pump manual - Genemco, Inc.
Contents
1. 29 82 757 50 24 88 27 88 1870 13 25 04 632 03 708 23 635 97 1 NPT EXHAUST PORT 2 00 50 80 l J l O et i ee E E 67 F i Aas 17 07 2 00 4X 0 75 HOLE 331 72 eee 126 69 am 50 80 19 05 101 60 10 00 50 80 254 7 99 202 89 16 00 ae 50 MOUNTING HOLES 406 40 12 70 R 25 6 35 13 00 330 20 16 00 9 00 406 40 228 60 H hoi E 70 VR SN ita EY 6 00 IE H 203 18 AIR INLET 3 4 NPT BOTTOM VIEW ANDPPER WWW SANDPIPERPUMP COM Model G20 Metallic 4 A WARREN RUPP INC BRAND g20mdl1sm rev0213 Principle of Pump Operation Gas Operated Double Diaphragm pumps are powered by compressed gas nitrogen or natural gas The main directional gas control valve distributes compressed gas to an gas chamber exerting uniform pressure over the inner surface of the diaphragm At the same time the exhausting gas from behind the opposite diaphragm is directed through the gas valve assembly s to an exhaust port Gas Line As inner chamber pressure P1 exceeds liquid chamber pressure P2 the rod connected diaphragms shift together creating discharge on one side and suction on the opposite side The discharged and primed liquid s directions are controlled by the check valves ball or flap orientation Oo O o a N Z N The pump primes as a result of the suction stroke The suction stroke lowers the chamber pr2. QO O o lt 7e N 3 EXP VIEW 5 WET END 6 OPTIONAL gt lt oc lt eS wn S LLI A 7 QO D A Your Model G Explanation of Pump Nomenclature Model G XX X Pump Brand Non Wetted Material Options G Gas Operated A Painted Aluminum Pump Size B Unpainted ELON wiin stainless Steel Gas Valve 20 2 D Unpainted Aluminum with Stainless Steel Gas Valve with FKM O rings X Unpainted Aluminum Check Valve Type 0 Unpainted Aluminum FKM Elastomers B Ball V Unpainted Aluminum FKM Elastomers S Stainless Steel S02 304 SS Hardware Design Level 1 arabe evel T Stainless Steel 316 Stainless Hardware 7 Painted Stainless Steel Wetted Material 8 Stainless Steel FKM Elastomers S Stainless Steel 9 Painted Stainless Steel FKM Elastomers a een Porting Options Diaphragm Check Valve Materials N a eae ae pei PIE B BSP Tapered Threads a ae R 150 Raised Face 2 ANSI Flange w Threaded Pipe Connections itrile i W 150 Welded Raised Face 2 ANSI Flanged Manifolds Check Valve Seat j B Nitrile Pump Style T PTFE S Standard Aa a Muffler Options Stainless Steel X No Muffler Permitted Your Serial ATEX Detail I 1GcT5 1 Ex ItGcT5 IL 1D c T100 C t IM1 c M2 c Models equipped with Wetted Option S Non Wetted Options S T 7 8 or 9 Pump Option X Note See ATEX Explanation of EC Type Certificate IL 2G c T5 2 I13 2GcT5 II 2D c T100
3. SERVICE amp OPERATING MANUAL Original Instructions SOddS dINNd 1 Certified Quality Level 1 Ic ign Model G20 Metall Des Natural Gas Operated Diaphragm Pumps QUAL Quality System ISO9001 Certified Environmental Management System 1SO14001 Certified Member of z y I GNJ LAM S C drauli 2 USA 8388 p Inc oration 67 Warren Rup A Unit of IDEX Cor 00 N Main St Mansfield Ohio 449 Telephone 419 52 ax 419 522 7 WWW SANDPIPERPUMP COM reer eeer we Copyright 2013 Warren Rupp Inc All rights reserved PIPER WWW SANDPIPERPUMP COM S INC BRAND A WARREN RUPP Safety Information IMPORTANT Read the safety warnings and instructions in this manual before pump installation and start up Failure to comply with the recommendations stated in this manual could damage the pump and void factory warranty When the pump is used for materials that tend to settle out or solidify the pump should be flushed after each use to prevent damage In freezing temperatures the pump should be completely drained between uses CAUTION Before pump operation inspect all fasteners for loosening caused by gasket creep Retighten loose fasteners to prevent leakage Follow recommended torques stated in this manual Nonmetallic pumps and plastic components are not UV Stabilized Ultraviolet radiation can damage these parts and negatively affect material propert
