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1. 7 AirVantage Servicing Power Generation Module sse 25 Air Line Moisture AirVantage Servicing Control Module ssseeeeeenenennnnnnnnnnnn 26 Air Valve L brication ertt ttt titer tenter tn rtc cete Here Free 7 AirVantage Servicing Sensor Assembly sse nentes 27 Air Inlet and Prifilhg s iri eret 7 AirVantage Servicing Poppet Valve 0 4 1 28 Between USES EM 7 AirVantage Servicing Poppet Valve 202 29 PUMP E 9 AirVantage Servicing Check Valve 20 08 30 AirVantage Troubleshooting 0 4 4 rnnt rnnt tette tentare rn tree 10 11 Grounding th PUMP rtr ete ce RE A eerie He Re eb icd 31 Composite Repair Parts List niuinntir 12 Pumping Hazardous Liquids Shutdown Procedure sse 32 Composite Repair Parts KIIS certet brennt nte t Renan ce tn 13 Converting the Pump for Piping Exhaust Air senem 33 Composite Repair Parts Drawing Wetted Side ssssssssseees 14 Material Codes for the Last 3 Digits of the Part Number sse 34 Diaphragm and Check Valve Servicing CE Decl
2. j 3 NPT 4 1 NPT HIGH FLOW L EXHAUST MUFFLER AIR INLET 1 NPT 1 T i d 14 Vy SUCTION N 2 3 NPT Je n por 4 A Foe H J English Metric 125 3mm Aluminum Stainless Aluminum Stainless Cast Iron Alloy C Cast Iron Alloy C A 2 35 2 41 60 62 B 15 82 15 88 402 403 C 17 15 17 21 436 438 D 29 98 30 04 761 763 32 08 32 14 815 817 3 74 95 G 11 40 290 H 13 50 343 J 25 16 639 K 19 65 499 L 10 13 257 M 12 00 305 N 11 75 299 P 52 13 62 16 Model RS30 Metallic Page 4 Dimensions RS30 Metallic ANSI Style Flange Connections DISCHARGE PORT K P 3 ANSI STYLE CONNECTION i m pep 1 NPT HIGH FLOW EXHAUST MUFFLER AIR INLET m 1 NPT NI f vi 1 H i n 1 i 1 N I P rm p 1 Poy orn SUCTION PORT 3 ANSI STYLE CONNECTION pale H M G H General Table English Metric N 3 125 3mm A 4 13 105 B 17 60 447 18 93 481 D 31 75 806 E 35 66 906 F 4 15 105 G 11 40 290 H 13 50 343 J 25 16 639 K 19 65 499 BOTH SUCTION AND DISCHARGE PORTS ARE L 10 13 257 AVAILABLE WITH 3 DIN STYLE CONNECTIONS M 12 00 305 N 11 75 299 P 68 17 Q 62 16 rs30mdl1sm r
3. per side Inspect the probe tips and o rings for wear For every diaphragm service these parts should be replaced and are available in kit form Consult the Composite Repair Parts Drawing for part numbers and quantities Step 4 Accessing the Sensor Assembly Use 7 hex key wrench and remove the four flat head socket cap screws on each inner chamber These bolts have been assembled using blue thread locker so they may be difficult to remove The inner chambers and gaskets can now be removed AirVantage CAUTION Remove the inner chamber from the intermediate with caution taking care not to damage the sensor Ifthe sensor needs to be replaced use a 13 16 socket and remove the plastic nut holding the connector to the intermediate Slide the connector out of the hole The sensor can now be removed from the intermediate assembly Step 5 Reinstallation Slide the new sensor assembly in the intermediate AirVantage CAUTION Make sure the cable assembly fits into the groove machined in the intermediate Failure to do so may damage the cable during assembly Feed the connector through the hole in the intermediate and install the plastic nut Hand tighten the nut using a 13 16 socket Make sure the gasket is to the inside of the intermediate The inner chambers and gaskets can now be reinstalled Use blue thread locker on the inner chamber bolts and torque them to 300 in Ibs Referto the Diaphragm Servic
4. 560 105 365 Seal Neoprene O ring 8 518 143 112 Manifold Suction Alloy C Units 1 720 055 608 Seal Conductive PTFE 8 518 143 112bE Manifold Suction Alloy C Units 1 46 724 007 000 Sensor Assembly AirVantage 1 518 143 156 Manifold Suction Aluminum Units 1 47 846 001 167 Tip AirVantage Probe 2 518 143 156E Manifold Suction Aluminum Units 1 48 894 014 000 Valve Check 1 518 171 010 Manifold Suction Cast Iron ANSI Flanged Units 1 48a 031 206 000 Cartridge Check Valve 1 518 171 010E Manifold Suction Cast Iron DIN Flanged Units 1 49 920 027 000 Wire Patch 1 518 171 110 Manifold Suction Stainless ANSI Flanged Units 1 518 171 110E Manifold Suction Stainless DIN Flanged Units 1 518 171 156 Manifold Suction Aluminum ANSI Flanged Units 1 518 171 156E Manifold Suction Aluminum DIN Flanged Units 1 rs30mdl1sm rev0115 Model RS30 Metallic Page 12 Composite Repair Parts Kits Available Service And Conversion Kits Air End Kit 476 282 000 RS30 Only Seals O rings Gaskets Retaining Rings Air Valve Assembly and Pilot Valve Assembly Wet End Kit 476 171 360 RS30 S30 metal Nitrile Diaphragms Balls and Seats Wet End Kit 476 171 364 RS30 S30 metal EPDM Diaphragms Balls and Seats Wet End Kit 476 171 365 RS30 S30 metal Neoprene Diaphragms Balls and Seats Wet End Kit 476 171 633 RS30 S30 metal FKM Diaphragms PTFE Balls and FKM Seats Wet End Kit 476 171 635 RS30 S30 metal Neoprene Diaphragms
5. Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Conductive PVDF Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Unfilled Conductive Polypropylene Conductive HDPE Glass Filled Conductive Polypropylene Rulon Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE 603 Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Integral Silicon 611 PTFE Integral FKM 632 Neoprene Hytrel 633 FKM Fluorocarbon PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE FKM Fluorocarbon PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 650 Bonded Santoprene and PTFE 654 Santoprene Diaphragm PTFE Overlay Balls and seals 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene Delrin and Hytrel are registered tradenames of E l DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Exxon Mobil Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co SANDPIPER PortaPump Tranquilizers and SludgeMaster are
6. Chamber Outer Stainless Units 2 612 194 157 Plate Assy Outer Diaphragm Aluminum Units 2 196 164 112 Chamber Outer Alloy C Units 2 39 612 229 150 Plate Air Inlet Adapter 1 196 200 156 Chamber Outer Aluminum Units 2 40 620 020 115 Plunger Actuator 2 18 196 207 156 Chamber Inner Right Side 1 41 675 042 115 Ring Retaining 2 19 196 208 156 Chamber Inner Left Side 1 42 685 040 120 Rod Diaphragm 1 20 286 098 354 Diaphragm Santoprene 2 43 720 004 360 Seal Diaphragm Rod 2 286 098 360 Diaphragm Nitrile 2 44 722 090 360 Seat Buna 4 286 098 363 Diaphragm FKM 2 722 090 363 Seat FKM 4 286 098 364 Diaphragm EPDM 2 722 090 364 Seat EPDM 4 286 098 365 Diaphragm Neoprene 2 722 090 365 Seat Neoprene 4 21 286 098 604 Diaphragm Teflon Overlay 2 722 090 550 Seat UHMW Polyethylene 4 22 360 093 360 Gasket Main Air Valve 1 722 090 600 Seat PTFE 4 23 360 104 379 Gasket Air Inlet Cap 1 722 090 080 Seat Carbon Steel must use with seals item 43 4 24 360 113 365 Gasket Inner Chamber 2 722 090 110 Seat Stainless must use with seals item 43 4 25 360 114 360 Gasket Pilot Valve 1 722 090 150 Seat Aluminum must use with seals item 43 4 26 518 143 010 Manifold Suction Cast Iron Units 1 45 560 105 360 Seal Nitrile O ring 8 518 143 010E Manifold Suction Cast Iron Units 1 560 105 363 Seal FKM O ring 8 518 143 110 Manifold Suction Stainless Units 1 560 105 364 Seal EPDM O ring 8 518 143 110E Manifold Suction Stainless Units 1
7. Model RS30 Metallic Page 26 AirVantage Servicing Sensor Assembly To service the control module first shut off and bleed the air being supplied to the pump For safety purposes the air supply line should be disconnected from the pump Then shut off the suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump During the servicing of the AirVantage consult the AirVantage Composite Repair Parts Drawing Step 1 Remove the Patch Cable Twistthe ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump Be sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Inspect the o ring between the poppet valve and the adapter plate for damage Step 3 Diaphragm Disassembly Referto the Diaphragm Servicing section p 15 of the manual to remove diaphragm assembly from the pump AirVantage CAUTION When the diaphragm assembly is removed watch for the brass probe tips located on the end of the sensor rod There is one brass probe tip and one o ring
8. and main air valve assembly Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuator pins Check for scores wear or damaged o rings Replace parts as necessary Refer to the exploded view drawing and air valve section P 18 amp 20 What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line What to Check Blocked pumping chamber Corrective Action Disassemble and inspect wetted chambers of the pump Remove or flush any obstructions Refer to page 14 for disassembly PUMP CYCLES BUT WILL NOT FLOW OR FLOW RATE IS UNSATISFACTORY What to Check Restricted or undersized air line Corrective Action Make sure there are no obstructions or restrictions in the air inlet to the pump Install proper size air line and or air line equipment Refer to air supply section p 7 air inlet plumbing recommendations What to Check Restricted or undersized suction piping Corrective Action Make sure there are no obstructions or restrictions in the suction line or related suction components such as screens or strainers Install the proper size suction line and or equipment It is recommended that any suction line components and pipe size be at least the same size as the suction line thread size to the pump Though best results will always be realized if the line size of the suction line is increased by one size Refer to the i
