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Model S1F Non-Metallic Design Level 3

1. sssssssssesseeeeeeeenneeteennetnennetntnennena 25 Diaphragm Service Drawing Non Overlay ii 26 Diaphragm Service Drawing with Overlay 26 Diaphragm Servicing ete durent etti eiecit ie e ended 27 Overlay Diaphragm Service rh i Oen c n Med Ha t e ehe dede 27 Pilot Valve Servicing Assembly Drawing amp Parts List i 28 P mpirig Hazardous Liq ids creer rea eere eec ote reae N 29 Converting the pump for piping the exhaust air sse 29 Exhaust Conversion Drawing erect eite cien cobre et eene lien repos 29 Converted Exhaust Illustration eec ec e eer d e rts ta ete nee etna as 29 Modular Check Valve Servicing iii 30 Modular Check Valve Drawing 1 ette ta bun A Eee tae ee eaae 30 Dual Port Option Drawing onore cte emet e tene oe od en Meco lan dea 31 Dual Porting Options rte sai 32 Dual porting of both suction and discharge ends of the pump 32 Single porting of the suction and dual porting of the pump discharge 32 Dual porting of the suction and single porting of the pump discharge 32 Leak Detection Options Drawihg entier attin rede tte t d e e tee 33 Electronic Leak Detector Installation
2. MANIFOLD ROTATE 90 FROM VERTICAL mo CENTERLINE SIDE VIEW Pulse Output Kit Mesh Muffler Sound Dampening Muffler Model S1F Non Metallic Page 7 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 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 on
3. Printed name of authorized person Title CE Declaration of Conformity
4. 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 604 606 607 608 610 611 632 633 634 635 637 638 639 643 644 650 654 656 661 PTFE PTFE Envelon Conductive PTFE PTFE Integral Silicon PTFE Integral FKM Neoprene Hytrel FKM Fluorocarbon PTFE EPDM PTFE Neoprene PTFE PTFE FKM Fluorocarbon PTFE PTFE Hytrel PTFE Nitrile TFE Santoprene EPDM Santoprene PTFE Bonded Santoprene and PTFE Santoprene Diaphragm PTFE Overlay Balls and seals Santoprene Diaphragm and Check Balls EPDM Seats 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 r
5. DISPOSAL AREA MUFFLER 1 DIAMETER AIR EXHAUST PIPING Illustration 1 Le MUFFLER La 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION ur LINE i Illustration 2 Law MUFFLER uns 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION 4 LINE Illustration 3 Model S1F Non Metallic Page 29 MODULAR CHECK VALVE SERVICING Before servicing the check valves first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the modular check valve remove the elbows items 18 and 19 from pump composite repair parts drawing Use a 9 16 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 14 Next remove the check valve seal item 36 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 31 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats items 37 s
6. 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 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 equi
7. and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 8 hex flange nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 17 is designed to fit snugly over the exterior of the standard TPE diaphragm item 16 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty 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 appliedbetween the inner plate and the diaphragm to facilitate assembly Insert the diaphragm rod assembly into the pump and install the ou
8. 096 551 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For Pumps 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 A AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 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 Alternate Mesh Muffler or Piped Exhaust A 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 Note ATEX Compliant s1fnmdl3sm REV0508 Model S1F Non Metallic Page 20 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 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 38 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 20 for cracks or damage Replace g
9. 150 Description Solenoid Valve NEMA4 Solenoid Coil 24VDC Solenoid Coil 24VAC 12VDC Solenoid Coil 120VAC Solenoid Coil 240VAC Connector conduit Capscrew Hex HD 5 16 18 x 1 50 Plug Note Pumps equipped with Explosion Proof Solenoid Coils are ATEX compliant A For Explosion Proof Solenoid Valve 57 219 009 001 219 009 002 219 009 003 219 009 004 219 009 005 219 009 006 s1fnmdl3sm REV0508 Solenoid Coil 120VAC 60 Hz Solenoid Coil 240VAC 60 HZ Solenoid Coil 12VDC Solenoid Coil 24VDC Solenoid Coil 110VAC 50 Hz Solenoid Coil 230VAC 50 Hz Qty 1 1 1 1 1 1 4 2 dd Ad n ln Model S1F Non Metallic Page 24 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 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 solen
