manual / parts
Contents
1. Limited to Style Optional O Surge Suppressor 100 psi 2 020 051 000 Filter Regulator Gauge 8 Air Dryer Flexible Shut Off Valve Connection lO En DISCHARGE a ee A CAUTION Hii The air exhaust should be piped to an area for safe disposition of the product Drain Port being pumped in the event of a diaphragm failure Flexible Connection Air Shut Off Pipe Connection Valve Style Optional Air Exhaust mE 5 qm Filter Regulator Air Dryer Gauge DIAP RP A Shut Off 5 D ur Valve H AIR INLET 4l Y Flexible SUCTION Hh Connection a 2 Drain Port s20nmdl3sm rev1110 Model S20 Non Metallic Page 7 RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 9 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed s20nmdl3sm rev1110 IMPORTANT SAFETY INFORMATION A IMPORTANT Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty CAUTION Before pump operation inspect all gasketed fasteners for2. iii Modular Check Valve Servicing ieget er eerte alia ille Modular Check Valve Drawing iii Dual Port Option Drawing iii Dual Porting ODptIODS x in re nta Tert Rie nate Eh eere Ses Dual Porting of Both Suction and Discharge Ends of the PuMp Single Porting of the Suction and Dual Porting of the Pump Discharge Dual Porting of the Suction and Single Porting of the Pump Discharge Leak Detection Options Electronic Leak Detector Installation i Mechanical Leak Detector Installation essen Pulse Output Kit Drawing ii Pulse Output Kit c pevencainad Optional Muffler Configurations i Grounding the Pip ELE E EE CE Declaration of Conformity Machinery CE Declaration of Conformity ATEX iii Explanation of ATEX Certifications ii Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA s20nmdl3sm rev1110 Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com Copyright 2010 Warren Rupp Inc All rights reserved WARREN RUPP Quality System See pages 2 33 and 34 for ATEX ratings SO9001 Certified Environmental Management System 15014001 Certified CE
3. a Note ATEX Compliant s20nmdl3sm rev1110 Model S20 Non Metallic Page 16 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 5 6 Allen wrench remove the four hex socket capscrews item 13 and four flat washers item 42 Remove the air valve assembly from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cuts wear or abrasion Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter ofthe spool Wipe spool with a soft cloth and inspect for scratches or wear s20nmdl3sm rev1110 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one e
4. 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 53 is in the vertical position Loosen the pipe plug item 50 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 16 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 50 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill containment chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instruc
5. A Non Wetted Material Options N Neoprene Neoprene Z One Piece Bonded PTFE Check Valve Seat K PVDF P Polypropylene C Carbon Filled Conductive Polypropylene E with Electronic Leak Detection 220V M with Mechanical Leak Detection S Standard V with Visual Leak Detection Pump Options A 0 None 12 Sound Dampening Muffler 2 Mesh Muffler 3 High temperature Air Valve P 40 Glass Filled Polypropylene w Integral Muffler PO 10 30VDC Pulse Output Kit o P1 Intrinsically Safe 5 30VDC 110 120VAC 220 240 VAC Pulse Output Kit P2 110 120 or 220 240VAC Pulse Output Kit E0 Solenoid Kit with 24VDC Coil A E1 Solenoid Kit with 24VDC Explosion Proof Coil E2 Solenoid Kit with 24VAC 12VDC Coil A Solenoid Kit with 230VAC 50 Hz Explosion Proof Coil SP Stroke Indicator Pins 1 Solenoid Kit with 12 VDC ATEX Compliant Coil 2 Solenoid Kit with 24 VDC ATEX Compliant Coil 3 Solenoid Kit with 110 120 VAC 50 60 Hz ATEX Compliant Coil A E3 Solenoid Kit with 12VDC Explosion Proof Coil 1 40 Glass Filled Polypropylene w PTFE Coated Hardware A4 Solenoid Kit with 220 240 VAC 50 60 Hz ATEX Compliant Coil lt IEC EEX m T4 SP 4 High temperature Air Valve w Sound Dampening Muffler Il 2G Ex ia c IIC 5 26 EEx m c II 5 Il 3 1 Gc T5 2 Il 3 2 G Ex iac IIC 5 3 x Il 3 2 2G EEx m c II T5 4 C 1 Il 1G c T5 Il 1D c T100 C Il 2D Ex c ia 20 IP67 1
6. Ball Valve Diaphragm Check Non Wetted Wetted Check Valve Material Material Materials Options S20B3P1PPUS000 00 S20B3K1KPUS000 S20B3P2PPUS000 00 95 43 S20B3K2KPUS000 00 130 59 S20B3PGPPUS000 00 126 57 S20B3KGKPUS000 00 131 59 S20B3C1PCUS000 00 94 43 Shipping Weight Ibs kg 90 41 00 125 57 S20B3C2PCUS000 Note Models listed in the table are for reference only See nomenclature below for other models Pump Brand S SANDPIPER Diaphragm Check Valve Materials 1 Santoprene Santoprene 2 PTFE Santoprene Backup PTFE Porting Options U Universal Flange Fits ANSI amp DIN Pump Options continued 5 High temperature Air Valve w Mesh Muffler 00 100 45 Kit Options continued E4 Solenoid Kit with 110VAC Coil A E5 Solenoid Kit with 110VAC epee 6 PTFE Pumping PTFE Neoprene 7 Dual Porting ANSI 6 Metal Muffler Explosion Proof Coil 20 22 ping p n Eas Backup Driver PTFE 8 Top Dual Porting ANSI 7 Metal Muffler with E6 Solenoid Kit with 220VAC Coil Check Valve Type B Nitrile Nitrile 9 Bottom Dual Porting ANSI grounding cable E7 zn 1 xplosion Proof Coi TE E ci Backup PTFE Pump Style Kit Options A E8 Solenoid Kit with 110VAC 50 Hz Design Level pi D with Electronic Leak Detection 110V A 00 None Explosion Proof Coil 3 Design Level 3 Wetted Material K PVDF P Polypropylene A C Conductive Polypropylene