9. form Consult the Composite Repair Parts Drawing for part numbers and quantities Step 5 Remove the Inner Chambers Use 77 hex key wrench and remove the four flat head socket cap screws on each inner chamber These bolts have been assembled using blue thread locker so they may be difficult to remove The inner chambers and gaskets can now be removed AirVantage CAUTION Remove the inner chamber from the intermediate with caution taking care not to damage the sensor Inspect the gaskets and u cup seals under each inner chamber and replace them as necessary Step 6 Accessing the Actuator Plunger Bushings and O rings The actuator plunger pin bushings and o rings can now be accessed If it is determined that these parts need to be replaced use a small screwdriver and remove the retaining rings NOTE It is recommended that new retaining rings be installed after disassembly The bushing and o ring can now be removed and inspected Step 7 Accessing the AirVantage Sensor Ifthe sensor needs to be replaced use 13 16 socket and remove the plastic nut securing the connector to the intermediate Slide the connector out of the hole taking care not to lose misplace the gasket on the connector The sensor can now be removed from the intermediate assembly Step 8 Reinstallation Slide the new sensor assembly in the intermediate AirVantage CAUTION Make sure the cable assembly fits into the groove machined in the i
10. line should be disconnected from the pump Then shut off the suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump Drain any remaining liquid from the pump During the servicing of the diaphragms consult the Composite Repair Parts Drawing p 7 Step 1 Removing the Manifolds Using a 9 16 wrench or socket remove the 16 cap screws hex nuts and lockwashers that fasten the manifolds to the outer chambers Remove the manifolds Step 2 Inspect Check Valve Components Inspect the four check balls for wear abrasion or cuts on the spherical surface Also inspect the four check valve seats for cuts abrasive wear or embedded material around the area where the ball contacts the seat Formaximum pump performance and efficiency the surface of the ball must seal against the seat without any gaps Replace worn or damaged parts as necessary Consult the Composite Repair Parts Drawing for part numbers and quantities Step 3 Removing the Outer Chambers Using an 11 16 and a 5 8 wrench or socket remove the 16 cap screws and hexnuts that fasten the outer chambers diaphragms and inner chambers Step 4 Removing the Diaphragm Assemblies Once the outer chambers are removed use a 1 1 16 27mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod by turning counterc
11. o rings and retaining ring Fasten the air valve assembly and gasket to the pump Connect the compressed air line to the pump Remove the safety clip The pump is now ready for operation A 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 Model RS30 Metallic Page 19 Pilot Valve and Actuator Plunger Servicing To service the pilot valve or the actuator plungers first shut off and bleed the air being supplied to the Step 7 Reassembly pump For safety purposes the air supply line should be disconnected from the pump Then shut off the Reinstall the pilot valve and gaskets Take caution during the installation to align the ends of the pilot valve suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines stem between the plunger pins If the pilot valve does not fit flush against the gasket check to make sure and remove the lines from the actuator plunger are pushed all the way Failure to do so may cause damage to the pilot valve or the the pump actuators Step 8 Reassemble AirVantage and Cable Reinstall the AirVantage using the four 5 16 18 x 5 cap screws and torque to 90 in Ibs Reattach the patch cable connector that connects the AirVantage module to t
12. on page 12 for part numbers Model RS30 Metallic Page 25 1 Iei Step 5 Reinstallin Ai rVantage Se rvicin g 2 ontrol M od le When reinstalling ihe nos control module make sure to feed the pilot valve connector wire through the To service the control module first shut off and bleed the air being supplied to the pump For safety hole in the poppet valve assembly Install the two 10 32 x 1 00 socket head cap screws and tighten to 30 in Ibs purposes the air supply line should be disconnected from the pump Then shut off the suction and Reinstall the power generation module Make sure to feed the control module wire through the hole in the discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove power generation case Install the four 10 32 x 2 socket head cap screws and tighten to 60 in Ibs the lines from the pump During the servicing of the AirVantage consult the AirVantage Composite AirVantage CAUTION Be sure to reattach the connector from the power generator to the Repair Parts Drawing control board eS P Reinstall the top cover making sure the o ring seal is still in the groove Tighten the four 10 32 screws Reinstall the AirVantage using the four 5 16 18 x 5 cap screws and torque to Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed fro
13. 0 361 363 364 365 366 368 370 371 374 Material Codes The Last 3 Digits of Part Number Die Cast Zinc Copper Alloy Carbon Steel Black Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compression Mold Urethane Rubber Nitrile Rubber Color coded RED FDA Accepted Nitrile FKM Fluorocarbon Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile 375 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 553 555 556 557 558 559 570 580 590 591 592 600 601 602 Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Cellulose Fiber Cork and Neoprene Compressed Fiber Blue Gard Vegetable Fiber Fiber Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled
14. 1 147 003 Assy Air Valve Pulse Output Kit See Exploded View 1 518 144 010E Manifold Discharge Cast Iron Units 1 2 032 051 000 Assy AirVantage See Exploded View for Details 1 518 144 110 Manifold Discharge Stainless Units 1 3 050 014 354 Check Ball Santoprene 4 518 144 110E Manifold Discharge Stainless Units 1 050 014 360 Check Ball Nitrile 4 518 144 112 Manifold Discharge Alloy C Units 1 050 014 364W Check Ball EPDM 4 518 144 112E Manifold Discharge Alloy C Units 1 050 014 365 Check Ball Neoprene 4 518 144 156 Manifold Discharge Aluminum Units 1 050 015 600 Check Ball PTFE 4 518 144 156E Manifold Discharge Aluminum Units 1 4 070 006 170 Bushing Intermediate 2 518 172 010 Manifold Discharge Cast Iron ANSI Flanged Units 1 5 095 110 000 Assy Pilot Valve See Exploded View for Details 1 518 172 010E Manifold Discharge Cast Iron DIN Flanged Units 1 6 114 029 157 Assy Intermediate See Exploded View for Details 1 518 172 110 Manifold Discharge Stainless ANSI Flanged Units 1 7 132 035 360 Bumper Diaphragm 2 518 172 110E Manifold Discharge Stainless DIN Flanged Units 1 8 135 034 506 Bushing Plunger 2 518 172 156 Manifold Discharge Aluminum ANSI Flanged Units 1 9 165 133 150 Cap Sensor Mount Plate 2 518 172 156E Manifold Discharge Aluminum DIN Flanged Units 1 10 170 006 115 Cap Screw Hex Head 3 8 16 x 1 Stainless 4 28 530 038 000 Muffler 1 170 006 330 Cap Screw Hex Head 3 8 16 x 1 Zinc Plated Steel 4 29 5
15. 219 99 00 219 99 00 260 118 RS30B1ABBANASOO RS30B1AEEANASOO RS30B1AGTANASOO RS30B1ANNANASOO RS30B1A1EANASOO RS30B1IBBANASOO RS30B1IEEANASOO RS30B1IGTANASOO RS30B1INNANASOO RS30B111EANASOO RS30B1SBBANASOO RS30B1SGTANASOO RS30B1SNNANASOO 530 151 500 RS30B1HGTANASOO UJ UJ w w w w w w w w w w w w w z o w z o m w z o m w a m z 4 m z 4 m w m z m b gt gt gt gt gt gt gt gt gt gt S S S S z z z z z z z z z z z z z 2 P gt gt gt gt gt gt S SSS S S gt gt wm ooo wm wm wm ol olol A A A A S S S S H Note Models listed in the table are for reference only See nomenclature below for other models Pump Brand Diaphragm Check Valve Materials Non Wetted Material Options Pump Options RS SANDPIPER 1 Santoprene Santoprene A Painted Aluminum P 110 VAC plug in Electrical AirVantage 2 PTFE Santoprene PTFE J Painted Aluminum w PTFE Hook up with High Flow Pump Size Coated Hardware Metal Muffler Y Painted Aluminum with 30 3 E EPDM EPDM Stainless 5 Self Contained Electrical i w ep Check Valve Type EPDM Santoprene Generation with High Flow B Ball PTFE Neoprene PTFE Porting Options Metal Muffler NPT T
16. 30 VDC 475 244 002 110 220 VAC 475 244 003 10 30VDC 110VAC and 220 VAC rs30mdl1sm rev0115 Model RS30 Metallic Page 21 This Page Intentionally Blank rs30mdl1sm rev0115 Model RS30 Metallic Page 22 Composite Repair Parts Drawing AirVantage Unit AirVantage Composite Parts List ITEM NO PART NUMBER DESCRIPTION 2 A 020 069 000 REGULATOR 031 199 000 POWER GENERATION MODULE 171 079 115 CAPSCREW HEX SOC HD 10 32 X 50 171 080 115 CAPSCREW HEX SOC HD 10 32 X 1 00 171 081 115 CAPSCREW HEX SOC HD 10 32 X 2 25 249 029 000 CONTROL MODULE 258 018 551 COVER 530 044 000 MUFFLER 560 200 360 O RING 720 071 360 SEAL O RING 765 004 000 VALVE SOLENOID 893 106 000 VALVE POPPET Optional 1 4 NPT Pipe Plug P N 618 011 330 Must be installed if performing direct spray wash down of pump Purchased Separately NYX NES 2 rs30mdl1sm rev0115 Model RS30 Metallic Page 23 AirVantage Servicing Pilot Valve and Pressure Regulator Pilot Valve and Pressure Regulator To service the pilot valve or the pressure regulator first shut off and bleed the air being supplied to the pump For safety purposes the air supply line should be disconnected from the pump Then shut off the suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump During the servicing of the AirVantage consult the AirVantage Composite Re
