VERDER HI-CLEAN VA-2H80 Use and care manual

Repair/Parts
Verder Verder
VerderHI HI HI- - -CLEAN CLEAN CLEANDiaphragm Diaphragm Diaphragm
Pump, Pump,
Pump,Model Model ModelVA VA VA- - -2H80 2H80 2H80812.0066
Rev.A
EN
For For
Fortransfer transfer transferof of of󰘱uids 󰘱uids 󰘱uidsin in insanitary sanitary sanitaryapplications. applications. applications.Not Not Notapproved approved approvedfor for foruse use usein in inEuropean European Europeanexplosive explosive explosiveatmosphere atmosphere atmosphere
locations. locations.
locations.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualbeforeusing
equipment.Save Save
Savethese these theseinstructions. instructions. instructions.
Maximum󰘱uidworkingpressure:6.9
bar(0.8MPa,100psi)
Maximumairinputpressure:6.9bar
(0.8MPa,100psi)

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................5
Troubleshooting..................................................7
Repair................................................................9
PressureReliefProcedure............................9
RepairorReplaceAirValve..........................9
CheckValveRepair.....................................12
StandardDiaphragmRepair.........................13
OvermoldedDiaphragmRepair.....................15
CenterSectionRepair..................................18
LeakDetectors............................................19
Parts..................................................................20
TechnicalData...................................................28
CustomerServices/Guarantee.............................31
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNumber Number NumberTitle Title Title
812.0062VerderHI-CLEANDiaphragmPumps,Operation
812.0254LeakDetectionSystem,Instructions/Parts
2812.0066

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area areacanigniteorexplode.Solvent󰘱owingthrough
theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygrounded󰘱uidlines.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Check󰘱uidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
812.00663

Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
4812.0066

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
811.0018):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:VA VA
VA- - -2H80XP 2H80XP 2H80XP- - -STTFTSD8SB21 STTFTSD8SB21 STTFTSD8SB21
VA VA
VA- - -2H 2H 2H80 80 80X X
XP P PST ST
STTF TF
TFTS TS
TSD8 D8 D8SB SB SB21 21 21
Pump
Model
Pump
Size
Wetted
Parts
Air
Section
SeatsBallsDiaphragmsConnectionsOptionsCerti󰘰cations
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Pump Pump
PumpPump Pump
PumpSize Size SizeWetted Wetted
WettedParts Parts PartsAir Air
AirSection Section SectionSeat Seat
SeatMaterial Material Material
VA VA
VA- - -2H 2H 2H80 80 8080mmX X
XHighSanitation,
3-A0.8μmP P
PPolypropyleneSB SB
SBStainlessSteel,
Buna-Ngasket
Y Y
YPharmaceutical,
0.5μmSE SE
SEStainlessSteel,
EPDMgasket
ST ST
STStainlessSteel,
EP-TFgasket
SV SV
SVStainlessSteel,
FKMgasket
Ball Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialConnections Connections
ConnectionsOptions Options OptionsCerti󰘰cation Certi󰘰cation Certi󰘰cation
BN BN
BNBuna-NBN BN BNBuna-ND8 D8
D8DIN11851
(DN80)3A 3A
3A3-A21 21 21EN10204
type2.1
EP EP
EPEPDMEO EO
EOEPDM
OvermoldedT8 T8
T8TRI-CLAMP
3”SB SB
SBSanitary
ball31 31
31EN10204
type3.1
NE NE
NEPolychloropreneSP SP
SPSantoprene
SP SP
SPSantopreneTS TS
TSPTFE/San-
toprene,
2-piece
TF TF
TFPTFEVT VT VTFKM
VT VT
VTFKM
812.00665

CongurationNumberMatrix
Approvals Approvals
Approvals
DiaphragmmaterialscodedEO,TO,orTS
combinedwithTFballcheckscomplywith:
EC1935/2004
DiaphragmmaterialscodedEOorTS
combinedwithTFballcheckscomplywith:
ClassVI
Allmodelsareapprovedto:
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
6812.0066

