Contents
1. 1 Air Valve Gasket and or mounting hardware inluded in Pump Adapter Kit Refer to Pulse Output Kit section chart page 3 for proper selection Intrinsically Safe Namur Connection z SGI e ocean va Channel 2 023 007 000 Switching Amplifier Non Harzardous Location qp mi 12 11 8 9 7 10 Loss output 20 125VDC Channel 1 Channel 2 20 250VAC 40 70 Hz OPI 4 To Customer Control Refer to Amplifier Wiring Diagram pokdl5sm rev0614 4 Conductor 22 AWG Supplied by End User Cd 250 VAC 2A x 500 VA 60 W Qe Pulse Output Kit Page 7 Pulse Output Pump Adapter Kit 475 245 001 SANDPIPER Pumps PB 1 4 A 475 245 001 Pulse Output Pump Adapter Kit Part Number Description Qty 031 110 000 Assembly Air Valve 360 084 360 Gasket Air Valve 3 360 085 360 Gasket Air Valve 1 Part Number Description Qty 031 109 000 Sleeve amp Spool w Pin 095 077 551 Body Main Air Valve 132 030 552 Bumper Valve Spool 165 123 147 Cap End 210 008 330 Clip Safety 560 029 360 O Ring 560 101 360 O Ring 675 051 115 Ring Retainer MN aAl MIN a gt o N Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection Q S 1 H AeF pokdl5sm rev02. 50 60Hz Channel 2 50 60Hz Output Output Channel 1 Channel 1 Refer to Wiring Refer to Wiring Diagram Diagram pokdl5sm rev0614 4 Conductor 22 AWG Supplied by End User WIRING DIAGRAM V lt 400mA Input 1r Common 250VAC SPDT 5A Relay Output CP12RC Only For 220VAC Wiring Diagram Refer to Page 6 Pulse Output Kit Page 5 Pulse Output Pump Kit 475 244 002 220VAC Wiring Diagram For Non Hazardous Locations 475 244 002 Pulse Output Pump Kit 1 147 000 000 Teminsiduneion 2 zeooiooo Comecior Feia Wing a 724 006 000 Sensor Proxmiy 3 a 025001000 Ampifer Switching s 021001000 SeketAmpie Notes 1 Air Valve Gasket and or mounting hardware inluded in Pump Adapter Kit Refer to Pulse Output Kit section chart page 3 for proper selection Connection VDC Output Channel 1 Common 220VAC 220VAC Supply Supply 15VA 15VA 50 60Hz Channel 2 50 60Hz 4 Conductor 22 AWG Supplied by End User WIRING DIAGRAM TV 400mA Input 1 Common 250VAC SPDT 5A Relay Output Output Output B CP12RC Channel 1 Channel 1 Refer to Wiring Refer to Wiring Only Diagram Diagram For 110VAC Wiring Diagram Refer to Page 5 pokdl5sm rev0614 Pulse Output Kit Page 6 Pulse Output Pump Kit 475 244 003 20 125VDC 20 250VAC Intrinsically Safe Wiring Diagram 475 244 002 Pulse Output Pump Kit z 3 Notes
3. Refer to Note 1 Containment Duty ET1 1 2 SM MP05D ET1 1 2 M MP07D Refer to Note 1 Refer to Note 1 ST1 1 2 ST40 475 245 009 Refer to Page 15 ET2 M MP08D Refer to Note 1 ET3 M MP12D 475 245 005 475 245 005 Refer to Note 1 Refer to Page 12 Refer to Page 12 Refer to Note 1 Special Duty Refer to Note 1 Refer to Note 1 Pulse Output Kit Refer to Note 1 Page 3 Pulse Output Pump Kit 475 244 001 10 30VDC Wiring Diagram Part Number Description 111 009 000 Terminal Junction 241 004 000 Connector Field Wiring 724 004 000 Sensor Proximity Notes 1 Air Valve Gasket and or mounting hardware inluded in Pump Adapter Kit Refer to Pulse Output Kit section chart page 3 for proper selection Connection VDC Output Channel 1 Common Output Channel 2 4 Conductor 22 AWG Supplied by End User pokdl5sm rev0614 Pulse Output Kit Page 4 Pulse Output Pump Kit 475 244 002 110VAC Wiring Diagram For Non Hazardous Locations 475 244 002 Pulse Output Pump Kit 9005000 2 2004 000 3 726004 000_ a 928 00 000_ 5 oseooron Notes 1 Air Valve Gasket and or mounting hardware inluded in Pump Adapter Kit Refer to Pulse Output Kit section chart page 3 for proper selection Connection J 2 Output Channel 1 Output Channel 2 110VAC 110VAC Supply Supply 15VA 15VA
