Model S15 Metallic Design Level 1
Contents
1. i Quality System a IO 0F00E C9rE Noe See page 2 D esi g n Level 1 Ehvronmeniai for ATEX ratings Management System Ba I I Va I ve ISO14001 Certified CE _ Air Inlet Side View Air Oper ated U S Patent Double Diaphragm Pump 5 996 627 Other U S Patents Air Exhaust Side View Applied for ENGINEERING PERFORMANCE FLUID amp METERING amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 1 NPT internal O to 106 gallons per minute No lube no stall Up to 25 in 6mm 125 psi or 289 ft of water 41 Gallon 1 55 liter 1 BSP Tapered internal 0 to 401 liters per minute design 8 6 Kg cm or 86 meters A CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like 190 F 10 F acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons 88 C 23 C EPDM Shows very good water and chemical resistance Has poor resistance to oil and solvents but is fair in ketones and alcohols 280 F 40 F 138 C 40 C Neoprene All purpose Resistant to vegetable oil Generally not affected by moderate chemicals fats greases and many oils and solvents Generally 200 F 10 F attacked by strong oxidizing acids ketones esters nitro hydrocarbons2. ccccsssceccceeeeeeeceeeeeeseaeeeeeseeeeeeeseeeenenaeeeees 19 Diaphragm Service Drawing with Overlay 20 Diaphragm Service Drawing Non Overlay nn 20 Diaphragm SSE ICI ete naar 21 Overlay Diaphragm Servicing cccccceeeseeeeeeeeeseeeeeeceeeaaeeeeeeesaaaaeeeeeseeaaneeeeeeeaas 21 Pilot Valve Servicing Assembly Drawing amp Parts LISt ennnen 22 Actuator UG FSU VIC IN Croat osonaly nc os Saat Sine escescnea Stes etee te eae la eden tesles 23 Check Valve Servicios 24 Checkvalve DIAWINg srlleo ti 24 Optional Muffler Configurations 25 Optional Muffler Configuration Drawing ccseeeeeeeeeeeeeeeeeeseeeeeeeeeeeaeeeeeeeeeneas 25 PUMPING Hazardous EIQUIAS siii 26 Converting Pump for Piping Exhaust Air 26 Converted Exhaust IIUStration cccceececeeeeeeeeseeeeeeeeeaaeeeeeeeeeaaaeeeeeseeaaaeeeeeeeaas 26 Pulse Output Kit Drawing ricer 27 Pulse QUIPUCKIFOPHONS Linn 27 Grounding the PUMP scellerata 28 CE Declaration of Conformity nne 29 WARREN RUPP INC A Unit of IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 e www warrenrupp com s15mdl1sm REV0708 Copyright 2008 Warren Rupp Inc All rights reserved WARREN 0 SANDPIPER A WARREN RUPP PUMP BRAND 15 Metallic
3. Model S15 Metallic Page 17 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Includes all items used on Composite Repair Parts List except as shown Item Part Number Description Qty 38 893 097 000 Solenoid Valve NEMA4 1 39 219 001 000 Solenoid Coil 24VDC 1 219 004 000 Solenoid Coil 24VAC 12VDC 1 219 002 000 Solenoid Coil 120VAC 1 219 003 000 Solenoid Coil 240VAC 1 40 241 001 000 Connector conduit 1 241 003 000 Conduit Connector with 1 Suppression Diode DC Only 41 170 029 330 Capscrew Hex HD 5 16 18 x 1 50 4 42 618 051 150 Plug 2 IEC EEX m T4 SP APPROVED For Explosion Proof Solenoid Coils used in North America and outside the European Union 39 219 009 001 Solenoid Coil 120VAC 60 Hz 1 219 009 002 Solenoid Coil 240VAC 60 Hz 1 219 009 003 Solenoid Coil 12VDC 1 219 009 004 Solenoid Coil 24VDC 1 219 009 005 Solenoid Coil 110VAC 50 Hz 1 219 009 006 Solenoid Coil 230VAC 50 Hz 1 Note Item 40 Conduit Connector is not required O Q Il 2G EEx m c T5 Il 2D c IP65 T100 C For Explosion Proof Solenoid Coils used in the European Union 39 219 011 001 Solenoid Coil 12 VDC 3 3W 0 531A 0 014A 1 219 011 002 Solenoid Coil 24 VDC 3 3W 0 531A 0 014A 1 219 011 003 Solenoid Coil 110 120 VAC 3 4W 0 212A 0 015A 1 219 011 004 Solenoid Coil 220 240 VAC 3 4W 0 212A 0 015A 1 Note Item 40 Conduit Connector is not required Special Conditions For Safe Use A fuse co
4. C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 A align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews AIR VALVE ASSEMBLY PARTS LIST AIR VALVE ASSEMBLY PARTS LIST Description Qty Air Valve Assembly 1 Body Air Valve 1 Sleeve and Spool Set 1 Bumper 2 O Ring 10 Cap End 2 Hex Head Capscrew 1 4 20 x 75 8 Muffler 1 Muffler Cap 1 Machine Screw 4 Air Valve Assembly 1 Consists of all components above except Hex Head Capscrew 1 4 20 x 75 8 Machine Screw 4 Note Pumps equipped with this valve assembly are not ATEX compliant Fasten the air valve assembly item 1 and gasket to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manua
5. and chlorinated aromatic hydrocarbons 93 C 23 C Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life 275 F 40 F Excellent abrasion resistance 135 C 40 C Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or 290 F gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures 104 C FKM Fluorocarbon Shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids 350 F 40 F animal and vegetable oils Hot water or hot aqueous solutions over 70 F will attack FKM 177 C 40 C Polypropylene 180 F 32 F 82 C 0 C Polyethylene 180 F 35 82 C 37 For specific applications always consult the Warren Rupp Chemical Resistance Chart SANDPIPER pumps are designed to be powered only by compressed air s15mdl1sm REV0708 Model S15 Metallic Page 1 Explanation of Pump Nomenclature S15 Metallic Design Level 1 Ball Valve Material Pump nel a 2 oO gt l l Z ie nd ST5B1AEWANS000 i SENSO STEBFIBWANSO00 5 18 B_ STSBIIEWANSO00 S 15 B_ STSBIIIWANS000 S 15 B I STSBIIVTANSO00 S 15 B_ SISBISGTANS000 S 15 B SIS