10. Non Metallic Design Level 3 Ball Valve Diaphragm Check Non Wetted Shipping Design Wetted Check Valve Material Porting Pump Pump Weight Level Material Materials Options Options Style Options S 0 0 0 0 S1FB3P1PPUS000 S1FB3P2PPUS000 S1FB3PBPPUS000 S1FB3PGPPUS000 B 3 P 1 P U B 3 P 2 P U S B 3 P B P U S B 3 P G P U S B 3 P N P U S B 3 K 1 K U S B 3 K 2 K U S B 3 P 3 P U V B 3 P 4 P U V 00 00 00 00 00 00 Pump Brand Diaphragm Check Valve Materials Continued Pump Options Kit Options Continued S SANDPIPER Y PTFE Pumping One Piece Bonded A 0 None P2 110 120 or 220 240VAC Pulse Output Kit Pump Size Driver PTFE 1 Sound Dampening Muffler E0 Solenoid Kit with 24VDC Coil F 1 Full Flow Z One Piece Bonded PTFE 2 Mesh Muffler A E1 Solenoid Kit with 24VDC Explosion Check Valve Seat 3 High temperature Air Valve Proof Coil Check Valve Type K PVDF w Integral Muffler E2 Solenoid Kit with 24VAC 12VDC Coil B Ball P Polypropylene 4 High temperature Air Valve E3 Solenoid Kit with 12VDC Design Level w Sound Dampening Muffler Explosion Proof Coil 3 Design Level 3 a Manes aei Options 5 High temperature Air E4 Solenoid Kit with 110VAC Coil be ROBI Valve w Mesh Muffler A E5 Solenoid Kit with 110VAC 60 Hz Wetted Material 1 40 Glass Filled Polypropylene A s K PVDF with PTFE hardware 6 Metal Muffler Explosion Proof Coil A 7 Metal Muffler
11. 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 9 16 wrench or socket remove the 16 capscrews items 8 hex flange nuts and washers that fasten the elbows items 18 and 19 to the outer chambers items 14 Remove the elbows with the manifolds and spacers attached Step 42 Removing the outer chambers Using a 9 16 wrench or socket remove the 16 capscrews items 10 hex flange nuts and washers that fasten the outer chambers diaphragms and inner chambers items 15 together Step 3 Removing the diaphragm assemblies Use a 13 5 35mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 33 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 28 Insert the protruding stud and the 1 4 s1fnmdl3sm REV0508 20 fastener loosely into a vise Use a 1 s wrench or socket to remove the outer diaphragm plate item 29 by turning counter clockwise Inspect the diaphragm item 116 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise
12. fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures PVDF Polypropylene 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 Neoprene All purpose Resistant to vegetable oil 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 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 will attack FKM For specific applications always consult the Warren Rupp Chemical Resistance Chart SANDPIPER pumps are designed to be powered only by compressed air s1fnmdl3sm REV0508 SANDPIPER A WARREN RUPP PUMP BRAND S1F Non Metallic Design Level 3 Ball Valve Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA HEADS UP TO DISPLACEMENT STROKE 100 psi or 231 ft of water 17 gallon 64 liter 7 bar or 70 meters Operating Temperatures Maximum Minimum Model S1F Non Metallic Page 1 Explanation of Pump Nomenclature S1F
13. onto the stud Use a torque wrench to tighten the diaphragm assembly together to 27 ft Lbs 36 61 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 the one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 33 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 15 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 14 to the pump using the capscrews items 10 hex flange nuts and flat washers On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 33 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber The molded directional arrows on the diaphragm must point vertically Fasten the remaining outer chamber item 14 to the pump using the capscrews items 10 hex flange nuts
14. pipe tee item 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Page 17 Option For TPE Equipped Pumps Drawing S1F SPILL CONTAINMENT REPAIR PARTS LIST FOR TPE EQUIPPED PUMPS Item Part Number Description Qty 43 170 114 115 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Cont
15. suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS Plus the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a surge suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of 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 disl