4. C t Models equipped with Wetted Options A or S All Non Wetted Options Pump Option X Note See ATEX Explanation of Type Examination Certificate 1 Model G20 Metallic WWW SANDPIPERPUMP COM SANDPIPER g20mdl1 sm rev0213 AWARREN RUPP INC BRAND Performance G20 METALLIC MODEL G20 Metallic Performance Curve een enone ee ee re A oga SCFM Mhr m CAPACITY 7 100 o 0 to 150 gallons per minute 90 2Ps 0 to 567 liters per minute 6 KS Da gt lg GAS DISTRIBUTION VALVE 9 86 PS N xX e No lube no stall design 5 70 anid STS T SOLIDS HANDLING m J ian a Up to 25 in 6mm 4 o Psy i Lu 50 4 9 B x g HEADS UP TO I C Bar oe _ 6 100 psi or 231 ft of water 3 40 a m u 7 bar or 70 meters 40 PS 2 gt x 2 30 2 Bar 3 30 9 1 MAXIMUM OPERATING PRESSURE 4 N D lt 25 7 6 e 100 psi 7 bar 20 20 16 l 0 P 15 4 5 DISPLACEMENT STROKE T 49 91 36 Bap lt ee ee ae 42 Gallon 1 59 liter 8 Inlet Brows Tele 5 45 ot oO gt 2 SHIPPING WEIGHT 0 20 40 60 80 100 120 140 160 e Aluminum 69 lbs 31kg U S Gallons per minute e Stainless Steel 114 Ibs 52kg 0 100 200 300 400 500 600 Liters per minute CAPACITY Materials Material Profile Operating Temperatures VENG A CAUTION Operating temperature limitations are as follows Min FKM Fluorocarbon Shows good resistance to a wide range 350 F
5. 40 F of oils and solvents especially all aliphatic aromatic and 177 C 40 C halogenated hydrocarbons acids animal and vegetable oils Hot water or hot aqueous solutions over 70 F 21 C will attack FKM Nitrile General purpose oil resistant Shows good solvent oil 10 F water and hydraulic fluid resistance Should not be used with 23 C highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons difluoride which readily liberate free fluorine at elevated Virgin PTFE PFA TFE Chemically inert virtually impervious 35 F Very few chemicals are known to chemically react with PTFE 37 C molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen temperatures 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 Metals Stainless Steel Equal to or exceeding ASTM specification A743 CF 8M for corrosion resistant iron chromium iron chromium nickel and nickel based alloy castings for general applications Commonly referred to as 316 Stainless Steel in the pump industry For specific applications always consult the Chemical Resistance Chart Ambient temperature range 20 C to 40 C Process temperature
6. Part Number Description Qty ltem Part Number Description Qty 031 183 000 Aluminum Gas Valve Assembly 1123 518 146 156 Manifold Discharge 1 031 183 363 Aluminum Gas Valve Assembly with FKM O rings 1 518 146 156E Manifold Discharge 2 BSP 1 031 179 000 Stainless Steel Gas Valve Assembly 518 146 156W Welded Raised Face 150 use with Option B 1 2 ANSI Flanged Manifold 1 031 179 363 Stainless Steel Gas Valve Assembly 518 146 110 Manifold Discharge 1 with FKM O rings used with Option D 1 518 146 110E Manifold Discharge 2 BSP 1 050 017 360 Ball Check 4 518 146 110W Welded Raised Face 150 050 018 600 Ball Check 4 2 ANSI Flanged Manifold 1 3 070 006 170 Bushing 2 24 545 005 330 Nut Hex 3 8 16 16 095 110 000 Pilot Valve Assembly 1 545 005 115 Nut Hex 3 8 16 16 095 110 363 Pilot Valve Assembly with FKM O rings 1 545 005 110 Nut Hex 3 8 16 Stainless Steel Midsection 16 095 110 110 Pilot Valve Assembly Stainless Steel Midsection 1 25 545 007 330 Nut Hex 7 16 14 16 095 110 363SS Pilot Valve Assembly with FKM O rings 945 007 115 Nut Hex 7 16 14 16 Stainless Steel Midsection 1 545 007 110 Nut Hex 7 16 14 Stainless Steel Midsection 16 5 114 024 157 Intermediate Bracket 1 560 001 360 O Ring 2 114 024 110 Intermediate Bracket Stainless Steel Midsection 1 560 001 363 O Ring 2 132 035 360 Bumper Diaphragm 2 28 612 192 157 Plate Inner Diaphragm 2 132 035 363 Bumper Diaphragm 2 612 192 334 Plate Inner Diaphragm Stainless St
7. Shut Off Valve A Le Pipe Connection e C wh Note Surge Suppressor and Style Optional SO ni Piping must be supported after Disch the flexible connection A ischarge Flexible Connector Check Valve Shut Off Muffler Valve Optional Piped Exhaust J21 I igi Air Inlet E E Flexible Connector Vacuum e K Gauge Flexible m Filter Regulator Connector an P N 020 V107 000 a E Air Dryer Suction CAUTION Shut Off Val u ANE The gas exhaust should Drain Port Pipe Connection be piped to an area Style Optional for safe disposition of the product being pumped in the event of a diaphragm failure 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 Gas Supply Connect the pump gas inlet to an gas supply with sufficient capacity and pressure to achieve desired performance A pressure regulating valve should be installed to insure gas supply pressure does not exceed recommended limits Gas Valve Lubrication The gas distribution system is designed to operate WITHOUT lubrication This is the standard mode of operation If lubrication is desired install an gas line lubricator set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of gas the pump consumes Consult the Performance Curve to determine gas consum