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpcyclesatstallor
failstoholdpressureat
stall.
Wornchecksorseats.Replace.
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Reduceairinletpressure.
Checkvalveballseverelywornor
wedgedinseatormanifold.
Replaceballandseatcomponent.
Seatseverelyworn.Replaceballandseatcomponent.
Outletorinletclogged.Unclog.
Inletoroutletvalveclosed.Open.
Inlet󰘰ttingsormanifoldsloose.Tightenclamp.
Pumpcyclesbutwillnot
prime.
Manifoldgasketsdamaged.Replacegaskets.
Airvalveisstuckordirty.Disassembleandcleanairvalve.Use󰘰ltered
air.
Checkballseverelywornand
wedgedinseatormanifold.
Replaceballandseatcomponent.
Checkvalveballisseverelywedged
intoseatduetooverpressurization.
FollowPressureReliefProcedure,page9.
Disassembleballcheckassemblyandinspect
fordamage.
Cloggeddispensingvalve.FollowPressureReliefProcedure,page9.
Clearvalve.
Pilotvalveworn,damaged,or
plugged.
Replacepilotvalve.
Airvalvegasketdamaged.Replacegasket.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleakdetector.
Pumpwillnotcycle,or
cyclesonceandstops.
Shaftsealswornordamaged.Replaceseals.
Suctionlineisloose.Tighten.
Diaphragmruptured.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Loosediaphragmshaftbolt.Tighten.
Airbubblesin󰘱uid.
Looseinletmanifold,damaged
sealbetweenmanifoldandseat,
damagedgaskets.
Tightenmanifoldclampsorreplacegasketsor
seatingcomponents.
812.00667

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballs.Cleanorreplace.
Diaphragmruptured.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Pilotvalvesdamagedorworn.Replacepilotvalves.
Airvalvedamaged.Replaceairvalve.
Airvalvegasketdamaged.Replaceairvalvegasket.
Airsupplyerratic.Replaceairsupply.
Exhaustmuf󰘱ericing.Usedrierairsupply.
Reducedpump
performance.
Restrictedexhaust.Removerestriction.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Misalignmentofinlet/outlet󰘱uidline
orpipe.
Use󰘱exible󰘱uidlinesatpumpinletandoutlet.
Leakininletoroutlet
sanitary󰘰tting.
Gasketdoesnotseal.Installcorrectaircovergasketsforthetypeof
diaphragmsinuse.Seepartslistforcorrect
gaskets.
Diaphragmruptured.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandardor
overmoldeddiaphragmrepairprocedure.
Wornairvalvecuporplate.Replace.
Damagedairvalvegasket.Replacegasket.
Damagedpilotvalve.Replacepilotvalves.
Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Airvalveor󰘱uidcoverclampsloose.Tighten.
Diaphragmdamaged.Replacediaphragm.
Airvalvegasketdamaged.Replacegasket.
Pumpleaksairexternally.
Aircovergasketdamaged.Replacegasket.
Pumpleaks󰘱uid
externallyfromjoints.
Loosemanifolds,damagedseal
betweenmanifoldandseat,
damagedgaskets.
Tightenmanifoldclampsorreplaceseatsor
clamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
between󰘱uidinletandoutletline
sizing.Noiseisaccentuatedwith
lightviscosity󰘱uids.
Reducesize/diameterofinletlinerelativeto
outletline.Outletlinesizeshouldnotexceed
pumpsize.
8812.0066