17. 45 007 115 Nut Hex 7 16 14 Stainless 16 171 059 115 Cap Screw Socket Head 3 8 16 x 2 50 Pulse Output Kit 545 007 330 Nut Hex 7 16 14 Zinc Plated Steel 16 171 059 330 Cap Screw Socket Head 3 8 16 x 2 50 Pulse Output Kit 30 545 008 115 Nut Hex 1 2 13 Stainless 16 11 170 055 115 Cap Screw Hex Head 1 2 13 x 2 1 2 Stainless 16 545 008 330 Nut Hex 1 2 13 Zinc Plated Steel 16 170 055 330 Cap Screw Hex Head 1 2 13 x 2 1 2 Zinc Plated Steel 16 31 560 001 360 O ring Plunger Pin 2 12 170 060 115 Cap Screw Hex Head 7 16 14 x 2 Stainless 16 32 560 011 360 O ring Adapter Plate 2 170 060 330 Cap Screw Hex Head 7 16 14 x 2 Zinc Plated Steel 16 33 560 033 360 O ring Sensor Bushing 2 13 170 122 115 Cap Screw Hex Head 5 16 18 x 5 Stainless 4 34 560 200 360 O ring 1 170 122 330 Cap Screw Hex Head 5 16 18 x 5 Zinc Plated Steel 4 35 560 201 360 O ring Probe Tip 2 14 171 059 330 Cap Screw Socket Flat Head 7 16 14 x 1 1 4 8 36 560 203 360 O ring Sensor Cap 2 15 171 082 115 Cap Screw Socket Head 5 16 18 x 1 1 4 Stainless 4 37 612 232 150 Plate Inner Diaphragm 2 171 082 330 Cap Screw Socket Head 5 16 18 x 1 1 4 Zinc Plated Steel 4 38 612 194 010 Plate Assy Outer Diaphragm Cast Iron Units 2 16 171 100 115 Cap Screw Socket Head 5 16 18 x 2 1 2 Stainless 4 612 194 110 Plate Assy Outer Diaphragm Stainless Units 2 17 196 164 010 Chamber Outer Cast Iron Units 2 612 194 112 Plate Assy Outer Diaphragm Hastalloy Units 2 196 164 110
18. ION With the pump lying on one inner chamber pull the sensor rod UP the full length of its stroke Insert the brass probe tip and o ring into the sensor rod Insert rod and diaphragm assembly into pump taking care not to damage the u cup seal Make sure the diaphragm plate contacts the brass probe tip and stays in contact with it This will help make sure the probe tip does not fall out during reassembly Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber Fasten the outer chamber to the pump using the cap screws and hex nuts but do not tighten Flip the pump over so that it is now setting on the outer chamber Pull the diaphragm rod out as far as possible Make sure the bumper is installed over the diaphragm rod AirVantage CAUTION Install the second brass probe tip and o ring on the sensor rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 34 until the diaphragm plate contacts the end surface of the diaphragm rod If the bolt holes in the diaphragm do not line up with the inner chamber use a 1 1 16 27 mm socket or wrench to tighten the assembly until they line up Fastenthe remaining outer chamber to the pump using the cap screws and hex nuts and once again do not tighten at this point Tip the pump 90 and set it on a flat surface with the discharge side of the chambers down This will allow the outer chambers to be alig
19. PTFE overlays PTFE Balls and Seats Wet End Kit 476 171 654 RS30 S30 metal Santoprene Diaphragms PTFE Overlays PTFE Balls and Seats Wet End Kit 476 171 656 RS30 S30 metal Santoprene Diaphragms Balls and EPDM Seats Sensor Kit 476 285 000 Sensor Probe Tips and O rings Poppet Valve Kit 476 271 000 Poppet Valve Assembly O ring Poppet Valve Assembly Kit 476 272 000 Poppet Valve Assembly O ring Regulator and Pilot Valve Cover Kit 476 273 000 Enclosures Hardware and O rings Control Module Kit 476 275 000 Power Gen AirVantage Only Control Module Assembly Gaskets Hardware and O rings Power Gen Kit 476 278 000 Power Gen AirVantage Only Power Gen Gasket Hardware and O ring Seal Kit 476 280 000 O rings and Gaskets Probe Tip Kit 476 283 000 Probe Tips and O rings Midsection Upgrade Kit 475 XXX 000 Consult Factory Replaces S30 Metallic Midsection with AirVantage Components rs30mdl1sm rev0115 WETTED END KIT AIR END KIT Model RS30 Metallic Page 13 Composite Repair Parts Drawing Wetted Side AVAILABLE WITH ANSI FLANGE PTFE OVERLAY OPTION AVAILABLE WITH Note Refer to Composite Parts ANSI FLANGE List on page 12 for part numbers Page 14 rs30mdl1sm rev0115 Model RS30 Metallic Page 14 DIAPHRAGM AND CHECK VALVE SERVICING To service the diaphragms first shut off and bleed the air being supplied to the pump For safety purposes the air supply
20. SERVICE amp OPERATING MANUAL SANDPIPERs A WARREN RUPP INC BRAND Model RS30 Metallic AirVantage Design Level 1 Table of Contents SAFETY PRECAUTIONS US Patent 6 241 487 US Patent 7 521 921 Pending Engineering Performance and Construciton Data Composite Repair Parts Drawing Air Side seen 16 Explanation of Pump Nomenclature eseeeeennenennnnnennnnnennnnnnnnnn Intermediate and AirVantage Sensor Servicing seen 17 Performance ERR 3 Air Valve Servicing Assembly Drawings and Parts List sss 18 DIMENSIONS 4 5 Air Valve Servicing with Stroke Indicators Assembly Drawings and Parts List 19 Important Installation Information seen 6 Pilot Valve and Actuator Plunger Servicing seen 20 Principle Of Pump Operalioh 2 tete ter 7 Pulse Output Kits and Drawing m irr remm n t ctae pat ier b gs 21 Principle of AlrVantatje etre rte E Ir e EO Rn T Composite Repair Parts Drawing AirVantage 2 2 44444 0000 06 23 Jhstallation and Start Up omnet tede memet ene ote is 7 AirVantage Servicing Pilot Valve and Pressure Regulator sss 24 SUPP 2
21. Step 5 Reassemble the Pilot Valve Generously lubricate the o rings on the pilot sleeve with multipurpose grease BP LSEP 2 or equivalent Carefully insert the sleeve in the pilot valve body taking care not to shear any of the o rings Install the retaining ring Generously lubricate the o rings on the pilot spool Carefully insert the spool in the Sleeve Step 6 Inspect the Actuator Plungers With the pilot valve assembly off the pump the actuator plungers can be accessed Remove the plungers and inspect them for nicks or unusual wear Replace them if necessary If the bushings or o rings need to be replaced refer to the Intermediate Servicing section p 17 Apply a generous amount of lubricant and install the plungers back in the intermediate Push the as far in as they will go Note Refer to Composite Repair Parts List on page 12 for part numbers rs30mdl1sm rev0115 Model RS30 Metallic Page 20 Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the Stroke Counter Batch Controller or user control devices such as a PLC The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the air valve and senses each stroke of the main spool Consult the factory for further information and availability Pulse Output Kits 475 244 001 10
22. TE AND AirVantage SENSOR SERVICING To service the intermediate and AirVantage sensor first shut off and bleed the air being supplied to the pump For safety purposes the air supply line should be disconnected from the pump Shut off both the suction and discharge lines to the pump Consult the Composite Repair Parts Drawing Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a 7 socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Step 3 Remove the Manifolds Chambers and Diaphragms See Diaphragm Servicing Section Step 4 Remove the Diaphragm Assemblies Refer to the Diaphragm Servicing section of the manual to remove diaphragm assembly from the pump AirVantage CAUTION When the diaphragm assembly is removed watch for the brass probe tips located on the end of the sensor rod There is one brass probe tip and one o ring per side Inspect the probe tips and o rings for wear For every diaphragm service these parts should be replaced and are available in kit
23. The pump piping valves containers or other miscellaneous equipment must be grounded rs30mdl1sm rev0115 Model RS30 Metallic Page 31 PUMPING HAZARDOUS LIQUIDS CONVERTED EXHAUST ILLUSTRATION When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic PUMP INSTALLATION AREA materials the exhaust air must be piped to an appropriate area for safe disposal See SAFE AIR illustration 1 at right EXHAUST Piping used for the air exhaust must not be smaller than 1 2 54 cm diameter Reducing DISPOSAL the pipe size will restrict air flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the AREA exhaust higher than the product source to prevent siphoning spills See illustration 2 at 4 DIAMETER AIR right EXHAUST PIPING CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Remove the muffler The air distribution valve has 1 NPT threads for piped exhaust MUFFLER IMPORTANT INSTALLATION NOTE Illustration 1 The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded threads of the air exhaust port Failure to do so may result in damage to the air distrib
24. age while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Inspect the o ring between the poppet valve and the adapter plate for damage Step 3 Access the Pilot Valve and Pressure Regulator Use a 5 32 hex key wrench and loosen the four 10 32 x 50 socket head cap screws securing the top cover on Lift the cover off exposing the pilot valve and pressure regulator There is a molded o ring seal located on the underside of the cap Make sure the o ring stays located within the groove Unplug the connector attached to it Use a miniature 4 way Phillips screwdriver and remove the two screws securing the pilot valve to the plate The valve and gasket can now be removed and or replaced Use slip joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction AirVantage CAUTION Do not loosen or tighten the regulator by turning the knurled portion of the unit Place the slip joint pliers on the smooth area underneath the knurled area of the regulator Reinstall the top cover and loosely reinstall the bolts Turn the assembly over and let it now rest on the top cover Step 4 Access the Power Generation Module Use a 5 32 hex key wrench and remove the four 10 32 x 50 socket head cap screws securing the bottom cover on Lift the bottom cover off exposing the power generation module There is a molded o ring seal lo