7. 196 188 551 Ay 196 188 559 196 190 520 196 190 552 A 196 190 557 286 005 354 286 005 360 286 005 363 286 005 365 286 114 000 286 119 600 312 102 520 312 102 552 Ay 312 102 557 s20nmdl3sm rev1110 DESCRIPTION Air Valve Assembly Air Valve Assembly Air Valve Assembly w PTFE coated Hardware Air Valve Assembly No Integral Muffler Air Valve Assembly No Integral Muffler Air Valve Assembly No Integral Muffler PTFE Coated Hardware Pilot Valve Assembly Ball Check Ball Check Ball Check Ball Check Intermediate Assembly Intermediate Assembly Bumper Diaphragm Bushing Plunger Air Inlet Cap Assembly Air Inlet Cap Assembly Capscrew Hex HD 1 2 13 x 2 50 Capscrew Hex HD 1 2 13 x 2 50 Capscrew Hex HD 1 2 13 x 2 25 Capscrew Hex HD 1 2 13 x 2 25 Capscrew Hex HD5 16 18 x 1 75 Capscrew Hex HD 5 16 18x 1 75 Capscrew Hex HD 1 2 13 x 4 00 Capscrew Hex HD 1 2 13 x 4 00 Capscrew Hex HD 5 8 11 x 2 75 Capscrew Hex HD 5 8 11 x 2 75 Capscrew Soc HD 3 8 16 X 2 75 Capscrew Soc HD 3 8 16X 2 75 Capscrew Flat HD 3 8 16 X1 25 Chamber Inner Chamber Inner Chamber Outer Chamber Outer Chamber Outer Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm One Piece Bonded PTFE Diaphragm Overlay Elbow Discharge Elbow Discharge Elbow Discharge QTY dA 2 da da _ LA LADOI d A 0 0DI i ANNA AAAA ITEM PAR
8. BEING 3rd Terminal forl ground s Before wiring remove 2 Terminal Neutral 1 Terminal conduit connector terminal block from A Negative Positive Model S20 Non Metallic Page 21 Diaphragm Service Drawing with Overlay PO qs Diaphragm Service Drawing Non Overlay Field conversion kit 475 256 000 available for conversion from PTFE Overlay to One Piece bonded Diaphragm Part Description Qty 286 114 000 One Piece Diaphragm 2 612 227 150 Plate Inner Diaphragm 2 s20nmdl3sm rev1110 Model S20 Non Metallic Page 22 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump composite repair parts drawing and the diaphragm servicing illustration Using a wrench or socket remove the 16 capscrews items 8 hex nuts and washers that fasten the elbows items 19 amp 20 to the outer chambers items 16 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a wrench or socket remove the 16 capscrews items 9 amp 11 hex nuts and washers that fasten the outer chambers diaphragms and inner chambers items 15 together Step 3 Removing t
9. FLUID amp METERING INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING 2 Universal Flange 0 160 US Gallons per minute No lube no stall Up to 66 in 17mm Fits ANSI amp DIN Flange 0 605 liters per minute design A CAUTION Operating temperature limitations are as follows Materials Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons PVDF A durable fluoroplastic with excellent chemical resistance Excellent for UV applications High tensile strength and impact resistance NEOPRENE All purpose Resistant to vegetable oils Generally not affected by moderate chemicals fats greases and many oils and solvents Generally attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocarbons PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures FKM Fluorocarbon shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids animal and vegetable oils Hot water or hot aqueous solutions over 70 F wil
10. Spill Containment models 1 031 146 000 Air Valve Assembly 1 1 A 031 143 000 Sleeve and Spool Set w Pins 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 559 Cap Muffler 1 1 E 165 098 147 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 4 710 015 115 Screw Self Tapping 4 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O Ring 2 For Pumps with PTFE Coated Hardware 1 031 146 002 Air Valve Assembly 1 1 J 710 015 308 Screw Self Tapping 4 includes all other items on 031 146 000 above For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 147 000 Air Valve Assembly 1 includes all items on 031 146 000 minus 1 D 1 F amp 1 J x A Note ATEX Compliant s20nmdl3sm rev1110 Model S20 Non Metallic Page 18 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 5 6 Allen wrench remove the four hex socket capscrews item 13 and four flat washers item 42 Remove the air valve assembly from the pump Remove and inspect gasket item 21 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 rin