8. Steel Black PTFE Coated 309 Aluminum Black PTFE Coated 313 Aluminum White Epoxy Coated 330 Zinc Plated Steel 332 Aluminum Electroless Nickel Plated 333 Carbon Steel Electroless Nickel Plated 335 Galvanized Steel 33 7 Silver Plated Steel 351 Food Grade Santoprene 353 Geolast Color Black 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 356 Hytrel 35 Injection Molded Polyurethane 358 Urethane Rubber Some Applications Compression Mold 359 Urethane Rubber 360 Nitrile Rubber Color coded RED 363 FKM Fluorocarbon Color coded YELLOW 364 EPDM Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile 368 Food Grade EPDM 371 Philthane Tuftane 374 Carboxylated Nitrile 3 5 Fluorinated Nitrile 378 High Density Polypropylene 379 Conductive Nitrile 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 500 Delrin 500 502 Conductive Acetal ESD 800 503 Conductive Acetal Glass Filled 506 Delrin 150 520 Injection Molded PVDF Natural color 040 Nylon 044 Nylon Injection Molded 990 Polyethylene 591 Glass Filled Polypropylene 552 Unfilled Polypropylene 555 Polyvinyl Chloride 556 Black Vinyl 558 Conductive HDPE 570 Rulon Il 580 Ryton 600 PTFE virgin materi
9. is cavitating the fluid by fast cycling Meet or exceed pump connections Product Leaking Th rough Exhaust Diaphragm stretched around center hole or bolt holes Check for excessive inlet pressure or gas pressure Consult Chemical Resistance Chart for compat ibility with products cleaners temperature limitations and lubrication Premature Diaphragm Enlarge pipe diameter on suction side of pump Failure Excessive flooded suction pressure Move pump closer to product Raise pump place pump on top of tank to reduce inlet pressure Install Back pressure device Tech bulletin 41r Add accumulation tank or pulsation dampener Misapplication chemical physical incompatibility Consult Chemical Resistance Chart for compatibility with products cleaners temperature limitations and lubrication Incorrect diaphragm plates or plates on backwards Check Operating Manual to check for correct part and installation Ensure outer plates have not been installed incorrectly or worn worn to a sharp edge Unbalanced Cycling Excessive suction lift For lifts exceeding 20 of liquid filling the chambers with liquid will prime the pump in most cases Undersized suction line Meet or exceed pump connections Pumped fluid in gas exhaust muffler Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Suction side gas leakage or gas in product Check valve obstructed Visually inspect all suct
10. 170 006 115 Capscrew Hex Hd 3 8 16 X 1 00 4 900 005 110 Washer Lock Stainless Steel Midsection 16 170 006 110 Capscrew Hex Hd 3 8 16 X 1 00 4 38 920 025 000 Ground Strap 1 Stainless Steel Midsection 560 106 360 O Ring use with metal seats 8 13 171 059 330 Capscrew Soc Hd 7 16 14 X 1 25 8 720 060 608 Seal use with metal seats 8 171 011 115 Capscrew Soc Hd 1 2 13 X 1 00 8 40 901 038 330 Flat Washer 4 171 011 110 Capscrew Soc Hd 1 2 13 X 1 00 8 901 038 110 Flat Washer 4 Stainless Steel Midsection 901 038 115 Flat Washer 4 14 196 167 156 Chamber Outer 2 196 167 110 Chamber Outer 2 Parts not shown used with Raised Face ANSI Flange Options R and W 15 196 168 156 Chamber Inner 2 170 035 330 Hex Cap Screw 4 196 168 110 Chamber Inner Stainless Steel Midsection 2 326 052 080 Mounting Foot 2 286 007 360 Diaphragm 2 545 007 330 Hex Nut 4 286 020 604 Diaphragm Overlay 2 900 006 330 Lock Washer 4 18 360 093 360 Gasket Natural Gas Valve 1 901 022 330 Flat Washer 8 19 360 103 360 Gasket Pilot Valve 1 20 360 104 379 Gasket Natural Gas Inlet 1 Parts not shown used with Raised Face ANSI Flange Option R ONLY 21 360 105 360 Gasket Inner Chamber 2 334 115 110 2 ANSI 150 Raised Face Flange 22 518 145 156 Manifold Suction 1 and Threaded Pipe Connection 2 518 145 156E Manifold Suction 2 BSP 1 538 024 110 2 NPT Pipe Nipple x 2 1 2 Long 2 518 145 156W Welded Raised Face 150 2 ANSI Flanged Manifold i 518 145 110 Manifold Suction 1 LEGEN
11. 25 ST1 ST40 G15 G20 I M2 c KEMA 09ATEX0072 X and G30 without the above listed options no aluminum parts Pump types DMF2 DMF3 Il 2 Gc T5 KEMA 09ATEX0072 X KEMA 09ATEX0072 X HDB1 2 HDB40 HDB2 Il 3 2 G c T5 CE KEMA 09ATEX0072 X HDB50 HDB3 HDF1 HDF25 Il 2 D c T100 C KEMA 09ATEX0072 X HDF2 HDF3M PB S05 S1F S15 S20 S30 SB1 SB25 SE ST1 ST25 ST1 ST40 U1F G05 G1F G15 G20 and G30 Surge Suppressors all types II 2 G T5 KEMA 09ATEX0073 KEMA 09ATEX0073 II 3 2 G T5 CE KEMA O9ATEX0073 II 2 D T100 C KEMA O9ATEX0073 EC Type Certificate No Pumps KEMA 09ATEX0071 X Type Certificate No Pumps KEMA 09ATEX0072 X Type Certificate No Suppressors KEMA 09ATEX0073
