Service Manual - Amalgamated Pumping Supplies
Contents
1. Fluorinated Nitrile High density Polypropylene Conductive Nitrile Conductive Neoprene Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Acrylic Resin Plastic Injection Molded PVDF Natural Color Nylon Nylon Nylon Nylon Injection Molded Polyethylene Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Conductive HDPE Rulon II Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluoroethylene TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE PTFE Conductive PTFE PTFE Encapsulated Silicon PTFE Encapsulated Viton Delrin Viton and Hytrel are registered tradenames of E I DuPont Gylonis a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Rulon Il is a registered tradename of Dixion Industries Corporation Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Company Valox is a registered tradename of General Electric Company Rupplon SandPIPER PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 8 Item 25 Part 612 101 110 Stainless Steel Units ONLY Suction 2004 Warren Rupp Inc All rights reserved SandPIPER is a registered tradena2. may prevent the spool from moving freely This can cause the spool to stick in a position that prevents the pump from operating If this is the case the sleeve and spool set should be removed from the valve body for cleaning and further inspection Remove the spool from the sleeve Using an arbor press or bench vise with an improvised mandrel press the sleeve from the valve body Take care not to damage the sleeve At this point inspect the o rings on the sleeve for nicks tears or abrasions Damage of this sort could happen during assembly or servicing A sheared or cut o ring can allow the pump s compressed air supply to leak or bypass within the air valve assembly causing the pump to leak compressed air from the pump air exhaust or not cycle properly This is most noticeable at pump dead head or high discharge pressure conditions Replace any of these o rings as required or set up a routine preventive maintenance schedule to do so on a regular basis This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent inspecting for signs of wear or damage and replacing worn components To re install the sleeve and spool set lightly lubricate the o rings on the sleeve with an o ring assembly lubricant or lightweight oil such as 10 wt air line lubricant Re install one end cap and retaining ring See safety warning on the valve body Using the arbor press or bench vise that was used in disassembly
3. 003 330 Washer Lock AL Wetted 2 e S at 25 612 023 330 Plate Outer 2 170 Bronze Bearing Type Oil Impregnated 612 101 110 Plate Outer 2 Le gee ied Kynar Coated 26 286 008 354 Diaphragm 2 S50 Pie PIC S16 286 008 356 Diaphragm 2 331 Chrome Plated Steel 286 008 360 Diaphragm 2 335 Galvanized Steel 286 008 363 Diaphragm 2 ee 286 008 364 Diaphragm 2 340 Nickel Plated 286 008 365 eel 2 342 _Filed Nylon p g 354 Injection Molded 203 40 Santoprene 27 612 022 330 Plate Inner 2 Duro 40D 5 Color RED 28 132 019 360 Bumper 2 355 Thermoplastic Elastomer 356 Hytrel 29 196 043 157 Chamber Inner left side AL Center 1 o Re Urethane Rubber Color coded PURPLE 196 084 010 Chamber Inner left side CI Center 1 SP eA n a S 30 196 042 157 Chamber Inner right side AL Center 1 359 Urethane Rubber _ 196 090 010 Chamber Inner right side CI Center 1 sa alt PUPPET Colorcoded PED 31 620 007 114 Plunger Actuator 2 363 Viton Fluorel Color coded YELLOW 32 560 001 360 O Ring 2 364 E P D M Rubber Color coded BLUE 33 135 034 506 Bushing 2 370 Butyl Rubber Color coded BROWN 34 675 042 115 Ring Retainer 2 E pateaens ees 35 170 043 330 Capscrew Hex Head AL Center 6 170 006 330 Capscrew Hex Head CI Center 6 36 196 012 157 Chamber Outer 2 196 012 110 Chamber Outer 2 37 170 029 330 Capscrew Hex Head 16 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 7 ITEM NO PART NUMBER 38 545 004 330 39 115 071
