Service Manual
Contents
1. 13 Composite Repair Parts 2 14 Spill Containment Option for Virgin PTFE Equipped Pumps se 15 Spill Containment Repair Parts List eene enemies 15 Spill Containment Concept 216 Spill Containment Option Diaphragm Servicing 16 Filling Spill Containment Chambers with Liquid eceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeenaeeeneeeneeeneee 16 Spill Containment Option for TPE Equipped Pumps eld Spill Containment Repair Parts List 17 Spill Containment Concept with TPE Diaphragms eene 18 Spill Containment Option with TPE Diapbragom eene 18 Air Distribution Valve Assembly Drawing enne nnrennnrnnnnns 19 Main Air Valve Assembly Parts List eese eene enne nnne nnne nennen Air Distribution Valve Servicing ssssssssssseeeeeneene nennen nennen nnne nennen nnne Air Distribution Valve with Stroke Indicator Options Air Distribution Valve with Stroke Indicator Parts List Air Distribution Valve with Stroke Indicator Servicing Solenoid Shifted Air Valve Drawing c cccsccseeeeeceeeceseceneceneeeeeaeeeseeeaeeeaeesaeseaeseneceeeeaeseaeeeeeeaeeeats Solenoid Shifted Air Valve Parts List ue Solenoid Shifted Air Distribution Valve Option Pilot Valve Assembly Drawirig epa nde Pilot Valve Assembly Parts2. o eec aa a 34 P lseQ tput Kit O POM TER RR ENTRE SENE 34 Optional Muffler Configurations Drawing nnnm 35 EC Declaration of Conformity Machinery ccecceeeeeeeeeeeeeeeeeeeeeeaeeseeeeaeeeeeeeaeseaesenesereeneeeineeaeens 36 Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA s30nmdl2sm rev0211 Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com Copyright 2011 Warren Rupp Inc All rights reserved SANDPIPERs A WARREN RUPP PUMP BRAND 30 Non Metallic Ball Valve Design Level 2 Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA WARREN RUPP Quality System 1809001 Certified Environmental CE Management System 15014001 Certified FLUID amp METERING CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 100 psi or 231 ft of water 9 US gallon 3 41 liter 7 bar or 70 meters INTAKE DISCHARGE PIPE SIZE 3 ANSI Flange or 0 to 238 US gallons per minute No lube no stall Up to 71 in 18mm 80mm DIN Flange 0 to 901 liters per minute design A CAUTION Maximum Operating Temperature Limit is 180 F for Polypropylene and 250 F for PVDF Models Temperature Limits Materials Maximum Minimum Santoprene Injection molded thermoplastic elastomer with no fabric layer
3. 37 15 16 3 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED 18 31 32 ON A 6 DIA BOLT CIRCLE Salz MANIFOLD ms rdi ROTATE 90 STANDARD INTEGRAL MUFFLER CO FROM VERT 1 NPT EXHAUST PORT CENTERLINE FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED i APPLICATIONS 40 5 8 35 5 8 RONT VIEW 20 1 4 o 16 4 7 8 Y Y AA A n 7 dg n 6 5 32 4 L2 1 2 SUCTION PORT 2 3 STANDARD 1254 FLANGE CONFIGURATION 2 18 1 4 pe 12 5 16 3 4 DIA 4 HOLES EQUALLY SPACED Le 17 5 16 BOLT PATTERN 15 ON A 6 DIA BOLT CIRCLE 3 4 TYP SYMMETRICAL SIDE VIEW Spine ES ABOUT CENTERLINES i A ZI 19 7 8 Dimension IR RECH 1 Standard Pump 12 11 16 Pulse Output Kit 6 9 16 12 11 16 Uem 5 1 8 J BOTTOM VIEW Sound Dampening Muffler 13 3 4 22 9 32 m AIR INLET Mesh Muffler 8 13 16 14 15 16 1 27 32 3 4 NPT 14 1 2 Note Porting Flanges are also available with ER PN10 40mm DIN bolting configuration s30nmdl2sm rev0211 Model S30 Non Metallic Page 6 Metric Dimensions S30 Non Metallic with Spill Containment Dimensions in Millimeters Dimens
4. Pilot Valve S rviCing EDD Diaphragm Service Drawing Non Overlay Diaphragm Service Drawing with Overlay esesssssessessereretreirsttsttstnstnstnttnttntrettntuntrntnnennnntnnnenne Diaphragm Servicing si sii cce ertt rettet ec ete ett rh ee dees he nadine interd Overlay Diaphragm Service cereis tore states ttd aoa ale sas dcl eaa in Pumping Hazardous B Te V o ss rx Converting the pump for piping the exhaust air Exhaust Conversion Drawing 2 2 ree totetu secu tenera rona ine atte Rc sa scares Rene Converted Exhaust Ilustration Modular Check Valve Servicing esses ener nnne nnne nennen tenerent Modular Check Valve Drawing AAA Dual Port Option Drawing Io rae cedi pe ede oe dicen patie urease Dual Porting Options Dual porting of both suction and discharge ends of the 32 Single porting of the suction and dual porting of the pump diecharge 32 Dual porting of the suction and single porting of the pump dscharge 32 Leak Detection Options Drawing canet te censeret recte der oe toa up oed 33 Electronic Leak Detector Installation sesssssssssesenenennen nen 33 Mechanical Leak Detector nstalloeton n 33 Pulse Output Kit Drawing
5. Remove and inspect gasket item 23 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 rings item 1 G for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumper for cuts wear or abrasions Replace if necessary Remove the spool part of item 1 C 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 s30nmdl2sm rev0211 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool 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 an o ring item 1 G 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 small unthreaded hole in the end cap Remove the new sleeve an 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