16. 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 careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 20 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 S1F Non Metallic Page 23 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Includes Items Used on Composite Repair Parts List Except as Shown Item 56 57 58 60 A Part Number 893 097 000 219 001 000 219 004 000 219 002 000 219 003 000 241 001 000 170 029 330 618 051
17. with Grounding Cable E6 Solenoid Kit with 220VAC Coil P Polypropylene AC Conductive Polypropylene E7 Solenoid Kit with 220VAC 60 H AC Conductive Polypropylene x Kit Options TSO ENOI AWI i AV Conductive PVDF Porting Options 00 None Explosion Proof Coil Gonductive U Universal Fits ANSI and DIN PO 10 30VDC Pulse Output Kit E8 Solenoid Kit with 110VAC 50 Hz Diaphragm Check Valve Materials 7 Dual Porting ANSI PA intnnsicallv Saf Explosion Proof Coil 1 Santoprene Santoprene 8 Top Dual Porting ANSI 5 5 30VDC E9 Solenoid Kit with 230VAC 50 Hz 2 PTFE Santoprene Backup PTFE 9 Bottom Dual Porting ANSI 3 Explosion Proof Coil 3 PTFE Pumping PTFE Santoprene 220 240VAC Pulse Output Kit i Backup Driver PTFE Pump Style SP Stroke Indicator Pins 4 Santoprene Pumping Santoprene D With Electronic Leak Detection 110 V B Nitrile Nitrile E With Electronic Leak Detection 220V G PTFE Neoprene Backup PTFE M With Mechanical Leak Detection Note Pumps are only ATEX compliant when ordered with N Neoprene Neoprene S Standard A wetted options C or V non wetted option C pump options 6 V FKM FKM V With Visual Leak Detection or 7 and kit options 00 P1 E1 E3 E5 E7 E8 or E9 s1fnmdl3sm REV0508 Model S1F Non Metallic Page 2 Performance Curve Model S1F Non Metallic Design Level 3 MODEL S1F Non Metallic Performance Curve Performance based on the following elastomer fitted pum
18. 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Threaded Bushing 4 618 031 308 Threaded Bushing 4 52 835 005 110 Tee Pipe 4 835 005 308 Tee Pipe 4 53 860 056 606 Tube Sight 2 54 866 060 110 Connector Tube 4 Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing Note Pump units with One Piece Bonded Diaphragm option will not include Overlay Diaphragms Items 18 and Outer Diaphragm Plate Item 45 The diaphragm is P Item 30 to be installed with the convex side facing toward the outer chambers s1fnmdl3sm REV0508 Model S1F Non Metallic Page 16 OPTIONS FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT The spill containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment 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 disconnec
19. 53 Insert leak detector into the 14 pipe tee item 52 s1fnmdl3sm REV0508 Model S1F Non Metallic Page 33 Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the Stroke Counter Batch Controller or user control devices such as a PLC The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the air valve and senses each stroke of the main spool Consult the factory for further information and availability Pulse Output Kits 475 244 001 10 30 VDC 475 244 002 110 220 VAC 475 244 003 Intrinsically Safe 10 30VDC 110VAC and 220 VAC s1fnmdl3sm REV0508 Model S1F Non Metallic Page 34 Optional Muffler Configurations Drawing OPTION 0 530 028 550 Integral Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to hold it in place OPTION 1 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element A OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body ATEX Compliant Option 0 Option 1 and 2 Option 6 s1fnmdl3sm REV0508 Model S1F Non Metallic Page 35 Grounding The Pump To be fully
20. CS A ES FRONT VIEW KA IN 2o SUNG 57 SIDE VIEW SUCTION PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION DIMENSION Standard Pump 5 5 8 10 1 4 Pulse Output Kit 5 5 8 10 1 4 Mesh Muffler 8 9 16 11 1 8 Sound Dampening Muffler 8 9 16 11 1 8 BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES INLET 1 2 NPT BOTTOM VIEW s1fnmdl3sm REV0508 Model S1F Non Metallic Page 6 Metric Dimensions S1F Non Metallic with Spill Containment Dimensions in Millimeters Dimensional tolerance 3mm FRONT VIEW 14mm TYP 4 PLACES IL HALLA FIA A p BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES 102mm 19mm AIR INLET 1 2 NPT BOTTOM VIEW s1fnmdl3sm REV0508 CONFIGURATION FITS TO EITHER 1 ANSI 125 DISCHARGE PORT 14mm x 17mm SLOTTED BOLTING FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD INTEGRAL MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN LI SUBMERGED APPLICATIONS SNA T HO q W A 435mm NAW NAN DANO SUCTION PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION DIMENSION Standard Pump n TD IF