4. 14 Pulse Output Kit Page 16 Wiring Diagram for Interface with 249 006 000 Batch Control Stroke Counter Non Hazardous Location 1 Re SandPIPER Air Valve Stroke counter Batch Control Mounted to Pump WARREN RUPP PUMP CONTROLS JE 96 6 0 6 6 6 0 0 6 06 e S a a EIE z E z E a cc amp s 8 2 2 OlEJE z 2 gt N c2 I a o S oEkEE E IgE gt fa S a Z S S S E amp al2 z zoojojla esz zie ug amp gzrilric ie jzizisia E BIEISISIE 25S gx g ZIggig 5 S aI3 E I o NY 22 AWG Cable Il Il 1 Common Il 2 Output Channel 1 3 Ground 4 Output Channel 2 Power Input ii l Terminal 1 cte sm Neutral Positive Terminal 42 l I Power Negative l s 2 Solenoid Air Valve Customer Supplied 3rd Terminal Remote Control for ground Momentary Switch pokdl5sm rev0614 Pulse Output Kit Page 17 Wiring Diagram for NAMUR Interface Intrinsically Safe NAMUR Interface with 249 006 000 Batch Control Stroke Counter 100 120 240VAC Non Hazardous Location m
5. 614 Pulse Output Kit Page 8 Pulse Output Pump Adapter Kit 475 245 002 SandPIPER Pumps S05 Metallic and S05 S07 S10 Non Metallic 475 245 002 Pulse Output Pump Adapter Kit Description Assembly Air Valve Gasket Air Valve 031 169 000 Main Air Valve Assembly Description Sleeve amp Spool w Pin Body Main Air Valve Bumper Valve Spool EC KCN pc 1D 165 123 147 Cap End EH KA 1 A 1 B 1 C 1 D 1 E 1 F 1 G 1 H 560 029 360 O Ring 1 G 560 101 360 O Ring 1 H 675 062 115 Ring Retainer Notes 1 Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection 210 008 330 Clip Safety pokdl5sm rev0614 Pulse Output Kit Page 9 Pulse Output Pump Adapter Kit 475 245 003 SandPIPER Pumps S1F S30 Metallic and Non Metallic 475 245 001 Pulse Output Pump Adapter Kit Part Number Description 031 147 000 Assembly Air Valve 360 093 360 Gasket Air Valve 031 147 000 Main Air Valve Assembly Part Number Description 031 139 000 Sleeve amp Spool w Pin 095 094 559 Body Main Air Valve Bumper Valve Spool EN 18 vC 132 029 552 Bem pe ET 1 A 1 B 1 C 1 D 1 E 1 F 1 G 1 H 560 020 360 O Ring 1 6 560 029 360 O Ring 1 H 675 044 115 Ring Retainer Notes 1 Proximity Sensors Terminal Junction and Connector shown in side view are incl
6. Output Kit Page 18
7. SERVICE AND OPERATING MANUAL SANDPIPER A WARREN RUPP INC BRAND PULSE OUTPUT KIT Design Level 5 FLUID amp METERING A WARNING A Pulse Output Interface Kits cannot be used if pump is to be submerged Pulse Output Interface The Pulse Output Interface Kits are designed for easy field installation The Kits are also available factory installed on new pumps The Pulse Output Interface Kit mounts on the pump and provides electrical pulses to operate the Warren Rupp Batch Control Stroke Counter or a customer supplied control The unit creates an electrical interface between the control and the air powered pump Pulse Output Kits can be purchased separately for use in applications where a process controller is already present in a system This provides a direct interface with the pump and the customer s system Operation Each pump stroke generates a signal through a proximity sensor PNP on either end of the air valve As the air valve reciprocates back and forth during pump operation targets on either end of the spool activate their respective proximity sensors Each sensor signals the control to register one count on the stroke counter batch control unit This method provides a positive signal for every pump stroke but with very few wearing parts Connecting a Factory Installed Kit Pulse Interface Kits are available factory installed on new SANDPIPER and MARATHON diaphragm pumps When installing always refer to the servic