6. 560 078 611 O ring 618 003 110 Plug Pipe 618 003 308 Plug Pipe 618 025 110 Plug Boss 618 025 308 Plug Boss 618 031 110 Plug Boss 618 031 308 Plug Boss 770 061 600 Spacer Manifold 770 061 552 Spacer Manifold 835 005 110 Tee Pipe 835 005 308 Tee Pipe 860 057 606 Tube Sight 866 060 110 Connector Tube Model S30 Non Metallic Page 17 QTY ara O SMS PPPE SEO PMP POH SPILL CONTAINMENT FOR EQUIPPED PUMPS CONCEPT The Spill Containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment SPILL CONTAINMENT OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the Spill Containment chambers This can be done by removing the bottom plug item 50 from each Spill Containment chamber After
7. removed for inspection or service Step 2 Disassembly of the pilot valve Remove the pilot valve spool item 2 F Wipe clean and inspect for dirt scratches or wear Replace the spool if necessary Remove the two retaining rings items 2 C from each end of the pilot valve body using clip ring pliers Remove the two pilot valve bushings items 2 B five spacers items 2 D and six spool wipers items 2 E by pushing gently from other end of the pilot valve body Inspect the wipers for cuts and or wear Replace any wipers as necessary s30nmdl2sm rev0211 Step 3 Re assembly of the pilot valve First install a spiral retaining ring to one end of the pilot valve body Install one bushing making sure the step side faces toward the wiper Apply a light coating of grease to the outside diameter of each wiper Next gently push in the wipers and spacers until they are against the installed retaining ring in the opposite end of the pilot valve body Install the remaining bushing making sure the step side faces the wiper Install the remaining retaining ring using clip ring pliers Apply a light coating of grease to the inner diameter of each wiper Also apply a light coating of grease to the outer diameter of the pilot valve spool and gently push the spool through each wiper Step 4 Inspect the actuator plungers See PUMP ASSEMBLY DRAWING The actuator plungers items 31 can be reached through the stem cavity of t
8. If the safety clip is installed on the bottom end cap fill the right Spill Containment chamber The volume of fluid is 3770 ml 127 5 fl oz Itis important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug to the filled Spill Containment chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 53 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure
9. Long mechanical flex life Excellent abrasion resistance Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures Polypropylene For specific applications always consult Chemical Resistance Chart Technical Bulletin Maximum and Minimum Temperatures are the limits for which these materials can be operated Temperatures coupled with pressure affect the CAUTION Nonmetallic pumps and plastic components are not UV stabilized Ultraviolet radiation can damage these parts and negatively affect material properties longevity of diaphragm pump components Maximum life should not be expected at the extreme limits of the temperature ranges Do not expose to UV light for extended periods of time SANDPIPER pumps are designed to be powered only by compressed air s30nmdl2sm rev0211 Model S30 Non Metallic Page 1 Explanation of Pump Nomenclature S30 Non Metallic Design Level 2 Ball Valve MODEL Pump Pump Valve Brand Size S30B2P1PQAS000 S Diaphragm Check Valve Materials Wetted Material Check Non Wetted Material Options Shipping Weight Ibs kg 231 105 Options Options S30B2P2PQAS000 231 105 S30B2K1KQAS000 315 143 S30B
10. Valve Assembly Drawing with Stroke Indicator Option 530 Design Level 2 Note Stroke Indicator is standard on Spill Containment models s30nmdl2sm rev0211 PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION QTY 1 031 146 000 Air Valve Assembly 1 1 A 031 143 000 Sleeve and Spool Set w Pins 1 1 B 095 094 551 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 551 Cap Muffler 1 1 E 165 098 147 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self Tapping 4 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O Ring 2 For Pumps with PTFE Coated Hardware 1 031 146 002 Air Valve Assembly 1 1 J 710 015 308 Screw Self Tapping 4 1 H 675 044 308 Ring Retaining 2 includes all other items on 031 146 000 above 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 S30 Non Metallic Page 21 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 16 Allen wrench remove the four hex socket capscrews item 14 and four flat washers item 41 Remove the air valve assembly from the pump
11. be converted to a dual port arrangement on both the suction and the discharge ends The porting can be configured to a single suction and a dual discharge The porting can be changed to a dual suction and a single discharge The above changes are possible because the porting flange of the elbows items 19 are designed to mate with standard 125 ANSI style 4 bolt 3 pipe flanges Dual porting of both suction and discharge ends of the pump Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals spacers and manifolds items 36 39 and 24 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows and optional positioning in the Dual Porting Drawing s30nmdl2sm rev0211 Single porting of the suction and dual porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing Dual porting of the suction and single porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual suction
