Service Manual - Amalgamated Pumping Supplies
Contents
1. A LEAK DETECTORS Model S15 Metallic Design Level 1 Page 27 RuppTech Pulse Output Kit Drawing amp Options RuppTech 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 RuppTech 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 Distribution Valve Assembly when the threaded exhaust port or an auxiliary muffler is being used See the individual kits listed on the Pump Repair Parts List for further information Note Pumps equipped with Pulse Output Kits are not ATEX compliant Exhaust Port or Auxiliary Muffler Configuration B amp C Pulse Output Kit 520 292 000 11 04 Rev C Integral Muffler Configuration A S A Pulse Output Kit Model S15 Metallic Design Level 1 Page 28 Grounding The Pump One eyelet is fastened to the pump hardware One eyelet is installed to a true earth ground This 8 foot long 244 centimeters Ground Strap Requires a maximum 5 16 or 8mm diameter bolt part number 920 025 000 can be ordered as a service part To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instructio2. an SPACER FOOT Stainless 20 3 8 1 31 32 3 8 11 3 8 21 21 32 Steel 518 50 10 289 550 gt Mesh 14 15 16 gt Muffler 379 a 13 Ae kg pane 14 15 16 AM 124 Dampening i Muffler 379 Metal 14 1 2 AR INLET Muffler 368 STANDARD ENCAPSULATED MUFFLER 1 R STYLES OR PIPING EXHAUST AIR IN SUBMERGED TIONS BOTTOM VIEW 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 5 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water 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 to
3. What to Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling 520 292 000 11 04 Rev C What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a Warren Rupp Tranquilizer Surge Suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust secti
4. surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 125 psi 8 6 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 1 2 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and filters must be supported by some means other than the air inlet cap Failure to provide support for the piping may result in damage to the pump A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended limits AIR VALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the preferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required The pump air system will operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compress
5. 10 1 E 165 127 157 313 Cap End 2 1 F 170 032 330 313 Hex Head Capscrew 1 4 20 x 75 8 1 G 530 028 550 Muffler 1 1 H 165 096 551 Muffler Cap 1 1 J 706 026 330 115 Machine Screw 4 AIR VALVE ASSEMBLY PARTS LIST 1 031 173 001 Air Valve Assembly 1 Consists of all components above except 1 F 170 032 115 Hex Head Capscrew 1 4 20 x 75 8 1 J 706 026 115 Machine Screw 4 Note For T15 Pumps Substitute The Digits in For The Last 3 Digits Of Part Number Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 A 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 Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews Fasten the air valve assembly item 1 and gasket to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Sta
6. 620 020 115 675 042 115 685 059 120 720 004 360 722 091 550 722 091 080 722 091 110 722 091 150 722 091 600 901 038 115 901 038 330 901 048 115 901 048 330 570 009 363 530 033 000 DESCRIPTION Diaphragm Diaphragm Diaphragm Overlay Gasket Air Valve Gasket Pilot Valve Gasket Air Inlet Gasket Inner Chamber Manifold Suction Manifold Suction 1 1 2 BSPT Manifold Suction Manifold Suction 1 1 2 BSPT Manifold Suction Manifold Suction 1 1 2 BSPT Manifold Discharge Manifold Discharge 1 1 2 BSPT Manifold Discharge Manifold Discharge 1 1 2 BSPT Manifold Discharge Manifold Discharge 1 1 2 BSPT Nut Hex 3 8 16 Nut Hex 3 8 16 Nut Hex 7 16 14 Nut Hex 7 16 14 O Ring Seal O Ring See item 34 Seal O Ring See item 34 Seal O Ring See item 34 O Ring Seal O Ring See item 34 Plate Outer Diaphragm Assembly Plate Outer Diaphragm Assembly Plate Outer Diaphragm Assembly Plate Inner Diaphragm Plate Inner Diaphragm Plunger Actuator Ring Retaining Rod Diaphragm Seal Diaphragm Rod Seat Check Ball Seat Check Ball seals required see item 27 Seat Check Ball seals required see item 27 Seat Check Ball seals required see item 27 Seat Check Ball Washer Flat 5 16 Washer Flat 5 16 Washer Flat 3 8 Stroke Indicator Only Washer Flat 3 8 Stroke Indicator Only Pad Wear use with 286 099 363 Metal Muffler for other muffler options see pg 24 Mode
7. END KIT S15 Santoprene Diaphragms Balls and Polyethylene Seats 476 182 365 WET END KIT S15 Neoprene Diaphragms Balls and Polyethylene Seats 476 182 633 WET END KIT S15 Viton Diaphragms PTFE Balls and Seats 476 182 635 WET END KIT S15 Neoprene Diaphragms PTFE Overlay Balls and Seats 476 182 351 WET END KIT T15 FDA Santoprene Diaphragms Balls and PTFE Encapsulated Seals 476 182 364 WET END KIT S15 EPDM Diaphragms Balls and UHMW Seats 476 182 654 WET END KIT S15 Santoprene Diaphragms PTFE Overlay PTFE Balls PTFE Seats 476 182 366 WET END KIT T15 FDA Nitrile Diaphragms Balls and PTFE Encapsulated Seals 476 194 666 WET END KIT T15 FDA Nitrile Diaphragms PTFE Overlay Balls and PTFE Encapsulated Seals 475 215 000 MIDSECTION CONVERSION KIT Replaces Aluminum Midsection With Cast Iron Components Air Inlet Cap Intermediate Bracket Inner Chambers and Inner Diaphragm Plates HARDWARE KITS 475 205 330 Zinc Plated Capscrews Washers and Hex Nuts 475 205 115 Stainless Steel Capscrews Washers and Hex Nuts PULSE OUTPUT KITS For use with 530 010 000 and 530 032 000 mufflers or piped exhaust For use with encapsulated 530 028 550 muffler ELECTRONIC LEAK DETECTOR KITS 475 198 001 DC Kit 475 198 006 DC Kit 032 040 000 100VAC 475 198 002 DC Intrinsically Safe Kit 475 198 007 DC Intrinsically Safe Kit 032 037 000 220VAC 475 198 003 110 120VAC or 220 240VAC Kit 475 198 008 110 120VAC or