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressureReliefProcedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbound󰘱uidvalvetorelieve󰘱uid
pressurefromthepump.
a.For For
Forsimple simple simpletransfer transfer transferapplications, applications, applications,openeither
the󰘱uidshutoffvalve(J)orthe󰘱uiddrain
valve(K).
b.For For
Forcirculating circulating circulatingapplications, applications, applications,ensurethatthe
󰘱uidshutoffvalve(J)isclosedandopenthe
󰘱uiddrainvalve(K).
Repair Repair
Repairor or orReplace Replace ReplaceAir Air AirValve Valve Valve
Replace Replace
ReplaceComplete Complete CompleteAir Air AirValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
2.Disconnectthesupplyairlineatthemotor.
3.Removethenuts(105).Removetheairvalve
andgasket(103).
4.Torepairtheairvalve,goto
DisassembleAirValve,page9.To
installareplacementairvalve,continuetothe
nextstep.
5.Alignthenewairvalvegasket(103)onthe
centerhousing,thenattachtheairvalve.Usinga
crisscrosspattern,tightentheairvalvenuts(105)
to5–6.2N•m(45–55in-lb).
6.Reconnectthesupplyairlineatthemotor.
Replace Replace
ReplaceSeals Seals Sealsor or orRebuild Rebuild RebuildAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Repairkitsareavailable.SeeAirValve
partssection.
Disassemble Disassemble
DisassembleAir Air AirValve Valve Valve
1.Removetheairvalvefromthe
centersection.Refertosteps1-3of
ReplaceCompleteAirValve,page9.
2.Removescrews(104j).Removethevalveplate
(104e),cupassembly(104m,104n,104s),spring
(104l),anddetentassembly(104c).
3.Pullthecup(104n)offofthebase(104m).
Removetheo-ring(104s)fromthecup.
4.Removetheretainingring(104k)fromeachend
oftheairvalve.Usethepiston(104b)topush
theendcap(104g)outofoneend.Removethe
u-cupseal(104h).Pullthepistonouttheendand
removetheotheru-cupseal(104h).Removethe
otherendcap(104g)andtheendcapo-rings
(104f).
5.Removethedetentcam(104d)fromtheairvalve
housing(104a).
812.00669

Repair
Reassemble Reassemble
ReassembleAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Ifrepairsinvolveremoving
󰘱uidcovers,performthestepsin
ReassembletheOvermoldedDiaphragms,page16,
priortoreassemblyoftheairvalve.Theairvalve
con󰘰gurationwillbemodi󰘰edtoaid󰘱uidcover
installation.
NOTE: NOTE:
NOTE:Applylithium-basedgreasewhenever
instructedtogrease.OrderVerderPN819.0184.
1.Useallpartsintherepairkits.Cleanotherparts
andinspectfordamage.Replaceasneeded.
2.Greasethedetentcam(104d)andinstallinto
housing(104a).
3.Greasetheu-cups(104h)andinstallonthe
pistonwithlipsfacingtowardthecenterofthe
piston.
4.Greasebothendsofthepiston(104b)andthe
housingbore.Installthepistoninthehousing
(104a),withthe󰘱atsidetowardthecup(104n).
Becarefulnottotearu-cups(104g)whensliding
pistonintohousing.
5.Greasenewo-rings(104f)andinstallonthe
endcaps(104g).Installtheendcapsintothe
housing.
6.Installaretainingring(104k)oneachendtohold
endcapsinplace.
1
Applylithium-based
grease.
2
U-cuplipsmustface
piston.
3
Applylithium-based
greasetocontact
surface.
KEY KEY
KEY
AI AI
AIAirInlet
10812.0066

Repair
7.Greaseandinstallthedetentassembly(104c)
intothepiston.Installtheo-ring(104s)onthe
cup(104n).Applyalight󰘰lmofgreasetothe
outsidesurfaceoftheo-ringandtheinside
matingsurfaceofthebase(104m).
Orienttheendofthebasethathasamagnet
towardtheendofthecupthathasthelarger
cutout.Engagetheoppositeendoftheparts.
Leavetheendwiththemagnetfree.Tiltthebase
towardthecupandfullyengagetheparts,using
caresothattheo-ringremainsinplace.Install
thespring(104l)ontotheprotrusiononthecup.
Alignthemagnetinthebasewiththeairinletand
installthecupassembly.
8.Greasethecupsideandinstallthevalveplate
(104e).Alignthesmallholeintheplatewiththe
airinlet(AI).Tightenthescrews(104j)tohold
itinplace.
812.006611