12. 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 ring and retaining ring Fasten the air valve assembly item 1 and gasket item 23 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 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 S30 Non Metallic Page 22 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Includes all items used on Composite Repair Parts List except as shown QTY ITEM 57 58 59 60 61 PART NUMBER DESCRIPTION 893 097 000 219 001 000 219 004 000 219 002 000 219 003 000 241 001 000 170 061 115 618 052 506 Solenoid Valve NEMA4 Solenoid Coil 24VDC Solenoid Coil 24VAC 12VDC Solenoid Coil 120VAC Solenoid Coil 240VAC Connector conduit Capscrew Hex HD 3 8 16 x 1 75 Plug For Explosion Proof Solenoid Valve 58 219 009 001 219 009 002 21
13. now be removed See diaphragm servicing section for detailed instructions The Spill Containment option has two additional virgin PTFE pumping diaphragms item 46 s30nmdl2sm rev0211 FILLING SPILL CONTAINMENT CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the Spill Containment chambers by removing the bottom two boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 11 fastening the discharge manifold and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The Spill Containment chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 F into the smaller unthreaded hole in one end cap This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety clip is installed on the bottom end cap fill the right Spill Contai
14. porting arrangement remove the only the suction bottom manifolds spacers and manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing 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 S30 Non Metallic Page 32 Leak Detection Options Drawing For pumps with 530 028 550 ENCLOSED MUFFLER s30nmdl2sm rev0211 VA LEAK DETECTION OPTION ELECTRONIC Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC To install electronic leak detectors remove the bottom NPT pipe plug on the visual sight tube item 52 Insert leak detector into the 74 pipe tee item 56 LEAK DETECTION OPTION MECHANICAL Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical leak detectors remove the bottom 74 NPT pipe p
15. 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 composite repair parts drawing and the diaphragm servicing illustration Using a Bel wrench or socket remove the 16 capscrews items 11 hex nuts and washers that fasten the elbows items 19 to the outer chambers items 15 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a wrench or socket remove the 20 capscrews items 9 amp 12 hex nuts and washers that fasten the outer chambers diaphragms and inner chambers items 16 together Step 3 Removing the diaphragm assemblies Use a 13 3 35mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 33 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 30 Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use a s30nmdl2sm rev0211 13 s wrench or socket to remove the outer diaphragm plate item 29 by turning counterclockwise Inspect the diaphragm item 17 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm T
16. 0 Plug Boss 4 618 025 308 Plug Boss 4 52 618 031 110 Plug Boss 4 618 031 308 Plug Boss 4 53 770 061 600 Spacer Manifold 4 770 061 552 Spacer Manifold 4 54 835 005 110 Tee Pipe 4 835 005 308 Tee Pipe 4 55 860 057 606 Tube Sight 2 56 866 060 110 Connector Tube 4 Model S30 Non Metallic Page 15 SPILL CONTAINMENT FOR PTFE EQUIPPED PUMPS CONCEPT The Spill Containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment SPILL CONTAINMENT OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the Spill Containment chambers This can be done by removing the bottom plug item 50 from each Spill Containment chamber After the fluid from the Spill Containment chambers has been drained the wet end components can
17. 0 minus items 1 D 1 F amp 1 J For pumps with alternate Mesh or Sound Dampening mufflers or piped exhaust 1 031 041 002 Air Valve Assembly 1 Includes all items used on 031 141 000 except 1 H 675 044 308 Ring Retaining 2 Model S30 Non Metallic Page 19 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 16 Allen wrench remove the four hex socket capscrews item 14 and four flat washers item 41 Remove the air valve assembly from the pump Remove and inspect gasket item 23 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 rings item 1 G for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cuts 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 spool with a soft cloth and inspect for scratches or wear s30nmdl2sm rev0211 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches
18. 2K2KQAS000 S30B2P4PQAV000 270 122 S30B2K4KQAVO000 Pump Brand S SANDPIPER Pump Size 30 3 Check Valve Type B Ball Design Level 2 Design Level 2 Wetted Material K PVDF P Polypropylene s30nmdl2sm rev0211 Diaphragm Check Valve Materials 1 Santoprene Santoprene 2 PTFE Santoprene Backup PTFE 3 PTFE Pumping PTFE Santoprene Backup Driver PTFE 4 Santoprene Pumping Santoprene Driver Santoprene Check Valve Seat K PVDF P Polypropylene U Polyurethane Polyurethane Non Wetted Material Options A Painted Aluminum J Painted Aluminum PTFE Q Epoxy Coated Aluminum K PTFE Coated Aluminum L PTFE Coated Aluminum with PTFE Coated Hardware R Epoxy Coated Aluminum with PTFE Coated Hardware Porting Options A ANSI Flange D DIN Flange 7 Dual Porting ANSI 8 Top Dual Porting ANSI 9 Bottom Dual Porting ANSI Pump Style D Spill Containment with Electronic Leak Detection 110V E Spill Containment with Electronic Leak Detection 220V M Spill Containment with Mechanical Leak Detection S Standard V Spill Containment with Visual Leak Detection Pump Options 0 None 1 Sound Dampening Muffler 2 Mesh Muffler 3 High temperature Air Valve w Integral Muffler 4 High temperature Air Valve with Sound Dampening Muffler 5 High temperature Air Valve w Mesh Muffler 105 105 143 315 143 122 161 354 161 Kit Options 00 None 10 30VDC
19. 3 308 PTFE Coated Stainless Steel Capscrews Hex Nuts Washers and Support Rod 475 174 308 For use with Spill Containment Options ELECTRONIC LEAK DETECTOR KITS 032 037 000 100VAC 50 2 or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz 032 045 000 12 32VDC s30nmdl2sm rev0211 OVERLAY OPTION MUFFLER OPTION Model S30 Non Metallic Page 13 Composite Repair Parts List ITEM 1 N N 10 11 12 13 14 15 16 17 PART NUMBER 031 140 000 031 140 002 031 141 000 095 089 000 050 039 354 050 039 357 050 039 600 114 021 156 114 021 307 114 021 309 114 021 332 115 133 080 115 133 305 115 133 306 115 133 333 132 019 360 135 032 506 165 099 156 165 099 307 165 099 309 165 099 332 170 017 115 170 017 308 170 052 115 170 052 308 170 111 115 170 111 308 170 112 115 170 112 308 171 004 115 171 053 115 171 053 308 196 151 520 196 151 552 196 152 156 196 152 307 196 152 309 196 152 332 286 077 354 286 077 357 s30nmdl2sm rev0211 DESCRIPTION QTY Air Valve Assembly Air Valve Assembly w PTFE coated Hardware Air Valve Assembly No Integral Muffler Pilot Valve Assembly Ball Check Ball Check Ball Check Intermediate Assembly Intermediate Assembly Intermediate Assembly Intermediate Assembly Bracket Mounting Bracket Mounting Bracket Mounting Bracket Mounting Bumper Diaphragm Bushing Plunger Cap Air Inlet Cap Air Inlet Cap Air Inlet Cap Air Inlet Capsc
20. 9 009 003 219 009 004 219 009 005 219 009 006 s30nmdl2sm rev0211 Solenoid Coil 120VAC 60 Hz Solenoid Coil 240VAC 60 HZ Solenoid Coil 12VDC Solenoid Coil 24VDC Solenoid Coil 110VAC 50 Hz Solenoid Coil 230VAC 50 Hz Mi A sch sch sch sch 2 A A cA c Model S30 Non Metallic Page 23 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION Warren Rupp s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your SANDPIPER s speed The solenoid coil is connected to a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate 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 so
21. Conformity Manufacturer Warren Rupp Inc 800 N Main Street P O Box 1568 Mansfield Ohio 44901 1568 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 the European Community Directive 2006 42 EC on Machinery according to Annex VIII This product has used Harmonized Standard EN 809 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance Lard Apa October 20 2005 Signature of authorized pers Date of issue David Roseberry Engineering Manager Printed name of authorized person Title May 27 2010 Revision Level E evision Leve Date of revision FLUID amp METERING Declaration of Conformity
22. 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 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 Bearing Type Oil Impregnated Die Cast Zinc Copper Alloy Carbon Steel Black Epoxy Coated s30nmdl2sm rev0211 306 307 308 309 310 313 330 331 332 333 335 336 337 340 342 351 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 MATERIAL CODES THE LAST 3 DIGITS OF PART NUMBER Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Aluminum White Epoxy 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 Food Grade S
23. E Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 637 PTFE FKM PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene 666 FDA Nitrile Diaphragm PTFE Overlay Balls and Seals 668 PTFE FDA Santoprene PTFE Delrin 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 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 PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Model S30 Non Metallic Page 11 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory Pump cycle seems unbalanced 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 mete
24. ION 3 4 DIA 4 HOLES EQUALLY SPACED 64mm DISCHARGE PORT 3 STANDARD 125 FLANGE CONFIGURATION FRONT VIE 3 4 DIA 4 HOLES EQUALLY SPACED ON A 6 DIA BOLT CIRCLE STANDARD INTEGRAL MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS SUCTION PORT ON A 6 DIA BOLT CIRCLE 28mm s30nmdl2sm rev0211 1 429mm m 47mm 368mm 406mm gt AIR INLET 3 4 NPT 130mm BO 1032mm 905mm Note Dimensions A is from the vertical center line to the end of the muffler 124mm e e r 514mm MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE Dimension A Standard Pump 6 9 16 Pulse Output Kit 6 9 16 Sound Dampening Muffler 13 3 4 Mesh Muffler 8 13 16 Note Porting Flanges are also available with PN10 80mm DIN bolting configuration Model S30 Non Metallic Page 5 Note Dimensions A is from Note Dimensions B is from D i mensions S30 N on M etal Ic the vertical center line to the the opposite side of the pump with Spill Containment end of the muffler to the end of the muffler Dimensions in Inches Dimensional tolerance s DISCHARGE PORT k 19 5 8