25. aration of Confotilly re ge ip de 35 Warren Rupp Inc A Unit of IDEX Corporation 800 Main St Mansfield Ohio 44902 USA Telephone 419 524 8388 Fax 419 522 7867 warrenrupp com rs30mdl1sm rev0115 Copyright 2015 Warren Rupp Inc All rights reserved Cautions Read Operating and Safety Precautions First 4 IMPORTANT Before installation and start up of the pump read these safety warnings and instructions in this manual completely 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 CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual A CAUTION Pump not designed tested or certified to be powered by compressed natural gas Powering the pump with natural gas will void the warranty Recycling Warren Rupp is committed to protecting the environment and preventing pollution for the benefit of our employees as well as local and global WARNING 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 which is hazardous or toxic the air exhaust mu
26. cated on the underside of the cap Make sure the o ring stays located within the groove Unplug the connector that connects the power generator to the control board Use a 5 32 hex key wrench to loosen the four 10 32 x 2 1 4 socket head cap screws The power generation module should now be loose Carefully lift the power generation module off the rest of the assembly making sure that the control board wire and connector slips through the hole in the power generation case Step 5 Access the Control Module Use a 5 32 hex key wrench and loosen the two 10 32 x 1 00 socket head cap screws securing the control module to the poppet assembly The control module should now be loose Carefully lift the control module off the poppet assembly making sure that the pilot valve connector wire slips through the hole in the poppet valve assembly The Poppet valve assembly can now be replaced rs30mdl1sm rev0115 Step 6 Reinstallation Install the control module on the poppet valve assembly Make sure to feed the pilot valve connector wire through the hole in the poppet valve assembly Install the two 10 32 x 1 00 socket head cap screws and tighten to 30 in Ibs Install the power generation module onto the control module Make sure to feed the control module wire through the hole in the power generation case Install the four 10 32 x 2 socket head cap screws and tighten to 60 in Ibs AirVantage CAUTION Be sure to reattach the connector from t
27. e sure patch cable plug is connected and locked Make sure power wire connectors are tight Corrective Action Consult Factory After Sales Support team PUMP RUNNING SLOWLY What to Check Run pump without AirVantage and check operation Cycle the power off on to the control module to reset controller Check ice buildup in exhaust area Inspect sleeve and spool set for damage Corrective Action Consult Factory After Sales Support team Cycle the power switch on the control module off on Model RS30 Metallic Page 10 AirVantage Troubleshooting Continued AirVantage RESETS AND ENTERS LEARN MODE TOO FREQUENTLY What to Check Check for excessive varying environmental pumping conditions changing head or suction Check ice buildup in exhaust area Inspect sleeve and spool set for damage Make sure patch cable plug is connected and locked Corrective Action Consult Factory After Sales Support Team CAPSCREW HEX SOC HD 10 32 X 50 COVER SEAL O RING VALVE SOLENOID REGULATOR PUMP STALLS RESETS LEARNS SEEKS AND REPEATS What to Check Make sure patch cable plug is connected and locked Check ice buildup in exhaust area Corrective Action Consult Factory After Sales Support Team VALVE POPPET PUMP MOVES OUT OF STEADY STATE AND NEVER ATTEMPTS TO RELEARN LED ON What to Check Make sure patch cable plug is connected and locked Cycle the power off on to the control module Corrective Ac
28. e to more energy being extracted from every pulse of air When more energy is extracted the temperature of the air is reduced Some method of air drying will be necessary Most refrigerant dryers installed on compressors can reduce the dewpoint to about 40 F This is normally adequate for most pumping applications If further drying needs to occur due to internal ice build up a desiccant dryer can be installed These air line dryers can lower the dewpoint to around 40 F AIR VALVE LUBRICATION The air valve and pilot valve are designed to operate without lubrication There may be instances of personal preference or when extremely dry air is being used instrument quality or nitrogen that a small amount of lubrication will improve the life of the rubber components being used on the air side of the pump The lubrication may be added using an air line lubricator PN 020 051 001 1 PN 020 052 001 At the point of operation use SAE 10 weight non detergent oil at a maximum rate of 1 drop per hour for every 20 scfm 9 4 liters sec of air consumption Consult the pump curve to determine this value The smallest amount needed is preferred AIR INLET AND PRIMING To start the pump make sure the AirVantage switch is in the off position Increase the pressure until the pump starts to cycle The pump stroke rate should slow slightly when the pump is primed Once the pump is fully primed increase the pressure at the regulator until the desired flo
29. ed A Warren Rupp Tranquilizer is recommended to reduce the pulsation in the flow If the fluid level is more than 10 feet 3 meters above the level of the pump a pressure regulating device may need to be added to the exhaust of the pump Consult the factory for recommendations AIR SUPPLY The air supply pressure cannot exceed 125 psi 8 6 bar The air line and associated components filters regulators solenoids valves etc should not be less than 72 13 mm Though 3 4 19mm or greater is preferred An air line filter regulator is necessary for the AirVantage installation The required component PN 020 107 000 is available through the distributor Rigid pipe should not be hooked directly to the air inlet of the AirVantage A flexible hose should be installed to reduce the strain Do not let the weight of the air line components be supported by the air inlet of the pump Failure to provide a means of supporting the weight may result in damage to the pump If the pump is going to be shut down for any extended length of time It is recommended that the air supply to the pump should be shut off rs30mdl1sm rev0115 AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing and freezing of the exhaust air The formation of ice in the exhaust can cause the pump to cycle erratically degrade efficiency or even stop the pump Fitting the pump with the AirVantage technology reduces the exhaust temperature This is du
30. eeds to be inspected at the point where the diaphragm contacts the outer chamber or where the diaphragm plates contacts the diaphragm Chemical attack of a diaphragm will usually result in swelling or deformity Replace the diaphragms if necessary Inspect the diaphragm connecting rod for scars nicks or any imperfection that could cause damage to the u cup seal Inspect the u cup seal for imperfections on the sealing lip Inspect the bumpers for damage on the face rs30mdl1sm rev0115 Replace components as necessary Consult the Composite Repair Parts Drawing for part numbers and quantities Step 6 Assemble the Diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise onto the stud Insert the loose assembly with the above 1 4 20 fastener back into the vise Use a torque wrench and 1 1 16 socket 27 mm to tighten the diaphragm assembly together to 480 in Ibs 54 23 Newton meters Allow a torqued assembly to set for 15 minutes This will allow the diaphragm to relax Re torque the assembly to compensate for stress relaxation in the clamped assembly Step 7 Installing the Diaphragm Assemblies to the Pump Make sure the bumper is installed over the diaphragm rod Thread the stud of the one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod until the inner diaphragm plate is flush to the end of the rod AirVantage CAUT
31. esign Level 1 C Ball Valve Quality System ISO 9001 Certified Environmental Management System ISO 14001 Certified US Patent 6 241 487 Air Operated US Patent 7 521 921 Pending Double Diaphragm Pump FLUID amp METERING ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 3 NPT internal 0 to 245 gallons per minute No lube no stall Up to 38 in 9mm 125 psi or 289 ft of water 1 00 Gallon 3 78 liter 3 BSP Tapered internal 0 to 927 liters per minute design 125 psi or 8 6 bar inlet 8 6 bar or 88 meters CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like 190 F 10 F acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons 88 23 C EPDM Shows very good water and chemical resistance Has poor resistance to oil and solvents but is fair in ketones and alcohols 280 F 40 F 138 C 40 C Neoprene All purpose Resistant to vegetable oil Generally not affected by moderate chemicals fats greases and many oils and solvents Generally 200 F 10 F attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocarbons 93 C 23 Santop
32. essure regulator needs to be replaced use slip joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction AirVantage CAUTION Do not loosen or tighten the regulator by turning the knurled portion of the unit Place the slip joint pliers on the smooth area underneath the knurled area of the regulator Step 4 Reinstallation Reinstall the top cover making sure the o ring seal is still in the groove Tighten the four 10 32 screws Reinstall the AirVantage using the four 5 16 18 x 5 cap screws and torque to 90 in Ibs AirVantage CAUTION Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate rs30mdl1sm rev0115 CAPSCREW HEX SOC HD 10 32 X 50 TOP COVER CONNECTOR To Solenoid SEAL O RING VALVE SOLENOID VALVE POPPET CONNECTER PRESSURE To Intermediate REGULATOR CABLE PATCH BOTTOM COVER Note Refer to Composite Repair Parts List on page 12 for part numbers Model RS30 Metallic Page 24 AirVantage Servicing Power Generation Module To service the power generation module first shut off and bleed the air being supplied to the pump For safety purposes the air supply line should be disconnected from the pump Then shut off the suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump During the servicing of the AirVan