12. D 518 145 110E Manifold Suction 2 BSP 1 O Items contained within Gas End Kits 518 145 110W Welded Raised Face 150 L_ Items contianed within Wet End Kits 2 ANSI Flanged Manifold 1 Note Kits contain components specific to the material codes x A ATEX Compliant 9 Model G20 Metallic WWW SANDPIPERPUMP COM SANDPIPER g20mdl1 sm rev0213 A WARREN RUPP INC BRAND A WARREN RUPP INC BRAND Material Codes The Last 3 Digits of Part Number 000 Assembly sub assembly and some purchased items 010 Cast lron 015 Ductile Iron 020 Ferritic Malleable Iron 080 Carbon Steel AISI B 1112 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel Electro Polished 112 Alloy C 113 Alloy Type 316 Stainless Steel Hand Polished 114 303 Stainless Steel 115 302 304 Stainless Steel 117 440 C Stainless Steel Martensitic 120 416 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 150 6061 T6 Aluminum 152 2024 T4 Aluminum 2023 1351 159 306 T6 Aluminum 156 306 T6 Aluminum 157 Die Cast Aluminum Alloy 380 158 Aluminum Alloy SR 319 162 Brass Yellow Screw Machine Stock 165 Cast Bronze 85 5 5 5 166 Bronze SAE 660 170 Bronze Bearing Type Oil Impregnated 180 Copper Alloy 305 Carbon Steel Black Epoxy Coated 306 Carbon Steel Black PTFE Coated 307 Aluminum Black Epoxy Coated 308 Stainless
13. OF s CO a aa oa includes all other items used on 095 110 000 For Pumps with stainless steel center section Item 4 4 A Part Number 095 110 110 095 095 110 Description Qty Pilot Valve Assembly 1 Valve Body 1 includes all other items used on 095 110 000 For pumps with stainless steel center section Item 4 4 B 4 C 4 D 4 E Part Number 095 110 363SS 755 052 363 560 033 363 775 055 363 560 023 363 Description Qty Pilot Valve Assembly Sleeve With FKM O Rings FKM O Ring Sleeve FKM Spool With FKM O Rings FKM O Ring Spool FKM oO Onn includes all other items used on 095 110 110 Model G20 Metallic 12 Intermediate Assembly Intermediate Assembly Drawing Step 1 Remove plunger actuator 32 from center of intermediate pilot valve cavity Step 2 Remove Ring Retaining 33 discard Step 3 Remove bushing plunger 7 inspect for wear and replace if necessary with genuine parts Step 4 Remove O Ring 26 inspect for wear and replace if necessary with genuine parts Step 5 Lightly lubricate O Ring 26 and insert into intermediate Step 6 Reassemble in reverse order Step 7 Remove Seal Diaphragm Rod 35 Step 8 Clean seal area lightly lubricate and install new Seal Diaphragm Rod 35 13 Model G20 Metallic Y INTERMEDIATE REPAIR PARTS LIST Item Part Number Description Qty 5 114 024 157 Bracket Intermediate 1 114 024 110 Bracket Intermedi
14. Ring 1 D and replace if necessary Step 6 Lightly lubricate O Rings 1 D Step 7 Press sleeve 1 B into body 1 A Step 8 Reassemble in reverse order starting with step 3 Note Sleeve and spool 1 B set is match ground to a specified clearance sleeve and spools 1 B cannot be interchanged WWW SANDPIPERPUMP COM ANDPIPER g20mdl1sm rev0213 A WARREN RUPP INC BRAND Pilot Valve Assembly Pilot Valve Servicing With Pilot Valve removed from pump Step 1 Remove snap ring 4 F Step 2 Remove sleeve 4 B inspect O Rings 4 C replace if required Step 3 Remove spool 4 D from sleeve 4 B inspect O Rings 4 E replace if required Step 4 Lightly lubricate O Rings 4 C and 4 E Reassemble in reverse order ANDPIPER WWW SANDPIPERPUMP COM A WARREN RUPP INC BRAND g 20mdl1sm rev0213 Pilot Valve Assembly Parts List Item 4 4 A 4 B 4 C 4 D 4 E 4 F Item 4 4 A 4 B 4 C 4 D 4 E Part Number 095 110 000 095 095 157 755 052 000 560 033 360 775 055 000 560 023 360 675 037 080 Part Number 095 110 000 095 095 157 755 052 363 560 033 363 775 055 363 560 023 363 Description Qty Pilot Valve Assembly Valve Body Sleeve With O Rings O Ring Sleeve Spool With O Rings O Ring Spool Retaining Ring C namn Description Qty Pilot Valve Assembly Valve Body Sleeve With FKM O Rings FKM O Ring Sleeve FKM Spool With FKM O Rings FKM O Ring Spool FKM