25. Pulse Output Kit P1 Intrinsically Safe 5 30VDC 110 120VAC 220 240VAC Pulse Output Kit P2 110 120 or 220 240VAC Pulse Output Kit E0 Solenoid Kit with 24VDC Coil E1 Solenoid Kit with 24VDC Explosion Proof Coil E2 Solenoid Kit with 24VAC 12VDC Coil E3 Solenoid Kit withf2VDC Explosion Proof Coil E4 Solenoid Kit with 110VAC Coil E5 Solenoid Kit with 110VAC 60 Hz Explosion Proof Coil E6 Solenoid Kit with 220VAC Coil E7 Solenoid Kit with 220VAC 60 Hz Explosion Proof Coil E8 Solenoid Kit with 110VAC 50 Hz Explosion Proof Coil E9 Solenoid Kit with 230VAC 50 Hz Explosion Proof Coil SP Stroke Indicator Pins Model S30 Non Metallic Page 2 Performance Curve Model S30 Non Metallic Design Level 2 Performance based on the following elastomer fitted pump flooded suction water at ambient conditions lt 20 34 The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 1 20 69 0 102 SCFM M h 7 7100 6 S W lm i PS SOR LL I Ll Q e N Y E Pa PSK S NE 2 9 1 7 6 6 1 4 5 3 1 5 0 0 20 40 60 80 100 120 140 160 180 200 220 U S Gallons per minute Pe ee 50 150 250 350 450 550 650 750 850 Liters per minute CAPACITY s30nmdl2sm rev0211 Model S30 Non Metallic Page 3 Dimensions S30 Non Metallic Dimensions in Inches Dimensional tolerance s Note Dimensions A is from the vertical center line to t
26. SERVICE amp OPERATING MANUAL Original Instructions SANDPIPER AWARREN RUPP INC BRAND Model 30 Non Metallic Design Level 2 Table of Contents Engineering Data and Temperature Limitations 1 Explanation of Pump Nomenclature 2 Performance Curve Model S30 Non Metallic Design Level 2 3 Dimensions S30 Non Metallio 2 iones retento rare teo ee Pede vd eek ener 4 Metric Dimensions S30 Non Metallic Dimensions S30 Non Metallic with Spill Containment 6 Metric Dimensions S30 Non Metallic with Spill 7 Principle of Pump Operation 8 Iristallatioriand Start p iio rate ce eae 8 ps o te 8 Air Valve EUbrication eoo e e u eaa aD 8 Air Di 8 Airinietand o i enel carens Pn 8 IR RULES 8 Installation EI peo rp ie etta Bee er ets rt ee Ead ti N 9 Important Safety Information 10 m 11 TROUDICSMOOUNG EP p 12 Watranty iiiec recense a t2 Composite Repair Parts Drawing irr estt EES AERCH 13 Overlay Option Drawing eie ire EUR em e ur
27. Valve Style Optional TOP Air Exhaust Filter Regulator Air Dryer 55 Gauge DIAPHRAGM Shut Off PUMP SE D Valve Oh AIR INLET m i Flexible SUCTION DER Connection Drain Port s30nmdl2sm rev0211 Model S30 Non Metallic Page 9 RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 11 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed s30nmdl2sm rev0211 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 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 AA 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 pressurized and must be bled of its pressure WARNING In the event of diaphragm rupture
28. ambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Department before performing this procedure A 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 S30 Non Metallic Page 12 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 176 000 AIR END KIT Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 177 000 AIR END KIT for Stroke Indicator Option Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 140 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and Seals 476 140 654 WETTED END Santoprene Diaphragms PTFE Overlay Diaphragms TFE Balls and TFE Seals 476 143 354 WETTED END KIT for Polypropylene Spill Containment Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 476 143 655 WETTED END KIT for PVDF Spill Containment Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals HARDWARE KITS 475 17
29. antoprene 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 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 374 375 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 540 541 542 544 550 551 552 553 555 556 558 570 580 590 591 592 600 601 602 603 604 606 Carboxylated Nitrile Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive HDPE Rulon 11 Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE PTFE 607 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTF
30. d material on the surfaces of both the external and internal chamfers The spherical surface of the check balls must seat flush to the surface of the inner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary s30nmdl2sm rev0211 Remove the remaining check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Re assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 37 into the cavity of the outer chamber item 15 Make sure the chamfer side of the seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 37 Make sure the chamfer side of the seal faces the chamfer on the check valve seat or retainer The pump can now reassembled reconnected and returned to operation Modular Check Valve Drawing Model S30 Non Metallic Page 30 X A l Va Ba A p QW e NS A W PA Q Resch op D AO Lf Gg CELA 2 Ko WSs fiA 3 ANSI STYLE FLANGE CONNECTION FOUR 2 75 HOLES ON A 6 00 BOLT CIRCLE 3 ANSI STYLE FLANGE CONNECTION FOUR 9 75 HOLES ON A 6 00 BOLT CIRCLE Dual Port Option Drawing Model S30 Non Metallic Page 31 s30nmdl2sm rev0211 DUAL PORTING OPTIONS Several dual porting options are possible The pump can
