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1. iJ Air Exhaust r Ag Gauge DIAPHRA Shut Off 5 E Valve l O Flexible SUCTION i db Ne Connection DMD Drain Port hdb15dl7sm rev0O711 K AIR INLET Models HDB1 2 HDB40 Page 7 AIR EXHAUST If a diaphragm fails the pumped liquid or fumes can enter the air end of the pump and be exhausted into the atmosphere When pumping hazardous or toxic materials pipe the exhaust to an appropriate area for safe disposition This pump can be submerged if materials of construction are compatible with the liquid The air exhaust must be piped above the liquid level Piping used for the air exhaust must not be smaller than 1 2 54 cm Reducing the pipe size will restrict air flow and reduce pump performance When the product source is at a higher level than the pump flooded suction pipe the exhaust higher than the product source to prevent siphoning spills Freezing or icing up of the air exhaust can occur under certain temperature and humidity conditions Use of an air dryer unit should eliminate most icing problems BETWEEN USES When used for materials that tend to settle out or transform to solid form the pump should be completely 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 valves and diaphragms at re start In freezing temperatures the pump must be drained between uses i
2. 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 180 305 306 307 308 309 310 313 330 331 332 333 335 336 337 340 342 351 MATERIAL CODES THE LAST 3 DIGITS OF PART NUMBER Assembly sub assembly and some purchased items Cast Iron Powered Metal Ductile Iron Ferritic Malleable Iron Music Wire Carbon Steel AISI B 1112 Alloy 20 Alloy Type 316 Stainless Steel Alloy Type 316 Stainless Steel Electro Polished Alloy C Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic 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 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 Br
3. SERVICE amp OPERATING MANUAL PIPERS Original Instructions PE CE Model HDB1 Type 7 S 21 amp 22 IESX x as Model HDB40 Type 7 A WARREN RUPP PUMP BRAND Table of Contents Engineering Data Temperature Limitations and Performance Curve 1 Explanation of Pump Nomenclature ccccccccecceecceeeneeseeeeeeeeeeeeeeeeeeeeeeeees 2 3 Side Ported Option Dimensions ccccceeceeeeeseeeeeeeeeeeeeeeeeeeeeeaneaasseeeeseeeeeeeeeees 4 Down Ported Option Dimensions cccccccceecececceeeeeeeeeeeeeeeeeseeeeeeeeeeseeeeneaanes 5 Principle of Operation seesmine E 6 WS tea OTN and Star Up ss cr ancsstcansvncrete aeee EEE E EE ESEE FEE A EEEE 6 PRU SUPPI sa E E R E E E 6 l stallation IE chats atibacedic a ad agian naa E r E e a REEE 7 Alr nl t amp Primin genaai et ee ete ee nea ee ce eee eae 8 AIMEXNAUST rerea a E 8 Between USES ceure eieae aaa ipn rei aaee ieena 8 Check Valve Servicing etre eter e E E aaae 8 Diaphragm lt I VICI O essseerec reinen vee spdaceslseedueas ves sesaanddsqadedeveecs raei eeereer ences 8 Air Valve LIMBIC AMON assiste ea aaa a aaa aaia aa aaa aa 8 ESADS Plus Externally Serviceable Air Distribution System eeee 9 Pilot AN Ss aisha R E E E wd bash E a a a A 9 Pilot Valve ActUatOr croiceand ecne naaar piian Eaa E EEren ES 9 Service Instructions Troubleshooting 2 cccccccccecceeeeeeeeeeeeeeeeeeseeeeeeedereeeeeeees 10 Waranty coere
4. 114 654 Plate Outer Diaphragm Assy Not Used with 286 114 654 Plug Pipe 1 4 Plug Pipe 1 4 Aluminum and Cast iron Units BSP Thread BSP Thread BSP Thread BSP Thread YS veo eo wa Models HDB1 HDB40 Page 16 TOTAL PNOANARARRNHMNNNNNND AH AH A A AH HA HAND NNUNNNNNNNNNVAZO2A22 2228 BHONMNNMNNN DN 618 003 110 Plug Pipe 1 4 Stainless Units 4 618 003 112 Plug Pipe 1 4 Hastalloy Units 4 39 620 011 114 Plunger Actuator 2 40 685 007 120 Rod Diaphragm 1 41 720 004 360 Seal U Cup 2 42 722 010 110 Seat Check Valve 2 722 010 110 Seat Check Valve Suction Side PTFE and Santoprene Fitted Units 1 722 010 112 Seat Check Valve 2 722 010 112 Seat Check Valve Suction Side PTFE and Santoprene Fitted Units 1 722 031 110 Seat Check Valve Discharge Side PTFE and Santoprene Fitted Units 1 722 031 112 Seat Check Valve Discharge Side PTFE and Santoprene Fitted Units 1 43 807 017 330 Stud Threaded Side Port Units Only 4 807 017 330 Stud Threaded Down Port Units Only 8 44 900 005 330 Washer Lock 3 8 6 45 900 006 330 Washer Lock 7 16 Side Ported Units 20 900 006 330 Washer Lock 7 16 Down Ported Units 24 46 905 001 330 Washer Tapered 4 47 312 020 156 Elbow Down Ported Units 2 312 020 110 Elbow Down Ported Units SST amp C I 2 312 020 112 Elbow Down Ported Units 2 48 545 004 330 Nut Hex 5 16 18 Down Ported Units 2 50 900 004 330 Washer Lock 5 16 Down Ported Uni