8. Spool w Pin 1 095 043 010 Body Main Air Valve 1 132 014 358 Bumper Valve Spool 2 170 032 115 Capscrew Hex Head 210 008 330 Clip Safety 360 010 425 Gasket End Cap 560 020 360 O Ring Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection pokdl5sm rev0614 Pulse Output Kit Page 14 Pulse Output Pump Adapter Kit 475 245 008 amp 475 245 009 SANDPIPER Pumps HDF3 A and HDF4 A 475 245 008 and ST1 1 2 A 475 245 009 475 245 008 Pulse Output Pump Adapter Kit see below Part Number Description 031 089 156 Assembly Air Valve 360 048 425 Gasket Air Valve 612 139 552 Plate Spacer 170 069 330 Capscrew Hex Hd 210 008 330 Clip Lockout Part Number Description 360 048 425 Gasket Air Valve 612 139 552 Plate Spacer 170 069 330 Capscrew Hex Hd Notes 1 Kit 475 245 009 does not include Air Valve 031 089 156 Air Valve The ST1 1 2 pump for which it is intended is already equipped with this valve pokdl5sm rev0614 Pulse Output Kit Page 15 Assembly Instructions SANDPIPER Pumps ET1 1 2 M HD1 1 2 A HDB2 A and HDF2 A When adapting kits 476 245 005 and 476 245 005 it is recommended that the capscrew located near the proximity sensors be installed in the opposite direction pokdl5sm rev06
9. Standard Duty Non Metallic S10 M10 S1F M1F 475 245 002 475 245 003 Refer to Page 9 Refer to Page 10 15 M15 475 245 003 Refer to Page 10 Standard Duty 20 M20 30 M30 S05 M05 S1F M1F 475 245 003 475 245 003 475 245 002 475 245 003 Refer to Page 10 Refer to Page 10 Refer to Page 9 Refer to Page 10 Metallic 15 M15 475 245 003 Refer to Page 10 Pump Class 20 M20 30 M30 Pump Model SB1 SB25 Mid Section 475 245 003 475 245 003 Kit Number 475 245 004 Refer to Page 10 Refer to Page 10 Comment Refer to Page 11 Assembly Notes Aluminum Note 1 Pulse Output Adapter Kits do not not require an Adapter Kit to install Pulse Output kits to that particular pump Order 475 245 005 Refer to Page 12 475 245 006 Refer to Page 13 475 245 005 Refer to Page 12 HDB1 1 2 HDB40 Cast Iron Heaw Duty Ball Aluminum Cast Iron only the appropriate Pulse Output Kit See Table 1 pokdl5sm rev0614 475 245 006 Refer to Page 13 HDF1 HDF25 475 245 007 475 245 007 475 245 004 Refer to Page 14 Refer to Page 14 Refer to Page 11 HDF2 Aluminum Cast Iron 475 245 005 475 245 006 Refer to Page 12 Refer to Page 13 Heavy Duty Flap HDF3 M 475 245 007 475 245 008 475 245 007 Refer to Page 14 Refer to Page 15 Refer to Page 14 ST1 ST25 475 245 008 Refer to Page 15 Refer to Note 1 ET1 M MP04D
10. Stroke counter Batch Control TOTAL PRESET START COUNT I COUNT Hazardous Location DIGIT SELECT RESET INCREASE DIGIT STOP RUPPTECH c c eee n JJ Q Q w w o eo o o zl o o e ele e ej e e e e e e e z z B B c e N N Ww Oo O 2 N rI I o5 z Z BE ez c E 2518 9 Io Channel 1 lalal5s amp B8 X aaae E o g Channel 1 Ialzi5lals xIs IElae Channel 2 amp leglert amp elaso ze SIRO Channel 2 S Egg eto die amp o Hazardous Location E 5 2 1 4 N C ega 3 E Power DNE ee Qe Input S ca S fil J t T N 9 S v pi Bate LW Note Switch the ra j uu J UUCD output mode to mau isse normally open for SSE i both channel 1 aS m j and channel 2 EN 1 A 5 2 or O o DD UE f b 12 LI 9 8 ii y GRND Proximity UN Customer Supplied 24VDC Sensor Input1 Sensor Input 2 Solenoid Remote Control e Air Valve Momentary Switch pokdl5sm rev0614 Pulse
11. ace Loosen the hex nut holding the proximity sensor in place Remove the sensor from the end cap Install the replacement sensor Set the clearance between the sensor and the actuator pin to 015 38mm using a feeler gauge or shim stock The gauge or shim stock should slide freely while making contact Tighten the hex nut provided with the replacement proximity sensor to lock in place Reattach terminal juction to proximity sensor Remove the safety clip from the end cap The pump is now ready for use Pump Selection amp Installation Air operated double diaphragm pumps AODD are semi positive displacement pumps designed with flexible