31. e 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 S30 Non Metallic Page 8 WARREN INSTALLATION GUIDE RUPP Top Discharge Ball Valve Unit Available from Warren Ru S PP Suppressor Pipe Connection Limited to Style Optional 9 Surge Suppressor 100 psi 2 020 051 000 Filter Regulator Gauge 8 Air Dryer Flexible Shut Off Valve Connection O HA DISCHARGE EE A CAUTION Hi The air exhaust should be piped to an area for safe disposition of the product Drain Port being pumped in the event of a diaphragm failure Flexible Connection Air Shut Off Pipe Connection
32. emaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite Spill Containment chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump 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 S30 Non Metallic Page 16 Spill Containment Option for TPE Equipped Pumps Drawing Discharge Manifold Suction Manifold 20 s30nmdl2sm rev0211 S30 SPILL CONTAINMENT FOR TPE EQUIPPED PUMPS REPAIR PARTS LIST ITEM PART NUMBER DESCRIPTION 1 43 44 45 46 47 48 49 50 51 52 54 55 56 031 146 000 Air Valve Assembly replaces 031 140 000 031 147 000 Air Valve Assembly replaces 031 141 000 170 113 115 Capscrew Hex HD 5 8 11 x 6 00 170 113 308 Capscrew Hex HD 5 8 11 x 6 00 170 115 115 Capscrew Hex HD 5 8 11 x 4 00 170 115 308 Capscrew Hex HD 5 8 11 x 4 00 196 156 552 Chamber Spill Containment 196 156 600 Chamber Spill Containment 286 080 354 Diaphragm Pumping 518 135 520 Manifold Spill Containment 518 135 520E Manifold 80mm DIN 518 135 552 Manifold Spill Containment 518 135 552E Manifold 80mm DIN 538 022 110 Pipe Nipple 538 022 308 Pipe Nipple
33. eversed 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 surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 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 7 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and fil
34. he end of the muffler FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST oy To AIR IN SUBMERGED APPLICATIONS 3 STANDARD 1254 FLANGE CONFIGURATION Lo A sl 16 11 16 3 4 DIA 4 HOLES EQUALLY SPACED ON 6 DIA BOLT CIRCLE BOT P dd FROM VERTICAL CENTERLINE STANDARD INTEGRAL MUFFLER ti 1 NPT EXHAUST PORT oa St a I FRONT VIEW o e 3 16 SUCTION PORT 6 5 32 4 3 STANDARD 1258 FLANGE CONFIGURATION 12 5 16 93 4 TYP 2 1 2 3 4 DIA 4 HOLES EQUALLY SPACED ge A 8 PLACES E 17 5 16 ON A 6 DIA BOLT CIRCLE BOLT PATTERN IS 18 1 4 SYMMETRICAL ABOUT CENTERLINES SIDE VIEW Dimension A Standard Pump 6 9 16 AB CNET S BOTTOM VIEW Pulse Output Kit 6 9 16 3 4 NPT Sound Dampening Muffler 13 3 4 Mesh Muffler 8 13 16 1 27 32 14 1 2 16 Note Porting Flanges are also available with PN10 80mm DIN bolting configuration s30nmdl2sm rev0211 Model S30 Non Metallic Page 4 Metric Dimensions S30 Non Metallic Dimensions in Millimeters Dimensional tolerance 3mm 423mm gt 846mm 156mm 03 4 TYP 8 PLACES BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES RY 313mm A 440mm 5mm 3 STANDARD 125 FLANGE CONFIGURAT
35. he pilot valve in the intermediate assembly item 4 Remove the plungers items 31 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 28 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 Step 5 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 20 air inlet cap item 8 capscrews and washers items 10 and 39 Connect the air supply to the pump Remove the safety clip item 1 F from the end cap item 1 E 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 S30 Non Metallic Page 26 Diaphragm Service Drawing Diaphragm Service Drawing Non Overlay with Overlay s30nmdl2sm rev0211 Model S30 Non Metallic Page 27 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
36. hragm Plate Plunger Actuator Retainer Ball Retainer Ball Rod Diaphragm Rod Support Rod Support Seal Diaphragm Rod Seal Manifold Spacer Seal Check Valve Assembly Seat Check Valve Seat Check Valve Spacer Manifold Spacer Manifold Spacer Manifold PTFE Overlays Only Spacer Manifold PTFE Overlays Only Washer Flat 5 8 Washer Flat 5 8 Washer Flat 3 8 Washer Flat 3 8 Nameplate Model S30 Non Metallic Page 14 QTY yN BPRRRRRWONNNHAFANNNNNNNAHANNNNAHANHAKAND a AR Spill Containment Option for Virgin PTFE Equipped Pumps Drawing s30nmdl2sm rev0211 Discharge Manifold 530 SPILL CONTAINMENT REPAIR PARTS LIST FOR VIRGIN PTFE EQUIPPED PUMPS ITEM PART NUMBER DESCRIPTION QTY 1 031 146 000 Air Valve Assembly 1 replaces 031 140 000 031 147 000 Air Valve Assembly 1 replaces 031 141 000 43 170 113 115 Capscrew Hex HD 5 8 11 x 6 00 16 170 113 308 Capscrew Hex HD 5 8 11 x 6 00 16 44 170 115 115 Capscrew Hex HD 5 8 11 x 4 00 4 170 115 308 Capscrew Hex HD 5 8 11 x 4 00 4 45 196 156 552 Chamber Spill Containment 2 196 156 600 Chamber Spill Containment 2 46 286 079 600 Diaphragm Pumping 2 47 518 135 520 Manifold 2 518 135 520E Manifold 80mm DIN 2 518 135 552 Manifold 2 518 135 552E Manifold 80mm DIN 2 48 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 49 560 078 611 O Ring 8 50 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 51 618 025 11