5. GREEN Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Color BLACK Unfilled Polypropylene Color NATURAL Polyvinyl Chloride Black Vinyl 557 Conductive Polypropylene Color BLACK Color Coded SILVER 558 Conductive HDPE Color BLACK Color Coded SILVER 559 Conductive Polypropylene Color BLACK Color Coded SILVER 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 TFE virgin material Tetrafluorocarbon TFE 601 PTFE Bronze and moly filled 602 Filled PTFE 603 Blue Gylon v 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE Color BLACK 610 TFE Encapsulated Silicon 611 TFE Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 Neoprene PTFE 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 v v Delrin is a registered tradename 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 Po
6. Roseberry Engineering Manager Printed name of authorized person Title MAY 27 2010 Revision Level E Date of vicion FLUID amp METERING AULWIOJUOTD JO uvonee paq AULIOJUOTD 40 vonese npag WARREN RUPP INC EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Equipment intended for use in potentially explosive environments Manufacturer Applicable Standard Warren Rupp Inc EN13463 1 2001 A Unit of IDEX Corportion EN13463 5 2003 800 North Main Street P O Box 1568 Mansfield OH 44901 1568 USA EN 60079 25 2004 For pumps equipped with Pulse Output ATEX Option KEMA Quality B V 0344 AODD Pumps and Surge Suppressors For Type Examination Designations see page 2 back AODD Air Operated Double Diaphragm Pumps EC Type Examination Certificate No Pumps KEMA O9ATEX0071 X KEMA Quality B V Utrechtseweg 310 6812 AR Arnhem The Netherlands SANDPIPER Tranquilizer A WARREN RUPP INC BRAND DATE APPROVAL TITLE 27 MAY 2010 WARREN RUPP INC EC Declaration of Conformity ATEX Summary of Markings Pump types S1F S15 S20 and S30 provided with the pulse output option Pump types S1F S15 S20 and S30 provided with the integral solenoid option Pump types HDB1 HDB40 HDB2 HDB50 HDB3 HDF 1 HDF25 HDF2 HDF3M PB S05 S1F S15 S20 S30 SB1 SB25 ST1 ST40 G15 G20 and G30 without the above listed options no aluminum parts Pump t
7. T 104 SI7II X X Cl Cl C CI 416SS_ 316SS PS l l CT A 104 SN7II X X Cl Cl Cc Cl 416SS_ 316SS PS N N CN A 104 SV7II X X CI CI Cc Cl 416SS_ 316SS PS Vv V CT T 104 SGN7II X X Cl Cl Cc Cl 416SS_ 316SS PS N T T CT T 104 SS7Il X X CI Cl Cc Cl 416SS_ 316SS PS S S CT A 104 SB7SS X X SS SS 356T6AL _416SS _ 316SS PS B B CB A 107 SC7SS X X SS SS 356T6AL 416SS 316SS PS V T CT T 107 SI7SS X X SS SS 356T6AL 416SS 316SS PS l CT A 07 SN7SS X X SS SS 356T6AL 416SS 316SS PS N N CN A 07 SV7SS X X SS SS 356T6AL 416SS 316SS PS V V CT T 07 SGN7SS X X SS SS 356T6AL 416SS_ 316SS PS N T T CT T 07 SGV7SS X X SS SS 356T6AL _416SS _ 316SS PS VIT T CT T 07 SS7SS X X SS SS 356T6AL 416SS__ 316SS PS S CT A 07 SB7SI X X SS SS CI 416SS_ 316SS PS B CB A 07 SC7SI X X SS SS Cl 416SS_ 316SS PS V CT T 07 SI7SI X X SS SS CI 416SS_ 316SS PS l CT A 07 SN7SI X X SS SS CI 416SS_ 316SS PS N CN A 07 SV7SI X X SS SS CI 416SS_ 316SS PS V CT T 07 SGI7SI X X SS SS CI 416SS_ 316SS PS CT T 07 SGN7SI X X SS SS Cl 416SS_ 316SS PS CT 07 SGV7SI X X SS SS Cl 416SS_ 316SS PS CT 07 SS7Sl X X SS SS CI 416SS_ 316SS PS CT 07 SGN7HC X X AlloyC Alloy C CI 416SS_ AlloyC PS CT 07 m A Compressed Fibre CB Conductive Nitrile DC Die Cast N Neoprene S Santoprene Meanings of AL Aluminum Cl Cast Iron H T Hytrel Backup PTFE Overlay N T Neoprene Backup PTFE Over SS Stainless Steel Abbreviations 8 Nitrile CN Con
8. diaphragm assemblies clamp the inner dia phragm plate no 35 around the outer diameter between jaws of a vise to hold it while you turn the outer diaphragm plate no 36 loose using a wrench Interior components consisting of shaft seals and sleeve bearings are now accessible for service if required REASSEMBLY All procedures for reassembling the diaphragms are just in reverse of previous instructions for disassembly The diaphragms are to be installed with their natural bulge outward or toward the outer diaphragm plate no 36 Make sure the inner plate is installed with the flat face against the diaphragm If needed the second diaphragm can be installed with the natural bulge toward the air side The can aid in the assembling of the outer chamber After all components are in position in vise and hand tight tighten with wrench to approximately 40 ft Ibs 54 23 Newton meters torque After each diaphragm assembly has been made thread one assembly into shaft no 40 hold shaft near middle in vise having soft jaws to protect finish Install this sub assembly into pump and secure by placing the outer chamber no 16 on the end with the diaphragm This will hold the assembly in place while the opposite side is installed Make sure the last diaphragm assembly is torqued to 30 ft Ibs 40 67 Newton meters This final torquing will lock the diaphragm assemblies together Place remaining outer chamber on open end and secure hdb15dl7sm rev0