6. and kit option 0 Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option P1 s15mdl1sm REV0708 None Sound Dampening Muffler Mesh Muffler Kit Options A 00 P0 10 30VDC Pulse Output Kit lt gt P1 Intrinsically Safe 5 30VDC High temperature Air Valve w Integral Muffler High temperature Air Valve w Sound Dampening Muffler High temperature Air Valve w Mesh Muffler Metal Muffler Metal Muffler with Grounding Cable 3 amp E2 AEs E4 Niss E6 II 2G EEx m c T5 Il 2D c IP65 T100 C Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option A1 or A4 P2 110 120 or 220 240VAC E0 A E1 Solenoid Kit with 24VDC Kit Options continued A E7 Solenoid Kit with 220VAC Explosion Proof Coil A E8 Solenoid Kit with 110VAC 50 Hz Explosion Proof Coil A E9 Solenoid Kit with 230VAC 50 Hz Explosion Proof Coil SP Stroke Indicator Pins A1 Solenoid Kit with 12 VDC Explosion Proof Coil A2 Solenoid Kit with 24 VDC Explosion Proof Coil A3 Solenoid Kit with 110 120 VAC 50 60 Hz Explosion Proof Coil A4 Solenoid Kit with 220 240 VAC 50 60 Hz Explosion Proof Coil None 110 120VAC 220 240 VAC Pulse Output Kit Pulse Output Kit Solenoid Kit with 24VDC Coil Explosion Proof Coil Solenoid Kit with 24VAC 12VDC Coil Solenoid Kit with 12VDC Exp
7. jo vonese paq WARREN RUPP FLUID amp METERING Declaration of Conformity Warren Rupp Inc 800 North Main Street Mansfield Ohio certifies that Air Operated Double Diaphragm Pumps Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic Containment Duty Gas UL High Pressure W Submersible and Tranquilizers comply with the European Community Directive 98 37 EC Safety of Machinery This product has used EN 809 Pumps and Pump Units for Liquids Common Safety Requirements harmonized standard to verify conformance baud K t T October 20 2005 Signature of authorized person Date of issue David Roseberry Engineering Manager Printed name of authorized person Title Declaration of Conformity
8. off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 18 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that s15mdl1sm REV0708 fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the bumpers as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B Item Part Number 1 031 173 000 095 109 157 031 139 000 132 029 357 560 020 360 165 127 157 170 032 330 530 028 550 165 096 551 706 026 330 L I I LIO nmo 1 031 173 001 1 F 170 032 115 1 J 706 026 115 Step 3 Reassembly of the air valve Install one bumper item 1
9. pump flooded suction condition pipe the exhaust higher than the product source to prevent siphoning spills See illustration 3 at right CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Remove the muffler item 43 The air distribution valve item 1 has 1 NPT threads for piped exhaust s15mdl1sm REV0708 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be conductive and physically supported Failure to support these connections could also result in damage to the air distribution valve body Air Valve Assembly On ATEX compliant units the pump comes equipped with a standard metal muffler CONVERTED EXHAUST ILLU PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING STRATION SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 O LIQUID LEVEL SUCTION Illustration 2 LIQUID LEVEL SUCTION LINE Illustration 3 MUFFLER 1 DIAMETER AIR EXHAUST PIPING LINE Li Ta 1 DIAMETER AIR EXHAUST PIPING Model S15 Metallic Page 26 Pulse Output Kit Drawing PULSE OUTPU
10. see item 27 4 171 011 115 Capscrew Soc Hd 1 2 13 x 1 00 Stainless Center 8 722 091 150 Seat Check Ball seals required see item 27 4 13 171 059 115 Capscrew Soc Hd 7 16 14 X 1 25 8 722 091 600 Seat Check Ball 4 171 059 330 Capscrew Soc Hd 7 16 14 X 1 25 8 35 901 038 115 Washer Flat 5 16 4 14 196 169 156 Chamber Outer 2 901 038 330 Washer Flat 5 16 4 196 169 010 Chamber Outer 2 36 901 048 115 Washer Flat 3 8 Stroke Indicator Only 4 196 169 110 Chamber Outer 2 901 048 330 Washer Flat 3 8 Stroke Indicator Only 4 15 196 170 157 Chamber Inner 2 37 570 009 363 Pad Wear use with 286 099 363 2 196 170 010 Chamber Inner 2 A43 530 033 000 Metal Muffler for other muffler options see pg 24 1 196 170 110 Chamber Inner 2 16 286 099 354 Diaphragm 2 Parts not shown used with Raised Face Flange Porting Option 286 099 360 Diaphragm 2 170 035 330 Hex Cap Screw 4 286 099 363 Diaphragm 2 326 051 080 Mounting Bracket 2 286 099 364 Diaphragm 2 334 113 110 1 Raised Face 150 ANSI Flange 2 286 099 365 Diaphragm 2 538 036 110 Pipe Nipple 1 NPT x 2 2 17 286 099 600 Diaphragm Overlay 2 545 005 330 Hex Nut 4 286 113 000 Diaphragm One Piece Bonded 2 900 006 330 Lock Washer 4 18 360 093 360 Gasket Air Valve 1 901 022 330 Flat Washer 8 s15mdl1sm REV0708 Model S15 Metallic Page 13 Air Valve Servicing Assembly Drawing Use with Aluminum Centers Only amp Parts List AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut
11. the inner diaphragm plate is towards the diaphragm as indicated on the diaphragm servicing illustration Thread the assembly onto the diaphragm rod leaving loose Step 5 Installing the diaphragm and rod assembly to the pump Make sure the bumper item 6 is installed over the diaphragm rod Insert rod into pump On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the second bumper is installed over the diaphragm rod Push the threaded stud of the other outer diaphragm plate assembly through the center of the other diaphragm and through the other inner diaphragm plate Make sure the radius on the inner diaphragm plate is towards the diaphragm Thread the assembly onto the diaphragm rod Use a 7 8 wrench or socket to hold one outer diaphragm plate Then use a torque wrench to tighten the other outer diaphragm plate to the diaphragm rod to 500 in Ibs 56 5 Newton meters Align one diaphragm with the intermediate and install the outer chamber to the pump using the 8 capscrews Tighten the opposite diaphragm plate until the holes in the diaphragm align with the holes in the intermediate Then install the other outer chamber using the 8 capscrews Step 6 Reinstall the manifolds to the pump using the 16 capscrews The pump is now ready to be reinstalled connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 17 is designed to fit over th
12. BISIWANS000 S 15 B_ S1SBISVTANSO00 S 15 B uae come ei CET ae S O S Diaphragm Wetted Check Valve Materials Check Non Wetted Material Options ni Shipping Porting i Options Pump Pump Style Options Z Z Z Z Z Z Z WD G GD GW WD Note Models listed in the table are for reference only See nomenclature below for other models Pump Options Pump Brand Diaphragm Check Valve Non Wetted Material Options S SANDPIPER Materials A Painted Aluminum 0 f I Cast Iron 1 Pump Size 1 Santoprene Santoprene 3 15 1 2 PTFE Santoprene PTFE J Painted Aluminum w PTFE 2 B Nitrile Nitrile Coated Hardware 3 Check Valve Type S Stainless Steel with _ C FKM PTFE B Ball E EPDM EPDM Stainless Steel Hardware 4 W Weighted Ball l PO Y Painted Aluminum with Design Level z antoprang Stainless Steel Hardware 5 G PTFE Neoprene PTFE Z Cast Iron with 1 Design Level z i N Neoprene Neoprene Stainless Steel Hardware Mc Wetted Material V FKM FKM A7 A Aluminum Z One Piece Bonded PTFE Porting Options I Cast Iron N NPT Threads S Stainless Steel Check Valve Seat B BSP Tapered Threads H Alloy C A Aluminum R Raised Face 150 C Carbon Steel Threaded ANSI Flange S Stainless Steel Pump Style T PTFE S Standard W UHMW 1 2 Il 2G Ex ia c IIC T5 Ex MOTI x II 2D c iaD 20 IP67 T100 C Note Pumps are only ATEX compliant when ordered with pump option 6 or 7
13. 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 chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Group before performing this procedure Any model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model 15 Metallic Page 8 Recycling Many components of SANDPIPER Metallic AODD pumps are made of recyclable materials see chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed IM2 c T5 Pump complies with EN809 Pumping x Il 2GD T5 Directive Directive 98 37 EC Safety of Machinery and Directive 94 9 EC EN13463 1 Equipment for use in Potentially Explosive CE Environments For reference t
14. LA Both Suction and Discharge 4 15 16 Ports Are Available With Applications PRUSAHODS E 1 2 1 1 2 BSP Tapered Connection Ne BOTTOM VIEW 4 7 8 ffl Integral Muffler 1 we Pulse Output Kit 12 11 32 20 5 16 1 29 32 5 16 11 5 16 21 19 32 eda 203 8 131 32 318 1138 2121 32 3 4 NPT Steel Mesh 14 15 16 Muffler Sound Dampening 14 15 16 Muffler Metal 14 1 2 Muffler s15mdl1sm REV0708 Model S15 Metallic Page 4 Metric Dimensions Dimensions in Millimeters Dimensional Tolerance 3mm Discharge Port 1 1 2 NPT FRONT VIEW Suction Port 1 1 2 NPT SIDE VIEW 59 Pump Shown With 530 028 550 Integral Muffler Integral Muffler 1 NPT Exhaust Port For Optional Muffler Styles or Piping Exhaust Air in Submerged Applications Both Suction and Discharge Ports Are Available With 1 1 2 BSP Tapered Connection _ BOTTOM VIEW 124 Integral Muffler 178 Pul tout oe Air Inlet nm e j Dampening Muffler Metal Muffler s15mdl1sm REV0708 Model S15 Metallic Page 5 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating ac