33. ev0115 Model RS30 Metallic Page 5 Important Installation Information Use of the standard AODD Installation Guide is recommended for pumps Suggested Installation Guide fitted with AirVantage technology Install shut off valves on both the suction and discharge of the pump This will help limit the amount of product that enters the center section of the pump in the event of a diaphragm failure Using shut off valves in conjunction with a drain port also provides a means of allowing the lines to be drained when maintenance needs to EIL be conducted When the supply liquid level is above the air inlet of the pump and SUE x ned sns e diaphragm fails the pumped liquid or fumes can enter the air end through NRI Optional the point of failure When a diaphragm failure is detected it is best to close the shut off valves and bleed the lines of product This will limit the ability imi Pressure Gauge of the material being pumped to enter the AirVantage Failure to do so may 82 a result in damage to the AirVantage and air distribution components Shut Off Valve If a diaphragm failure has been detected in pumps fitted with AirVantage the following procedure for shut down must be used Pipe Connection ae Style Optional C Hd HE ar Flexible Connector 1 Close the suction shut off valve this will limit any new product from entering the p
34. he intermediate Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module ITEM NO PART NUMBER DESCRIPTION QTY Step 2 Remove the AirVantage from the Pump Use a socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the m 80087 pump Be sure to support the weight of the AirVantage while removing the last cap screw After the 5 B 755 051 148 SLEEVE PILOT VALVE 1 AirVantage is removed from the pump carefully set the unit down on the plastic cover located on the 5C 560 033 360 O RING 6 bottom 5 D 715 055 110 SPOOL PILOT VALVE 1 Step 3 Remove the Air Inlet Adapter Plate Adapter 5 E 560 023 360 O RING 3 Use a 7 hex key wrench and remove the four 5 16 18 1 74 socket head cap screws This will allow 5F 675 037 080 RING RETAINING 1 access to the pilot valve gaskets and actuator plungers Step 4 Disassemble the Pilot Valve Remove the pilot spool and wipe it clean Inspect the spool and o rings for dirt cuts or wear Replace parts if necessary Use a set of outside snap ring pliers and remove the retaining ring holding the sleeve in the pilot valve body Gently push the sleeve from the body and wipe it clean Inspect the sleeve and o rings Replace parts if necessary
35. he power generator to the control board Install the bottom cover making sure the o ring seal is still in the groove Tighten the four 10 32 screws The unit can now be turned over and set on the bottom cover Install the pilot valve tighten the screws snug with a miniature 4 way Phillips screwdriver AirVantage CAUTION Be sure to reattach the connector to the pilot valve AirVantage CAUTION Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate If the pressure regulator needs to be replaced use slip joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction AirVantage CAUTION Do not loosen or tighten the regulator by turning the knurled portion of the unit Place the slip joint pliers on the smooth area underneath the knurled area of the regulator Step 4 Reinstallation Reinstall the top cover making sure the o ring seal is still in the groove Tighten the four 10 32 screws Reinstall the AirVantage using the four 5 16 18 x 5 cap screws and torque to 90 in lbs AirVantage CAUTION Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate Refer to Page 28 for Illustration Model RS30 Metallic Page 29 AirVantage Servicing Check Valve AirVantage Check Valve Assembly To service the check valve first shut off and bleed the air being supplied to the pump For safety purpose
36. hreads Kit Options Design Level Check Valve S B BSP Tapered Threads a 1 Design Level eck Valve Seat ANSI Flanae None A Aluminum 9 10 30VDC Wetted Material B Nitrile D DIN Flange Pulse Output Kit A Aluminum C Carbon Steel Raised Face 150 P2 110 120 or 220 240VAC Cast Iron E EPDM Threaded ANSI Flange Pulse Output Kit S Stainless Steel N Neoprene Pump Style SP Stroke Indicator Pins Alloy C S Stainless Steel A Anodized Aluminum T PTFE i i V FKM Air Saving Valve rs30mdl1sm rev0115 Model RS30 Metallic Page 2 Performance Curve RS30 Metallic Design Level 1 Performance 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 a 10 17 SCFM M hr 100 0 20 40 60 80 100 120 140 160 180 200 220 240 260 U S Gallons per minute nu sp e ce Xd Es E 0 100 200 300 400 500 600 700 800 900 Liters per minute CAPACITY rs30mdl1sm rev0115 METERS aO Model RS30 Metallic Page 3 Dimensions RS30 Metallic Standard NPT Port Connections DISCHARGE PORT rs30mdl1sm rev0115 BOTH SUCTION AND DISCHARGE PORTS ARE AVAILABLE WITH 3 BSP CONNECTIONS
37. ing section of the manual to finish the diaphragm installation procedure rs30mdl1sm rev0115 SENSOR FEEDBACK FLAT EDGE BRACKET INTERMEDIATE ASSEMBLY Note Refer to Composite Parts List on page 12 for part numbers PLATE OUTER DIAPHRAGM DIAPHRAGM PLATE INNER DIAPHRAGM PROBE TIP O RING Model RS30 Metallic Page 27 AirVantage Servicing CAPSCREW HEX SOC HD 10 32 X 50 Poppet Valve Drawing COVER SEAL O RING VALVE SOLENOID REGULATOR VALVE POPPET SEAL O RING O RING CONTROL MODULE Must be installed if performing direct spray wash down of pump Purchased Separately MUFFLER SEAL O RING ASSEMBLY POWER GENERATOR CAPSCREW HEX SOC HD 10 32 X 1 00 CAPSCREW HEX SOC HD 10 32 X 2 25 SEAL O RING CAPSCREW HEX SOC HD 10 32 X 50 Note Refer to AirVantage Composite Repair Parts List on page 23 for part numbers rs30mdl1sm rev0115 LS 1 4 NPT Pipe Plug P N 618 011 330 Model RS30 Metallic Page 28 AirVantage Servicing Poppet Valve Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a 77 socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump Be sure to support the weight of the AirVant
38. irVantage is a special air side device which uses equipment that can accurately monitor the operation of the pump Based on the monitored information meter the correct amount of air needed to perform the work required and NOTHING MORE Once the pump starts up and the AirVantage is turned on the LED indicator light will go through a series of patterns Initially the light will be solid green This indicates the AirVantage is allowing the pump to reach a steady state Next the light will pulse at a very rapid rate This is called the learn phase Learn is where the AirVantage monitors the pump in non AirVantage mode This will set the parameters for operation in AirVantage mode In less than one minute the pump will change tones The LED indicator light will start an uneven blink when optimization has started Optimization will be completed once the LED light is blinking in unison with the stroke rate of the pump All this is completed without sacrificing a significant amount of flow INSTALLATION AND START UP The pump should be located near the product being pumped keeping the suction line as short as possible Keep the number of fittings between the product and the pump to a minimum and maintain the line size if possible Better results will always be realized if the line size of the suction line is increased by one size It s not recommended to hook up rigid pipe directly to the pump Some method of expansion joint or vibration isolator should be us
39. lockwise AirVantage CAUTION When diaphragm assemblies are removed watch for the brass probe tips located on the end of the sensor rod There is one brass probe tip and one o ring per side Inspect the probe tips and o rings for wear For every diaphragm service these parts should be replaced and are available in kit form Consult the Composite Repair Parts Drawing for part numbers and quantities The diaphragm connecting rod will usually stay with one of the diaphragm assemblies Install the rod in a vise fitted with soft jaws and loosen the diaphragm assembly from the rod Take care not to scar the surface of the rod Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use the 1 1 16 wrench or socket to remove the outer diaphragm plate by turning counter clockwise Step 5 Inspect Diaphragms Diaphragm Connecting Rod U cup Seals and Bumpers Inspect the diaphragms for cuts and or punctures in the flexing area Even the smallest hole or crack can allow product to get to the air side of the pump If there is product noticed on the air side of the diaphragm there is a good possibility the diaphragm needs to be replaced AirVantage CAUTION If product is observed on the air side of the diaphragm refer to the AirVantage Servicing section of the service manual Abrasive wear of the diaphragm n
40. m the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a 7 socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump Be sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Inspect the o ring between the poppet valve and the adapter plate for damage Step 3 Access the Pilot Valve Use a 5 32 hex key wrench and loosen the four 10 32 x 50 socket head cap screws securing the top cover on Lift the cover off exposing the pilot valve There is a molded o ring seal located on the underside of the cap Make sure the o ring stays located within the groove The connector will need to be removed from the pilot valve Once the plug has been removed feed the wire assembly into the hole in the valve body to the point where the connector just enters the valve body Reinstall the top cover and loosely reinstall the bolts The connector will eventually need to be reconnected Step 4 Access the Control Module Use a 5 32 hex key wrench and loosen the four 10 32 x 50 socket head cap screws securing the bottom cover on Lift the bottom cover off exposing the power generation module There is a molded o ring seal located on the underside of the cap Make sure the o ring stays located within the groove Unplug the connector that connects the po