11. 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 s20nmdl3sm rev1110 Model S20 Non Metallic Page 29 Optional Muffler Configurations Drawing OPTION 0 530 028 550 Encapsulated Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to hold it in place OPTION 1 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element A OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body x ATEX Compliant Option 0 Option 1 and 2 Option 6 s20nmdl3sm rev1110 Model S20 Non Metallic Page 30 Grounding The Pump To be fully groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet end is fastened to the pump hardware s20nmdl3sm rev1110 The other end is installed to a true earth ground This optional 8 foot long 244 centimeters Ground Strap 920 025 000 is available for easy ground connection To reduce the risk of static electrical sparking t
12. damage to the air distribution valve body Exhaust Conversion Drawing CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 MUFFLER r gt _ 1 DIAMETER AIR EXHAUST PIPING EE MUFFLER a LIQUID LEVEL SUCTION LINE Illustration 3 1 DIAMETER AIR EXHAUST PIPING Model S20 Non Metallic Page 25 MODULAR CHECK VALVE SERVICING Before servicing the check valves first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the modular check valve remove the elbows items 19 amp 20 from pump composite repair parts drawing Use wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seen in the cavities of the outer chamber items 16 Next remove the check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect
13. location of the installation usually 1500 A A maximum permissible ripple of 2096 is valid for all magnets of direct current design s20nmdl3sm rev1110 Model S20 Non Metallic Page 20 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION Warren Rupp s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your SANDPIPER s speed The solenoid coil is connected to a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate OPERATION The Solenoid Shifted SANDPIPER has a solenoid operated air distribution valve in place of the standard SANDPIPER s pilot operated air distribution valve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard SANDPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage s20nmdl3sm rev1110 Solenoid Connector Wiring Diagram
14. 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 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 AWARNING 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 31 AWARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly A WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly 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 non operational so th
15. 00 Il 2D c IP65 T100 C x IM1c IM2c Note Pumps ordered with the options listed Note Pump models equipped with these explosion proof solenoid kit options E1 E5 E7 E8 or E9 are certified and approved by the above agencies They are NOT ATEX compliant in 1 to the left are ATEX compliant when ordered with kit option A1 A2 A3 or A4 Compressed Air Temperature Range Maxi mum Ambient Temperature to plus 50 C Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option P1 A Note Pumps are only ATEX compliant when ordered with wet ted material option C non wetted material option C pump option 0 6 or 7 and kit option 0 Note See page 20 for Special Conditions For Safe Use s20nmdl3sm rev1110 Model S20 Non Metallic Page 2 Performance Curve Model S20 Non Metallic Design Level 3 Performance based on the following elastomer fitted pump flooded suction water at ambient conditions The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 em ao M 7 SCFM M hr 6 Displacement Per Stroke 46 Gallons 1 74 Liters Flow Capacity 0 160 Gallons Per Min CC 5 0 605 Lilters Per Min T o 4 Z Q T3 E 10 30 2 8 20 6 1 4 10 2 0 0 0 0 20 40 60 80 100 120 140 160 U S Gallons per minute 100 200 300 400 500 600 Liters per minute CAPACITY s20nmdl3sm rev1110 Model S20 Non M
16. 0nmdl3sm rev1110 306 307 308 309 310 313 330 331 332 333 335 336 337 340 342 351 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 MATERIAL CODES THE LAST 3 DIGITS OF PART NUMBER Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Aluminum White Epoxy Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Food Grade Santoprene Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compression Mold Urethane Rubber Nitrile Rubber Color coded RED Nitrile FKM Fluorocarbon Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane 374 375 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 540 541 542 544 550 551 552 553 555 556 558 570 580 590 591 592 600 601 602 603 604 606 Carboxylated Nitrile Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Cellulose Fibre Cork and Neoprene Compressed Fib