21. FE Balls PTFE Seals ELECTRONIC LEAK DETECTOR KITS 032 037 000 110 VAC 220 VAC 032 045 000 12 32 VDC ONE PIECE BONDED OPTION s1fnmdl3sm REV0508 Model S1F Non Metallic Page 14 Composite Repair Parts List ITEM PART NUMBER 1 031 140 000 031 140 001 031 140 002 031 141 000 031 141 001 031 141 002 031 146 000 031 147 000 2 050 042 354 050 042 360 050 042 363 050 042 365 050 042 600 3 095 110 558 4 114 024 551 114 024 559 5 132 035 360 6 135 034 506 7 165 125 551 A 165 125 559 8 170 020 115 170 020 308 9 170 030 115 170 030 308 10 170 052 115 170 052 308 11 170 069 115 170 069 308 12 171 053 115 13 171 015 115 171 015 308 14 196 157 520 A 196 157 521 196 157 552 196 157 557 15 196 177 551 A 196 177 559 16 286 107 354 286 107 360 289 115 000 286 107 363 286 107 365 17 286 108 600 18 312 104 520 A312 104 521 A312 104 557 s1fnmdl3sm REV0508 DESCRIPTION Air Valve Assembly Air Valve Assembly No Muffler Air Valve Assembly w PTFE Coated Hardware Air Valve Assembly No Muffler Air Valve Assembly No Muffler Air Valve Assembly No Muffler PTFE Hardware Air Valve Assembly With Stroke Indicator Option Air Valve Assembly No Muffler w Stroke Indicator Ball Check Ball Check Ball Check Ball Check Ball Check Pilot Valve Assembly Intermediate Assembly Intermediate Assembly Bumper Diaphragm Bushing Plunger Cap Air Inlet Cap Air Inlet Cap
22. PTION 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 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 38 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 20 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 K 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 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 s1fnmdl3sm REV0508 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
23. SERVICE amp OPERATING MANUAL SANDPIPERs A WARREN RUPP PUMP BRAND Model S1F Non Metallic Design Level 3 Table of Contents Engineering Data and Temperature LimitationS iii 1 Explanation of Pump Nomenclature iii 2 Performance Curve Model S1F Non Metallic Design Level 3 3 Dimensions Si ne bee eerie bebe 4 Metric Dimensions S1F Non Metallic esistente 5 Dimensions S1F Spill Containment iii 6 Metric Dimensions S1F Spill Containment iii 7 Pririciple of Pump Operation ii ica dt A e eH eet eee 8 Installatton and 8 Air SUPPI errare 8 Air Valve bubrication occ cie cdd iUic uit e d ede n RTT 8 Air Line 8 Air Inletand Priming tec sane ia De eee cent 8 IIRURIICM M ii 8 Install tion Guide 2 ttt eR Rte LR iaia 9 Important Safety Informiatior 2 2 encre deterrere eir tete ittis etin tides aient en 10 MaterialiGodess mede ARIS Ani ili noe init iii 11 TROUDIOSM ODEN aati encanta cca 12 Warranty D 12 Comiposite Repair Parts Drawing taedet cbe e vr ede 14 Overlay Option Drawing is iain et te tine eei cii t ee a 14 Compos
24. ainment 2 196 159 520 Chamber Spill Containment 2 46 518 180 520 Manifold Spill Containment 2 Replace 518 179 520 518 180 552 Manifold Spill Containment 2 Replace 518 179 552 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Threaded Bushing 4 c dE 5 618 031 308 Threaded Bushing 4 a 52 835 005 110 Tee Pipe 4 NE 835 005 308 Tee Pipe 4 53 860 056 606 Tube Sight 2 2 A SALT 54 866 060 110 Connector Tube 4 ING M AMO SS 55 286 092 354 Diaphragm Pumping 2 BN AAY v 18 286 108 600 Diaphragm Overlay is not used 2 aA al Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing Item 55 The diaphragm is to be installed with the convex side facing toward outer chambers s1fnmdl3sm REV0508 Model S1F Non Metallic Page 18 OPTION FOR TPE EQUIPPED PUMPS CONCEPT The spill containment option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the a
25. arranty Certificate Model S1F Non Metallic Page 12 s1fnmdl3sm REV0508 Model S1F Non Metallic Page 13 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 217 000 AIR END KIT For Polypropylene Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 218 000 AIR END KIT Stroke Indicator Option For Polypropylene Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 197 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and PTFE Seals 476 197 360 WETTED END KIT Nitrile Diaphragms Nitrile Balls and PTFE Seals 476 197 363 WETTED END KIT FKM Diaphragms FKM Balls and PTFE Seals A 476 197 365 WETTED END KIT 7 Neoprene Diaphragms Neoprene Balls and P di PTFE Seals 476 197 635 WETTED END KIT Neoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals 476 197 654 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms TFE Balls and TFE Seals 476 197 659 WETTED END KIT One Piece Bonded Diaphragms PTFE Balls PTFE Seals 476 198 655 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 476 198 354 WETTED END KIT Santoprene Diaphragms Santoprene Pumping Diaphragms Santoprene Check Balls and PTFE Seals 476 198 659 WETTED END KIT One Piece Bonded Diaphragms PTFE Pumping Diaphragms PT