9. 09 363 570 009 364 570 009 365 612 052 157 612 052 010 612 219 150 612 039 157 612 039 010 612 097 110 612 097 112 618 003 330 618 003 330 hdb15dl7sm rev0711 DESCRIPTION Diaphragm Overlay Flange Discharge Flange Discharge Flange Discharge Flange Discharge Flange Suction Flange Suction Flange Suction Flange Suction Flange Threaded Flange Threaded Flange Threaded Flange Threaded Flange Threaded HDB40 Only Flange Threaded HDB40 Only Flange Threaded HDB40 Only Flange Threaded HDB40 Only Gasket Manifold Seat Gasket Manifold Seat Gasket Manifold Seat Gasket Manifold Side Ported Units Gasket Manifold Down Ported Units Gasket Manifold Side Ported Units Gasket Manifold Down Ported Units PTFE and FKM Fitted Units Only Gasket Pilot Valve Gasket Air Valve Manifold Manifold Manifold Manifold Muffler Nut Hex 3 8 16 Nut Hex 7 16 14 Side Ported Units Nut Hex 7 16 14 Down Ported Units O Ring Sold with Item 39 O Ring O Ring O Ring PTFE and FKM Fitted Units Only Pad Wear Pad Wear Pad Wear Also used with Santoprene 354 Fitted Units Pad Wear Plate Inner Diaphragm Plate Inner Diaphragm Plate Inner Diaphragm Used with 286 114 654 One Piece Bonded PTFE Diaphragm Plate Outer Diaphragm Assy Not Used with 286 114 654 Plate Outer Diaphragm Assy Not Used with 286 114 654 Plate Outer Diaphragm Assy Not Used with 286
10. 7 11 Models HDB1 z HDB40 Page 8 A Note about Air Valve Lubrication The SANDPIPER pump s pilot valve and main air valve assemblies 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 supplies Proper lubrication of the compressed air supply would entail the use of an air line lubricator available from Warren Rupp set to deliver one drop of 10 wt non detergent oil for every 20 SCFM of air the pump consumed at its point of operation Consult the pump s published Performance Curve to determine this It is important to remember to inspect the sleeve and spool set routinely It should move back and forth freely This is most important when the air supply is lubricated If a lubricator is used oil accumulation will over time collect any debris from the compressed air This can prevent the pump from operating properly 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 This can be addressed by using a point of use air dryer to supplement a plant s air drying equipment This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem ESADS Plus Exte
11. E PORT He 12 04 306 AIR INLET 3 4 NPT 1 1 2 NPT 1 1 2 BSP TAPERED 1 11 59 294 15 81 401 10 55 268 i Ad aa a a 23 31 592 I afifi i 7 7 253 ie 17 28 439 16 26 413 6 27 159 5 22 132 J i SUCTION PORT i 10 64 270 me 11 2 NPT 1 1 2 BSP TAPERED O 14 50 368 8X 44 11 MOUNTING HOLES E T v y 12 50 318 10 50 267 i AIR EXHAUST 8 64 219 3 4 NPT INDICATES DIMENSIONS WITH SUCTION AND DISCHARGE PORTS ROTATED 180 TO A VERTICAL POSITION Model HDB172 A features 12 NPT threaded connections Model HDB40 A features 1 2 BSP Tapered connections hdb15dl7sm rev0O7 11 Models HDB1 HDB40 Page 5 a SANDPIPERs A WARREN RUPP PUMP BRAND See pages 21 amp 22 for ATEX ratings FLUID amp METERING PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 pres sure ratio design It alternately pressurizes the inner side of one diaphragm chamber while simultaneously exhausting the otherinner chamber This causes the diaphragms which are connected by a common rod to move endwise Air pressure is applied over the entire s
12. HDB 1 2 Type 7 HDB40 Type 7 Heavy Duty Ball Valve Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE See page 21 amp 22 amp CONSTRUCTION DATA for ATEX ratings FLUID amp METERING INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE HDB1 1 NPT 0 to 105 gallons per minute No lube no stall Up to in 6 3mm 125 psi or 289 ft of water 37 Gallon 1 29 liter HDB40 1 BSP Tapered 0 to 397 liters per minute design 8 8 Kg cm or 88 meters Quality System 1S09001 Certified Environmental Management System 18014001 Certified 1 AIR CONSUMPTION MODEL HDB1 Performance Curve 3 h Performance based on the following elastomer fitted pump flooded suction SCFM M hr er at ambient conditions The use of other materials and varying hydraulic 30 51 conditions may result in deviations in excess of 5 4068 0 2 72 a 20 PSI Air Inlet 1 36 BAR 0 10 40 50 60 U S Gallons per minute ee a a a a a a E 0 50 150 200 250 Liters per minute CAPACITY SANDPIPER pumps are designed to be powered only by compressed air hdb15dl7sm rev07 11 Models HDB1 2 HDB40 Page 1 Explanation of Pump Nomenclature HDB1 1 2 amp HDB40 MATERIALS OF CONSTRUCTION To order a pump or replacement parts first enter the Model Number HDB15 or HDB40 followed by the Type Designation l
13. ass Silver Plated Steel Nickel Plated Filled Nylon Food Grade Santoprene Color NATURAL hdb15dl7sm rev0711 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 378 379 384 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 555 556 Geolast Color BLACK Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Color BLUE Injection Molded Polyurethane Color GREEN Urethane Rubber Color NATURAL Some Applications Compression Mold Urethane Rubber Color NATURAL 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 Color WHITE Food Grade EPDM Color GRAY Butyl Rubber Color Coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Color Coded RED amp SILVER Conductive Neoprene Color Coded GREEN amp SILVER Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Color BLACK Conductive Acetal Glass Filled Color BLACK Color Coded YELLOW Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Color NATURAL Injection Molded Conductive PVDF Color BLACK Color Coded LIGHT