diaphragms AODD have successfully been applied in metering and batching applications where system design allows for minimal variation of Air Inlet Pressure Suction Head Lift Discharge Head Pump Speed Stroke Rate Product Viscosity NPSH a Variations of any of the above can result in variable volumetric displacement per pumping stroke which normally holds to 1 to 3 repeatability To verify actual displacement in your application it is essential to follow a calibration procedure This allows the batch control to be set for the actual average displacement per pump stroke The larger the calibration volume the more precise the average Sizing Follow the normal pump sizing procedures using published data DO NOT OVERSIZE THE PUMP Select the smallest pump suitable f
12. e manual for pump installation and operation recommendations After installing the pump connect the interface to the control source To connect the interface to the control source Install input cable according to the wiring diagram for your specific interface kit Connect to Warren Rupp Batch Controller or existing system control Field Installation of Kit Before adding an interface kit to an existing SANDPIPER or MARATHON pump verify the compatibility of the pump model kit number and voltage being used A complete listing appears on page 3 Field Installation Remove the main air valve body assembly and gasket Install the Pulse Output Kit and pulse output pump adapter kit tighten and torque the screws according to the pump service manual instructions Refer to the applicable wiring diagram when connecting to control source 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 pokdl5sm rev0614 Copyright 2014 Warren Rupp Inc All rights reserved Replacing Proximity Sensors Shift the main air valve spool toward the sensor being replaced A CAUTION Lock the spool in place by inserting the safety clip Seren elp locks pump for security or service Pum included in the kit through the small hole of the opposite end cap will NOT operate with Safety Disconnect the sensors from terminal junction clip in pl
13. or your use to ensure greater accuracy The batch size from a SANDPIPER pump will be within one stroke Installation To ensure consistent repeating of the batch size keep the suction piping short straight simple and as large a diameter as is practical Differential pressure across the check valves of the pump will insure that the check valves seat properly and consistently Discharge pressure must always be greater than the suction pressure in the application For consistent fluid displacement and system accuracy it is mandatory to keep the discharge line full of product from the pump to the point of discharge A one way check valve installed in the end of the discharge line will accomplish this In suction lift applications the pump must be kept primed at all times Suction lift must be kept to a minimum and a foot valve may be required in the suction line to keep the pump primed In flooded suction applications a back pressure device located in the discharge line may be required to insure sufficient differential pressure across the pump check valves The one way check valve mentioned above may provide sufficient back pressure to properly seat the pump check valves although additional means may be necessary in some applications Install an air line pressure regulator This ensures a constant air pressure feed to the pump eliminating low to peak usage pressure spikes which will increase and or decrease the stroke rate of the pump resulting in va