26. asket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K 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 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 s1fnmdl3sm REV0508 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 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 installa
27. boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Page 19 Air Distribution Valve Assembly Drawing 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 H 1 B 095 094 551 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165
28. boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 K into the smaller unthreaded hole in one end cap item 1 E This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill prevention chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber 6 Loosely reinstall one boss plug item 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the
29. e 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 s1fnmdl3sm REV0508 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 supply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance
30. e 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 S1F Non Metallic Page 10 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 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 308 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 A
31. egistered 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 SludgeMaster are registered tradenames of Warren Rupp Inc Model S1F Non Metallic Page 11 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory Pump cycle seems unbalanced Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 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 s1fnmdl3sm REV0508 What to Check Undersized
32. eing pumped in the event of a diaphragm failure Flexible Connection Air Shut Off Pipe Connection Valve Style Optional Air Exhaust ilter Regulator Air Dryer 5 Gauge DIAPHRAGM Shut Off PUMP LC OH Valve rf AIR INLET Flexible SUCTION ECCO Connection MER MN Drain Port s1fnmdl3sm REV0508 Model S1F Non Metallic Page 9 RECYCLING IMPORTANT SAFETY Many components of SANDPIPER INFORMATION Metallic AODD pumps are made of recyclable materials see chart on page 11 for material specifications We encourage pump users to recycle A IMPORTANT worn out parts and pumps whenever Read these safety waminas possible after any hazardous pumped and instructions in this fluids are thoroughly flushed manual compl tely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual A WARNING Before mai
33. groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet end is fastened to the pump hardware The other end is installed to a true earth ground s1fnmdl3sm REV0508 O 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 this 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 S1F Non Metallic Page 36 Pm1ILLLJOJUO JO 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 bu Feat Len October 20 2005 Signature of authorized person Date of issue David Roseberry Engineering Manager
34. he top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 K into the smaller unthreaded hole in one end cap item 1 E This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety Clip is installed on the bottom end cap fill the right spill prevention chamber The volume of fluid is 1198 ml 40 49 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 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost
35. hould 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 s1fnmdl3sm REV0508 Remove the remaining check valve seal item 36 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 36 into the cavity of the outer chamber item 14 Make sure the chamfer side of the seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 36 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 S1F Non Metallic Page 30 Dual Port Option Drawing A Q N NU Ws Sp NN ay L e ALS RL SUD ui S S S DER LE CS Model S1F Non Metallic Page 31 s1fnmdl3sm REV0508 DUAL PORTING OPTIONS Several dual porting options are possible 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 suc