41. mply Wipe spool with a soft cloth and inspect for scratches or wear pump The pump is now ready for operation with the recommendations stated in this Inspect the inner diameter of the sleeve for dirt scratches or other contaminants Remove the sleeve if manual will damage the pump and void needed and replace with a new sleeve and spool set factory warranty rs30mdl1sm rev0115 Model RS30 Metallic Page 18 Air Valve with Stroke Indicator Assembly Drawing and Parts List NOTE Check gap after assembly to insure complete installation of Retaining Ring AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 28 1 031 147 003 Air Valve Assembly 1 1 A 031 143 162 Sleeve and Spool Set 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 098 147 Cap End 2 1 E 560 020 360 O Ring 8 1 F 675 044 115 Ring Retaining 2 1 G 210 008 330 Clip Safety 1 1 H 560 029 360 O Ring 2 Air Distribution Valve With Stroke Indicator Option Servicing Step 3 Reassembly of the air valve To service the air valve first shut off the compressed air supply bleed the pressure from the pump and Install one bumper and one end cap with o rings into one end of the air valve body Install one retaining disconnect the air supply line from the pump ring into the groove on the same end Insert the safety clip through the smaller unthreaded hole in the endcap Remove the new sleeve and spool set from the plastic bag Caref
42. ned with each other Tighten the sixteen fasteners Make sure to use a cross tightening pattern to ensure an even sealing on the diaphragm Step 8 Re install the Check Valve Components and Manifolds While the pump is setting on the discharge side insert the check balls and seats on the suction side of the pump Make sure the seats fit within the counter bore of the chambers The suction manifold can now be installed using the eight cap screws hex nuts and lock washers Flip the pump 180 and install the seats and check balls on the discharge side Now the discharge manifold can be installed and fastened using the remaining cap screws hex nuts and lock washers A IMPORTANT Read these instructions completely before OVERLAY DIAPHRAGM SERVICING instullaion and startup The overlay diaphragm is a PTFE diaphragm that fits over the exterior of the diaphragm The PTFE diaphragm is used to protect the standard diaphragm from the chemicals being pumped Repeat step 6 when diaphragms need to be serviced Itis 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 Model RS30 Metallic Page 15 Composite Repair Parts Drawing Air Side PTFE OVERLAY OPTION Note Refer to Composite Parts List on page 12 for part numbers Model RS30 Metallic Page 16 rs30mdl1sm rev0115 INTERMEDIA
43. nstallation section p 5 for recommended suction plumbing recommendations What to Check Blocked air exhaust muffler Corrective Action Remove muffler clean or de ice and reinstall rs30mdl1sm rev0115 What to Check Excessive Suction Lift Corrective Action For lifts exceeding 20 feet 6 meters filling the pump chambers with liquid will prime the pump in most cases If not place pump closer to fluid level What to Check Suction line cavitation Corrective Action If no obstructions are in the suction line of the pump decrease the inlet air pressure and or volume to the pump This will slow down the diaphragm speed and reduce the cavitation What to Check Partially blocked exhaust muffler Corrective Action Remove muffler and make sure that some of the material being pumped has not migrated into the muffler element If it has replace the element or clean it and reinstall If product has made it to the muffler then the diaphragm assembly will need to be inspected Refer to the Diaphragm Replacement section p 15 What to Check Suction side air leakage or air in the product Corrective Action Visually inspect all suction side gaskets seals as well as pipe and pipe connections PUMP CYCLE SEEMS UNBALANCED OR PRODUCES EXCESSIVE VIBRATION What to Check Excessive flooded suction in system Corrective Action Check height of fluid above pump For flooded conditions exceeding 10 fee
44. nt replace with new cartridge valve assembly Remove any remaining fluid contamination on inside of body and or cartridge valve Be careful not to lose the large and small o rings on either face of the check valve body Step 5 Re assembly of Check Valve Apply a thin layer of white lithium grease to the threads on the valve cartridge Insert cartridge valve into body and hand tighten being careful not to pinch o ring Using a 9 torque wrench with crow foot torque cartridge vale to 250 in lbs Re apply o rings as necessary to both faces of check valve After applying Blue Loctite 248 222 or equivalent secure check valve back to pump with four 5 16 x 2 7 cap screws re torque to 90 in Ibs To secure the AirVantage re install the four 5 16 x 5 7 cap screws torquing to 90 in Ibs Re install Patchcable rs30mdl1sm rev0115 Model RS30 Metallic Page 30 Grounding The Pump One eyelet is fastened to the pump hardware This 8 foot long 244 centimeters Ground Strap part number 920 025 000 can be ordered as a One eyelet is installed to a true earth ground service item Requires a 5 16 or 8mm maximum diameter bolt To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required A WARNING Take action to prevent static Sparking Fire or explosion can result especially when handling flammable liquids
45. ntermediate Failure to do so may damage the cable during assembly rs30mdl1sm rev0115 Feed the connector through the hole in the intermediate making sure the gasket is on the connector before installation The flat edge on the connector should line up with the inside of the intermediate Install the nut and hand tighten it using a 13 16 socket The inner chambers and gaskets can now be reinstalled Use blue thread locker on the inner chamber bolts and torque them to 300 in lbs Referto the Diaphragm Servicing section of the manual to finish the diaphragm installation procedure SENSOR FEEDBACK BRACKET INTERMEDIATE ASSEMBLY Note Refer to Composite Parts List on page 12 for part numbers PLATE OUTER DIAPHRAGM DIAPHRAGM PLATE FLAT EDGE INNER DIAPHRAGM PROBE TIP Model RS30 Metallic Page 17 Air Valve Servicing Assembly Drawing amp Parts List AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 183 003 Air Valve Assembly 1 1 A 095 109 157 Body Air Valve 1 1 B 031 139 162 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 360 O Ring 10 1 E 165 127 157 Cap End 2 1 F 170 032 330 Hex Head Capscrew 1 4 20 x 75 8 AIR DISTRIBUTION VALVE SERVICING Step 3 Reassembly of the air valve To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect Install one bumper and one end cap with two o rings and fasten with four hex cap
46. or slips through the hole in the power generation case AirVantage CAUTION Take caution not to loosen the o ring that seals between the components Step 4 Reinstallation When reinstalling the new module make sure to feed the control module wire through the hole in the power generation case Install the four 10 32 x 2 socket head cap screws and tighten to 60 in Ibs AirVantage CAUTION Be sure to reattach the connector from the power generator to the control board Reinstall the bottom cover making sure the o ring seal is still in the groove Tighten the four 10 32 x 50 socket head cap screws to 30 in lbs Reinstall the top cover making sure the o ring seal is still in the groove Tighten the four 10 32 screws Reinstall the AirVantage using the four 5 16 18 x 5 cap screws and torque to 90 in Ibs AirVantage CAUTION Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate rs30mdl1sm rev0115 p CAPSCREW HEX SOC HD 10 32 X 50 Z EC NS 2 E BOTTOM COVER Nn 7 LT N 2 lt X 22 SEAL O RING 1 SS Y Za merear in SS CAPSCREW HEX SOC HD ontrol Module to 10 32 X 2 25 Power Generation Module POWER GENERATION MODULE m udi T SEAL O RING 2 CABLE PATCH 9 X CONTROL MODULE 2 lt gt gt I 1 1 6 O RING 0 VALVE POPPET 1 8 O TOP COVER Note Refer to Composite Repair Parts List
47. pair Parts Drawing Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump Be sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Inspect the o ring between the poppet valve and the adapter plate for damage Step 3 Access the Pilot Valve and Pressure Regulator Use a 5 32 hex key wrench and remove the four 10 32 x 50 socket head cap screws securing the top cover on Lift the cover off exposing the pilot valve and pressure regulator There is a molded o ring seal located on the underside of the cap Make sure the o ring stays located within the groove Ifthe pilot valve needs to be replaced unplug the connector attached to it Use a miniature 4 way Phillips screwdriver and remove the two screws holding the pilot valve to the plate The valve and gasket can now be removed and replaced When reinstalling the pilot valve tighten the screws to snug with a miniature 4 way Phillips screwdriver AirVantage CAUTION Be sure to reattach the connector to the pilot valve fthe pr