17. ARRADWANANAANNNNNNDHAPABNNNMN A ANNN Model S20 Non Metallic Page 13 Spill Containment Option Note Items 46 the diaphragms are to be installed with the concave side facing toward the outer chambers s20nmdl3sm rev1110 S20 Spill Containment Repair Parts List ITEM 1 43 44 45 46 47 48 49 50 51 52 53 54 55 PART NUMBER 031 146 000 031 147 000 170 073 115 170 073 308 170 102 115 170 102 308 196 189 520 196 189 552 286 120 600 518 200 520 518 200 552 538 022 110 538 022 308 560 078 611 618 003 110 618 003 308 618 025 110 618 025 308 618 031 110 618 031 308 835 005 110 835 005 308 860 055 606 866 060 110 DESCRIPTION QTY Air Valve Assembly 1 replaces 031 140 000 Air Valve Assembly 1 replaces 031 141 000 Capscrew Hex HD 1 2 13 x 4 50 8 replaces 170 068 115 Capscrew Hex HD 1 2 13 x 4 50 8 replaces170 068 115 Capscrew Hex HD 1 2 13 x 6 00 replaces 170 095 115 Capscrew Hex HD 1 2 13 x 6 00 Chamber Spill Prevention Chamber Spill Prevention Diaphragm Pumping Manifold replaces 518 199 520 Manifold replaces 518 199 552 Nipple Pipe Nipple Pipe O Ring Plug Pipe Plug Pipe Plug Boss Plug Boss Plug Boss Plug Boss Tee Pipe Tee Pipe Tube Sight Connector Tube NO N ANAABRAHRAHRHROAA Model S20 Non Metallic Page 14 SPILL CONTAINMENT CONCEPT The spill containment option preven
18. CATIONS OPTIONAL THREADED va 1 NPT SOUND DAMPENING OR BRASS MESH 32 25 MUFFLER T X Au MIN pO WA CES oy SUCTION PORT 78 X 87 SLOTTED UNIVERSAL FLANGE 16 06 FITS ANSI 125 CONNECTION OR PN10 50mm DIN CONNECTION 3 4 NPT s20nmdl3sm rev1110 Model S20 Non 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 action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing and exha
19. SERVICE amp OPERATING MANUAL Original Instructions SANDPIPER A WARREN RUPP PUMP BRAND Model S20 Non Metallic Design Level 3 Table of Contents Engineering Data and Temperature Limitations 1 Explanation of Pump Nomenclature i 2 Performance Curve Model S20 Non Metallic Design Level 3 Dimensions S20 Non Metallic nennen 4 Dimensions S20 Non Metallic with Spill Containment 5 Principle of Pump Op eratioD pieni ail 6 Installation and Start up nale iaia 6 Air SUPPI Yz 6 Air Valve Lubrication 6 Air Line M 6 Air Inlet and Priming eisidein andia eens acte Dade d Dee ee c dau 6 Between USES arreen 6 Installation uiarni aaaeaii Ea 7 Recycling E iii laine ae ale 8 Important Safety Information cee arial erri reete iaia iaia 8 COdeS 9 acere 10 abla lihd 10 Composite Repair Parts Drawing i 12 Repair Parts Servicing Kits Composite Repair Parts List Spill Containment Option ii Spill Containment Repair Par
20. T NUMBER 20 312 116 520 312 116 552 Ay 312 116 557 21 360 093 360 22 360 103 360 23 360 104 360 A 360 104 379 24 360 107 360 25 518 199 520 518 199 552 A 518 199 557 26 545 008 110 545 008 308 27 545 009 110 545 009 308 28 560 001 360 29 612 195 157 612 227 150 30 612 225 520 612 225 552 31 620 004 114 32 670 046 520 670 046 552 33 675 042 115 34 685 063 120 35 720 004 360 36 720 038 600 37 720 041 600 38 722 075 520 722 075 552 39 901 038 115 901 038 308 40 901 046 115 901 046 308 41 901 047 115 901 047 308 42 901 048 115 901 048 308 NOT SHOWN 535 010 000 530 027 000 A 530 033 000 DESCRIPTION Elbow Suction Elbow Suction Elbow Suction Gasket Main Air Valve Gasket Pilot Valve Gasket Air Inlet Cap Gasket Air Inlet Cap Conductive Models Only Gasket Inner Chamber Manifold Manifold Manifold Nut Hex 1 2 13 Nut Hex 1 2 13 Nut Hex 5 8 11 Nut Hex 5 8 11 O Ring Inner Diaphragm Plate Inner Diaphragm Plate One Piece Bonded Option Outer Plate Diaphragm Outer Plate Diaphragm Plunger Actuator Retainer Ball Retainer Ball Ring Retainer Rod Diaphragm Seal U Cup Seal Manifold Seal Check Valve Assembly Seat Check Valve Seat Check Valve Washer Flat 5 16 Washer Flat 5 16 Washer Flat 1 2 Washer Flat 1 2 Washer Flat 5 8 Washer Flat 5 8 Washer Flat 3 8 Washer Flat 3 8 Muffler Muffler Muffler 4 Note ATEX Compliant QTY NIN PR
21. UAL What to Check Check ESADS Plus the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a surge suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of 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 ofthe 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 necessa
22. at 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 A WARNING Airborne particles and loud noise hazards Wear ear and eye protection Model S20 Non Metallic Page 8 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 180 305 Assembly sub assembly and some purchased items Cast Iron Powered Metal 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 s2
23. clean and inspect spool and o rings for dirt cuts or wear Replace the o rings 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 S20 Non Metallic Page 24 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
24. 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 pump flooded suction condition pipe the exhaust higher than the product source to prevent siphoning spills See illustration 3 at right CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Use a 8 Torx or flat screwdriver to remove the six self tapping screws item 1 4 Remove the muffler cap and muffler items 1 D and 1 F The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed IMPORTANT INSTALLATION s20nmdl3sm rev1110 NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be physically supported Failure to support these connections could also result in
