and 244) “O” rings, (199 and 200) gas-
kets and (233) adapter plate to (135) valve block.
9. Attach (135) valve block and components to (101) motor
body, using (133) washers and (134) bolts. NOTE: Torque
to 40 - 50 in. lbs (4.5 - 5.6 Nm).
199141140
135
133
134
Assemblewith2identicationdots
toward (199 and 200) gaskets.
111
136
67395
Included but not shown:
94276Lubriplategrease
107
236
137
105
244
96582
95276
243 233
200 232
k
.
k
g
.
g
g
Torque (105) to 15 -20in. lbs(1.7-2.3Nm).
Torque (134) to 40 -50in. lbs(4.5-5.6Nm).
Included in 67391 kit.
.
.
g
Figure 7

67168 (en) Page 5 of 8
67392 COUNTER INSTALLATION
1” AND 1-1/2” DIAPHRAGM PUMP WITH
METALLIC CENTER BODY
Kit Models
67392
PD10A-XXX-XXX, PE10A-XXX-XXX, PD10S-XXX-XXX,
PE10S-XXX-XXX, PM10A-XXX-XXX, PM10S-XXX-XXX,
PP10A-XXX-XXX, PW10A-XXX-XXX, PD15A-XXX-XXX,
PE15A-XXX-XXX, PD15S-XXX-XXX, PE15S-XXX-XXX,
PM15A-XXX-XXX and PM15S-XXX-XXX.
Refer to figure 8. NOTE: Apply Lubriplate FML-2 grease
(94276) to all “O” rings, “U” cups and mating parts upon as-
sembly.
1. Remove (134) screws and remove (135) valve block.
2. Insert a small at blade screwdriver into the notch in the
side of (135) valve block and push in on tab to remove
(233) adapter plate, releasing (140) valve insert, (141)
valve plate and (200) gasket.
3. Remove (105) screws, releasing (136) end cap and (137)
gasket.
4. Remove (111) spool and replace with 67398 spool assem-
bly as shown.
5. Install (137) gasket on (136) end cap and assemble end
cap, 96583 bracket and 95276 sensor to (135) valve block,
securing with (105) screws. NOTE: Torque (105) screws to
40 - 50 in. lbs (4.5 - 5.6 Nm).
6. Install (140) valve insert and (141) valve plate in (135)
valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with part number identication toward (140)
valve insert.
7. Assemble (200) gasket and (233) adapter plate to (135)
valve block. NOTE: Assemble (233) adapter plate with
notched side down.
8. Attach (135) valve block to (101) motor body, using (133)
washers and (134) bolts. NOTE: Torque to 40 - 50 in. lbs (4.5
- 5.6 Nm).
200141140
135
133
134
Assemblewith part number identication
toward(140) valve insert.
111
136
67398
Included butnot shown:
94276 Lubriplate grease
137
105
233
96583
95276
Notch
Insert screwdriver heret
o
remove (233)adapter
plate.
k
.
k
g
.
g
g
Torque to 40 -50in. lbs(4.5-5.6 Nm).
Included in 67392kit.
.
g
Figure 8
67393 COUNTER INSTALLATION
2” AND 3” DIAPHRAGM PUMP WITH
METALLIC CENTER BODY
Kit Models
67393
PD20A-XXX-XXX, PE20A-XXX-XXX, PD20S-XXX-XXX,
PE20S-XXX-XXX, PM20A-XXX-XXX, PM20S-XXX-XXX,
SD20S-XXX-XXX, PP20A-XXX-XXX, PF20A-XXX-XXX,
PF20S-XXX-XXX, PD30A-XXX-XXX, PE30A-XXX-XXX,
PD30S-XXX-XXX, PE30S-XXX-XXX, PM30A-XXX-XXX,
and PM30S-XXX-XXX.
Refer to figure 9. NOTE: Apply Lubriplate FML-2 grease
(94276) to all “O” rings, “U” cups and mating parts upon as-
sembly.
1. Remove (134) screws and remove (135) valve block and
components.
2. Remove (240) screws to remove (233) adapter plate, re-
leasing (140) valve insert, (141) valve plate, (199, 200 and
241) gaskets and (243 and 244) “O” rings.
3. Remove (105) screws, releasing (136) end cap and (137
and 242) “O” rings.
4. Remove (111) spool and replace with 67395 spool assem-
bly as shown.
5. Install (137 and 242) “O” rings on (136) end cap and as-
semble end cap, 96584 bracket and 95276 sensor to (135)
valve block, securing with (105) screws. NOTE: Torque
screws to 40 - 50 in. lbs (4.5 - 5.6 Nm).
6. Install (140) valve insert and (141) valve plate in (135)
valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with identication dots toward (199 and 200)
gaskets.
7. Assemble (199, 200 and 241) gaskets, (243 and 244)“O”
rings and (233) adapter plate to (135) valve block. NOTE:
Assemble (233) adapter plate to (135) valve block, secur-
ing with (240) screws. NOTE: Torque screws to 40 - 50 in.
lbs (4.5 - 5.6 Nm).
8. Attach (135) valve block to (101) motor body, using (133)
washers and (134) bolts. NOTE: Torque to 40 - 50 in. lbs (4.5
- 5.6 Nm).
199141140
135
133
134
Assemblewith2identication dots
toward(199and 200) gaskets.
111
136
67395
Included butnot shown:
94276Lubriplategrease
137
105
244
96584
95276
243 233
200 241
242
240
k
.
k
g
.
g
g
,
Torque (105, 134 and 240 to 40 -50in. lbs(4.5-5.6 Nm)
.
Included in 67393kit.
.
g
Figure 9

Page 6 of 8 67168 (en)

67168 (en) Page 7 of 8

Page 8 of 8 67168 (en)
PN 97999-775