15. al Tetrafluorocarbon TFE 603 Blue Gylon 607 Envelon 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE FKM PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene 666 FDA Nitrile Diaphragm PTFE Overlay Balls and Seals 668 PTFE FDA Santoprene PTFE ANDPIPER WWW SANDPIPERPUMP COM g20mdl1sm rev0213 e Delrin and Hytrel are registered tradenames of E I DuPont e Nylatron is a registered tradename of Polymer Corp e Gylon is a registered tradename of Garlock Inc e Santoprene is a registered tradename of Exxon Mobil Corp e Rulon Il is a registered tradename of Dixion Industries Corp e Ryton is a registered tradename of Phillips Chemical Co e Valox is a registered tradename of General Electric Co gt o gt lt fr co RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed Model G20 Metallic 10 Gas Distribution Valve Assembly IMPORTANT Read these instructions completely before installation and start up It is the respon
16. ate 1 T 135 034 506 Bushing Plunger 2 26 560 001 360 O Ring 2 560 001 363 O Ring FKM 2 32 620 020 115 Plunger Actuator 2 33 675 042 115 Ring Retaining 2 35 720 004 360 Seal Diaphragm Rod 2 720 004 363 Seal Diaphragm Rod FKM 2 Note It is recommended that when plunger components are serviced new retaining rings be installed IMPORTANT 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 In the event of a diaphragm failure a complete rebuild of the center section is recommended WWW SANDPIPERPUMP COM SANDPIPER g20mdl1 sm rev0213 AWARREN RUPP INC BRAND Diaphragm Service Drawing with Overlay m Lu _ LLI Ts SANDPIPER _WWW SANDPIPERPUMP COM Mode G20 Metallic 14 g20mdl1sm rev0213 m LLI LLI F Diaphragm Servicing Step 1 With manifolds and outer chambers removed remove diaphragm assemblies from diaphragm rod DO NOT use a pipe wrench or similar tool to remove assembly from rod Flaws in the rod surface may damage bearings and seal Soft jaws in a vise are recommended to prevent diaphragm rod damage Step 1 A NOTE Not all inner diaphragm plates are threaded Some models utilize a through hole in the inner diaphragm plate If required to separate diaphragm assembly place assembly in a vise gripping on the exterior cast diameter of the inner plat
17. atic electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required Refer to nomenclature page for ordering information 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 WWW SANDPIPERPUMP COM S DPIPERD g20mdl1 sm rev0213 AWARREN RUPP INC BRAND Table of Contents SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 7 SANDPIPER PUMP SPECIFICATIONS Explanation of Nomenclature Performance e Materials e Dimensional Drawings INSTALLATION amp OPERATION e Principle of Pump Operation e Recommended Installation Guide e Troubleshooting Guide EXPLODED VIEW ssccsseseees e Composite Repair Parts Drawing e Composite Repair Parts List e Material Codes GAS END sceeeeeeeeeeeeeeeeeeneee Aluminum Gas Valve Assembly e Stainless Steel Gas Valve Assembly Pilot Valve Assembly Intermediate Assembly WET END ssssnnnnnun2002 e Diaphragm Drawings Diaphragm Servicing WARRANTY amp CERTIFICATES e Warranty CE Declaration of Conformity Machinery e ATEX Declaration of Conformity e ATEX Summary of Markings WWW SANDPIPERPUMP COM g20mdl1sm rev0213 15 1 PUMP SPECS
18. d use purchaser that no product sold by Warren Rupp that bears a Warren Rupp brand shall fail under normal use and service due to a defect in material or workmanship within five years from the date of shipment from Warren Rupp s factory Warren Rupp brands include SANDPIPER MARATHON PortaPump SludgeMaster and Tranquilizer See complete warranty at www sandpiperoump com About guaranteesandwarranties html WARKEN RUPP INC Declaration of Conformity Manufacturer Warren Rupp Inc 800 N Main Street P O Box 1568 Mansfield Ohio 44901 1568 USA Certifies that Air Operated Double Diaphragm Pump Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic T Series G Series 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 EN809 1998 A1 2009 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance avid Freahery October 20 2005 Signature of authorized pers Date of issue David Roseberry Engineering Manager Printed name of authorized person Title August 23 2012 Date of revision Revision Level F gt lt oc lt CORPORATION WARKEN RUPP INC EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Equipment i