25. e 2nd diaphragm assembly is tight enough that the inner plate is flush to the end of the rod The bead of the end of the diaphragm should fit into the groove of the inner chamber Fasten the remaining outer chamber item 16 to the pump using the capscrews items 9 amp 11 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 8 hex nuts and flat washers Ref pg 12 The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 18 is designed to fit over the exterior of the standard diaphragm item 17 Follow the same procedures described for the standard diaphragm for removal and installation 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 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 A IMPORTANT Read these instructions completely before installation and start up Itis the responsibility of the purchaser to retain th
26. efer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill containment chambers by removing the bottom two boss plugs items 51 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 8 fastening the discharge manifold and elbows to the outer chambers items 16 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 51 The spill containment chambers are filled through the exposed ports 4 Install safety clip item 1 N into the smaller unthreaded hole in one end cap item 1 D This locks the valve spool to one side keeping the pump from shifting Apply air pressure to the air distribution valve 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety clip is installed on the bottom end cap fill the right spill containment chamber The volume of fluid is 1950 ml 65 9 fl oz It is important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug item 51 to the filled spill containment chamber
27. etallic Page 3 Dimensions S20 Non Metallic Dimensions in Inches Dimensional tolerance 1 8 in Millimeters 3mm DISCHARGE PORT 78 X 87 SLOTTED UNIVERSAL FLANGE FITS ANSI 125 CONNECTION OR PN10 50mm DIN CONNECTION MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS SUCTION PORT 78 X 87 SLOTTED UNIVERSAL FLANGE FITS ANSI 125 CONNECTION OR PN10 50mm DIN CONNECTION 9 24 11 50 235 292 AIR INLET 3 4 NPT s20nmdl3sm rev1110 4 00 102 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE RUA he 1272 Avis 16 00 al a 406 62 3 81 16 97 i 32 25 SAT Sal 819 Za CEN OPTIONAL THREADED 49 1 NPT SOUND 28 19 DAMPENING OR 716 BRASS MESH MUFFLER s eto VA A I OPTIONAL THREADED DU De 1 NPT METAL WI m4 MUFFLER FOR ATEX S COMPLIANT PUMPS Model S20 Non Metallic Page 4 Dimensions S20 Non Metallic with Spill Containment Dimensions in Inches in Millimeters Dimensional tolerance 1 8 1 3mm DISCHARGE PORT 78 X 87 SLOTTED UNIVERSAL FLANGE FITS ANSI 125 CONNECTION OR PN 28 43 10 50mm DIN CONNECTION 722 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE MAG RA XT e AY MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLI
28. geMaster are registered tradenames of Warren Rupp Inc Model S20 Non Metallic Page 9 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory Pump cycle seems unbalanced Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device Whatto Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling What to Check Undersized suction line s20nmdl3sm rev1110 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 MAN
29. gs item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumper for cuts wear or abrasions Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter ofthe spool Wipe spool with a soft cloth and inspect for scratches or wear s20nmdl3sm rev1110 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the small unthreaded hole in the end cap Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a 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 carefu
30. he diaphragm assemblies Use a 1 38mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 34 by turning counterclockwise Inspect the diaphragm item 17 for cuts punctures abrasive wear or chemical attack Replace the s20nmdl3sm rev1110 diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise onto the stud Use a torque wrench to tighten the diaphragm assembly together to 480 in Lbs 54 23 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 5 is installed over the diaphragm rod Thread the stud of one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 34 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Fasten the remaining outer chamber item 17 to the pump using the capscrews items 11 amp 12 hex nuts and flat washers and tighten Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the other diaphragm assembly clockwise into the tapped hole at the end ofthe diaphragm rod item 34 make sure th