37. hread the inner plate clockwise onto the stud Use a torque wrench to tighten the diaphragm assembly together to 480 in Lbs 54 23 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 6 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 item 33 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 16 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 15 to the pump using the capscrews items 9 amp 12 hex nuts and flat washers On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 33 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber The molded directional arrows on the diaphragm must point vertically Fasten the remaining outer chamber item 15 to the pump using the cap
38. ional tolerance 3mm DISCHARGE PORT Le 498mm e _ _ 3 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED 127mm m 482mm 4 ON A 6 DIA BOLT CIRCLE MANIFOLD l A ROTATE 90 STANDARD INTEGRAL MUFFLER FROM VERTI 1 NPT EXHAUST PORT CENTERLINE FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS 1032mm RA FRONI VIEW elo 5mm 1 y i 127 156mm Le 64mm SUCTION PORT uo 3 STANDARD 1254 FLANGE CONFIGURATION Te 313mm Fy 3 4 DIA 4 HOLES EQUALLY SPACED 440mm BOLT PATTERN IS ON A 6 DIA BOLT CIRCLE 3 4 TYP SYMMETRICAL SIDE VIEW ABOUT CENTERLINES al 28mm 47mm 214mm 429mm i Standard Pump 130mm Pulse Output Kit AIR INLET BOITOM VIEW Sound Dampening Muffler SC EEN Mesh Muffler 225mm 380mm 408mm Note Porting Flanges are also available with PN10 80mm DIN bolting configuration s30nmdl2sm rev0211 Model S30 Non Metallic Page 7 PRINCIPLE OF PUMP OPERATION Thi
39. lenoid make certain it is compatible with your system voltage s30nmdl2sm rev0211 Before wiring remove terminal block from conduit connector A mL ILLI 4 Wiring Diagram 3rd Terminal for ground M 2 Terminal Neutral 1 Terminal Negative Power Positive es Deg A E Model S30 Non Metallic Page 24 Pilot Valve Assembly Drawing PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION Q 2 095 089 000 Pilot Valve Assembly 2 A 095 081 551 Body Pilot Valve 2 B 135 033 506 Bushing 2 C 675 055 115 Ring Retaining 2 D 770 049 175 Spacer S mew o 2 2 0 e 2 2 F 775 033 506 Spool Pilot W x Ep esses NALA O s30nmdl2sm rev0211 Model S30 Non Metallic Page 25 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Insert the safety clip item 1 F from Air Distribution Valve assembly drawing into the smaller unthreaded holes in the end cap item 1 E from air distribution valve assembly drawing Step 1 See PUMP ASSEMBLY DRAWING Using a he wrench or socket remove the four capscrews items 10 and four flat washers items 41 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly item 2 can now be
40. lug on the visual sight tube item 52 Insert leak detector into the 77 pipe tee item 56 Model S30 Non Metallic Page 33 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 30 VDC 475 244 002 110 220 VAC 475 244 003 10 30VDC 110VAC and 220 VAC s30nmdl2sm rev0211 Model S30 Non Metallic Page 34 Optional Muffler Configurations Drawing OPTION 0 530 028 550 Integral Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to hold it in place OPTION 1 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body Option 0 Option 1 and 2 Option 6 s30nmdl2sm rev0211 Model S30 Non Metallic Page 35 ALILUIOJUOT JO UOIneJej3ag WARREN RUPP Declaration of
41. lustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 MUFFLER aa baw E Reg 1 DIAMETER AIR EXHAUST PIPING E MUFFLER LT LIQUID Si LEVEL SUCTION LINE Illustration 3 Mode 1 DIAMETER AIR EXHAUST PIPING 1 S30 Non Metallic Page 29 MODULAR CHECK VALVE SERVICING Before servicing the check valves 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 modular check valve remove the elbows items 19 from pump composite repair parts drawing Use a As5 wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seen in the cavities of the outer chamber items 15 Next remove the check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 32 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 3 for wear abrasion or cuts on the spherical surface The check valve seats items 38 should be inspected for cuts abrasive wear or embedde
42. nment chamber The volume of fluid is 3770 ml 127 5 fl oz It is important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug to the filled Spill Containment chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 53 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any r
43. 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 Use a 8 Torx or flat screwdriver to remove the six self tapping screws item 1 J Remove the muffler cap and muffler items 1 D and 1 F The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed IMPORTANT INSTALLATION s30nmdl2sm rev0211 NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic 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 physically supported Failure to support these connections could also result in damage to the air distribution valve body Exhaust Conversion Drawing CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Il