8. SUCTION LINE Illustration 2 C MUFFLER LA i 1 DIAMETER AIR EXHAUST PIPING MUFFLER LA LIQUID _ LEVEL SUCTION LINE Illustration 3 A 1 DIAMETER AIR EXHAUST PIPING Model S15 Metallic Design Level 1 Page 26 RuppTech Leak Detection Options Drawing Note Pumps equipped with these options are not ATEX compliant 520 292 000 RuppTech ELECTRONIC LEAK DETECTOR Kit 032 037 000 100VAC 50Hz or110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC CONFIGURATION A To be used with the Encapsulated muffler option You will need to mount the terminal box directly to the muffler cap on the air valve using the 2 710 014 330 self tapping screws Then insert the leak detectors into the bottom port in the inner chambers CONFIGURATION B To be used with either of the muffler options or if your exhaust is piped away You will need to mount the terminal box to the 612 185 552 mounting plate using the 2 710 014 330 self tapping screws Then mount the mounting plate directly to the air valve body using the 4 710 009 115 self tapping screws Then insert the leak detectors into the bottom port in the inner chambers MECHANICAL LEAK DETECTOR Kit 031 023 110 Insert the leak detectors into the bottom part in the inner chambers 11 04 Rev C Configuration B TO CONTROL BOX
9. 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 4 WARNING Before maintenance or repair shut off the com pressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure 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 must 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 28 A WARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARNING Before doing any main tenance on the pump be certain al
10. maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool 520 292 000 11 04 Rev C shifts to the opposite end of the valve body the pressure to the chambers is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A Warren Rupp Tranquilizer
11. pumps are designed to be powered only by compressed air 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 1 Explanation of Pump Nomenclature 15 Metallic Design Level 1 Ball Valve 15B1ABWANSOO0 wn Design Level ius Wetted Material gt Diaphragm Check Valve Materials ive Non Wetted Material Options Porting Options Z n Shipping Weight Ibs kg Pump Kit Options Options o 15B1AEWANSOOO 15B1AGTANSOOO 15B1ANWANSOOO 15B1A1WANSOOO 15B1AVTANSOOO 15B1IBWANSOOO 15B1IEWANSOOO 15B1IGTANSOOO 15B1INWANSOOO 15B111WANSOOO S15B1IVTANSOOO 15B1IEWANSOO0 15B1SGTANSOOO 15B1SNWANSOOO 15B1S1WANSOO0 15B1SVTANSOOO viw wvv w ww w wwo ww ow ololojloliololololojlojojlolojlojJojo T15B1SFSWTS000 Pump Brand S SANDPIPER T FDA Compliant Pump Size 15 1 Check Valve Type B Soild Ball W Weighted Ball Design Level 1 Design Level Wetted Material A Aluminum Cast Iron S Stainless Steel 520 292 000 ADI DI DIDN NINININI NINI nno 11 04 Rev C a h h h h A d ae ul ep ef of Md j Ml j MA is Diaphragm Check Valve Materials 1 Santoprene Santoprene A PTFE FDA Nitrile Backup PTFE B Buna Buna D FDA Santoprene FDA Santoprene E EPDM EPDM F FDA Nitrile FDA Nitrile G PTFE Neoprene PTFE l E
12. reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Page 23 CHECK VALVE SERVICING Before servicing the check valve components first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the check valve components remove the manifold item 23 or item 22 not shown Use a 1 2 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 34 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled reconnected and returned to operation METALLIC SEATS Two o rings or conductive PTFE seals item 27 are required for metallic seats 520 292 000 11 04 Rev C Check Valve D
13. the product being pumped in the event of a diaphragm failure Air Exhaust SUCTION For Metallic Pumps Surge Suppressor Pipe Connection Air Inlet Limited to Style Optional Line 125 psi Gauge Flexible Connection Shut Off Valve MT DISCHARGE CE U W Drain Port Flexible Connection Air Shut Off Pipe Connection Valve Style Optional pees TOP Air Dryer Gauge DISCHARGE DIAPHRAGM 1 Ge AIR INLET O Flexible Connection oo M 520 292 000 11 04 Rev C A Drain Port Model S15 Metallic Design Level 1 Page 7 TROUBLESHOOTING Possible Symptoms e Pump will not cycle e Pump cycles but produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device
14. to 500 in Ibs 56 5 Newton meters Align one diaphragm with the intermediate and install the outer chamber to the pump using the 8 capscrews Tighten the opposite diaphragm plate until the holes in the diaphragm align with the holes in the intermediate Then install the other outer chamber using the 8 capscrews Step 6 Reinstall the manifolds to the pump using the 16 capscrews The pump is now ready to be reinstalled connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 17 is designed to fit over the exterior of the standard diaphragm item 16 Follow the same procedures described for the standard diaphragm for removal and installation except tighten the outer diaphragm plate assembly diaphragms and inner diaphragm plate to the diaphragm rod to 500 in lbs 56 5 Newton meters A IMPORTANT Read these instructions completely before in Stallation 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 S15 Metallic Design Level 1 Page 22 ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 1 2 wrench or socket remove the fou