31. his pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded Model S20 Non Metallic Page 31 ALILUIOJUOT JO UOIneJej3ag WARREN RUPP 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 U Series EH and SH High Pressure RS Series W Series SMA and SPA Submersibles and Tranquilizer Surge Suppressors comply with the European Community Directive 2006 42 EC on Machinery according to Annex VIII This product has used Harmonized Standard EN 809 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance did Apa October 20 2005 Signature of authorized pers Date of issue David Roseberry Engineering Manager Printed name of authorized person Title May 27 2010 Revision Level E evision Leve Date of revision FLUID amp METERING CE Declaration of Conformity ALILUIOJUOT JO UOIneJej3ag WARREN RUPP EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Eq
32. ion Seals O Rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 257 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and TFE Seals Overlay Option 476 257 360 WETTED END KIT Drawing Nitrile Diaphragms Nitrile Balls and PTFE Seals 476 257 365 WETTED END KIT Neoprene Diaphragms Neoprene Balls and PTFE Seals 476 257 633 WETTED END KIT FKM Diaphragms PTFE Balls and PTFE Seals 79 Vig A 4 476 257 635 WETTED END KIT Neoprene Diaphragms One Piece PTFE Overlay Diaphragms Bonded Option PTFE Balls and PTFE Seals 476 257 654 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals 476 258 640 WETTED END KIT For Spill Containment Pumps Neoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals Fluid End Section Assembly Air End Section Assembly s20nmdl3sm rev1110 Model S20 Non Metallic Page 12 Composite Repair Parts List ITEM PART NUMBER 1 10 11 12 13 14 15 16 17 18 19 031 140 000 031 140 001 031 140 002 031 141 000 A 031 141 001 031 141 002 095 110 558 050 038 354 050 038 360 050 038 365 050 038 600 114 024 551 A 114 024 559 132 035 360 135 034 506 165 116 551 A 165 116 559 170 055 115 170 055 308 170 066 115 170 066 308 170 069 115 170 069 308 170 092 115 170 092 308 170 015 115 170 015 308 171 053 115 171 053 308 171 078 115
33. is manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Insert the diaphragm rod assembly 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 DO NOT LEAVE THE ASSEMBLY LOOSE Model S20 Non Metallic Page 23 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION QTY 4 095 110 558 Pilot Valve Assembly 1 4 A 095 095 558 Valve Body 1 4 B 755 052 000 Sleeve With O rings 1 4 C 560 033 360 O ring Sleeve 6 4 D 775 055 000 Spool With O rings 1 4 E 560 023 360 O ring Spool 3 4 F 675 037 080 Retaining Ring 1 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 10 Remove the air inlet cap item 7 and air inlet gasket item 23 The pilot valve assembly item 2 can now be removed for inspection and service s20nmdl3sm rev1110 STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 D Wipe
34. l attack FKM Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance Polypropylene A thermoplastic polymer Moderate tensile and flex strenght Resists strong acids and alkalie Attacked by chlorine fuming nitric acid and other strong oxidizing agents For specific applications always consult the Warren Rupp Chemical Resistance Chart CAUTION Nonmetallic pumps and plastic components are not UV stabilized Ultraviolet radiation can damage these parts and negatively affect material properties Do not expose to UV light for extended periods of time SANDPIPER pumps are designed to be powered only by compressed air s20nmdl3sm rev1110 SANDPIPERs A WARREN RUPP PUMP BRAND S20 Non Metallic Ball Valve Design Level 3 Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA HEADS UP TO DISPLACEMENT STROKE 100 psi or 231 ft of water 46 US gallons 1 73 liter 7 bar or 70 meters Operating Temperatures Maximum Minimum 190 F 10 F 88 C 23 C 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 Model S20 Non Metallic Page 1 Explanation of Pump Nomenclature S20 Non Metallic Design Level 3
35. l not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 21 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 Itis 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 S20 Non Metallic Page 19 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 56 893 097 000 Solenoid Valve NEMA4 1 57 219 001 000 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 58 241 001 000 Connector Conduit 1 59 170 029 330 Capscrew Hex HD 5 16 18 x 1 50 4 60 618 051 150 Plug 2 IEC EEX m T4 SP APPROVED For Explosion Proof Solenoid Coils used in North America and outside the European Union 57 219 009 001 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 S
36. le The pump can be converted to a dual port arrangement on both the suction and the discharge ends The porting can be configured to a single suction and a dual discharge The porting can be changed to a dual suction and a single discharge The above changes are possible because the porting flange of the elbows are designed to mate with a 2 ANSI Flange Connection DUAL PORTING OF BOTH SUCTION AND DISCHARGE ENDS OF THE PUMP Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals and manifolds from the pump The discharge elbows can be rotated in 90 increments and the suction elbows can be rotated in 180 increments see optional positioning in the Dual Porting Drawing SINGLE PORTING OF THE SUCTION AND DUAL PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing DUAL PORTING OF THE SUCTION AND SINGLE PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds a