48. pressurized and must be bled of its pressure communities now and in the future Users of electrical and electronic equipment EEE with the WEEE marking per Annex IV of the WEEE Directive must not dispose of end of life EEE as unsorted municipal waste but use the collection framework available to them for the return recycle recovery of WEEE and minimize any potential effects of R S None of me equipment supplied within the unit j EEE on the environment and human health due to the presence of hazardous of exceed the amounts stated above hazardous substances A signe recyclable materials see chart on page 32 for material specifications We en substances The WEEE marking applies only to countries within the European A from our supplier orne portion courage pump users to recycle worn out parts and pumps whenever possible Union EU and Norway Appliances are labeled in accordance with European irVantage unit will be held on file stating their adherence to the RoHS ge pump y pump Directive 2002 96 EC Contact your local waste recovery agency for COMPLIANT 2002 95 EC regulation Follow all applicable guidelines if hazardous material has been pumped esignated collection facility in your area 2002 95 EC Many components of SANDPIPER Metallic AODD pumps are made of WARREN RUPP INC SANDPIPER A WARREN RUPP INC BRAND RS30 Metallic AirVantage D
49. ptimize 1 Second ON 0 1 Seconds OFF Steady State Air Savings OFF ON in rhythm with Cycle Rate of Pump AirVantage LED DOES NOT LIGHT UP AT ALL What to Check Make sure power switch on the control module is turned on depressed to the left Make sure air is being supplied to pump or make sure 110 VAC unit has power being supplied to it Corrective Action Cycle power switch off on Unplug patch cable and cycle power switch off on Consult Factory After Sales Support team AirVantage LED LIGHTS UP AND STAYS ON SOLID What to Check Make sure patch cable is plugged in and locked Corrective Action Consult Factory After Sales Support team VALVE FIRES ONCE AND IMMEDIATELY RESETS Corrective Action Consult Factory After Sales Support team rs30mdl1sm rev0115 VALVE LED NEVER LEAVES SEEK MODE AirVantage LED PULSING IN TIME TO PUMP BUT VALVE NOT ACTUATING AND THE PUMP IS NOT SAVING AIR Corrective Action Consult Factory After Sales Support team UNEXPECTED OPERATING CONDITION AIR SAVINGS OR FLOW RATE What to Check Check for varying environmental pumping conditions changing head or suction Check ice buildup in exhaust area Inspect sleeve and spool set for damage Corrective Action Consult Factory After Sales Support team PUMP CYCLING IS UNSTABLE OR ERRATIC What to Check Run pump without AirVantage and check pump operation Make sure pump has correct sleeve and spool set installed Mak
50. registered tradenames of Warren Rupp Inc Model RS30 Metallic Page 33 WARREN RUPP INC Declaration of Conformity Manufacturer Warren Rupp Inc 800 N Main Street Mansfield Ohio 44902 USA Certifies that Air Operated Double Diaphragm Pump Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic T Series G Series U Series EH and SH High Pressure RS Series W Series SMA and SPA Submersibles and Tranquilizer Surge Suppressors comply with A the European Community Directive 2006 42 EC on Machinery according to Annex VIII This product has used Harmonized Standard EN809 1998 A1 2009 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance October 20 2005 Signature of authorized pers Date of issue David Roseberry Engineering Manager Printed name of authorized person Title August 23 2012 Date of revision FLUID amp METERING Revision Level F
51. rene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life 275 F 40 F Excellent abrasion resistance 135 C 40 C Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or 220 F 35 F gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures 104 C 37 C FKM Fluorocarbon Shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids 350 F 40 F animal and vegetable oils Hot water or hot aqueous solutions over 70 F will attack FKM 177 C 40 C Polypropylene 180 F 32 F 82 C oc UHMW Polyethylene 180 F 32 F 82 C oc For specific applications always consult The Warren Rupp Chemical Resistance Chart SANDPIPER pumps are designed to be powered only by compressed air rs30mdl1sm rev0115 Model RS30 Metallic Page 1 Explanation of Pump Nomenclature RS30 Metallic Design Level 1 Ball Valve Diaphragm Non Wetted Shipping Model Wetted Check Valve Material Porting Pump Kit Weight Material Materials Options Options Options Options Ibs kg A N S 00 141 64 00 141 64 00 141 64 00 141 64 00 141 64 00 240 109 00 240 109 00 240 109 00 240 109 00 240 109 00 219 99 00 219 99 00
52. s stroke a Pilot Valve is mechanically actuated sending an air signal back to the Main Air Valve which redirects air to the opposite diaphragm This causes the diaphragm assemblies which are connected by a common Diaphragm Rod to move in a reciprocating action Air is directed to the inboard side of the diaphragm which is closest to the center of the pump This is referred to as the air side of the diaphragm The opposite side is commonly called the fluid side Most AODD pumps have a 1 1 ratio design This means when the discharge of the pump is closed completely dead headed the maximum pressure the pump will create will be equal to the air pressure being applied to the pump At this point and only at this point the diaphragm will be completely balanced The air pressure is equivalent to the fluid pressure and there will be no movement of the diaphragm If the pump is stroking then the system is not balanced There will be more pressure applied to the air side than fluid pressure on the fluid side During each stroke of the pump there are two distinct operations that happen One diaphragm is moving away from the center of the pump moving fluid out of the Discharge Manifold while the other diaphragm is moving toward the center bringing fluid into the Suction Manifold Considering that the pump has a common suction and discharge port these two operations are separated from each other through a series of Check Valves PRINCIPLE OF AIRVANTAGE A
53. s the air supply line should be disconnected from the pump Then shut off the suction and discharge lines to the pump Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump During the servicing of the AirVantage consult the AirVantage Composite Repair Parts Drawing Page 11 Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in the counterclockwise direction until it un threads from the connector The cable can be either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use 7 socket and remove the four 5 16 x 5 gt cap screws that hold the AirVantage to the pump Remove the two chamber bolts nuts that are holding the right side bracket to be able to remove the right bracket and the AirVantage unit from the pump Be sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the bottom Inspect the o ring between the poppet valve and adapter plate for damage Step 3 Remove the Check Valve from the Pump Use 7 socket and remove the four 5 16 x 2 gt cap screw that holds the check valve to the pump Step 4 Inspect Check Valve Using a 1 7 open socket wrench remove the cartridge valve Inspect o rings and mechanism for any signs of wear degradation or damage If any is prese
54. screws to the valve the air supply line from the pump body Remove the new sleeve and spool set from the plastic bag Carefully remove the spool from the sleeve Step 1 Install the six o rings into the six grooves on the sleeve Apply a light coating of grease to the o rings Using a 9 16 wrench or socket remove the four hex capscrews Remove the air valve assembly from before installing the sleeve into the valve body fis tlre lady asthe Remove and inspect gasket for cracks or damage Replace gasket if needed Be caref l scratcivor damada the A IMPORTANT Step 2 Disassembly of the air valve during installation Carefully insert the sleeve Read these instructions Using a 7 16 wrench or socket remove the eight hex capscrews that fasten the end caps to the valve into the bumper and end cap 2 completely before body Next remove the two end caps Inspect the two o rings on each end cap for damage or wear with o rings and fasten with the remaining hex installation and Replace the bumpers as needed Capscrews start up It is the Remove the bumpers Inspect the bumpers for damage or wear Replace the bumpers as needed Fasten the air valve assembly and gasket to the responsibility or B pump Connect the compressed air line to the purchaser to retain this emove the spool from the sleeve Be careful not to scratch or damage the outer diameter of the spool f manual for reference Failure to co
55. st be piped to an appropriate area for safe disposition 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 See page 30 WARNING This pump is pressurized internally with air during operation Always make certain that all bolts are in good condition and that all of the correct bolts are reinstalled during assembly A WARNING Use safe practices when lifting WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn at all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death WARNING Airborne particles and loud noise hazards Wear ear and eye protection WARNING Before maintenance or repair shut off the compressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be