15. 0 eeeccceeeeeeeeeeeeeeeeeeeeneeeeaeeeeeeeeaeeseeeenaeeseeeeeeeeeees 9 Material CodeS inisini oense nia enoei ieis Ta eh iaaiiai niti 10 Composite Repair Parts Drawing cecceeseeseeeeeeeeceeeeeeeeseeeeeeeeneeeeeeseaeeeeete 12 Available Service and Conversion Kits cccecceesceeeeeeeeeeeeneesteeseaeesneeeeeeeneees 12 Composite Repair Parts List S15 ceeeeceesceeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeneeseaeeeneete 13 Composite Repair Parts List T15 eeceeeesseeeeeeeeeeeeneeeeeeeeeesieeeeaeesteeseeeeneete 14 Air Valve Drawing Parts List Service Instructions Cast Iron Centers Only 15 Note Not ATEX compliant M2 c b T5 II 2GD b T5 U S Patent 5 996 627 Other U S Patents Applied for CE Air Valve Drawing Parts List Service Instructions Aluminum Centers Only 16 Air Valve w Stroke Indicator Drawing and Parts List cceeeeeeeeeeeeeeeeeeees 17 Air Valve w Stroke Indicator Servicing cceeceeeceeeeeeeeeeeeeeeeeeeneeteeeeeeeeenees 18 Solenoid Shifted Air Valve Drawing c cceccecceceseeseeceeeeeseeceereeeeeeeeeteeeneaes 19 Solenoid Shifted Air Valve Parts List cecceceeceeeeceeeeeeeeeeeecaeeseeseeeteeeereees 19 Solenoid Shifted Air Valve Option cceccccecceceescesceseeceeeceeceseeeeseesereeeateaes 20 Diaphragm Service Drawing with Overlay ecceeeeseeeeeeeeseeeeeeeeeeeeteeeeneeeaes 21 Diaphragm Service Drawing Non Overlay e
16. 220 240VAC Kit 475 198 004 110 120VAC Intrinsically Safe Kit 475 198 009 110 120VAC Intrinsically Safe Kit 475 198 005 220 240VAC Intrinsically Safe Kit 475 198 010 220 240VAC Intrinsically Safe Kit 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 12 Composite Repair Parts List For 15 ITEM 1 10 11 12 13 14 15 16 520 292 000 PART NUMBER 031 146 000 031 141 000 031 146 000 031 147 000 031 173 001 031 183 000 031 179 000 050 005 354 050 005 360 050 005 360W 050 005 363 050 005 364 050 005 365 050 005 365W 050 010 600 070 006 170 095 110 000 095 110 110 114 024 157 114 024 010 132 035 360 135 034 506 165 118 157 165 118 010 170 060 115 170 060 330 170 061 115 170 061 330 170 069 115 170 069 330 170 006 115 170 006 330 171 053 115 171 053 330 171 011 115 171 059 115 171 059 330 196 169 156 196 169 010 196 169 110 196 170 157 196 170 010 286 099 354 286 099 360 286 099 363 11 04 Rev C DESCRIPTION Air Valve Assembly Cast Iron Only Air Valve Assembly Cast Iron Only Air Valve Assembly Stroke Indicator Only Air Valve Assembly Stroke Indicator Only Air Valve Assembly w Stainless Steel Hardware Air Valve Assembly w Stainless Steel Hardware Air Valve Assembly ATEX compliant w Cast Iron centers only Ball Check Ball Check Ball Weighted Check Ball Check Ball Check Ball Check Ball Weighted Check Ball Check Bushing Pi
17. Aluminum Alloy 380 158 Aluminum Alloy SR 319 159 3342 Anodized Aluminum 162 Brass Yellow Screw Machine Stock 165 Cast Bronze 85 5 5 5 166 Bronze SAE 660 170 Bronze Bearing Type Oil Impregnated 520 292 000 11 04 Rev C Material Codes The Last 3 Digits of Part Number TS ex Die Cast Zinc 180 Copper Alloy 305 Carbon Steel Black Epoxy Coated 306 Carbon Steel Black PTFE Coated 307 Aluminum Black Epoxy Coated 308 Stainless Steel Black PTFE Coated 309 Aluminum Black PTFE Coated 310 Kynar Coated 313 Aluminum White Epoxy Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminum Electroless Nickel Plated 333 Carbon Steel Electroless Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 351 Food Grade Santoprene 353 Geolast Color Black 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 355 Thermal Plastic 356 Hytrel 35T fi Injection Molded Polyurethane 358 Urethane Rubber Some Applications Compression Mold 359 Urethane Rubber 360 Buna N Rubber Color coded RED 361 Buna N 363 Viton Flurorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile 368 F
18. Body Air Valve Bumper Cap Muffler Cap End Muffler O Ring Ring Retaining Screw Self Tapping Clip Safety O Ring Qty MIA ANMAANMANAA a For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 147 000 Air Valve Assembly 1 includes all items on 031 146 000 minus 1 D 1 F amp 1 J Model S15 Metallic Design Level 1 Page 17 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 5 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 36 Remove the air valve assembly from the pump Remove and inspect gasket item 18 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 item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o ring items 1 G and 1 M for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cut wear or abrasion Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spoo