37. nd cap item 1 E with an o ring item 1 G and one bumper item 1 C into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until it touches the bumper on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 21 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 Itis 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 S20 Non Metallic Page 17 Air Valve Assembly Drawing with Stroke Indicator Option S20 Design Level 3 PILOT VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty Note Stroke Indicator is standard on
38. nd manifold seals Position the suction elbows in the desired direction at 180 increments See arrows and optional positioning in the Dual Porting Drawing Model S20 Non Metallic Page 27 Leak Detection Options Drawing LEAK DETECTION OPTION ELECTRONIC Follow instructions found elsewhere in this manual Filling the Spill Prevention Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC To install electronic leak detectors remove the bottom 1 4 NPT pipe plug on the visual sight tube item 50 Insert leak detector into the 74 pipe tee item 53 LEAK DETECTION OPTION MECHANICAL Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical leak detectors remove the bottom 4 NPT pipe plug on the visual sight tube item 50 Insert leak detector into the 74 pipe tee item 53 TO CONTROL s20nmdl3sm rev1110 30x q jN Vara LEAK DETECTORS d Model S20 Non Metallic Page 28 Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the Stroke Counter Batch Controller or user control devices such
39. olenoid Coil 110VAC 50 Hz 1 219 009 006 Solenoid Coil 230VAC 50 Hz 1 Note Item 58 Conduit Connector is not required For Explosion Proof Solenoid Coils used in the European Union Il 2G EEx mc Il 5 Il 3 2 G Ex mc Il T5 Il 2D c IP65 T100 C For ATEX Compliant Solenoid Coils used in the European Union 57 219 011 001 Solenoid Coil Single mounting 12 VDC 3 3W 267mA 219 011 002 Solenoid Coil Single mounting 24 VDC 3 3W 136mA 219 011 003 Solenoid Coil Single mounting 110 120 VAC 3 4W 29mA 219 011 004 Solenoid Coil Single mounting 220 240 VAC 3 4W 15mA Note Item 37 Conduit Connector is not required dda dia Compressed Air Temperature Range Maximum Ambient Temperature to plus 50 C Special Conditions For Safe Use A fuse corresponding to its rated current max 3 l 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
40. p 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 72 to 34 turn After the pump primes the air valve can be opened to increase air flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient air flow to pump flow ratio BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model S20 Non Metallic Page 6 WARREN INSTALLATION GUIDE RUPP Top Discharge Ball Valve Unit Available from Warren Rupp Surge Suppressor Pipe Connection
41. re Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive HDPE Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE PTFE 607 X Envelon 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 637 PTFE FKM PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene 666 FDA Nitrile Diaphragm PTFE Overlay Balls and Seals 668 PTFE FDA Santoprene PTFE Delrin and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Exxon Mobil Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co PortaPump Tranquilizer and Slud
42. rkings Marking Il 2 G Ex ia c IIC T5 11 3 2 G Ex ia c IIC 5 Il 2 D Ex c iaD 20 IP67 T100C Il 2 G EEx mc II T5 Il 3 2 G EEx mc II T5 II 2 D c IP65 T100C Il 1 GcT5 Il 3 1 Gc T5 Il 1 Dc T100 C IM1c I M2 c 112GcT5 Il 3 2 G c T5 Il 2 D c T100 C II 2 G T5 Il 3 2 G T5 Il 2 D T100C EC Type Certificate No Pumps KEMA 09ATEX0071 X Type Certificate No Pumps KEMA 09ATEX0072 X Type Certificate No Suppressors KEMA 09ATEX0073 KEMA 09ATEX0071 X CE 0344 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 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0073 KEMA 09ATEX0073 KEMA 09ATEX0073 SFE Non Conductive Fluids Declaration of Conformity IEX FLUID amp METERING
43. ry Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Department before performing this procedure A model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S20 Non Metallic Page 10 s20nmdl3sm rev1110 Model S20 Non Metallic Page 11 Composite Repair Drawing 476 253 000 AIR END KIT Seals O Rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 254 000 AIR END KIT for Stroke Indicator Opt