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballsin
arangeofmaterials.Gasketkitsalsoareavailable.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
DisconnectallDisconnectall󰘱uidandairlines.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.Insertthe
quick-releasepinstopreventundesiredrotation.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.Thestand
haslocksat90degreeincrements.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingtheoutlet
manifoldtoavoiddamagetocheckvalve
components.
4.Removeremainingclamps(23),manifolds(16,
17),gaskets(18),andcheckvalves(19,20).
5.Cleanandinspectgaskets,balls,ballstops,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page13.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclamps,clampingsurfaces,and
gasketswithwaterproof,sanitarylubricant.
1.Reassemblecheckvalvecomponentsinreverse
order.
2.Attachthemanifoldstothe󰘱uidcovers.Tighten
clampshandtight.
12812.0066

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page15.
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•18mmwrench
•7/8inopenendwrench
•O-ringpick
•Diaphragminstalltool(812.0268)
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Ifchangingdiaphragmmaterials,center
sectiongasketmayalsoneedtobereplacedwith
somediaphragmtypes.SeeDiaphragms
foraffectedaircovergaskets.
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Withboth󰘱uidcoversremoved,usingtwo18mm
wrenches,holdthewrench󰘱atsontheplates(Y)
ofeachdiaphragmassemblyandloosen.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.
5.Disassemblethefreediaphragmassembly.
6.Removeplate(12)withbolt(14)installed,
diaphragm(10),backer(11)ifpresent,andplate
(9).
7.Pulltheotherdiaphragmassemblyandthe
diaphragmshaft(24)outofthecenterhousing
(101).Holdtheshaft󰘱atswitha7/8in.openend
wrench,andremovethediaphragmassembly
fromtheshaft.Disassembletheremaining
diaphragmassembly.
8.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(107)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
812.006613

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,seeCenterSectionRepair,page18,before
youputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(110)so
thelipsface
out out
out
ofthehousing(101)andtoward
thebearing(107)theyarebehind.
2.Assemblediaphragm(10),backer(11)ifpresent,
andplate(9)ontoplate(12)withscrew(14).
Roundedsideofplate(9)shouldfacediaphragm.
MakesurethesidemarkedAIRSIDEfacesthe
centerhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usingthe18mmwrenchesholdthewrench󰘱ats
ofonediaphragmassemblyandtorquetheother
diaphragmto81-94N•m(60-70ft-lb).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
NOTE: NOTE:
NOTE:Fluidcovermovementmaybeneeded
wheninstallingmanifolds.Installcoverclamps
looseenoughtoallowcovermovementfor
spacingandalignmentofmanifolds.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
14812.0066

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•7/8in.openendwrench
•O-ringpick
•Diaphragminstalltool(812.0268)
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Ifchangingdiaphragmmaterials,center
sectiongasketmayalsoneedtobereplacedwith
somediaphragmtypes.SeeDiaphragms
foraffected󰘱uidandairlines.
Disassemble Disassemble
Disassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Oncethe󰘱uidcoversareremoved,the
diaphragmonthesideofthepumpwhichwas
lastpressurizedwithairwillbeseparatedfrom
thecentersection/aircover.Thisallowsyouto
gripthediaphragms.
5.Diaphragmsareassembledhandtight.To
loosen,gripbothdiaphragmssecurelyaround
theouteredgeandrotatecounterclockwise.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.Removethe
freeddiaphragm(10)andairsideplate(9).
6.Pulltheoppositediaphragmassemblyandshaft
(24)outofthecenterhousing(101).Holdthe
shaft󰘱atswitha7/8in.openendwrenchand
removethediaphragmandairsideplatefrom
theshaft.
7.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(107)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
8.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
812.006615

Repair
Reassemble Reassemble
Reassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,seeCenterSectionRepair,page18,before
youputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101)andtoward
thebearing(107)theyarebehind.
2.Assembleplate(9)ontodiaphragm(10),with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgesandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
NOTE: NOTE:
NOTE:Fluidcovermovementmaybeneeded
wheninstallingmanifolds.Installcoverclamps
looseenoughtoallowcovermovementfor
spacingandalignmentofmanifolds.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)and
handtighten.If,afterinstallingthe󰘰rst󰘱uid
cover,theopposingdiaphragmprotrudesaway
fromthecenterhousing,leavingagapbetween
thecenterhousingandthesecond󰘱uidcover,
donottrytoforcethediaphragmintoposition.
Instead,completethefollowingprocedures
inUsingDiaphragmInstallTool,page17,to
positionthediaphragmandallow󰘱uidcover
installation.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
16812.0066