19. E 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene 666 FDA Nitrile Diaphragms PTFE Overlay Balls and Seals Delrin Viton and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Warren Rupp SANDPIPER PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Model S15 Metallic Design Level 1 Page 10 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 11 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS Note Pumps equipped with these components are not ATEX compliant 476 227 000 AIR END KIT Use With Aluminum Center Air Valve Assembly Pilot Valve Assembly Seals Bumpers a Gaskets Plunger and O rings 476 170 000 AIR END KIT Air Valve with Stroke Indicator Pin Aluminum Center Seals O ring Gaskets Retaining Rings Air Valve Sleeve and Spool Set and Pilot Valve Assembly 476 182 360 WET END KIT S15 Buna Diaphragms Balls and Polyethylene Seats 476 182 354 WET
20. Metallic Design Level 1 Page 2 Performance Curve S15 Metallic Design Level 1 tI SCFM M hr MODEL S15 Metallic Performance Curve a 10 17 20 34 Performance based on water at ambient temperature e LRT kL Nee Et EE ET EE EE EE Pors RES M 5 4 5 ESTN LEER e A O en ee 4 60 PS7 4 08 Bap n wn LL Ti Fra TRE EAN 72 Ban T 5 ar lt n i i 6 Pf 4 5 els ee S z j gt 1 5 TEAR SRE 0 10 20 30 40 80 90 100 110 U S e a ie 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 Liters per minute CAPACITY 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 3 Dimensions in Inches Dimensions S15 Metallic Dimensional Tolerance s Discharge Port 1 1 2 NPT Suction Port 1 1 2 NPT SIDE VIEW FRONT VIEW 2 5 16 Pump Shown With 530 028 550 Encapsulated Muffler 6 3732 12 3 716 16 21 32 Encapsulated Muffler 1 NPT Exhaust Port For optional Muffler Styles or Piping Exhaust Air In Sumerged Dimensions in Millimeters Applications Dimensional Tolerance 3mm Both Suction and Discharge 4 15716 Ports Are Available With a 1 2 1 1 2 BSP Tapered Connection 5H BOTTOM VIEW Discharge Port Air Inlet 11 2 NPT 314 NPT e eae Encapsulated 12 11 32 C SIDE VIEW Mufer oi Kit Pump Shown With 530 028 550 J Aumin 20 5 16 129 32 5 6 115 16 21 19 32 Encaps
21. Overlay QTY er ai nae raek NNa a NAAA Jk iit ao O MPNNNNNWDOOH HR HL ITEM 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 43 PART NUMBER 360 093 360 360 103 360 360 104 379 360 105 360 518 151 110TC 518 152 110TC 545 005 115 545 007 115 560 001 379 560 084 611 720 061 608 612 097 110 612 195 157 620 020 115 675 042 115 685 059 120 720 004 360 722 091 110 901 038 115 901 048 115 530 033 000 DESCRIPTION Gasket Air Valve Gasket Pilot Valve Gasket Air Inlet Gasket Inner Chamber Manifold Suction Manifold Discharge Nut Hex 3 8 16 Nut Hex 7 16 14 O Ring Seal O Ring See item 34 Seal O Ring See item 34 Plate Outer Diaphragm Assembly Plate Inner Diaphragm Plunger Actuator Ring Retaining Rod Diaphragm Seal Diaphragm Rod Seat Check Ball seals required see item 27 Washer Flat 5 16 Washer Flat 3 8 Stroke Indicator Only Metal Muffler for other muffler options see pg 24 Parts Not Shown For Rubber Mounting Feet 350 001 360 170 018 115 545 005 115 400 005 115 901 005 115 Foot Rubber Capscrew Hex HD Nut Hex Washer Lock Washer Flat Model S15 Metallic Design Level 1 A AAN NNNN OON orp A A Page 14 Air Valve Servicing Assembly Drawing amp Parts List Use With Aluminum Centers Only AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air b
22. PDM Santoprene N Neoprene Neoprene V Viton Viton Check Valve Seat A Aluminum C Carbon Steel S Stainless Steel T PTFE W UHMW Polyethylene DNIN N O MO S S gt T lt Ziom lt zZiI0Im wW lt ziom Non Wetted Material Options A Painted Aluminum ojja SSM MSSM J Painted Aluminum w PTFE Coated Hardware S Stainless Steel w Stainless Steel Hardware W White Epoxy Coated Aluminum amp Stainless Steel Hardware Y Painted Aluminum w Stainless Steel Hardware Porting Options N NPT Threads B BSPT Tapered Threads SSS SlSl S S S S S S S S S S S S gt AIZ Z Z zZz Z zZ Z zZz zZ Z zZz Z zZ zZz z z Pump Style S Standard Pump Options 0 1 2 3 None 3M Muffler Mesh Muffler High temperature Air Valve w Encapsulated Muffler High temperature Air Valve w 3M Muffler High temperature Air Valve w Mesh Muffler Metal Muffler DIDIDI DI DI DI DNDN N MD Nnnn oe Kit Options 00 None M P0 0 30VDC Pulse Output Kit P1 Intrinsically Safe 10 30VDC Pulse Output Kit P2 110 120 or 220 240VAC Pulse Output Kit P3 Intrinsically Safe 110 120VAC Pulse Output Kit P4 Intrinsically Safe 220 240VAC Pulse Output Kit SP Stroke Indicator Pins Note ATEX compliant pumps must be ordered with a metal muffler and no kit options Z amp Release Pending Model S15
23. SERVICE amp OPERATING MANUAL SANDPIPERs A WARREN RUPP PUMP BRAND Model 15 Metallic Design Level 1 Including T15 FDA Compliant Models Table of Contents Engineering Data and Temperature Limitations e cc eeeeeeseeeeeseeeeeeneeeeeneeees 1 Explanation of Pump Nomenclature ceeseceseseeeeeseeeeeeneeeeeneeeeeneeeeseneeeneneees 2 Performance Curve ccecceeeccesseeeneeeeeeeeneeseaeeeaeecaeeeaeesaeeeaeeseeeeeaeeseaeseeesiaeeeeeesnaees 3 Dimensions S15 i stecssczssseeesetessenensecascteaeeecesescedpnngsteed ei nietatieatienionn gic dere 4 Dimensions 115 oe eeeeeeeeeeeeeeeeeeeeneeeeeeeeaeeseaeeeaeesaeeeaeeeaeeeeaeeseeeeaeeseaeeeaeessaeeeaeeeaees 5 Principle of PUMP Operation ceeccceceseeeeeeeeeceeeeeeeseeeeaeeseeeseaeeseaeeeaeessaeeeeeenaees 6 Installation ANd Start Up 0 eee eece cee eeneeeeeeeeeeteeeseaeeeaeeseeeesaeeseaeeeaeeseaeseaeeeneeee 6 Ar SUPPIV qepeters ince trey erecerer cer a a a EN 6 Air Valve Lubrication ccccsececeseceeeeeeeeeeeeeeeseeeesnaneeseeeeeeseeeeeseeeseseseneeeeeesees 6 Air Gne MOIStUNG sseni raer deca te iin eee eek 6 Air Inlet and PriminG sosise aaa ia 6 Betweeit USE Siaran e a a iiaa ii 6 Installation Guide 0 cece ceceeeseeceeeeeeeeeseeeeaeeeeeeeeaeesaeeeaeeseaeeeaeeseaeeseeeenaeessaeeeaeeneaees 7 TROUDIGSMOOUNG ss isai aaa eaea ETN amet 8 Warranty socors npn np paa o a ea A iE Eoi 8 FROCYCIING cossrnni n are a eia earar i TN 9 Important Safety Information 2