15. Mufflers or Piped Exhaust Ai 031 147 000 1 includes all items on 031 146 000 minus 1 D 1 F amp 1 4 x A ATEX Compliant Model S15 Metallic Page 16 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 5 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 36 Remove the air valve assembly from the pump Remove and inspect gasket item 18 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o ring items 1 G and 1 M for cuts or wear Replace the O rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cut wear or abrasion Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear s15mdl1sm REV0708 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminants Remove the sleeve if needed and repl
16. O NOT LEAVE THE ASSEMBLY LOOSE Model S15 Metallic Page 21 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER DESCRIPTION QTY 4 095 110 000 Pilot Valve Assembly 4 A 095 095 157 Valve Body 4 B 755 052 000 4 C 560 033 379 4 D 775 055 000 4 E 560 023 379 4 F 675 037 080 Sleeve With O rings O ring Sleeve Spool With O rings O ring Spool Retaining Ring MA O a FOR PUMPS WITH CAST IRON CENTER SECTION ITEM PART NUMBER DESCRIPTION QTY 4 095 110 558 Pilot Valve Assembly 1 4 A 095 095 558 Valve Body 1 includes all other items used on 095 110 000 FOR PUMPS WITH STAINLESS STEEL CENTER SECTION ITEM PART NUMBER DESCRIPTION QTY 4 095 110 110 Pilot Valve Assembly 1 4 A 095 095 110 Valve Body 1 includes all other items used on 095 110 000 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 STEP 1 See pump assembly drawing Using a 1 2 wrench or socket remove the four capscrews item 11 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly item 4 can now be removed for inspection and service s15mdl1sm REV0708 STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 D Wipe clean and inspect spool and o rings for dirt cuts or wear Replace the o ri
17. SERVICE amp OPERATING MANUAL SANDPIPER A WARREN RUPP PUMP BRAND Model 15 Metallic Design Level 1 Table of Contents Engineering Data and Temperature LimitationS rerne 1 Explanation of Pump Nomenclature 2 Performance CUVE sanson ea E aiar 3 DIMENSIONS rtl eni 4 Metric DIMENSIONS pe aiar 5 Principle of Pump Operation 6 Installation ANd Start Up 6 AIO UPDI Y srie 6 Alir Vave PUBIC ATION arenaene ei 6 APENS IONS US ra so asad e o E a a aE 6 AlFINGCanNdPEMN green 6 BCIWEehi USeS rl ae n nt nn 6 instalialion GUIGe s liete ata 7 MOS SROONN anria 8 MVM eM NEE EE NEEE E NET E AATA EATI C E EO E I 8 Cei 9 Important Safety Information 9 Material Codes 10 Composite Repair Parts Drawing 12 Available Service and Conversion Kits 12 Composite Repair Parts LISt ie 13 Air Valve Drawing Parts List Service Instructions 14 Air Valve Drawing Parts List Service Instructions 15 See page 2 for ATEX ratings U S Patent 5 996 627 6 241 487 Other U S Patents Applied for Air Valve w Stroke Indicator Drawing and Parts LISt i 16 Air Valve w Stroke Indicator Servicing 17 Solenoid Shifted Air Valve Drawing 18 Solenoid Shifted Air Valve Parts List 18 Solenoid Shifted Air Valve Option
18. Set 1 Bumper 2 O Ring 10 Cap End 2 Hex Head Capscrew 1 4 20 x 75 8 Air Valve Assembly 1 Hex Head Capscrew 1 4 20 x 75 8 Description Qty Air Valve Assembly 1 Body Air Valve 1 Sleeve and Spool Set 1 Bumper 2 O Ring 10 Cap End 2 Hex Head Capscrew 1 4 20 x 75 8 Fasten the air valve assembly item 1 and gasket to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before 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 S15 Metallic Page 15 Air Valve with Stroke Indicator Assembly Drawing amp Parts List s15mdl1sm REV0708 NOTE CHECK GAP AFTER ASSEMBLY TO INSURE COMPLETE INSTALLATION OF RETAINING RING 3 hl nl nl L k a a ee ZXLIONMVOWI Part Number 031 146 000 031 143 000 095 094 559 132 029 552 165 096 559 165 098 147 530 028 550 560 020 360 675 044 115 710 015 115 210 008 330 560 029 360 AIR VALVE ASSEMBLY PARTS LIST Description Air Valve Assembly Sleeve and Spool Set Body Air Valve Bumper Cap Muffler Cap End Muffler O Ring Ring Retaining Screw Self Tapping Clip Safety O Ring Air Valve Assembly lt N BR PO CO MA PO For Pumps with Alternate Mesh Sound Dampening
19. T 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 s15mdl1sm REV0708 Model S15 Metallic Page 27 Grounding The Pump To be fully groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet is fastened to the pump hardware This 8 foot long 244 centimeters Ground Strap part number 920 025 000 can be ordered as a One eyelet is installed to a true earth ground service part Requires a maximum 5 16 or 8mm diameter bolt To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required 4 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 s15mdl1sm REV0708 Model S15 Metallic Page 28 AULIOJUOTD
20. ace with a new sleeve and spool set item 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with o rings item 1 G and 1 M into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the smaller unthreaded hole in the endcap Remove the new sleeve and spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B Align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o rings and retaining ring Fasten the air valve assembly item 1 and gasket item 18 to the pump Connect the compressed air line to the pump Remove the safety clip The pump is now ready for operation A IMPORTANT Read these instructions completely before 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