44. the check valve retainer item 32 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 3 for wear abrasion or cuts on the spherical surface The check valve seats items 38 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chamfers The spherical surface of the check balls must seat flush to the surface of the inner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary s20nmdl3sm rev1110 Remove the remaining check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Re assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 37 into the cavity of the outer chamber item 17 Make sure the chamfer side ofthe seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 37 Make sure the chamfer side of the seal faces the chamfer on the check valve seat or retainer The pump can now reassembled reconnected and returned to operation Modular Check Valve Drawing Model S20 Non Metallic Page 26 Dual Port Option Drawing 2 ANSI STYLE FLANGE CONNECTION FOUR 4 78 HOLES ON A 04 75 BOLT CIRCLE s20nmdl3sm rev1110 DUAL PORTING OPTIONS Several dual porting options are possib
45. tions completely before installation and start up Itis 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 S20 Non Metallic Page 15 Air Distribution Valve Assembly Drawing S20 Design Level AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 140 000 Air Valve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 B 095 094 551 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 551 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 4 710 015 115 Screw Self tapping 4 For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 141 000 Air Valve Assembly 1 Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty A 1 031 140 001 Air Valve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 559 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For Pumps with Metal Mesh Muffler or Piped Exhaust 1 031 141 001 Air Valve Assembly 1 Includes all items used on 031 140 001 minus items 1 D 1 F amp 1 J A
46. ts List i 14 Spill Containment Concept ione iaia Ai 14 Spill Containment Option Diaphragm Servicing 15 Filling Chambers with I ena pui desde 15 Air Distribution Valve Assembly Drawing i 16 Main Air Valve Assembly Parts List i 16 Air Distribution Valve Servicing iii 17 Air Distribution Valve with Stroke Indicator Options 18 Air Distribution Valve with Stroke Indicator Parts List 18 Air Distribution Valve with Stroke Indicator Servicing i 19 See pages 2 33 and 34 for ATEX ratings CE Solenoid Shifted Air Valve Drawing nennen nennen Solenoid Shifted Air Valve Parts List nennen Solenoid Shifted Air Distribution Valve Option ii Diaphragm Service Drawing Non OverlaYy i Diaphragm Service Drawing with Overlay Diaphragm Servicing igi ec dia eee deer ila An Overlay Diaphragm Service ii Pilot Valve Assembly Drawing ii Pilot Valve Assembly Parts List Pilot Valve Servicing 1 alari Pumping Hazardous Liquids ilaele Converting the Pump for Piping the Exhaust Air Exhaust Conversion DraWiNg silence iaia Converted Exhaust Illustration
47. ts the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill containment chambers This can be done by removing the bottom plug item 51 from each spill containment chamber After the fluid from the spill containment chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill containment option has two additional virgin PTFE pumping diaphragms item 46 These diaphragms are installed with the natural concave curve toward the s20nmdl3sm rev1110 outer chamber items 16 from the pump assembly drawing FILLING CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you pr
48. uipment intended for use in potentially explosive environments Manufacturer Warren Rupp Inc A Unit of IDEX Corportion 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 Applicable Standard KEMA Quality B V 0344 EN13463 1 2001 EN13463 5 2003 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 09ATEX0071 X KEMA Quality B V Utrechtseweg 310 6812 AR Arnhem The Netherlands SANDPIPER Tranquilizer A WARREN RUPP PUMP BRAND DATE APPROVAL TITLE mA 27 MAY 2010 David Roseberry Engineering Manager FLUID amp METERING Declaration of Conformity ALILUIOJUOT JO UOIneJej3ag Pump types S1F 515 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 HDF1 HDF25 HDF2 HDF3M S05 S1F 15 S20 S30 SB1 SB25 ST1 ST40 G15 G20 and G30 without the above listed options no aluminum parts Pump types DMF2 DMF3 HDB175 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 S1F 15 S20 S30 SB1 SB25 SEX ST1 ST25 ST1 ST40 605 G1F G15 G20 and G30 Surge Suppressors all types WARREN RUPP EC Declaration of Conformity ATEX Summary of Ma
49. upply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 72 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and filters must be supported by some means other than the air inlet cap Failure to provide support for the piping may result in damage to the pump A pressure regulating valve should be installed to insure air supply pressure does not exceed recommended limits AIR VALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the preferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required The pump air system will operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing or freezing of the exhaust air causing the pum
50. usting 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 s20nmdl3sm rev1110 is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air s
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