19. e Turn the outer plate clockwise to separate the assembly Always inspect diaphragms for wear cracks or chemical attack Inspect inner and outer plates for deformities rust scale and wear Inspect intermediate bearings for elongation and wear Inspect diaphragm rod for wear or marks Clean or repair if appropriate Replace as required Step 2 Reassembly There are two different types of diaphragm plate assemblies utilized throughout the Sandpiper product line Outer plate with a threaded stud diaphragm and a threaded inner plate Outer plate with a threaded stud diaphragm and an inner plate with through hole Secure threaded inner plate in a vise Ensure that the plates are being installed with the outer radius against the diaphragm Step 3 Lightly lubricate with a compatible material the inner faces of both outer and inner diaphragm plates when using on non Overlay diaphragms For EPDM water is recommended No lubrication is required 15 Model G20 Metallic Step 4 Push the threaded outer diaphragm plate through the center hole of the diaphragm Note Most diaphragms are installed with the natural bulge out towards the fluid side S05 S07 and S10 non metallic units are installed with the natural bulge in towards the gas side Step 5 Thread or place outer plate stud into the inner plate For threaded inner plates use a torque wrench to tighten the assembly together Torque values are called out on the exploded vie
20. ed gas exhaust muffler Remove muffler screen clean or de ice and re install z Pumped fluid in gas exhaust muffler Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly T Pump chamber is blocked Disassemble and inspect wetted chambers Remove or flush any obstructions Pump Cycles and Will Cavitation on suction side Check suction condition move pump closer to product N Not Prime or No Flow _ Check valve obstructed Valve ball s not seating Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket properly or sticking Clean out around valve ball cage and valve seat area Replace valve ball or valve seat if damaged Use heavier valve ball material Valve ball s missing pushed into chamber or Worn valve ball or valve seat Worn fingers in valve ball cage replace part Check Chemical manifold Resistance Guide for compatibility For lifts exceeding 20 of liquid filling the chambers with liquid will prime the pump in most cases Pump Cycles Running Sluggish Stalling Flow Unsatisfactory Deadhead system pressure meets or exceeds gas Increase the inlet gas pressure to the pump Pump is designed for 1 1 pressure ratio at zero flow supply pressure Does not apply to high pressure 2 1 units For lifts exceeding 20 of liquid filling the chambers with liquid will prime the pump in most cases Decrease inlet gas press and vol to the pump Pump
21. eel Midsection 2 135 034 506 Bushing Plunger 2 29 612 194 156 Plate Outer Diaphragm Assembly 2 165 116 157 Cap Gas Inlet Assembly 1 612 194 110 Plate Outer Diaphragm Assembly 2 165 116 110 Cap Gas Inlet Assembly 30 612 195 157 Plate Inner Diaphragm PTFE overlays only 2 fa Stainless Steel Midsection 1 612 195 334 Plate Inner Diaphragm Stainless Steel Midsection 2 fi 170 060 330 Capscrew Hex Hd 7 16 14 X 2 00 16 31 612 039 157 Plate Outer Diaphragm PTFE overlays only 2 Bes 170 060 115 Capscrew Hex Hd 7 16 14 X 2 00 16 612 097 110 Plate Diaphragm PTFE overlays only 2 170 060 110 Capscrew Hex Hd 7 16 14 X 2 00 16 G2 620 020 115 Plunger Actuator 2 Stainless Steel Midsection 33 675 042 115 Ring Retaining 2 170 052 330 Capscrew Hex Hd 3 8 16 X 2 25 16 34 685 058 110 Rod Diaphragm 1 170 052 115 Capscrew Hex Hd 3 8 16 X 2 25 16 65 720 004 360 Seal Diaphragm Rod 2 170 052 110 Capscrew Hex Hd 3 8 16 X 2 25 16 720 004 363 Seal Diaphragm Rod 2 Stainless Steel Midsection 722 040 360 Seat Check Ball 4 11 170 069 330 Capscrew Hex Hd 5 16 18 X 1 75 4 722 040 600 Seat Check Ball 4 170 069 115 Capscrew Hex Hd 5 16 18 X 1 75 4 722 040 110 Seat Ckeck Ball requires seals see item 39 4 170 069 110 Capscrew Hex Hd 5 16 18 X 1 75 4 722 040 150 Seat Ckeck Ball requires seals see item 39 4 Stainless Steel Midsection 37 900 005 330 Washer Lock 16 12 170 006 330 Capscrew Hex Hd 3 8 16 X 1 00 4 900 005 115 Washer Lock 16
22. essure P3 increasing the chamber volume This results in a pressure differential necessary for atmospheric pressure P4 to push the fluid through the suction piping and across the suction side check valve and into the outer fluid chamber 5 oe Ce Stroke Suction side stroking also initiates the reciprocating shifting stroking or cycling action of the pump The suction diaphragm s movement is mechanically pulled through its stroke The diaphragm s inner plate makes contact with an actuator plunger aligned to shift the pilot signaling valve Once actuated the pilot valve sends a pressure signal to the opposite end of the main directional gas valve redirecting the compressed gas to the opposite inner chamber SUBMERGED ILLUSTRATION MUFFLER 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The gas exhaust must be piped above the liquid level 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 5 ModelG20 Metalic 0 SANDPIPERPUMP COM_ SAN DPIPERD g20mdl1 sm rev0213 AWARREN RUPP INC BRAND Recommended Installation Guide Available Accessories 1 Surge Suppressor Unregulated Air 2 Filter Regulator A uppressor 3 Gas Dryer Surge Suppressor i Pressure Gauge No