56. t 3 meters of liquid install a back pressure device in the exhaust side of the pump What to Check Worn or misaligned check valve or check valve seat Corrective Action Disassemble the wet end of the pump and inspect check valves and seats for wear and proper seating Replace them if necessary Refer to the Check Valve section p 15 for disassembly instructions What to Check Obstructed check valves Corrective Action Disassemble the wet end of the pump and look for obstructions that may prevent the check valve from seating on the seat Look for damage on the valve and the seat Replace them as necessary Refer to the Check Valve section for disassembly p 15 What to Check Rigid pipe connections Corrective Action Install flexible pipe isolators or expansion joints between the plumbing and the pump What to Check Pulsation in the discharge line Corrective Action Excessive pulsation in the discharge line may be corrected by installing a Warren Rupp Tranquilizer Surge Suppressor Model RS30 Metallic Page 9 AirVantage Troubleshooting A Caution Whenever troubleshooting or performing any repairs on any Warren Rupp Inc equipment always remove air supply line to the pump and wear proper personal protective equipment LED OUTPUT FOR AirVantage UNIT STATE LED OUTPUT Startup Settle Deadhead Solid Standby Low Flow 1 Second ON 1 Second OFF Learn Mode 0 1 Seconds ON 0 1 Seconds OFF Seek O
57. tage consult the AirVantage Composite Repair Parts Drawing Step 1 Remove the Patch Cable Twist the ribbed portion of the patch cable connector in a counterclockwise direction until it unthreads from the connector The cable can either be removed from the intermediate or from the control module Step 2 Remove the AirVantage from the Pump Use a 77 socket and remove the four 5 16 18 x 5 cap screws that hold the AirVantage to the pump Be sure to support the weight of the AirVantage while removing the last cap screw After the AirVantage is removed from the pump set the unit down on the plastic cover located on the top of the unit Inspect the o ring between the poppet valve and the adapter plate for damage Step 3 Access the Power Generation Module Use a 5 32 hex key wrench and loosen the four 10 32 x 50 socket head cap screws securing the bottom cover Lift the bottom cover off exposing the power generation module There is a molded o ring seal located on the underside of the cap Make sure the o ring stays located within the groove Ifthe power generation module needs to be replaced unplug the connector that connects the power generator to the control board Use a 5 32 hex key wrench to loosen the four 10 32 x 2 socket head cap screws The power generation module should now be loose Carefully lift the power generation module off the rest of the assembly making sure that the control board wire and connect
58. tion Consult Factory After Sales Support Team O RING Cycle the power switch on the control module off on SEAL O RING LS 1 4 NPT Pipe Plug P N 618 011 330 Must be installed if performing direct spray wash down of pump Purchased Separately O RING CONTROL MODULE MUFFLER SEAL O RING WHAT TO DO IN THE EVENT OF A DIAPHRAGM FAILURE If a diaphragm failure has been detected in pumps fitted with AirVantage see page 5 for shut down procedure ASSEMBLY POWER GENERATOR What to Check Has product migrated to the sensor Corrective Action If the sensor has been submerged in product the sensor will need to be CAPSCREW HEX SOC HD 10 32 X 1 00 CAPSCREW HEX SOC HD 10 32 X 2 25 SEAL O RING replaced Consult the AirVantage servicing section of the manual for detailed instructions CAPSCREW HEX SOC HD 10 32 X 50 What to Check Has product contaminated the check valve cartridge Correct Action Ifa significant amount of product has made it into the check valve assembly then the unit will need to be disassembled for inspection If the check valve assembly is damaged then it will need to be replaced Consult parts list for information rs30mdl1sm rev0115 Model RS30 Metallic Page 11 Composite Parts List Item Part Number Description Qt Item Part Number Description Qty 1 031 183 003 Assy Air Valve See Exploded View for Details 1 27 518 144 010 Manifold Discharge Cast Iron Units 1 03
59. ully remove the spool from the sleeve Install the six o rings into the six grooves on the sleeve Apply a light coating of grease to the o rings Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 5 16 Allen wrench remove the four hex socket capscrews and four flat washers Remove the air valve assembly from the pump Remove and inspect gasket for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings from each end of the air valve assembly using clip ring pliers Next remove the two end caps Inspect the o ring for cuts or wear Replace the o rings if necessary Remove the two bumpers Inspect the bumpers for cuts wear or abrasion Replace if necessary Remove the spool from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear Inspect the inner diameter of the sleeve for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set rs30mdl1sm rev0115 before installing the sleeve into the valve body Align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with
60. ump 2 Close the discharge shut off valve this will stop any product from Shut Off reentering the pump Valve Close the air supply shut off valve Drain the discharge line Drain the suction line 5 Perform maintenance cali E 0 Dessicant Dryer Optional Flexible Connection ce o Caution When performing a direct spray washdown a plug must be installed in place of the AirVantage muffler Failure to do so may damage internal components See page 23 Te C AWARNING A f Muffler Optional Piped Exhaust In the event of diaphragm rupture pumped material 4 may enter the air end of the Note Pipe weight should not be supported Flexible Connector by pump connections pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition Shut Off Valve Drain Port Pipe Connection ee Style Optional rs30mdl1sm rev0115 Model RS30 Metallic Page 6 PRINCIPLE OF PUMP OPERATION This ball valve fitted pump has been equipped with IDEX s patented AirVantage equipment To fully understand the operation of the AirVantage one must first understand the basics of Air Operated Double Diaphragm AODD pumps AODD s are powered by compressed air The compressed air is directed behind each of the flexible diaphragms by a Main Air Valve Once the diaphragm has reached the end of it
61. ution valve body Failure to support these connections could also result in damage to the air distribution valve body MUFFLER 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Illustration 2 rs30mdl1sm rev0115 Model RS30 Metallic Page 32 000 010 012 015 020 025 080 110 111 123 147 148 149 150 152 154 155 156 157 158 159 162 166 167 170 Assembly sub assembly and some purchased items Cast Iron Powered Metal Ductile Iron Ferritic Malleable Iron Music Wire Carbon Steel AISI B 1112 Alloy 20 Alloy Type 316 Stainless Steel Alloy Type 316 Stainless Steel Electro Polished Alloy C Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Clear Anodized Aluminum Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 Almag 35 Aluminum 356 T6 Aluminum 356 T6 Aluminum Die Cast Aluminum Alloy 380 Aluminum Alloy SR 319 Anodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Alloy 954 ASTM B505 Bronze Bearing Type Oil Impregnated rs30mdl1sm rev0115 175 180 305 306 307 308 309 310 330 331 332 333 335 336 337 340 342 353 354 355 356 357 358 359 36
62. w rate is achieved Again the pump curve can be used to derive this value If increasing the pressure to the pump does not generate a higher flow rate then cavitation has occurred Back the regulator off slightly To gain the most efficiency from the pump try to run the pump fully primed at all times BETWEEN USES When the pump is being used to move materials that tend to settle out or solidify the pump should be flushed to prevent damage The product that remains in the pump could dry and settle out This could potentially cause damage to the diaphragms and or check valves during restart In freezing temperatures the pump must be completely drained between uses Due to the addition of the new technology it is recommended the air supply to the pump be shut off if the pump is going to be shut down for an extended length of time Model RS30 Metallic Page 7 This Page Intentionally Blank rs30mdl1sm rev0115 Model RS30 Metallic Page 8 PUMP TROUBLESHOOTING CAUTION WHENEVER TROUBLESHOOTING OR PERFORMING ANY REPAIRS ON ANY WARREN RUPP INC EQUIPMENT ALWAYS REMOVE THE AIR SUPPLY LINE TO THE PUMP AND WEAR PROPER PERSONAL PROTECTIVE EQUIPMENT PUMP WILL NOT CYCLE What to Check system head exceeds the air supply pressure to the pump Corrective Action Increase the air inlet pressure to the pump Most diaphragm pumps designed for 1 1 pressure at zero flow What to Check Check ESADS including pilot valve assembly
63. wer generator to the control board Use a 5 32 hex key wrench to loosen the four 10 32 x 2 1 4 socket head cap screws The power generation module should now be loose Carefully lift the power generation module off the rest of the assembly making sure that the control board wire and connector slips through the hole in the power generation case AirVantage CAUTION Take caution not to lose the o ring seals between the components Ifthe control module needs to be replaced use a 5 32 hex key wrench and loosen the two 10 32 X 1 00 socket head cap screws holding the control module to the poppet assembly The control module should now be loose Carefully lift he control module off the poppet assembly making sure that the pilot valve connector wire slips through the hole in the poppet valve assembly AirVantage CAUTION Take caution not to loosen the o ring that seals between the components rs30mdl1sm rev0115 90 in Ibs AirVantage CAUTION Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate CAPSCREW HEX SOC HD ec 10 32 X 50 BOTTOM COVER SEAL O RING CONNECTORS Control Module to Power Generation Module CAPSCREW HEX SOC HD 10 32 X 2 25 MUFFLER POWER GENERATION MODU CONNECTOR To Intermediate CABLE PATCH CONTROL MODULE SEAL O RING VALVE POPPET Note Refer to AirVantage Composite Repair Parts List on page 23 for part numbers

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