520-136-000 10/02 Model MP04D Design Level 3 Page 1
Warren Rupp, Inc., A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901 USA • (419)524-8388 • Fax (419)522-7867
PLEASE NOTE!
The photos shown in this manual are for general instruction only. Your specific model
may not be shown. Always refer to the parts list and exploded view drawing for your
specific model when installing, disassembling or servicing your pump.
PRINCIPLE OF OPERATION
This ball check valve pump is powered by compressed air and is a 1:1 pressure ratio
design. It alternately pressurizes the inner side of one diaphragm chamber, while
simultaneously exhausting the other inner chamber. This causes the diaphragms, which
are connected by a common rod, to move endwise. Air pressure is applied over the entire
surface of the diaphragm, while liquid is discharged from the opposite side. The
diaphragm operates under a balanced condition during the discharge stroke, which
allows the unit to be operated at discharge heads over 200 feet (61 meters) of water head.
Since the diaphragms are connected by a common rod, secured by plates to the
center of the diaphragms, one diaphragm performs the discharge stroke, while the other
is pulled to perform the suction stroke in the opposite chamber.
For maximum diaphragm life, keep the pump as close to the liquid being pumped as
possible. Positive suction head in excess of 10 feet of liquid (3.048 meters) may require
a back pressure regulating device. This will maximize diaphragm life.
Alternate pressuring and exhausting of the diaphragm chamber is performed by
means of an externally mounted, pilot operated, four-way spool type air distribution
valve. When the spool shifts to one end of the valve body, inlet air pressure is applied to
one diaphragm chamber and the other diaphragm chamber exhausts. When the spool
shifts to the opposite end of the valve body, the porting of chambers is reversed. The air
distribution valve spool is moved by an internal pilot valve which alternately pressurizes
one side of the air distribution valve spool, while exhausting the other side. The pilot valve
is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact
with the end of the pilot valve spool. This pushes it into position for shifting of the air
distribution valve.
The chambers are manifolded together with a suction and discharge check valve for
each chamber, maintaining flow in one direction through the pump.
This MARATHON pump differs from other models in that it utilizes four diaphragms
instead of two. The two rod-connected diaphragms are the driver diaphragms, and the
other two (outermost) diaphragms are the actual pumping diaphragms. Each driver
diaphragm (of Neoprene or other elastomer), and the pumping diaphragm (of TFE), are
separated by a chamber filled with liquid which transmits the reciprocating motion of the
driver diaphragm to the pumping diaphragm. The pumping diaphragms, create the
alternating suction and discharge action to each outer diaphragm chamber. The pumping
diaphragms are the only ones in contact with the liquid being pumped.
INSTALLATION & START-UP
Locate the pump as close to the product being pumped as possible, keeping suction
line length and number of fittings to a minimum. Do not reduce line size.
For installations of rigid piping, short flexible sections of hose should be installed
between pump and piping. This reduces vibration and strain to the piping system. A
MARATHON surge suppressor is recommended to further reduce pulsation in flow.
This pump was tested at the factory prior to shipment and is ready for operation. It is
completely self-priming from a dry start for suction lifts of 10-15 feet (9-14 meters) or less.
For suction lifts exceeding 15 feet of liquid, fill the chambers with liquid prior to priming.
IMPORTANT
Read 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.
WARNING
Take action to prevent static sparking.
Fire or explosion can result, especially
when handling flammable liquids. The
pump, piping, valves, containers or other
miscellaneous equipment must be
grounded.
BEFORE OPERATION
Before pump operation, inspect all
gasketed fasteners for looseness
caused by gasket creep. Retorque loose
fasteners to prevent leakage. Follow
recommended torques stated in this
manual.
CAUTION
This pump should not be applied in
pumping applications where the driver
liquid coming in contact with the pumped
liquid would create a hazardous
condition. This could happen in the case
of a TFE pumping diaphragm failure.
This diaphragm normally separates the
two liquids. Do not operate this unit if it
has been subjected to freezing
temperatures. Because of the driver liquid
used, possible diaphragm failure may
result.
Fig. 1 Air Inlet
SERVICE AND OPERATING MANUAL
SPILL PREVENTION Design Level 3
Model MP04D
(9 pages)
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