21. alve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard SANDPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage s15mdl1sm REV0708 ee a e Solenoid Connector Cn ot Before wiring remove terminal block from conduit connector Wiring Diagram renne anna Model 15 Metallic Page 19 wey We wy sea ge ats ee 1 3rd Terminal for na ground rsa 1 Terminal Power Positive Sn i i i i i i l Diaphragm Service Drawing Diaphragm Service Drawing One Piece Bonded with Overlay Non Overlay DiaphragmService Drawing AVAILABLE FOR FIELD CONVERSION FROM OVERLAY TO ONE PIECE BONDED DIAPHRAGM KITS Kit 475 254 000 2 286 113 000 One Piece Diaphragm 2 612 217 150 Inner Plates s15mdl1sm REV0708 Model S15 Metallic Page 20 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction t
22. ced e Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air Supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling s15mdl1sm REV0708 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 sect
23. d and replace with a new sleeve and spool set item 1 B x A ATEX Compliant AIR VALVE ASSEMBLY PARTS LIST Use w Aluminum centers only ltem Part Number 1 031 183 000 1 A 095 109 157 1 B 031 139 000 1 C 132 029 357 1 D 560 020 360 1 E 165 127 157 1 F 170 032 330 1 031 183 001 1 F 170 032 115 Item Part Number 1 031 179 000 1 A 095 109 110 031 139 000 132 029 357 560 020 379 165 127 110 170 032 115 1m O W Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six O rings item 1 D into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 A align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews AIR VALVE ASSEMBLY PARTS LIST C onsists of all components above except AIR VALVE ASSEMBLY PARTS LIST Use w Cast Iron and Stainless Steel centers only Description Qty Air Valve Assembly 1 Body Air Valve 1 Sleeve and Spool
24. dicator Only 1 22 518 151 156 Manifold Suction 1 031 173 000 Air Valve Assembly w Integral muffler 1 518 151 156E Manifold Suction 1 1 2 BSP Tapered 1 031 173 001 Air Valve Assembly with Stainless Steel Hardware 1 518 151 010 Manifold Suction 1 A 031 183 000 Air Valve Assembly 1 518 151 010E Manifold Suction 1 1 2 BSP Tapered 1 A 031 179 000 Air Valve Assembly Cast Iron or Stainless Steel Centers Only 1 518 151 110 Manifold Suction 1 2 050 005 354 Ball Check 4 518 151 110E Manifold Suction 1 1 2 BSP Tapered 1 050 005 360 Ball Check 4 23 518 152 156 Manifold Discharge 1 050 005 360W Ball Weighted Check 4 518 152 156E Manifold Discharge 1 1 2 BSP Tapered 1 050 005 363 Ball Check 4 518 152 010 Manifold Discharge 1 050 005 364 Ball Check 4 518 152 010E Manifold Discharge 1 1 2 BSP Tapered 1 050 005 365 Ball Check 4 518 152 110 Manifold Discharge 1 050 005 365W Ball Weighted Check 4 518 152 110E Manifold Discharge 1 1 2 BSP Tapered 1 050 010 600 Ball Check 4 24 545 005 115 Nut Hex 3 8 16 16 3 070 006 170 Bushing 2 545 005 330 Nut Hex 3 8 16 16 4 095 110 000 Pilot Valve Assembly 1 25 545 007 115 Nut Hex 7 16 14 16 095 110 558 Pilot Valve Assembly Cast Iron Centers Only 1 545 007 330 Nut Hex 7 16 14 16 095 095 110 Pilot Valve Assembly Stainless Steel Centers Only 1 26 560 001 379 O Ring 2 5 114 024 157 Intermediate Bracket 1 27 560 084 360 Seal O Ring See item 34 8 114 024 010 Intermediate Bracket 1 560 084 363 Seal O R
25. e exterior of the standard diaphragm item 16 Follow the same procedures described for the standard diaphragm for removal and installation except tighten the outer diaphragm plate assembly diaphragms and inner diaphragm plate to the diaphragm rod to 500 in Ibs 56 5 Newton meters One Piece Bonded DIAPHRAGM SERVICING Bonded PTFE with integral plate The one piece bonded diaphragm item 17 has a threaded stud installed in the integral plate at the factory The inner diaphragm plate has a through hole instead of a threaded hole 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 Place the inner plate over the diaphragm stud and thread the first diaphragm inner plate onto the dia phragm rod only until the inner plate contacts the rod Do not tighten A small amountof grease may be applied between the inner plate and the diaphragm to facilitate assembly Insert the diaphragm rod as sembly into the pump and install the outer chamber Turn the pump over and thread the second diaphragm inner plate onto the diaphragm rod Turn the diaphragm until the inner plate contacts the rod and hand tighten the assembly Continue tightening until the bolt holes align with the inner chamber holes D
26. ee page 28 WARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly 44 WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn 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 15 Metallic Page 9 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 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 Po