24. aeeaes 28 RuppTech Pulse Output Kit Options 2 cecceceecceceeeeeeeereeeeeeeeeteeeeeeeeeateaes 28 Grounding the PUMP espirisi ereere eana E e E a REA E 29 WARREN RUPP INC A Unit of IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com 520 292 000 11 04 Rev C Copyright 2004 Warren Rupp Inc All rights reserved SANDPIPERs A WARREN RUPP PUMP BRAND I M2 c b T5 ZED TS 15 Metallic WARREN RUPP Quality System ISO9001 Certified U S Patent Design Level 1 Environmental 5 996 627 Management System Other U S Patents Ba I I Va Ive 1S014001 Certified Applied for Air Inlet Side View Air Powered CE Double Diaphragm Pump Eef IDEX CORPORATION Air Exhaust Side View ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIRVALVE SOLIDS HANDLING HEADS UPTO DISPLACEMENT STROKE 1 NPT internal Oto 106 gallons per minute No lube no stall Up to 25 in 6mm 125 psi or 289 ft of water 41 Gallon 1 55 liter 112 BSPT Tapered internal 0 to 401 liters per minute design 8 6 Kg cm or 86 meters A CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum Buna N White Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resitance Should not be used with highly polar solvents I ke 190 F 10 F acetone an
25. apor lock in one or both pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Group before performing this procedure Any model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S15 Metallic Design Level 1 Page 8 Recycling Many components of SANDPIPER Metallic AODD pumps are made of recyclable materials see chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed M2 c b T5 Pump complies with EN809 Pumping Directive and II 2GD b T5 Directive 98 37 EC Safety of Machinery and ATEX 100a Directive 94 9 EC Equipment for use in Potentially CE Explosive Environments For reference to the directive certificates visit www warrenrupp com 520 292 000 11 04 Rev C Important Safety Information A IMPORTANT Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to
26. cceecceeeceeeeeeseeeeeteeeeeeeeneeeeeeeeaes 21 Diaphragm Servicing ceccceeccceeeseeeeeeeeeeeeeeeeeeeeeeeeeeseeseaeeeeeseaeeeeessatesieesnaeeeaes 22 Overlay Diaphragm Servicing cccceeeeeeceseeeeeeeeeseeeeeeeeeeeeaeeseaeeeaeessaeeeeeeaees 22 Actuator Plunger Servicing cccccescessceseneeeeeeeeaeeeseeeeaeeeaeeseaeeeaeeseaeesseeeeeeeeaees 23 Check Valve Servicing cccceesceeeceeeeeeeeeeeeeeeseeeeaeeeaeeseaeeeeeeeaeeseaeseeeseaeeeeeeteates 24 Check Valve Drawing ecceeceeeeeeseeeeeeeeeeeeeceeeeaeeeaeeeeaeeseeeeaeeseaeseaeeseaeesieeeenees 24 Optional Muffler Configurations c ccscecceseeceeceesceceeceeeeeeeeeeereeeeeeeeeteesaneaes 25 Optional Muffler Configuration Drawing c ccecceceecseseeeeeeteeeeeesteeteetereeees 25 Pumping Hazardous Liquid eeseceeseeeeeneeeeeeeeeeeeeeeeeeneeeseaneeeesneeensneeensaaes 26 Converting Pump for Piping Exhaust Air ceecesseeeeeeseeeneeseeeeeeeesneeeeeeeneees 26 Converted Exhaust Illustration cccceeceeeeeneeeeeeeeeeseeeeeaeeeeeeeeseeseeeeeneeeeaeeeeees 26 Leak Detection Options amp Drawing c cc cesceseeseesceseeeeeeeeeteeeeeeeeeeeeetaneateaes 27 RuppTech Electronic Leak Detector Installation cscceceeeeteeeeeeeseeees 27 RuppTech Mechanical Leak Detector Installation cccceeeeeeeeeeeeees 27 RuppTech Pulse Output Kit Drawing esceccecceseeceeeeeeceeeeeereeteeeee
27. d MEK ozone chlorinated hydrocarbons and nitro hyrdrocarbons 88 C 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 C Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance 275 F 40 F 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 Viton Shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids animal and 350 F 40 F vegrtable oils Hot water or hot aqueous solutions over 70 F will attack Viton 177 C 40 C Polpropylene 180 F 32 F 82 C 0 C Polyethylene bee i a For specific applications always consult the Warren Rupp Chemical Resistance Chart SANDPIPER
28. e Inspect the diaphragm for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEALS 520 292 000 11 04 Rev C Step 4 Assembling the diaphragm and diaphragm plates to the diaphragm rod Push the threaded stud of one outer diaphragm plate assembly through the center of one diaphragm and through one inner diaphragm plate Install the diaphragm with the natural bulge facing away from the diaphragm rod and make sure the radius on the inner diaphragm plate is towards the diaphragm as indicated on the diaphragm servicing illustration Thread the assembly onto the diaphragm rod leaving loose Step 5 Installing the diaphragm and rod assembly to the pump Make sure the bumper item 6 is installed over the diaphragm rod Insert rod into pump On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the second bumper is installed over the diaphragm rod Push the threaded stud of the other outer diaphragm plate assembly through the center of the other diaphragm and through the other inner diaphragm plate Make sure the radius on the inner diaphragm plate is towards the diaphragm Thread the assembly onto the diaphragm rod Use a 7 8 wrench or socket to hold one outer diaphragm plate Then use a torque wrench to tighten the other outer diaphragm plate to the diaphragm rod