Repair
Using Using
UsingDiaphragm Diaphragm DiaphragmInstall Install InstallTool Tool Tool
Toreducetheriskofseriousinjury,donotput
your󰘰ngersorhandbetweentheaircoverandthe
diaphragm.
Ifrepairsinvolveremovalof󰘱uidcovers,thesesteps
willeaseinstallationof󰘱uidcovers.Thediaphragm
installtoolkit812.0268isavailableseparately.
1.Removetheairvalvenuts(105),airvalve(104)
andgasket(103).
2.Installthesupplieddiaphragminstalltoolsothat
thearrow(A)pointstowardthesideofthepump
withthediaphragmagainsttheaircover.Install
theairvalve(104)andnuts(105).Snugtheair
valvecovernuts.
3.Supplythepumpwithlowpressureair,just
enoughtomovethediaphragm.Useabout0.7
bar(0.07MPa,10psi)forstandarddiaphragms
or1.4bar(0.14MPa,20psi)forovermolded
diaphragms.Shopairmaybeused.The
diaphragmwillshiftsothesecond󰘱uidcover
willseatproperly.Keepairpressureonuntilthe
second󰘱uidcoverisinstalled.
4.Installtheremaining󰘱uidcoverandclamp.
5.Removeairsupplyfrompump.
6.FollowthePressureReliefProcedure,page9.
Disconnecttheairvalveandthetool.
7.Ifnootherairvalverepairsareneeded,install
thegasket(103),airvalve(104)andnuts(105).
Useacrisscrosspatternandtorquenutsto5-6.2
N•m(45–55in-lb)
812.006617

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•10mmsocketwrench
•9/16in.socketwrench
•Bearingpuller
•O-ringpick
•Press,orblockandmallet
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
1.FolloweithertheDisassembletheStandard
Diaphragms,page13orDisassemblethe
OvermoldedDiaphragms,page15,as
appropriate.
2.Removepilotvalves(111).
3.Usea3/8hexwrenchtoremovetwobolts(113),
thenremoveoneaircover(110)andalignment
pins(108).Repeatfortheotheraircover.
4.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(107)inplace.Iftheyaredamaged,usea
bearingpullertoremovethem.
NOTE: NOTE:
NOTE:Donotremoveundamagedbearings.
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
NOTE: NOTE:
NOTE:Uselithium-basedgreasewhenever
instructedtogrease.OrderVerderPN819.0184.
1.Cleanallpartsandinspectfordamage.Replace
partsasneeded.
2.Greaseandinstallthediaphragmshaftu-cups
(106)sothelipsface
out out
out
ofthehousingand
towardthebearingtheyarebehind.
3.Ifreplacingtheshaftbearings,insertthenew
bearings(107)intothecenterhousing.Usea
pressorablockandrubbermallettopress-󰘰t
thebearingsoitis󰘱ushwiththesurfaceofthe
centerhousing.
4.Installtheaircovers:
a.Putoneaircoveronthebench.Installthe
alignmentpins(108)andanewgasket(109).
b.Carefullyplacethecentersectionontheair
cover.
c.Installthesecondsetofalignmentpins(108)
andgasket(109)inthecentersection.Lower
thesecondaircoverontothecenterhousing.
d.Applymedium-strength(blue)threadlocker
onthebolts(113).Installtwoboltsand
torqueto41-54N•m(30-40ft-lb).Turnthe
pumpoveronthebenchandinstalland
torquetheothertwobolts.
5.Greaseandinstallpilotvalves(111).Torqueto
2.3-2.8N•m(20-25in-lb).Donotover-torque.
1
Applylithium-based
grease.
2
Lipsmustfaceoutof
housing.
3
Torqueto41–54N•m
(30–40ft-lb).
4
Torqueto2.3-2.8N•m
(20-25in-lb).
18812.0066