36. iii 33 Mechanical Leak Detector Installation iii 33 Pulse Output Kit Drawirg o reload 34 Pulse Output Kit Opliori 5 2 bets 34 Optional Muffler Configurations Drawing 35 Grounding The Pump x terret texte rece e reden 36 CE Declaration of Conformity 2 2 eolie barale dae ie AON 37 WARREN RUPP INC A Unitof IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com s1fnmdl3sm REV0508 Copyright 2007 Warren Rupp Inc All rights reserved WARREN RUPP Quality System I 1 tified 509001 Certifie Il 2GD T5 Environmental Management System 15014001 Certified CE U S Patent 5 996 627 400 210 6 241 487 Other U S Patents Applied for FLUID amp METERING INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING 1 ANSI Flange or 0 to 45 gallons per minute No lube no stall Up to 25 in 6mm PN10 25mm DIN Flange 0 to 170 liters per minute design A CAUTION Operating temperature limitations are as follows Materials Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few
37. illimeters Dimensional tolerance 3mm MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE DISCHARGE PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD INTEGRAL MUFFLER 1 NPT EXHUST PORT FOR OPTIONAL J PN MUFFLER STYLES OR PIPING R I EXHAUST AIR IN SUBMERGED UN N gt FRONTE VIEW i APPLICATIONS Me IA AES SIDE VIEW SUCTION PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION 2 1 30mm BOLT PATTERN IS SYMMETRICAL ABOUT 14mm TYP CENTERLINES 4 PLACES T 7 dL 123mm BOTTOM VIEW e HH SS I DIMENSION T Standard Pump Pulse Output Kit AIR INLET 1 2 NPT Mesh Muffler Sound Dampening Muffler Metal Muffler s1fnmdl3sm REV0508 Model S1F Non Metallic Page 5 Dimensions S1F Non Metallic with Spill Containment Dimensions in Inches Dimensions in Inches Dimensional tolerance 1 DISCHARGE PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD INTEGRAL MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL Fr gt MUFFLER STYLES OR PIPING EXHAUST AIR IN A A SUBMERGED APPLICATIONS A
38. in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Page 32 Leak Detection Options Drawing 710 014 330 Self tapping Screws Qty of 2 LEAK DETECTION OPTION A ELECTRONIC Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC To install electronic leak detectors remove the bottom NPT pipe plug MOUNTING PLATE on the visual sight tube item 53 Insert leak detector into the pipe tee item 52 For pumps 530 028 550 Enclosed Muffler 710 009 115 SELF TAPPING SCREWS QTY OF 4 For pumps with Alternate Mufflers Leak Detection Option B 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 NPT pipe plug on the visual sight tube item
39. ir 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 prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber Afterthe fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional TPE pumping diaphragms item 55 These diaphragms are installed with the natural concave curve toward s1fnmdl3sm REV0508 the outer chamber items 15 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two
40. ite Repair Parts List te cem e Nee detect c e tita rc aee EDU da 15 Spill Containment Option for Virgin PTFE Equipped PUMPSs esee 16 Spill Containment Repair Parts List ire aaa 16 Spill Gontainment Concept ue ctim eite catene t te te e tete tiene e 17 Spill Containment Option Diaphragm Servicing iii 17 Filling Spill Containment Chambers with Liquid iii 17 Spill Containment Option for Equipped Pumps 18 Spill Containment Repair Parts LiSt iii 18 Spill Containment Concept with TPE Diaphragms sss 19 Spill Containment Option with TPE 19 Air Distribution Valve Assembly Drawing iii 20 Il 2GD T5 CE U S Patent 400 210 5 996 627 6 241 487 Main Air Valve Assembly Parts List iii 20 Air Distribution Valve Servicing iii 21 Air Distribution Valve with Stroke Indicator OptionSs iii 22 Air Distribution Valve with Stroke Indicator Parts List iii 22 Air Distribution Valve with Stroke Indicator Servicing iii 23 Solenoid Shifted Air Valve Drawing iii 24 Solenoid Shift d Air eae ec ecd rte nee e ce EA Vete 24 Solenoid Shifted Air Distribution Valve Option
41. nodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc s1fnmdl3sm REV0508 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 Accepted 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
42. ntenance 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 Pump complies with EN809 Pumping Directive Directive 98 37 EC Safety of Il 2GD T5 Machinery and Directive 94 9 EC EN13463 1 A WARNING Equipment for use in Potentially Explosive In the event of diaphragm CE Environments For reference to the directive rupture pumped maioria may enter the air end of the certificates visit www warrenrupp com pump and be discharged The Technical File No AX1 is stored at into the atmosphere If KEMA Notified Body 0344 under Document pumping a product which is hazardous or toxic i the air exhaust must be piped to an appropriate 203040000 area for safe disposition s1fnmdl3sm REV0508 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 36 AWARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly A WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly AWARNING Before doing any maintenance on th