14. ductive Neoprene EPDM lay T PTFE CT Conductive PTFE IT EPDM Backup PTFE Overlay PS Plated Steel V FKM Alloy C Alloy C Note For bottom ported option replace 1st character S with D 1GceTs I2GcTS x 13 1 G c T5 x Il 3 2 G c T5 Il 1D c T1000C I1 2 D c T1000C IM1c All models including pumps equipped with IM2c Aluminum wetted and midsection parts Models equipped with Cast Iron Stainless See page 22 for ATEX Explanation of Type Steel or Alloy C wetted parts and Cast Iron Examination Certificate midsection parts See page 22 for ATEX Explanation of EC Type Certificate hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 2 Maximum and Minimum Temperatures are the limits for which these materials can be operated Temperatures coupled with pressure affect the longevity of diaphragm pump components Maximum life should not be expected at the extreme limits of the temperature ranges Operating Temperatures Materials acim Aar Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should 190 F 10 F not be used with highly polar solvents 88 C 23 C like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons EPDM Shows very good water and chemical resistance Has poor resistance to oil and solvents but is fair in 280 F 40 F ketones and alcohols 138 C 40 C NEOPRENE All purpose Resistant to vegetable oils Generally not affec
15. eassembly Take care that the bumper stays in place allowing the sleeve to press in all the way Re install the spool the opposite end cap gasket and bumper on the valve body After inspecting and cleaning the gasket surfaces on the valve body and intermediate re install the valve body on the pump using new gaskets Tighten the four hex head capscrews evenly and in an alternating cross pattern PILOT VALVE The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing Most problems with the pilot valve can be corrected by replacing the o rings Always grease the spool prior to inserting it into the sleeve If the sleeve is removed from the body reinsertion must be at the chamfered side Grease the o rings to slide the sleeve into the valve body Securely insert the retaining ring around the sleeve When reinserting the pilot valve push both plungers see 39 on drawing located inside the intermediate bracket out of the path of the pilot valve spool ends to avoid damage PILOT VALVE ACTUATOR The bushings no 8 for the pilot valve actuators threaded into the intermediate bracket no 5 from the outside The plunger no 39 may be removed for inspection or replacement from the inside by removing the air distribution valve body no 1 and the pilot valve body no 4 from the pump The plungers no 39 should be visible as you loo
16. fasteners to prevent leakage Follow recommended torques stated in this manual 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 13 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 A IMPORTANT Read these safety warnings and instructions in this WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly 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 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 RECYCLING A WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made n
17. ific applications always consult Chemical Resistance Chart Technical Bulletin hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 3 Dimensions HDB1 1 2 amp HDB40 Side Ported Dimensions are 13 3mm Figures in parenthesis millimeters DISCHARGE PORT 1 1 2 NPT 1 1 2 BSP TAPERED 15 50 394 9 96 253 13 87 352 14 84 377 S INLET 3 4 NPT 9 15 232 8 71 221 7 67 195 12 06 6 81 173 SUCTION PORT 9 00 229 1 1 1 2 NPT 1 1 2 BSP TAPERED AIR EXHAUST 3 4 NPT N S A k 1 18 30 4X 47 12 MOUNTING HOLES aA INDICATES DIMENSIONS WITH SUCTION AND DISCHARGE PORTS ROTATED 180 TO A VERTICAL POSITION Model HDB172 A features 12 NPT threaded connections Model HDB40 A features 1 BSP Tapered connections hdb15dl7sm rev07 11 Models HDB1 z HDB40 Page 4 Dimensions HDB1 1 2 amp HDB40 Down Ported Dimensions are 13 3mm Figures in parenthesis millimeters 17 72 450 DISCHARG
18. isted below in the far left column Outer Inner Ball Manifold Manifold Manifold Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard Diaphragm Valve Seat Sealing Shipping 3 3 Chamber Chamber Plate Plate Housing Rod Seat ware Material Gasket Rings Wt Ibs SB7A X X__B56 T6AL 356 T6AL 356 T6AL 416SS__ 316SS PS B B CB A 75 SC7A X X__ 356T6AL 356T6AL 356T6AL 416SS_ 316SS PS V T CT T 75 SI7A X X__ 356T6AL 356T6AL 356T6AL 416SS__ 316SS PS l l CT A 75 SN7A X X__ 856T6AL 356T6AL 356T6AL 416SS_ 316SS PS N N CN A 75 SV7A X X__ 856T6AL 356T6AL 356T6AL 416SS_ 316SS PS V V CT T T5 SGN7A X X__ 356T6AL 356T6AL 356T6AL 416SS_ 316SS PS N T T CT T 75 SS7A X X__ 356T6AL 356T6AL 356T6AL 416SS_ 316SS PS S S CT A 75 SB7Cl X X Cl Cl 356T6AL 416SS__ 316SS PS B B CB A 102 SC7Cl X X CI Cl Cc 356T6AL 416SS__ 316SS PS V T CT I 102 SI7CI X X CI CI C 356T6AL _416SS __ 316SS PS l l CT A 102 SN7CI X X CI CI C 356T6AL _416SS _ 316SS PS N N CN A 102 SV7CI X X CI Cl Cc 356T6AL 416SS__ 316SS PS V V CT T 102 SGN7CI X X Cl Cl Cc 356T6AL 416SS_ 316SS PS N T T CT T 102 SS7Cl X X CI Cl Cc 356T6AL 416SS__ 316SS PS S S CT A 102 SB7II X X CI CI Cc Cl 416SS__ 316SS PS B B CB A 104 SC7Il X X CI CI C CI 416SS__ 316SS PS V T CT