27. et item 18 The pilot valve assembly item 4 can now be removed Step 2 Inspect the actuator plungers See ILLUSTRATION AT RIGHT The actuator plungers items 30 can be reached through the pilot valve cavity in the intermediate assembly item 5 Remove the plungers item 30 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 26 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go To remove the bushings item 7 first remove the retaining rings item 31 by using a flat screwdriver NOTE It is recommended that new retaining rings be installed s15mdl1sm REV0708 Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 18 air inlet cap item 8 and capscrews item 11 Connect the air supply to the pump The pump is now ready for operation ACTUATOR PLUNGER 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 war
28. ettle 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 15 Metallic Page 6 WARREN RUPP Available from Warren Rupp 1 TD1 or TD40 Tranquilizer 2 020 050 000 Filter Regulator 3 020 050 001 Lubricator 4 Air Dryer A CAUTION The air exhaust should be piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure Air Exhaust s15mdl1sm REV0708 SUCTION a a L U TYPICAL INSTALLATION GUIDE For Metallic Pumps Surge Suppressor Pipe Connection Air Inlet Limited to Style Optional Line 125 psi Gauge Shut Off Valve Flexible Connection Du TaN I DISCHARGE 00 E CY Drain Port p Flexible Connection Air Shut Off Pipe Connection Valve Style Optional TOP Filter Regulator Air Dryer Gange DISCHARGE DIAPHRAGM Shut Off PUMP pa Valve EE C TI II C AIRINLET Flexible Connection Model S15 Metallic Page 7 TROUBLESHOOTING Possible Symptoms e Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalan
29. ffler Configurations Drawing OPTION 0 530 028 550 Integral Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to Note Cannot be used with Air Valve hold it in place Assembly 031 179 000 used on models equipped with cast iron or OPTION 1 stainless steel centers 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 A OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body x A ATEX Compliant Option 0 Option 1 and 2 Option 6 s15mdl1sm REV0708 Model S15 Metallic Page 25 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The air exhaust must be piped above the liquid level See illustration 2 at right Piping used for the air exhaust must 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
30. hen shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump assembly drawing and the diaphragm servicing illustration Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the manifolds items 22 amp 23 to the outer chambers item 14 Step 2 Removing outer chambers Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the outer chambers item 13 diaphragms item 14 and intermediate item 5 together Step 3 Removing the diaphragms and diaphragm plates Use a 7 8 wrench or six point socket to remove the outer diaphragm plate assemblies diaphragms item 16 and inner diaphragm plates item 29 from the diaphragm rod item 32 by turning counterclockwise Inspect the diaphragm for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEALS s15mdl1sm REV0708 Step 4 Assembling the diaphragm and diaphragm plates to the diaphragm rod Push the threaded stud of one outer diaphragm plate assembly through the center of one diaphragm and through one inner diaphragm plate Install the diaphragm with the natural bulge facing away from the diaphragm rod and make sure the radius on
31. ing See item 34 8 114 024 110 Intermediate Bracket Stainless Steel Centers Only 1 560 084 364 Seal O Ring See item 34 8 6 132 035 360 Bumper Diaphragm 2 560 084 365 O Ring 8 7 135 034 506 Bushing Plunger 2 720 061 608 Seal O Ring See item 34 8 8 165 118 157 Cap Air Inlet Assembly 1 28 612 039 157 Plate Outer Diaphragm Assembly 2 165 118 010 Cap Air Inlet Assembly 1 612 039 010 Plate Outer Diaphragm Assembly 2 165 118 110 Cap Air Inlet Assembly Stainless Steel Centers Only 1 612 097 110 Plate Outer Diaphragm Assembly D 9 170 060 115 Capscrew Hex Hd 7 16 14 X 2 00 16 29 612 195 157 Plate Inner Diaphragm 2 170 060 330 Capscrew Hex Hd 7 16 14 X 2 00 16 612 195 010 Plate Inner Diaphragm 2 10 170 061 115 Capscrew Hex Hd 3 8 16 X 1 75 16 612 217 150 Plate Inner Diaphragm use with one piece diaphragm 2 170 061 330 Capscrew Hex Hd 3 8 16 X 1 75 16 30 620 020 115 Plunger Actuator 2 11 170 069 115 Capscrew Hex Hd 5 16 18 X 1 75 4 31 675 042 115 Ring Retaining D 170 069 330 Capscrew Hex Hd 5 16 18 X 1 75 4 32 685 059 120 Rod Diaphragm 1 12 170 006 115 Capscrew Hex HD 3 8 16 X 1 00 4 33 720 004 360 Seal Diaphragm Rod 2 170 006 330 Capscrew Hex HD 3 8 16 X 1 00 4 34 722 091 550 Seat Check Ball 4 171 053 115 Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only 4 722 091 080 Seat Check Ball seals required see item 27 4 171 053 330 Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only 4 722 091 110 Seat Check Ball seals required