23. ies Do not expose to UV light for extended periods of time Grounding the Pump WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly Before maintenance or repair shut off the compressed gas line bleed the pressure and disconnect the gas line from the pump Be certain that approved eye protection and protective clothing are worn at all times Failure to follow these recommendations may result in serious injury or death Gasborne particles and loud noise hazards Wear eye and ear protection In the event of diaphragm rupture pumped material may enter the gas end of the pump and be discharged into the atmosphere If pumping a product that is hazardous or toxic the gas exhaust must be piped to an appropriate area for safe containment Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers and other miscellaneous equipment must be properly grounded This pump is pressurized internally with gas pressure during operation Make certain that all fasteners are in good condition and are reinstalled properly during reassembly To be fully groundable the pumps must be ATEX Compliant Refer to the nomenclature page for ordering information Optional 8 foot long 244 centimeters Ground Strap is available for easy ground connection To reduce the risk of st
24. ion side gaskets and pipe connections Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Check valve and or seat is worn or needs adjusting Entrained gas or vapor lock in chamber s Purge chambers through tapped chamber vent plugs Inspect check valves and seats for wear and proper setting Replace if necessary For additional troubleshooting tips contact After Sales Support at service warrenrupp idexcorp com or 419 524 8388 7 Model G20 Metallic WWW SANDPIPERPUMP COM ANDPIPER g20mdl1 sm rev0213 AWARREN RUPP INC BRAND Composite Repair Parts Drawing O Torque 90 in lbs ATTACH EYELET TO ONE OF THE 11 FOUR CAPSCREWS ITEM 12 3 EXP VIEW Torque 480 in Ibs Plate to Plate Service amp Repair Kits 476 227 000 Gas End Kit Seals O Rings Gaskets Retaining Rings Gas Valve Assembly and Pilot Valve Assembly 476 227 363 Gas End Kit FKM Seals O Rings Gaskets Retaining Rings Gas Valve Assembly and Pilot Valve Assembly 476 206 360 Wetted End Kit Nitrile Diaphragms Nitrile Check Balls and Nitrile Check Valve Seats 476 206 649 Wetted End Kit Nitrile Diaphragms PTFE Overlay Diaphragms PTFE Check Balls and PTFE Check Valve Seats 476 206 672 Wetted End Kit Nitrile Diaphragms PTFE Check Balls PTFE Seats ANI DPIPERD _WWW SANDPIPERPUMP COM Mode G20 Metallic 8 A WARREN RUPP INC BRAND g 20mdl1sm rev0213 Composite Repair Parts List Item
25. ntended 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 AODD Air Operated Double Diaphragm Pumps EC Type Examination Certificate No Pumps KEMA O9ATEX0071 X KEMA Quality B V Utrechtseweg 310 6812 AR Arnhem The Netherlands SANDPIPERs Tranquilizer DATE APPROVAL TITLE Aai 27 MAY 2010 David Roseberry Engineering Manager CORPORATION ATEX Summary of Markings Non Conductive Fluids Pump types S1F S15 S20 Ex ia c IIC T5 KEMA 09ATEX0071 X KEMA 09ATEX0071 X No and S30 provided with the G Ex ia c IIC T5 KEMA 09ATEX0071 X Yes pulse output option Ex c iaD 20 IP67 T100 C KEMA 09ATEX0071 X Yes Marking Listed In Pump types S1F S15 S20 EEx mc II T5 KEMA 09ATEX0071 X KEMA 09ATEX0071 X No and S30 provided with the G EEx mc II T5 CE 0344 KEMA 09ATEX0071 X Yes integral solenoid option c IP65 T100 C KEMA 09ATEX0071 X Pump types HDB1 2 HDB40 KEMA 09ATEX0071 X KEMA 09ATEX0071 X HDB2 HDB50 HDB3 HDF1 Il 3 1 G c T5 KEMA 09ATEX0072 X KEMA 09ATEX0071 X HDF25 HDF2 HDF3M PB II 1 D c T100 C CE 0344 KEMA 09ATEX0071 X S05 S1F S15 S20 S30 SB1 IM1 c KEMA 09ATEX0071 X SB