19. k down into the intermediate from the top Depending on their position you may find it necessary to use a fine piece of wire to pull them out There is an o ring no 31 on the plunger Under some circumstances it may become necessary to replace the threaded bushings no 8 The pump will need to be disassembled by removing the manifold assembly no 27 outer chamber no 16 and diaphragm no 18 Once the parts have been removed the threaded bushing no 8 can be removed from the interme diate no 5 hdb15dl7sm rev07 11 Models HDB1 z HDB40 Page 10 TROUBLESHOOTING PROBLEM Pump cycles but will not pump Note higher suction lifts require faster cycling speed for priming POSSIBLE CAUSES Air leak in suction line Excessive suction lift Check valve not seating properly Leakage at joint of suction manifold or elbow flange Suction line or strainer plugged Diaphragm ruptured MOo0QW gt PROBLEM Pump will not cycle Note Always disconnect air supply to relieve air pressure before disassembling any portion of pump POSSIBLE CAUSES A Discharge hose or line plugged or discharge head requirement greater than air supply pressure Disconnect discharge line to check B Spool in air distribution valve not shifting Remove end cap and check spool must slide freely C Diaphragm ruptured Air will escape out discharge line in this case D Blockage in diaphragm chamber preventing movement Sh
20. n all cases CHECK VALVE SERVICING For best priming and most efficient pumping performance itis important to maintain check valves and valve seats in good condition for proper sealing Need for inspection or service of ball valves is usually indicated by poor priming unstable cycling reduced performance or pump cycles but will not pump Inspection and service of check valves requires the removal of six bolts which provide access to all four ball valves and both suction and discharge valve seats New ball check valves are 2 5 715 cm diameter and will require replacement when worn to approximately 2 5 08 cm diameter DIAPHRAGM SERVICING Need for inspection or service of diaphragm is usually indicated when unit pumps from one chamber only and air is discharged out pump discharge port or when liquid being pumped is discharged through air exhaust port To service diaphragms remove the eight 7 16 bolts that secure the outer chamber to the inner chamber items 11 amp 15 as well as the nuts lock washers and tapered washers items 30 45 amp 46 that secure the manifold to the chamber To remove diaphragms loosen diaphragm assembly outer plate no 36 diaphragm no 18 inner plate no 35 by turning out of the shaft using a wrench A1 2 54 cm square lug is provided on the outer plate no 36 forthis purpose Removal of opposite outer chamber will permit removal of second diaphragm assembly and shaft as a unit To disassemble the
21. ncia r a a i aae e a OR E A 10 Recommended Accessories viisincivcatveseasssincadstssanarvospendcnnadiedsanteentbammadinemacsnenseas 10 Important Safety Information wicicccasicecdeesocescussesnacisdsastshantaacssneadioasdosdesuasnedeoeescdeaaa 11 RECYCIING Beene men eer rnp ere error ren erence a EEEE 11 Grounding The PUMP semee mere errs nema a ot ee tyre gre terre rr mer ener erat toe Ore 12 Maternal GOS Sah iraisasiecaipeanrnten ccamiain tuiiitema duacecadutannmecnncdendmmn sama tuientelmsdisaonatedopunwncintumcatadaens 13 Declaration OF GC OnMON NEY secenek EE 14 Composite Repair Parts List cccccccccssseseeeeeeeeeseeeeeeeeeeeeseeeeeeeeeeeeeseseeess 15 17 Composite Repair Drawing Side Ported sceceeeeeeeeeeeeeeeeeeesseeeeeeeeeess 18 Composite Repair Drawing Down Ported eeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeees 19 CE Declaration of Conformity Machinery cccceceeeeeeeeeeeeeeeeeeeeeeeeeenttenaaaees 20 CE Declaration fo Conformity ATEX c seeeceeeeeeeeeeeeeeeeeeeeeeeeeaeeeeseeeeeeeeess 21 Explanation of ATEX Certification ccs cxcaccmucinnccegnascbecadenccmcustanandoancdindsintaedparedaadaned 22 Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com hdb15dl7sm rev07 11 Copyright 2010 Warren Rupp Inc All rights reserved SANI DPIPER A WARREN RUPP PUMP BRAND