14. per Valve Spool 165 066 010 Cap End 170 032 115 Capscrew Hex Head 210 008 330 Clip Safety 360 010 425 Gasket End Cap 560 020 360 O Ring Oo v o m mio Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection Refer to page 15 for special assembly instructions pokdl5sm rev0614 Pulse Output Kit Page 12 Pulse Output Pump Adapter Kit 475 245 006 SandPIPER Pumps HD1 1 2 A HDB2 A and HDF2 A with Cast Iron Midsections 475 245 006 Pulse Output Pump Adapter Kit Description Assembly Air Valve Gasket Air Valve 031 089 010 Main Air Valve Assembly a 210 008 330 Clip Safety 360 010 425 Gasket End Cap Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection ELE EH EE A 1 B C D 1 E 1 F G 1 H 170 032 115 Capscrew Hex Head Refer to page 15 for special assembly instructions pokdl5sm rev0614 Pulse Output Kit Page 13 Pulse Output Pump Adapter Kit 475 245 007 SANDPIPER Pumps HDB3 A HDB4 A HDF3 M and HDF4 M 475 245 007 Pulse Output Pump Adapter Kit Part Number Description 031 090 010 Assembly Air Valve 360 048 425 Gasket Air Valve 031 090 010 Main Air Valve Assembly Part Number Description 031 069 000 Sleeve amp
15. riable non controlled flow pokdl5sm rev0614 Pulse Output Kit Page 2 Pulse Output Literature Ordering IMPORTANT Pulse Output Interface Kit Selection Instructions Step 1 Determine the required system voltage and then chose one of the three Pulse Output Kits from Table 1 Each kit will include Proximity Sensor Field Connector and Terminal Junction Determine the pump model being used and then choose the required Pulse Output Adapter Kit from Table 2 Each Kit include all parts required for field installation of kit which may include Air Valve Assembly Gaskets Spacer Plate and or Hardware Order the combination of the Pulse Output Kit and the Pulse Output Adapter Kit together to successfully field install a Pulse Output Interface When ordering a pump with a factory installed Pulse Output interface refer to Pump and Assecories Price Sheet for proper pump model number Information Table 1 Pulse Output Kits System Voltage Kit Number Comment Standard 10 30VDC Standard 110VAC 475 244 001 475 244 002 Refer to Page 4 Refer to Page 5 Standard 220VAC 475 244 002 Refer to Page 6 Intrinsically Safe 10 30VDC 110VAC amp 220VAC Pulse Output Adapter Kits Pump Class Size Pump Model PB1 4 A MPO1P 475 244 003 Kit Number 475 245 001 Refer to Page 7 Comment Refer to Page 8 S05 M05 475 245 002 Refer to Page 9 S07 M07 475 245 002 Refer to Page 9
16. uded in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection 165 098 147 Cap End 210 008 330 Clip Safety pokdl5sm rev0614 Pulse Output Kit Page 10 Pulse Output Pump Adapter Kit 475 245 004 SANDPIPER Pumps HDF1 amp SB1 475 245 004 Pulse Output Pump Adapter Kit Part Number Description 031 111 557 Assembly Air Valve 360 057 360 Gasket Air Valve 360 058 360 031 111 558 Main Air Valve Assembly Part Number Gasket Air Valve Description 031 083 000 Sleeve amp Spool w Pin 095 051 557 1 C 132 028 552 Bumper Valve Spool 165 078 147 Body Main Air Valve Cap End Vn EN S 210 008 330 Clip Safety 560 029 360 O Ring 560 058 360 O Ring 675 043 115 Ring Retainer N O N N N Proximity Sensors Terminal Junction and Connector shown in side view are included in Pulse Output Kit Refer to Pulse Output Kit section chart page 3 for proper selection pokdl5sm rev0614 Pulse Output Kit Page 11 Pulse Output Pump Adapter Kit 475 245 005 SANDPIPER Pumps HD1 1 2 A HDB2 A and HDF2 A with Aluminum Midsections 475 245 005 Pulse Output Pump Adapter Kit Part Number Description 031 089 156 Assembly Air Valve 360 048 425 Gasket Air Valve 031 089 156 Main Air Valve Assembly Part Number Description 031 066 000 Sleeve amp Spool w Pin 095 043 156 Body Main Air Valve 132 014 358 Bum
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