4. 080 115 070 330 41 706 013 330 42 350 002 360 43 547 002 330 44 618 003 330 44A 618 003 330 618 003 110 45 132 022 360 46 312 017 335 47 170 045 330 48 518 015 156 518 015 110 518 059 156 49 338 007 360 338 007 363 338 007 364 338 007 365 50 722 021 360 722 021 363 722 021 364 722 021 365 51 360 031 379 360 031 384 360 031 608 52 334 013 157 334 013 110 334 036 156 334 036 110 334 013 157E 334 013 110E 334 036 156E 334 036 110E 53 171 010 330 54 905 001 015 55 360 030 425 360 030 600 56 807 029 330 807 029 330 807 054 330 57 900 004 330 58 545 004 330 59 530 036 000 61 545 005 330 62 255 012 335 Items Not Shown 031 030 000 535 022 115 545 005 330 705 001 330 Optional Item 800 008 000 DESCRIPTION Nut Hex Foot Bracket Foot Bracket Top Ported Screw Machine Foot Rubber Nut Stop Plug Pipe Plug Pipe Plug Pipe Bumper Actuator 90 Elbow 3 4 NPT Exhaust Port used w Top Ported Manifold Capscrew Hex Head Manifold Manifold Manifold Dual Ported Flap Valve Flap Valve Flap Valve Flap Valve Valve Seat Valve Seat Valve Seat Valve Seat Gasket Gasket Gasket Flange Porting Flange Porting Flange Dual Ported Flange Dual Ported Flange Porting BSP Flange Porting BSP Flange Dual Ported BSP Flange Dual Ported BSP Capscrew Flanged Washer Taper Gasket Manifold Gasket Manifold use with Viton or TFE Stud Stud Dual Porting
5. carefully press the sleeve back into the valve body without shearing the o rings You may have to clean the surfaces of the valve body where the end caps mount Material may remain from the old gasket Old material not cleaned from this area may cause air leakage after reassembly Take care that the bumper stays in place allowing the sleeve to press in all the way Reinstall the spool opposite end cap and retaining ring see safety warning on the valve body After inspecting and cleaning the gasket surfaces on the valve body and intermediate reinstall the valve body on the pump using new gaskets Tighten the four hex head capscrews evenly and in an alternating cross pattern PILOT VALVE The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing Most problems with the pilot valve can be corrected by replacing the o rings Always grease the spool prior to inserting it into the sleeve If the sleeve is removed from the body reinsertion must be at the chamfered side Grease the o rings to slide the sleeve into the valve body Securely insert the retaining ring around the sleeve When reinserting the pilot valve push both plungers located inside the intermediate bracket out of the path of the pilot valve spool ends to avoid damage PILOT VALVE ACTUATOR Bushings for the pilot valve actuators are held in the inner chambers with retaining r
6. gasket creep Retorque loose fasteners to prevent leakage Follow recommended torques stated in the card attached to the new pump A DANGER A Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death HAZARD WARNING POSSIBLE EXPLOSION HAZARD can result if 1 1 1 Trichloroethane Methylene Chloride or other Halogenated Hydrocarbon solvents are used in pressurized fluid systems having Aluminum or Galvanized wetted parts Death serious bodily injury and or property damage could result Consult with the factory if you have questions concerning Halogenated Hydrocarbon solvents WARREN RUPP INC A Unit of IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA e 419 524 8388 Fax 419 522 7867 www warrenrupp com remain in the proper operating position hanging downward Make certain that the flap valves are opening outward from the manifold Note Low profile mounting feet are available when the top porting configuration is used AIR SUPPLY Air supply pressures cannot ex
7. SERVICE AND OPERATING MANUAL ANDPIPERs A WARREN RUPP PUMP BRAND x N2GDbTs CE PLEASE NOTE The photos shown in this manual are for general instruction only Your specific model may not be shown Always refer to the parts list and exploded view drawing for your specific model when installing disassembling or servicing your pump PRINCIPLE OF PUMP OPERATION This flap swing check valve pump is powered by compressed air and is a 1 1 pressure ratio design It alternately pressurizes the inner side of one diaphragm chamber while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod to move endwise Air pressure is applied over the entire surface of the diaphragm while liquid is discharged from the opposite side The diaphragm operates under a balanced condition during the discharge stroke which allows the unit to be operated at discharge heads over 200 feet 61 meters of water head Since the diaphragms are connected by a common rod secured by plates to the center of the diaphragms one diaphragm performs the discharge stroke while the other is pulled to perform the suction stroke in the opposite chamber 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 This will maximize diaphragm life Alternate pressuring and exhau