22. ng of the air distribution valve The chambers are manifolded together with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION amp START UP Locate the pump as close to the product being pumped as possible keeping suction line length and number of fittings to a minimum Do not reduce line size For installations of rigid piping short flexible sections of hose should be installed between pump and piping This reduces vibration and strain to the piping system A Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsation in flow Tighten all gaskets prior to start up This pump was tested at the factory prior to shipment and is ready for operation AIR SUPPLY Air supply pressures cannot exceed 125 psi 8 61 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air line is solid piping use a short length of flexible hose not less than 19mm in diameter between pump and piping to eliminate strain to pipes AIR INLET amp PRIMING For start up open an air valve approximately to turn After the unit primes an air valve can be opened to increase flow as desired If opening the valve increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be closed slightly For the most efficient use of compressed air and the lo
23. ngest diaphragm life throttle the air inlet to the lowest cycling rate that does not reduce flow hdb15dl7sm rev0O711 SERVICE amp OPERATING MANUAL CE Original Instructions Model HDB 11 2 Type 7 Model HDB40 Type 7 A WARNING amp HAZARD WARNING POSSIBLE EXPLOSION HAZARD can result if 1 1 1 Trichloroethane Methylene Chloride or other Halogenated Hydrocarbon solvents are used in pressurized fluid systems having Aluminum or Galvanized wetted parts Death serious bodily injury and or property damage could result Consult with the factory if you have questions concerning Halogenated Hydrocarbon solvents Models HDB1 HDB40 Page 6 WARREN RUPP Available from Warren Rupp Tranquilizer Surge Supressor 2 Filter Regulator Air Exhaust Air Inlet Surge INSTALLATION GUIDE Top Discharge Ball or Flap Valve Unit A CAUTION The air exhaust should be piped to an area for safe disposition of the product being pumped in the event Pipe Connection of a diaphragm failure Suppressor Style Optional Gauge Flexible i Shut Off Valve Connection D a ry DISCHARGE Eii e L A L LI i Drain Port Flexible Connection Air Shut Off Pipe Connection Valve Style Optional
24. on 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 Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 14 for material specifica tions We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 12 Grounding The Pump A 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 The clamp end is installed to a true earth ground This 8 foot long 244 centimeters Ground Strap part number 920 025 000 can be ordered as a service item To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required or in the absence of local codes an industry or nationally recognized code having jurisdiction over specific installations hdb15dl7sm rev0711 Models HDB1 HDB40 Page 13
25. r bench vise with an improvised mandrel press the sleeve from the valve body Take care not to damage the sleeve At this point inspect the o rings on the sleeve for nicks tears or abrasions Damage of this sort could happen during assembly or servicing A sheared or cut o ring can allow the pump s compressed air supply to leak or bypass within the air valve assembly causing the pump to leak compressed air from the pump air exhaust or not cycle properly This is most noticeable at pump dead head or high discharge pressure conditions Replace any of these o rings as required or set up a routine preventive maintenance schedule to do so on a regular basis This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent inspecting for signs of wear or damage and replacing worn components hdb15dl7sm rev07 11 Models HDB1 Z HDB40 Page 9 To re install the sleeve and spool set lightly lubricate the o rings on the sleeve with an o ring assembly lubricant or lightweight oil such as 10 wt air line lubricant Re install one end cap gasket and bumper on the valve body Using the arbor press or bench vise that was used in disassembly carefully press the sleeve back into the valve body without shearing the o rings You may have to clean the surfaces of the valve body where the end caps mount Material may remain from the old gasket Old material not cleaned from this area may cause air leakage after r
26. rnally Serviceable Air Distribution System Please refer to the exploded view drawing and parts list in the Service Manual supplied with your pump If you need replacement or additional copies contact your local Warren Rupp Distributor or the Warren Rupp factory Literature Department at the number shown below To receive the correct manual you must specify the MODEL and TYPE information found on the name plate of the pump Models with 1 suction discharge or larger and METAL center sections The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head capscrews The valve body assembly is removed from the pump by removing these four hex head capscrews With the valve body assembly off the pump access to the sleeve and spool set is made by removing four hex head capscrews each end on the end caps of the valve body assembly With the end caps removed slide the spool back and forth in the sleeve The spool is closely sized to the sleeve and must move freely to allow for proper pump operation An accumulation of oil dirt or other contaminants from the pump s air supply or from a failed diaphragm may prevent the spool from moving freely This can cause the spool to stick in a position that prevents the pump from operating If this is the case the sleeve and spool set should be removed from the valve body for cleaning and further inspection Remove the spool from the sleeve Using an arbor press o
27. rtaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Models HDB1 HDB40 Page 14 Composite Repair Parts List ITEM NO 1 1 1 1 2 N e ae NO 17 18 PART NUMBER 031 019 156 031 019 010 031 012 000 095 043 156 095 043 010 132 014 358 165 011 157 165 011 010 170 032 330 360 010 425 560 020 360 050 005 360W 050 005 363 050 005 364 050 005 365W 050 005 354 050 010 600 070 006 170 095 073 000 095 070 551 560 023 360 560 033 360 675 037 080 755 025 162 775 026 115 114 002 156 114 002 010 115 046 080 115 057 080 132 002 360 135 016 162 170 023 330 170 035 330 170 024 330 170 035 330 170 040 330 170 045 330 170 058 330 170 060 330 196 193 156 196 193 010 196 193 110 196 193 112 196 194 156 196 194 010 286 005 360 286 005 363 286 005 364 286 005 365 286 005 354 286 114 659 hdb15dl7sm rev0711 DESCRIPTION Assembly Main Air Valve Aluminum Center Assembly Main Air Valve Cast Iron Center Sleeve and Spool Set Body Air Valve Aluminum Center Body Air Valve Cast Iron Center Bumper Air Valve Cap End Aluminum Center Cap End Cast Iron Center Capscrew Hex Hd 1 4 20 X 75 Gasket End Cap O ring Ball Check Ball Check Ball Check Ball Check Ball Check Ball Check Bearing Assembly Pilot Valve Body Pilot Valve O ring O ring Ring Retaining Sleeve Spool Pilot Valve Bracket Intermediate Bracket Intermedia
28. s available in alse a kit form only Order PN 475 102 000 Optional Rubber Foot Kit These items available in kit form only Order PN 475 101 000 2010 Warren Rupp Inc All rights reserved SANDPIPER is a registered tradename of Warren Rupp Inc Printed in U S A hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 18 Composite Repair Drawing Down Ported Optional Down Ported Conversion Kits 475 022 156 Down Ported Conversion Kit 475 022 010 Down Ported Conversion Kit 475 022 110 Down Ported Conversion Kit 475 022 112 Down Ported Conversion Kit Conversion Kit Includes the Following items 6 24 30 43 45 47 48 50 51 hdb15dl7sm rev07 11 Models HDB1 z HDB40 Page 19 WARREN RUPP INC Declaration of 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 RS Series U Series EH and SH High Pressure 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 Laid ke E October 20 2005 Signature of authorized pergon Date of issue David
29. te Bracket Leg Side Ported Only Bracket Leg Down Ported Only Bumper Diaphragm Rod Bushing Threaded Capscrew Hex Hd 7 16 14 X 1 75 Capscrew Hex Hd 7 16 14 X 1 50 Stainless Units Only Capscrew Hex Hd 7 16 14 X 1 00 Capscrew Hex Hd 7 16 14 X 1 50 Capscrew Hex Hd 3 8 16 X 5 50 Capscrew Hex Hd 5 16 18 X 1 25 Capscrew Hex Hd 7 16 14 X 1 25 Capscrew Hex Hd 7 16 14 X 2 00 Chamber Outer Includes Plug Item 38 Chamber Outer Includes Plug Item 38 Chamber Outer Includes Plug ltem 38 Chamber Outer Includes Plug Item 38 Chamber Inner Includes Plug Item 37 Chamber Inner Includes Plug Item 37 Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm One Piece Bonded PTFE Diaphragm TOTAL NN nanm MNNYONNYNNYNNYNNYNHAATDARAANNNN ASP ABAANBANARARARANO Models HDB1 HDB40 Page 15 21 22 23 24 25 27 28 30 31 33 34 35 36 37 38 PART NUMBER 286 020 604 334 006 156 334 006 010 334 006 110 334 006 112 334 007 156 334 007 010 334 007 110 334 007 112 334 008 156 334 008 010 334 008 110 334 008 112 334 008 156E 334 008 010E 334 008 110E 334 008 112E 360 017 379 360 017 384 360 017 608 360 022 425 360 022 425 360 022 600 360 022 600 360 041 379 360 048 425 518 003 156 518 003 010 518 003 110 518 003 112 530 036 000 545 005 330 545 007 330 545 007 330 560 001 360 560 022 360 560 028 360 560 028 610 570 009 360 570 0
30. ted by moderate chemicals fats 200 F 10 F greases and many oils and solvents Generally 93 C 23 C attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocar bons HYTREL Good on acids bases amines and glycols at room temperature 220 F 20 F 104 C 29 C PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with 220 F 35 F PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as 104 C 37 C chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures FKM Fluorocarbon shows good resistance to a wide range of oils and solvents especially all aliphatic 350 F 40 F aromatic and halogenated hydrocarbons acids animal 177 C 40 C and vegetable oils Hot water or hot aqueous solutions over 70 F will attack FKM Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excel 275 F 40 F lent abrasion resistance 135 C 40 C CF 8M Stainless Steel equal to or exceeding ASTM specification A743 for corrosion resistant iron chro mium iron chromium nickel and nickel based alloy castings for general applications Commonly referred to as 316 Stainless Steel in the pump industry ALLOY C CW 12MW equal to or exceeding ASTM A494 specification for nickel and nickel alloy castings For spec