Repair
Leak Leak
LeakDetectors Detectors Detectors
Leakdetectorsaresensorsthataremountedinthe
aircoversofthepumptomonitorfor󰘱uidleakage
causedbyadiaphragmrupture.Leakdetectors
areprovidedwith3-Apumpsandcanbeordered
separatelyforotherpumps.Forleaksensorelectrical
andcon󰘰gurationinformation,refertotheleak
detectionsystemmanual(812.0254).
Availableleakdetectionkits:
Kit Kit
KitDescription Description Description
812.0003Kit,Standard,non-ATEX,2sensors,
2bushings;providedwith3-Apumps
812.0004Kit,ATEX,2sensors,2bushings,2
o-rings
812.0005Kit,Leakdetectioncontrolbox;
notapprovedforuseinanATEX
environment
812.0006Kit,Leakdetectioncontrolbox
mountingbracketandmounting
hardware
Leak Leak
LeakDetector Detector DetectorTesting Testing Testing
1.Obtainasmallcontainerofthematerialbeing
pumped.
2.PerformthePressureReliefProcedure,page9.
3.Unscrewandremovebothleakdetectorbushings
(withinstalledleakdetectors)fromtheairside
diaphragmcovers.
4.Foreachleakdetector,dipthebushing,with
theleakdetectorstillinstalled,intothematerial
containerinanorientationthatmimicshowit
wouldbeorientedintheairsidediaphragm
cover.Observewhethertheleakdetectorsenses
thepresenceofthematerial.
5.Iftheleakdetectorsuccessfullydetectedthe
material,cleanthebushingandleakdetector
andre-installtheleakdetectorandbushing
asdescribedinstep6.Ensurethatbothleak
detectorssuccessfullydetectedthematerial
beforeinstalling.
NOTE: NOTE:
NOTE:Iftheleakdetectorfailstosensethe
material,troubleshoottheleakdetectortoseeif
theleaksensorhasfailedortheleakdetectoris
unabletodetectthematerial.
6.Toinstallleakdetectortothepump:
a.Iftheleakdetectorneedstobeinstalledin
thebushing,simplyscrewtheleakdetector
injustpast󰘰ngertight.
NOTE: NOTE:
NOTE:IfusingtheATEXleakdetector,
installtheo-ringontotheleakdetectorbefore
installationintothebushing.
b.Ifthebushingisnotinstalledintheairside
diaphragmcover,screwthebushingintothe
airsidediaphragmcover.
c.Iftheleakdetectorwasdisconnectedfrom
themonitoringdevice,re-attachtheleak
detectorwirestothemonitoringdevice.
7.Repeatsteps3–6fortheotherleakdetector.
Leak Leak
LeakDetector Detector DetectorRemoval Removal Removal
1.FollowthePressureReliefProcedure,page9.
2.Notetheconnectionlocationsoftheleak
detectorwireswithinthemonitoringdevice,then
disconnecttheleakdetectorwires.
3.Removetheleakdetectorfromthebushinginthe
airsidediaphragmcover.
4.Ifdesired,repeattoremovetheotherleak
detectorfromtheotherairsidediaphragmcover.
Leak Leak
LeakDetector Detector DetectorReassembly Reassembly Reassembly
1.Iftheleakdetectorneedstobeinstalledinthe
bushing,simplyscrewtheleakdetectorinjust
past󰘰ngertight.
NOTE: NOTE:
NOTE:IfusingtheATEXleakdetector,installthe
o-ringontotheleakdetectorbeforeinstallation
intothebushing.
2.Ifthebushingisnotinstalledintheairside
diaphragmcover,screwthebushingintotheair
sidediaphragmcover.
3.Ifremoved,re-attachtheleakdetectorwiringto
themonitoringdevice.
812.006619

Parts
Parts Parts
Parts
VA-2H80modelshown
20812.0066