43. odge obstruction in the check valve pocket Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both pumping 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 W
44. oid 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 s1fnmdl3sm REV0508 Before wiring remove terminal block from conduit connector Wiring Diagram 3rd Terminal for ground 1 Terminal A 2 Terminal Power Neutral Positive 1 Negative Min n PE ini I E Model S1F Non Metallic Page 25 Diaphragm Service Drawing Diaphragm Service Drawing with Overlay Non Overlay 7 K VA EE 2 Field conversion kit 475 258 000 available for 4 conversion from PTFE Overlay to One Piece A bonded Diaphragm X Va x 4 T PSs SZ N gt MN i gt CA LS e Part Description Qty GI 286 115 000 One Piece Diaphragm 2 o 9 S 612 220 150 Plate Inner Diaphragm 2 Q A s1fnmdl3sm REV0508 Model S1F Non Metallic Page 26 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
45. p flooded suction water at ambient conditions The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 5 85 15 25 5 SCFM M hr 6 5 e 4 I LLI 3 gt 2 9 7 7 6 6 1 4 5 3 1 5 0 U S Gallons per minute 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Liters per minute CAPACITY s1fnmdl3sm REV0508 Model S1F Non Metallic Page 3 Dimensions S1F Non Metallic Dimensions in Inches Dimensional tolerance 1 DISCHARGE PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD INTEGRAL MUFFLER 1 NPT EXHUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED FRONT VIEW APPLICATIONS 20 3 4 SUCTION PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION 5 1 8 9 16 TYP 4 PLACES BOTTOM VIEW E Nall 11 44 LI P DIMENSION 1 2 NPT Standard Pump SIDE VIEW 6 7 8 11 3 4 Pulse Output Kit 6 7 8 11 3 4 Mesh Muffler 8 9 16 11 5 32 Sound Dampening Muffler 8 9 16 11 5 32 Metal Muffler s1fnmdl3sm REV0508 9 Model S1F Non Metallic Page 4 14 Metric Dimensions S1F Non Metallic Dimensions in M
46. pment 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 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 S1F Non Metallic Page 8 WARREN INSTALLATION GUIDE RUPP Top Discharge Ball Valve Unit Available from Surge abd lids Suppressor Pipe Connection 1 Surge Suppressor 100 psi Style Optional 2 020 050 000 Filter Regulator Gauge 3 Air Dryer Flexible Shut Off Valve Connection TO ph rT DISCHARGE Iis ee A CAUTION The air exhaust should be piped to an area for safe Drain Port disposition of the product b
47. screw Hex HD 3 8 16 x 2 00 Capscrew Hex HD 3 8 16 x 2 00 Capscrew Hex HD 1 2 13 x 2 00 Capscrew Hex HD 1 2 13 x 2 00 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 3 8 16 x 2 25 Capscrew Hex HD 5 16 18 x 1 75 Capscrew Hex HD 5 16 18 x 1 75 Capscrew Soc HD 3 8 16 x 2 50 Capscrew Soc HD 3 8 16 x 88 Capscrew Soc HD 3 8 16 x 88 Chamber Outer Chamber Outer Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Diaphragm One Piece Bonded Diaphragm Diaphragm Diaphragm Overlay Elbow Elbow Elbow QTY NNT A RR ww BBB oA AAU ci ch CE Em dd NNNNNNNNNNNNNNNQOOSA ITEM PART NUMBER 312 104 552 19 312 113 520 A 312 113 521 312 113 552 A 312 113 557 20 360 093 360 21 360 103 360 22 360 104 360 A 360 104 379 23 360 107 360 24 518 179 520 A 518 179 521 518 179 552 A 518 179 557 25 544 002 115 544 002 308 26 545 008 115 545 008 308 27 560 001 360 28 612 200 157 612 200 082 612 220 150 29 612 204 520 612 204 552 30 620 020 115 31 670 048 520 670 048 552 32 675 042 115 33 685 058 120 34 720 004 360 35 720 044 600 36 720 047 600 37 722 079 520 722 079 552 38 901 038 115 901 038 308 39 901 046 115 901 046 308 40 901 048 115 901 048 308 41 901 049 115 901 049 308 Not Shown 535 069 000 DESCRIPTION Elbow Elbow Suction Elbow Suction Elbow Suction Elbow Suction Gasket Air Valve Gasket Pilot Val
48. t 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 prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber Afterthe fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional virgin PTFE pumping diaphragms item 45 These diaphragms are installed with the natural convex curve toward the outer chamber items 14 from the s1fnmdl3sm REV0508 pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING CHAMBERS WITH LIQUID The chambers are filled with water at the factory If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 50 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 15 The discharge manifolds and elbows can now be removed 3 Remove t