44. or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one end cap item 1 E with an o ring item 1 G and one bumper item 1 C 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 Remove the new sleeve an 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 it touches the bumper on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 23 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 S30 Non Metallic Page 20 Air
45. 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 AWARNING 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 A WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly AWARNING 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 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 S30 Non Metallic Page 10 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 180 305 Assembly sub assembly and some purchased items Cast Iron Powered Metal
46. rew Hex HD 5 8 11 x 1 75 Capscrew Hex HD 5 8 11 x 1 75 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 5 8 11 x 3 25 Capscrew Hex HD 5 8 11 x 3 25 Capscrew Hex HD 5 8 11 x 3 75 Capscrew Soc HD 5 8 11 x 3 75 Capscrew Soc HD 1 2 13 x 1 25 Capscrew Soc HD 3 8 16 X 2 75 Capscrew Soc HD 3 8 16 X 2 75 Chamber Outer Chamber Outer Chamber Inner Chamber Inner Chamber Inner Chamber Inner Diaphragm Diaphragm Ww MNONNNNNNNARPONNAAAPAAPPRAAHAANMNNNNNNH HH KFA PARR A ITEM PART NUMBER 18 286 078 600 19 312 103 520 312 103 552 20 360 090 360 21 360 091 360 22 360 092 360 23 360 093 360 24 518 133 520 518 133 520E 518 133 552 518 133 552E 25 530 027 000 530 010 000 27 545 009 110 545 009 308 28 560 001 360 29 612 161 520 612 161 552 30 612 162 150 31 620 017 115 32 670 047 520 670 047 552 33 685 051 120 34 685 052 115 685 052 308 35 720 010 375 36 720 039 600 37 720 043 600 38 722 076 520 722 076 552 39 770 055 520 770 055 552 770 059 520 770 059 552 40 901 047 115 901 047 308 41 901 048 115 901 048 308 SHOWN 535 069 000 DESCRIPTION Diaphragm Overlay Elbow Elbow Gasket Air Inlet Gasket Inner Chamber Gasket Pilot Valve Gasket Main Air Valve Manifold Manifold 80mm DIN Manifold Manifold 80mm DIN Muffler Muffler Nut Hex 5 8 Nut Hex 5 8 O ring Assembly Outer Diaphragm Plate Assembly Outer Diaphragm Plate Assembly Inner Diap
47. rs of liquid install a back pressure device Whatto 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 s30nmdl2sm rev0211 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 Plus 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 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 section of yo
48. s 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 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 shifts to the opposite end of the valve body the pressure to the chambers s30nmdl2sm rev0211 is r
49. screws items 9 amp 12 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 11 hex nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 18 is designed to fit snugly over the exterior of the standard TPE diaphragm item 17 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation 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 S30 Non Metallic Page 28 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 must
50. ters 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 compressed 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 75 to 34 turn After the pump primes the air valv
51. the fluid from the Spill Containment chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The Spill Containment option has two additional TPE pumping diaphragms item 46 s30nmdl2sm rev0211 FILLING SPILL CONTAINMENT CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the Spill Containment chambers by removing the bottom two boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 11 fastening the discharge manifold and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The Spill Containment chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 F into the smaller unthreaded hole in one end cap This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left Spill Containment chamber
52. to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite Spill Containment chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump 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 S30 Non Metallic Page 18 Air Distribution Valve Assembly Drawing S30 Design Level 2 s30nmdl2sm rev0211 MAIN AIR VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER DESCRIPTION QTY 1 031 140 000 Main Air Valve Assembly 1 1 A 031 139 000 Spool Assembly 1 1 B 095 094 551 Body Air Valve 1 1 132 029 552 Bumper 2 1 D 165 096 551 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For pumps equipped with PTFE Coated Hardware 1 031 140 002 Air Valve Assembly 1 Includes all items used on 031 140 000 except 1 J 710 015 308 Screw Self tapping 4 1 H 675 044 308 Ring Retaining 2 For pumps equipped with PTFE coated hardware option 1 031 141 000 Air Valve Assembly 1 Includes all items used on 031 140 00
53. ur 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 vapor lock in one or both pumping ch
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