31. ts 2 51 685 032 080 Rod Connecting Down Ported Units 1 Repair Parts shown in DARKER type are more likely to need replacement after extended periods of normal use These parts are readily available from most Warren Rupp Distributors Pump owners may prefer to maintain a limited inventory of these parts to reduce repair downtime Air End Repair Kit 476 247 000 contains items 1 1 1 3 1 6 1 7 4 8 25 26 39 41 Wet End Repair Kit 476 244 354 for Santoprene equipped pumps Includes items 2 18 23 24 33 34 476 244 360 for Nitrile equipped pumps Includes items 2 18 23 24 33 34 476 244 363 for FKM equipped pumps Includes items 2 18 23 24 33 34 476 244 364 for EPDM equipped pumps Includes items 2 18 23 24 33 34 476 244 365 for Neoprene equipped pumps Includes items 2 18 23 24 33 34 476 244 644 for Santoprene with PTFE check balls Includes items 2 18 23 24 33 34 476 036 659 for One Piece Bonded PTFE Diaphragms Includes items 2 18 23 24 33 35 476 261 635 for PTFE Overlay Diaphragms and Neoprene backers Includes items 2 18 19 23 24 33 To convert a pump to One Piece Bonded PTFE Diaphragms order kit number 475 255 000 2010 Warren Rupp Inc All rights reserved SANDPIPER is a registered tradename of Warren Rupp Inc Printed in U S A hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 17 Composite Repair Drawing Side Ported E ke Optional Angle Valve Kit E EN These item
32. urface of the diaphragm while liquid is discharged from the opposite side The diaphragm operates under a balanced condition during the discharge stroke which allows the unit to be operated at discharge heads over 200 feet 61 meters of water head Since the diaphragms are connected by a common rod secured by plates to the center of the diaphragms one diaphragm performs the discharge stroke while the other is pulled to perform the suction stroke in the opposite chamber For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Do not install on suction head in excess of 10 feet of liquid 3 048 meters Consult factory if conditions exceed this recommendation Alternate pressuring and exhausting of the diaphragm chamber is performed by means of an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet air pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool shifts to the opposite end of the valve body the porting of chambers is reversed The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool while exhausting the other side The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot spool This pushes it into position for shifti
33. ut off air supply and reopen after pressure is relieved E Muffler clogged PROBLEM Uneven discharge flow Indicates one chamber not operating properly POSSIBLE CAUSES Check valve not sealing properly in one chamber Diaphragm failure in one chamber Air leak at suction manifold joint or elbow flange one side Muffler clogged vow For additional information see the Warren Rupp Troubleshooting Guide WARRANTY This unit is guaranteed for a period of five years against defective material and workmanship RECOMMENDED WARREN RUPP ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE Tranquilizer Surge Suppressor For nearly pulse free flow Warren Rupp Filter Regulator For modular installation and service convenience Warren Rupp Speed Control For manual or programmable process control Manual adjustment or 4 20mA reception For more detailed information on these accessories contact your local Warren Rupp Factory Authorized Distributor or Warren Rupp corporate headquarters hdb15dl7sm rev07 11 Models HDB1 HDB40 Page 11 IMPORTANT SAFETY INFORMATION 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 A CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose
34. ypes DMF2 DMF3 HDB1 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 S1F 15 S20 S30 SB1 SB25 SE ST1 ST25 ST1 ST40 U1F G05 G1F G15 G20 and G30 Surge Suppressors all types Marking Il 2 G Ex ia c IIC T5 Il 3 2 G Ex ia c IIC T5 Il 2 D Ex c iaD 20 IP67 T100C Il 2 G EEx mc II T5 Il 3 2 G EEx m c II T5 Il 2 D c IP65 T100 C I1 GcT5 Il 3 1 G c T5 Il 1 D c T100 C IM1 c I M2 c I2 GcT5 Il 3 2 G c T5 Il 2 D c T100 C I2 G T5 Il 3 2 G TS Il 2 D T100 C EC Type Certificate No Pumps KEMA O9ATEX0071 X Type Certificate No Pumps KEMA 09ATEX0072 X Type Certificate No Suppressors KEMA 09ATEX0073 KEMA 09ATEX0071 X KEMA 09ATEX0071 X CE 0344 KEMA 09ATEX0071 X KEMA 09ATEX0072 X CE 0344 KEMA 09ATEX0072 X CE KEMA 09ATEX0073 CE Listed In KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA O9ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA O9ATEX0072 X KEMA 09ATEX0073 KEMA 09ATEX0073 KEMA O9ATEX0073 Non Conductive Fluids No Yes Yes No Yes Yes gt FLUID amp METERING

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