29. e a a pk a ee er 71 Wiring Diagram mpo E 3rd Terminal for ground A i l om i Henle 1 Terminal f Power Negative Positive Le eee l a SS l l l l l l l P m l Ol I l L fom e om l SEE aoe Model S15 Metallic Design Level 1 Page 20 Diaphragm Service Drawing Diaphragm Service Drawing with Overlay Non Overlay 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 21 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump assembly drawing and the diaphragm servicing illustration Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the manifolds items 22 amp 23 to the outer chambers item 14 Step 2 Removing outer chambers Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the outer chambers item 13 diaphragms item 14 and intermediate item 5 together Step 3 Removing the diaphragms and diaphragm plates Use a 7 8 wrench or six point socket to remove the outer diaphragm plate assemblies diaphragms item 16 and inner diaphragm plates item 29 from the diaphragm rod item 32 by turning counterclockwis
30. ed air supply can create problems such as icing or freezing of the exhaust air causing the pump to cycle erratically or stop operating Water in the air supply can be reduced by using a point of use air dryer to supplement the user s air drying equipment This device removes water from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 1 2 to 3 4 turn After the pump primes the air valve can be opened to increase air flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient air flow to pump flow ratio BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model S15 Metallic Design Level 1 Page 6 WARREN TYPICAL INSTALLATION GUIDE RUPP Available from Warren Rupp Q TA1 or TA25 Tranquilizer 020 050 000 Filter Regulator 3 020 050 001 Lubricator Air Dryer A CAUTION The air exhaust should be piped to an area for safe disposition of
31. he solenoid coil is connected to the Warren Rupp Solenoid Rate Controller Batch Control or a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate AIR OPERATION The Solenoid Shifted SANDPIPER has a solenoid operated air distribution valve in place of the standard SANDPIPER s pilot operated air distribution valve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard SANDPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage 520 292 000 11 04 Rev C l l l l l l l l l l l l l L Solenoid Connector 9 Before wiring remove terminal block from conduit connector f Vasna 7 a feo ee a
32. hes or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B M2 c b T5 Il 2GD b T5 AIR VALVE ASSEMBLY PARTS LIST Use w Aluminum centers only Item Part Number Description Qty 1 031 183 000 313 Air Valve Assembly 1 1 A 095 109 157 313 Body Air Valve 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 360 O Ring 10 1 E 165 127 157 313 Cap End 2 1 F 170 032 330 115 Hex Head Capscrew 1 4 20 x 75 8 AIR VALVE ASSEMBLY PARTS LIST 1 031 183 001 Air Valve Assembly 1 Consists of all components above except 1 F 170 032 115 Hex Head Capscrew 1 4 20 x 75 8 AIR VALVE ASSEMBLY PARTS LIST Use w Cast Iron centers only Item Part Number Description Qty 1 031 179 000 Air Valve Assembly 1 1 A 095 109 110 Body Air Valve 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 379 O Ring 10 1 E 165 127 110 Cap End 2 1 F 170 032 115 Hex Head Capscrew 1 4 20 x 75 8 Note For T15 Pumps Substitute The Digits in For The Last 3 Digits Of Part Number Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D into the six grooves on the slee
33. l S15 Metallic Design Level 1 QTY sli dak ae eon nn nn nnn poe on np np wo PH PRP PHP PRN HA NYNNNNN N DO WO OO WO CO PO Page 13 Composite Repair Parts List For T15 ITEM PART NUMBER 1 031 146 000 031 147 000 031 173 313 031 183 313 031 179 000 2 050 005 351 050 005 366 050 010 600 3 070 006 170 4 095 110 313 095 110 110 5 114 024 313 114 024 110 6 132 035 360 7 135 034 506 8 165 118 313 165 118 110 9 170 060 115 10 170 061 115 11 170 069 115 12 170 006 115 171 053 115 13 171 059 115 171 011 115 14 196 169 110 15 196 170 313 196 170 110 16 286 099 351 286 099 366 17 286 099 600 520 292 000 11 04 Rev C DESCRIPTION Air Valve Assembly Stroke Indicator Only Air Valve Assembly Stroke Indicator Only Air Valve Assembly Air Valve Assembly Air Valve Assembly ATEX compliant w Cast Iron centers only Ball Check Ball Check Ball Check Bushing Pilot Valve Assembly Pilot Valve Assembly use w Cast Iron centers only Intermediate Bracket Intermediate Bracket Bumper Diaphragm Bushing Plunger Cap Air Inlet Assembly Cap Air Inlet Assembly Capscrew Hex Hd 7 16 14 X 2 00 Capscrew Hex Hd 3 8 16 X 1 75 Capscrew Hex Hd 5 16 18 X 1 75 Capscrew Hex HD 3 8 16 X 1 00 Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only Capscrew Soc Hd 7 16 14 X 1 25 Capscrew Soc Hd 1 2 13 X 1 00 Stainless Center Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Diaphragm