49. ter chamber Turn the pump over and thread the second diaphragm inner plate onto the diaphragm rod Turn the diaphwwragm 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 S1F Non Metallic Page 27 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER DESCRIPTION 3 095 110 558 Pilot Valve Assembly 3 A 095 095 558 Valve Body 3 B 755 052 000 Sleeve With O rings 3 C 560 033 360 O ring Sleeve 3 D 775 055 000 Spool With O rings 3 E 560 023 360 O ring Spool 3 F 675 037 080 Retaining Ring 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 7 and air inlet gasket item 22 The pilot valve assembly item 3 can now be removed for inspection and service s1fnmdl3sm REV0508 QTY U STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 3 D Wipe 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 3 F from the end of the sleeve item 3 B and remo
50. 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 four self tapping screws item 1 L Remove the muffler cap and muffler items 1 E and 1 G The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed s1fnmdl3sm REV0508 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be physically supported Failure to support these connections could also result in damage to the air distribution valve body Exhaust Conversion Drawing CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA SAFE AIR EXHAUST
51. tion 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 20 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 S1F Non Metallic Page 21 Air Valve Assembly Drawing With Stroke Indicator Option s1fnmdl3sm REV0508 A AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 146 000 Air Valve Assembly 1 1 A 031 143 000 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 165 098 147 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O ring 2 For Pumps with Alternate Mesh Muffler or Piped Exhaust A 1 031 147 000 Air Valve Assembly Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J A A Note ATEX Compliant Model S1F Non Metallic Page 22 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR O
52. tion and a dual discharge The porting can be changed to a dual suction and a single discharge The above changes are possible because the porting flange of the elbows items 18 and 19 are designed to mate with standard 1254 ANSI style 4 bolt 1 pipe flanges DUAL PORTING OF BOTH SUCTION AND DISCHARGE ENDS OF THE PUMP Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals spacers and manifolds items 35 and 23 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows and optional positioning in the Dual Porting Drawing s1fnmdl3sm REV0508 SINGLE PORTING OF THE SUCTION AND DUAL PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing DUAL PORTING OF THE SUCTION AND SINGLE PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds spacers and manifold seals Position the suction elbows
53. ve Gasket Air Inlet Gasket Air Inlet Gasket Inner Chamber Manifold Manifold Manifold Manifold Nut Hex 3 8 16 Nut Hex 3 8 16 Nut Hex 1 2 13 Nut Hex 1 2 13 O ring Inner Diaphragm Plate Inner Diaphragm Plate Inner Diaphragm Plate One Piece Bonded Option Outer Diaphragm Plate Outer Diaphragm Plate Plunger Actuator Retainer Ball Retainer Ball Ring Retainer Rod Diaphragm Seal Diaphragm Rod Seal Manifold Spacer Seal Check Valve Seat Check Valve Seat Check Valve Washer Flat 5 16 Washer Flat 5 16 Washer Flat 1 2 Washer Flat 1 2 Washer Flat 3 8 Washer Flat 3 8 Washer Flat 3 8 Washer Flat 3 8 Nameplate Model S1F Non Metallic Page 15 QTY NNNNNH AANNNN WW AAA RWANHNAANNNNNNNDANN Ww Ww Note ATEX Compliant Option For Virgin PTFE Equipped Pumps Drawing S1F SPILL CONTAINMENT REPAIR PARTS LIST FOR VIRGIN PTFE EQUIPPED PUMPS Item Part Number Description Qty 43 170 114 115 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Containment 2 196 159 520 Chamber Spill Containment 2 45 286 094 600 Diaphragm Pumping 2 46 518 180 520 Manifold Spill Containment 2 Replace 518 179 520 518 180 552 Manifold Spill Containment 2 Replace 518 179 520 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8
54. ve the sleeve from the valve body item 3 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 S1F Non Metallic Page 28 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The air exhaust must be piped above

Model S1F Non-Metallic Design Level 3

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