32. ion of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a Warren Rupp Tranquilizer Surge Suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to
33. l for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S15 Metallic Page 14 Air Valve Servicing Assembly Drawing amp Parts List AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 18 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that s15mdl1sm REV0708 Note Cannot be used with Integral Muffler option 0 fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the O rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if neede
34. lished 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 s15mdl1sm REV0708 180 305 306 307 308 309 310 330 331 332 333 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 Material Codes The Last 3 Digits of Part Number Copper Alloy Carbon Steel Black Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compression Mold Urethane Rubber Nitrile Rubber Color coded RED FDA Acce
35. losion Proof Coil Solenoid Kit with 110VAC Coil Solenoid Kit with 110VAC Explosion Proof Coil Solenoid Kit with 220VAC Coil 4 lt gt IEC EEX m T4 Sp APPROVED Note Pump models equipped with these explosion proof solenoid kit options E1 E3 E5 E7 E8 or E9 are certified and approved by the above agencies They are NOT ATEX compliant A2 AS Note See page 18 for Special Conditions For Safe Use Model S15 Metallic Page 2 Performance Curve S15 Metallic Design Level 1 MODEL 15 Metallic Performance Curve Performance based on the following elastomer fitted pump flooded suction water at ambient conditions D The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 m A 3 10 17 SCFM M hr 7 100 20 34 6 5 O 4 lt T dp LLI OC Lu L 3 LU gt 2 9 1 7 6 6 4 5 3 1 5 0 0 10 20 30 40 50 60 70 80 90 100 110 U S Gallons per minute O 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 Liters per minute CAPACITY s15mdl1sm REV0708 Model S15 Metallic Page 3 Dimensions S15 Metallic Dimensions in Inches Dimensional Tolerance s Discharge Port 1 1 2 NPT Suction Port 1 1 2 NPT FRONT VIEW SIDE VIEW a 2 5 16 E 12 3 16 16 21 32 Pump Shown With 530 028 550 Integral Muffler Integral Muffler 1 NPT Exhaust Port For optional Muffler Styles or Piping Exhaust Air In Sumerged SIE LELZ
36. ngs and spool if necessary Remove the retaining ring item 4 F from the end of the sleeve item 4 B and remove the sleeve from the valve body item 4 A Wipe clean and inspect sleeve and o rings for dirt cuts or wear Replace the o rings and sleeve if necessary STEP 3 Re assembly of the pilot valve Generously lubricate outside diameter of the sleeve and o rings Then carefully insert sleeve into valve body Take CAUTION when inserting sleeve not to shear any o rings Install retaining ring to sleeve Generously lubricate outside diameter of spool and o rings Then carefully insert spool into sleeve Take CAUTION when inserting spool not to shear any o rings Use BP LS EP 2 multipurpose grease or equivalent STEP 4 Re install the pilot valve assembly into the intermediate Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate Re install the gasket air inlet cap and capscrews Connect the air supply to the pump The pump is now ready for operation Model S15 Metallic Page 22 ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 1 2 wrench or socket remove the four capscrews items 11 Remove the air inlet cap item 8 and air inlet gask
37. o the directive certificates visit www warrenrupp com The Technical File No AX1 is stored at KEMA Notified Body 0344 under Document 203040000 s15mdl1sm REV0708 IMPORTANT SAFETY INFORMATION 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 A 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 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 44 WARNING In the event of diaphragm rupture pumped material may enter the air end of the pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded S
38. oprene Diaphragms Balls and Polyethylene Seats WET END KIT Neoprene Diaphragms Balls and Polyethylene Seats WET END KIT FKM Diaphragms PTFE Balls and Seats WET END KIT Neoprene Diaphragms PTFE Overlay Balls and Seats WET END KIT EPDM Diaphragms Balls and UHMW Seats WET END KIT Santoprene Diaphragms PTFE Overlay PTFE Balls PTFE Seats WETTED END KIT One Plece Bonded PTFE Nitrile Diaphragm PTFE Balls PTFE Seats MIDSECTION CONVERSION KIT Replaces Aluminum Midsection With Cast Iron Components Air Inlet Cap Intermediate Bracket Inner Chambers and Inner Diaphragm Plates Zinc Plated Capscrews Washers and Hex Nuts Stainless Steel Capscrews Washers and Hex Nuts ELECTRONIC LEAK DETECTOR KITS 032 040 000 032 037 000 100VAC 220VAC Overlay Diaphragm Option Note Pumps equipped with these components are not ATEX compliant s15mdl1sm REV0708 One Piece Bonded Diaphragm Option Model S15 Metallic Page 12 Ex ATEX Compliant Composite Repair Parts List ITEM PART NUMBER DESCRIPTION QTY ITEM PART NUMBER DESCRIPTION QTY 1 031 140 000 Air Valve Assembly w Integral muffler Cast Iron Centers Only 1 19 360 103 360 Gasket Pilot Valve 1 031 141 000 Air Valve Assembly Cast Iron Centers Only 1 20 360 104 379 Gasket Air Inlet 1 A 031 146 000 Air Valve Assembly w Integral muffler Stroke Indicator Only 1 21 360 105 360 Gasket Inner Chamber 2 031 147 000 Air Valve Assembly Stroke In