34. l 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 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 Model S15 Metallic Design Level 1 Page 9 000 Assembly sub assembly and some purchased items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable Iron 025 Music Wire 080 Carbon Steel AISI B 1112 100 Alloy 20 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel Electro Polished 112 Alloy C Hastelloy equivalent 113 Alloy Type 316 Stainless Steel Hand Polished 114 303 Stainless Steel 115 302 304 Stainless Steel 117 440 C Stainless Steel Martensitic 120 416 Stainless Steel Wrought Martensitic 123 410 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 149 2024 T4 Aluminum 150 6061 T6 Aluminum 151 6063 T6 Aluminum 152 2024 T4 Aluminum 2023 T351 154 Almag 35 Aluminum 155a 356 T6 Aluminum 156 356 T6 Aluminum 157 Die Cast
35. l with a soft cloth and inspect for scratches or wear 520 292 000 11 04 Rev C Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with o rings item 1 G and 1 M into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the smaller unthreaded hole in the endcap Remove the new sleeve and spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B 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 o rings and retaining ring Fasten the air valve assembly item 1 and gasket item 18 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 in S
36. leed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 18 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that 520 292 000 11 04 Rev C fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the bumpers as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B 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 part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B Note Pumps equipped with this valve assembly are not ATEX compliant AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 173 000 313 Air Valve Assembly 1 1 A 095 109 157 313 Body Air Valve 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 360 O Ring
37. llation 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 S15 Metallic Design Level 1 Page 15 Air Valve Servicing Assembly Drawing amp Parts List x AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 18 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that 520 292 000 11 04 Rev C fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the o rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B 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 part of item 1 B for dirt scratc
38. lot Valve Assembly Pilot Valve Assembly use w Cast Iron centers only Intermediate Bracket Intermediate Bracket Bumper Diaphragm Bushing Plunger Cap Air Inlet Assembly Cap Air Inlet Assembly Capscrew Hex Hd 7 16 14 X 2 00 Capscrew Hex Hd 7 16 14 X 2 00 Capscrew Hex Hd 3 8 16 X 1 75 Capscrew Hex Hd 3 8 16 X 1 75 Capscrew Hex Hd 5 16 18 X 1 75 Capscrew Hex Hd 5 16 18 X 1 75 Capscrew Hex HD 3 8 16 X 1 00 Capscrew Hex HD 3 8 16 X 1 00 Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only Capscrew Soc Hd 1 2 13 x 1 00 Stainless Center Capscrew Soc Hd 7 16 14 X 1 25 Capscrew Soc Hd 7 16 14 X 1 25 Chamber Outer Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Diaphragm QTY Bsennaesaean anu pK RA RA RA A e SR wk AS St ede coke a2 2a a ann MPNNNANNNN WTO WOHPHPHP PHA ITEM 17 18 19 20 21 22 23 24 25 26 27 28 29 31 RER 37 PART NUMBER 286 099 364 286 099 365 286 099 600 360 093 360 360 103 360 360 104 379 360 105 360 518 151 156 518 151 156E 518 151 010 518 151 010E 518 151 110 518 151 110E 518 152 156 518 152 156E 518 152 010 518 152 010E 518 152 110 518 152 110E 545 005 115 545 005 330 545 007 115 545 007 330 560 001 379 560 084 360 560 084 363 560 084 364 560 084 365 720 061 608 612 039 157 612 039 010 612 097 110 612 195 157 612 195 010
39. n and the type of equipment required 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 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 29
40. on of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or v
41. ood Grade EPDM 370 Butyl Rubber Color coded BROWN 371 Philthane Tuftane 374 Carboxylated Nitrile 375 0 Fluorinated Nitrile 378 High Density Polypropylene 379 Conductive Nitrile 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 502 Conductive Acetal ESD 800 503 Conductive Acetal Glass Filled 505 Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF Natural color 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene 551 Glass Filled Polypropylene 552 Unfilled Polypropylene 553 Unfilled Polypropylene 555 Polyvinyl Chloride 556 Black Vinyl 558 Conductive HDPE 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 PTFE virgin material Tetrafluorocarbon TFE 601 PTFE Bronze and moly filled 602 Filled PTFE 603 Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated Viton 632 Neoprene Hytrel 633 Viton PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE Viton PTFE 638 PTFE Hytrel PTFE 639 Buna N TF
42. r capscrews items 11 Remove the air inlet cap item 8 and air inlet gasket item 18 The pilot valve assembly item 4 can now be removed Step 2 Inspect the actuator plungers See ILLUSTRATION AT RIGHT The actuator plungers items 30 can be reached through the pilot valve cavity in the intermediate assembly item 5 Remove the plungers item 30 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 26 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go To remove the bushings item 7 first remove the retaining rings item 31 by using a flat screwdriver NOTE It is recommended that new retaining rings be installed 520 292 000 11 04 Rev C Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 18 air inlet cap item 8 and capscrews item 11 Connect the air supply to the pump The pump is now ready for operation ACTUATOR PLUNGER SERVICING Model S15 Metallic Design Level 1 A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for