26. ption Gas Line Moisture Water in the compressed gas supply may cause icing or freezing of the exhaust gas causing the pump to cycle erratically or stop operating Water in the gas supply can be reduced by using a point of use gas dryer Gas Inlet And Priming To start the pump slightly open the gas shut off valve After the pump primes the gas valve can be opened to increase gas 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 gas flow to pump flow ratio ANI DPIPERD _WWW SANDPIPERPUMP COM Mode G20 Metallics A WARREN RUPP INC BRAND g 20mdl1sm rev0213 QO O o lt _ 7e N Troubleshooting Guide Symptom Potential Cause s Recommendation s Pump Cycles Once Deadhead system pressure meets or exceeds gas supply pressure Increase the inlet gas pressure to the pump Pump is designed for 1 1 pressure ratio at zero flow Does not apply to high pressure 2 1 units Pump Will Not Operate I Cycle Discharge line is blocked or clogged manifolds Check for inadvertently closed discharge line valves Clean discharge manifolds piping Increase the inlet gas pressure to the pump Pump is designed for 1 1 pressure ratio at zero flow Deadhead system pressure meets or exceeds gas O supply pressure Does not apply to high pressure 2 1 units o Block
27. range 20 C to 80 C for models rated as category 1 equipment 20 C to 100 C for models rated as category 2 equipment In addition the ambient temperature range and the process temperature range do not exceed the operating temperature range of the applied non metallic parts as listed in the manuals of the pumps ANI DPIPER _WWW SANDPIPERPUMP COM Mode G20 Metallic 2 A WARREN RUPP INC BRAND g 20mdl1sm rev0213 Dimensional Drawings G20 Metallic Dimensions in inches mm dimensions in brackets Dimensional Tolerance 1 8 3mm The dimensions on this drawing are for reference only A certified drawing can be requested if physical dimensions are needed wn S Lu Oo N ai D A 2 NPT DISCHARGE PORT 1 AIR EXHAUST PORT 24 90 se 632 56 672 31 13 85 351 77 2 NPT SUCTION PORT 155 55 12 25 l R 25 6 35 i A N M 10 00 j ene aoe 228 60 K T 3 4 NPT AIR INLET 255 59 BOTTOM VIEW g20mdl1 sm rev0213 A WARREN RUPP INC BRAND Dimensional Drawings G20 Metallic ANSI Flange Dimensions in inches mm dimensions in brackets Dimensional Tolerance 1 8 3mm The dimensions on this drawing are for reference only A certified drawing can be requested if physical dimensions are needed wn S Lu QO N QO A 5 82 147 95 2 RF 150 ANSI FLANGE DISCHARGE PORT
28. sibility 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 Ex Ay ATEX Compliant 11 Model G20 Metallic Valve Assembly for Aluminum Mid Sections Natural Gas Assembly Parts List Item Part Number Description Qty 1 031 183 000 Gas Valve Assembly 1 1 A 095 109 157 Valve Body 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 360 O Ring 10 1 E 165 127 157 Cap End 2 1 F 170 032 330 Capscrew 8 Item Part Number Description Qty 1 031 183 363 Gas Valve Assembly FKM 1 1 D 560 020 363 O Ring FKM 10 includes all other items used on 031 183 000 Valve Assembly for Stainless Steel Mid Sections Natural Gas Assembly Parts List Item Part Number Description Qty 1 031 179 000 Gas Valve Assembly 1 1 A 095 109 110 Valve Body 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 360 O Ring 10 1 E 165 127 110 Cap End 2 1 F 170 032 115 Capscrew 8 170 032 110 3 16 Stainless Steel Option 8 Item Part Number Description Qty 1 031 179 363 Gas Valve Assembly FKM 1 1 D 560 020 363 O Ring FKM 10 includes all other items used on 031 179 000 Gas Distribution Valve Servicing Step 1 Remove cap screws 1 F Step 2 Remove end cap 1 E and bumper 1 C Step 3 Remove spool part of 1 B caution do not scratch Step 4 Press sleeve 1 B from body 1 A Step 5 Inspect O
29. w Repeat procedure for second side assembly 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 6 Thread one assembly onto the diaphragm rod with sealing washer when used and bumper Step 7 Install diaphragm rod assembly into pump and secure by installing the outer chamber in place and tightening the capscrews Step 8 On opposite side of pump thread the remaining assembly onto the diaphragm rod Using a torque wrench tighten the assembly to the diaphragm rod Align diaphragm through bolt holes always going forward past the recommended torque Torque values are Called out on the exploded view NEVER reverse to align holes if alignment cannot be achieved without damage to diaphragm loosen complete assemblies rotate diaphragm and reassemble as described above WWW SANDPIPERPUMP COM 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 ANDPIPER A WARREN RUPP INC BRAND g20mdl1sm rev0213 Written Warranty 5 YEAR Limited Product Warranty Quality System ISO9001 Certified Environmental Management Systems IS014001 Certified Warren Rupp Inc Warren Rupp warrants to the original en
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