39. oprene EPDM 644 Santoprene PTFE 650 Bonded Santoprene and PTFE 654 Santoprene Diaphragm PTFE Overlay Balls and seals 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene Delrin and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Warren Rupp SANDPIPER Portapump Tranquilizers and SludgeMaser are registered tradenames of Warren Rupp Inc Model 15 Metallic Page 10 s15mdl1sm REV0708 Model S15 Metallic Page 11 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 227 000 476 170 000 476 182 360 476 182 354 476 182 365 476 182 633 476 182 635 476 182 364 476 182 654 476 182 659 475 215 000 HARDWARE KITS 475 205 330 475 205 115 AIR END KIT Use With Aluminum Center Air Valve Assembly Pilot Valve Assembly Seals Bumpers Gaskets Plunger and O rings AIR END KIT Air Valve with Stroke Indicator Pin Aluminum Center Seals O ring Gaskets Retaining Rings Air Valve Sleeve and Spool Set and Pilot Valve Assembly WET END KIT Nitrile Diaphragms Balls and Polyethylene Seats WET END KIT Sant
40. pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 125 psi 8 6 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 1 2 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and filters must be supported by some means other than the air inlet cap Failure to provide support for the piping may result in damage to the pump A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended limits AIR VALVE LUBRICATION The air distribution valve and the pilot
41. pted Nitrile FKM Fluorocarbon Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 553 555 556 557 558 559 570 580 590 591 592 600 601 602 603 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 Conductive PVDF Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive Polypropylene Conductive HDPE Glass Filled Conductive Polypropylene Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Integral Silicon 611 PTFE Integral FKM 632 Neoprene Hytrel 633 FKM Fluorocarbon PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE FKM Fluorocarbon PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Sant
42. ranty Model 15 Metallic Page 23 CHECK VALVE SERVICING Before servicing the check valve components first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the check valve components remove the manifold item 23 or item 22 not shown Use a 1 2 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 34 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled reconnected and returned to operation METALLIC SEATS Two o rings or conductive PTFE seals item 27 are required for metallic seats s15mdl1sm REV0708 Check Valve Drawing with Metallic Seats with Non Metallic Seats Model S15 Metallic Page 24 Optional Mu
43. rresponding to its rated current max 3 I according IEC 60127 2 1 or a motor protecting switch with short circuit and thermal instantaneous tripping set to rated current shall be connected in series to each solenoid as short circuit protection For very low rated currents of the solenoid the fuse of lowest current value according to the indicated IEC standard will be sufficient The fuse may be accommodated in the associated supply unit or shall be separately arranged The rated voltage to the fuse shall be equal to or greater than the stated rated voltage of the magnet coil The breakage capacity of the fuse link shall be as high as or higher than the maximum expected short circuit current at the location of the installation usually 1500 A A maximum permissible ripple of 20 is valid for all magnets of direct current design s15mdl1sm REV0708 Model S15 Metallic Page 18 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION Warren Rupp s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your SANDPIPER speed The solenoid coil is connected to the Warren Rupp Solenoid Rate Controller Batch Control or a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate OPERATION The Solenoid Shifted SANDPIPER has a solenoid operated air distribution valve in place of the standard SANDPIPER s pilot operated air distribution v
44. tion 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 s15mdl1sm REV0708 is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the
45. 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 1 2 to 3 4 turn After the pump primes the air valve can be opened to increase air flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient air flow to pump flow ratio BETWEEN USES When the pump is used for materials that tend to s
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