43. rawing with Non Metallic 0 with Metallic Seats Model S15 Metallic Design Level 1 Page 24 Optional Muffler Configurations Drawing Note the pump is built with a metal muffler for static electrical dissipation to meet ATEX requirements The options shown on this page are not ATEX compliant CONFIGURATION A 530 028 550 Encapsulated Muffler uses 1 165 096 551 Cap and 4 710 015 115 Self Tapping Screw plastic valves or 4 706 026 330 Machine Screws Aluminum Valves to hold it in place CONFIGURATION B 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element CONFIGURATION C 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element Configuration A Configuration B and C 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 25 PUMPING HAZARDOUS LIQUIDS 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 materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The air exhaust must be piped above the liquid level See illustration 2 at right Piping used for the air exhaust mu
44. st not be smaller than 1 2 54 cm diameter Reducing 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 exhaust higher than the product source to prevent siphoning spills See illustration 3 at right 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 item 43 The air distribution valve item 1 has 1 NPT threads for piped exhaust 520 292 000 11 04 Rev C IMPORTANT INSTALLATION NOTE 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 distribution valve body Any piping or hose connected to the pump s air exhaust port must be conductive and physically supported Failure to support these connections could also result in damage to the air distribution valve body Air Valve Assembly Ay Ni m AY woa On ATEX compliant units the pump comes equipped with a standard metal muffler CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL
45. tallation 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 S15 Metallic Design Level 1 Page 18 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Note Pumps equipped with Integral Solenoid Valves are not ATEX compliant Includes all items used on Composite Repair Parts List except as shown Item Part Number Description Qty 38 893 097 000 Solenoid Valve NEMA4 1 39 219 001 000 Solenoid Coil 24VDC 1 219 004 000 Solenoid Coil 24VAC 12VDC 1 219 002 000 Solenoid Coil 120VAC 1 219 003 000 Solenoid Coil 240VAC 1 40 241 001 000 Connector conduit 1 241 003 000 Conduit Connector with 1 Suppression Diode DC Only 41 170 029 330 Capscrew Hex HD 5 16 18 x 1 50 4 42 618 051 150 Plug 2 For Explosion Proof Solenoid Valve Connector not required for explosion proof coil coil is integral with valve 38 893 098 001 Solenoid Valve NEMA 7 9 24VDC 1 893 098 002 Solenoid Valve NEMA 7 9 24VAC 12VDC 1 893 098 003 Solenoid Valve NEMA 7 9 120VAC 1 893 098 004 Solenoid Valve NEMA 7 9 220VAC 1 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 19 SOLENOID SHIFTED DISTRIBUTION VALVE OPTION Warren Rupp s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your SANDPIPER s speed T
46. ulated Muffler 516 48 8 287 548 Stainless 20 3 8 1 31 32 3 8 11 3 8 21 21 32 Both Suction and Discharge Steel 518 50 10 289 550 2 Ports Are Available With f 1 1 2 BSP Tapered Connection Mesh 14 15 16 Muffler 379 ka 4 BOTTOM VIEW Sound f Dampening 1415 16 i Muffler 379 FRONT VIEW Suction Port 1 1 2 NPT Encapsulated Muffler 1 NPT Exhaust Port For Optional Muffler Styles or Piping Exhaust Air in Submerged Applications Air Inlet ajan NOT Metal 14 1 2 Muffler 368 520 292 000 11 04 Rev C Model S15 Metallic Design Level 1 Page 4 Dimensions T15 Metallic Dimensions in Inches Dimensional Tolerance s DISCHARGE PORT 2 SANITARY CLAMP 21 13 16 an SIDE VIEW 22 13 16 FRONT VIEW SUCTION PORT 2 SANITARY CLAMP 21 9 16 1 16 16 y ae 26 16 mam Wo 23 4 tee L 1 OPTIONAL SPACER FOOT STANDARD ENCAPSULATED MUFFLER 4 Tm FOR OPTIONAL MUFFLER 8 Ser STYLES OR PIPING EXHAUST AIR IN SUBMERGED 9 7 8 APPLICATIONS 4 15 16 1 2 7 7 3 1 2 3 9 1 2 3 3 Ab o Dimensions in Millimeters l Dimensional Tolerance 3mm BOTTOM VIEW t 12 3 8 oye NeT DISCHARGE PORT 2 SANITARY CLAMP ee Lee Encapsulated 12 11 32 Muffler 314 SIDE VIEW Pulse Output 13 23 32 Kit 349 FRONT VI EW SUCTION PORT 2 SANITARY CLAMP Aluminum 20 5 16 1 29 32 5 16 11 5 16 21 19 32 516 48 8 287 548 L
47. ve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 A 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 Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews Fasten the air valve assembly item 1 and gasket to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation 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 S15 Metallic Design Level 1 Page 16 Air Valve with Stroke Indicator Assembly Drawing Parts List 520 292 000 11 04 Rev C NOTE CHECK GAP AFTER ASSEMBLY TO INSURE COMPLETE INSTALLATION OF RETAINING RING Note Pumps equipped with this valve assembly are not ATEX compliant Part Number 031 146 000 031 143 000 095 094 551 132 029 552 165 096 551 165 098 147 530 028 550 560 020 360 675 044 115 710 015 115 210 008 330 560 001 360 z 3 E SET SE OEE EN CE SE SEE EE O e E Y 1 zAcCTOTMmMIODS AIR VALVE ASSEMBLY PARTS LIST Description Air Valve Assembly Sleeve and Spool Set
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