8. Stud Longer Dual Porting Washer Lock Nut Hex Muffler Nut Hex SS amp Alloy C units only Coupling 3 4 NPT Exhaust Port use w Bottom Ported Manifold Valve Body Assembly Includes Items 8 9 10 11 amp 12 Name Plate AL Outer Chamber Only Nut Hex S S Only Drive Screw AL Outer Chamber only Strainer AL Only Item 14 available in kit form Order 031 060 000 which also includes Items 2 13 15 31 amp 45 Item 25 612 101 110 does not require Items 23 and 24 Items 41 42 amp 43 noted are available in kit form only Kit 475 221 000 TOTAL RQD NMNMORARAADN NONPADMNNNNPNNNNNPNNNNNNNNNNA HA AA o A4 nVo LAO nN AAN Repair Parts shown in bold face darker type are more likely to need replacement after extended periods of normal use They are readily available from most Warren Rupp distributors The pump owner may prefer to maintain a limited inventory of these parts in his own stock to reduce repair downtime to a minimum IMPORTANT When ordering repair parts always furnish pump model number serial number and type number MATERIAL CODES The Last 3 Digits of Part Number Continued from previous page 375 378 379 384 405 408 425 426 440 465 500 501 505 520 540 541 542 544 550 551 552 553 555 558 570 580 590 591 592 600 601 602 603 604 606 608 610 611
9. The pump piping valves containers or other miscellaneous equipment must be grounded One eyelet is installed to a true earth ground Requires a maximum 5 16 or 8mm maximum diameter blot One eyelet is fastened to the pump hardware This 8 foot long 224 centimeters Groundstrap part number 920 025 000 can be ordered as a service item 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 or in the absence of local codes an industry or nationally recognized code having juristiction over specific installations 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 6 SERVICE AND OPERATING MANUAL Model SA1 A x l2eDbTs CE Model SAZ5A ITEM TOTAL Type 4 NO PART NUMBER DESCRIPTION RQD ANDPIPER A WARREN RUPP PUMP BRAND Repair Parts shown in bold face darker type are more likely to need replacement after extended periods of normal use They 1 165 042 157 Cap Valve Body AL Center 1 i 165 042 558 Cap Valve Body CI Center 1 are ready available from most Warren 2 360 058 360 Gasket Valve Cap 1 Rupp distributors The pump owner may 3 170 063 330 Capscrew Hex Head prefer to maintain a limited inventory of 4 170 033 330 Capscrew Hex Head 4 these parts in his own stock to reduce 5 901 035 330 Washer Flat AL Center 7 repair downtime to a minimum 901 035 330 Washer Flat CI C
10. at and flap valve on the side of the unit marked OUT with the flap valve hanging down and swinging away from the manifold into the flange Install the flap valve and seat on the other side of the unit marked IN with the flap valve hanging down and swinging into the manifold away from the flange Inlet and outlet direction is determined by how the check valves are installed DIAPHRAGM SERVICING Remove the four bolts securing the manifold flange to the chamber Remove the eight nuts securing the outer diaphragm chamber flange and remove the chamber Loosen the capscrew securing the diaphragm and plate to the rod by leaving the diaphragm engaged with the capscrews around the outer flange preventing rotation of the rod DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEAL During reassembly make certain that the rubber bumper is on the rod on each side Install the diaphragm with the natural bulge outward as indicated on the iy 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 2 diaphragm Install the heavier plate on the outside of the diaphragm and make certain that the large radius side of both plates are toward the diaphragm Place the sealing washer between the inner diaphragm plate and the end of the rod Tighten the capscrew to approximately 25 ft lbs 83 9 Newton meters Torque while allowing diaphragm to turn freely with plates except for EPDM rubber use a light weight oil betw
11. bility of an air trap in the liquid chambers D Unstable cycling indicates improper check valve seating on one chamber This condition is confirmed when unstable cycling repeats consistently on alternate exhausts Cycling that is not consistently unstable may indicate partial exhaust restriction due to freezing and thawing of exhaust air Use of an air dryer should solve this problem WARRANTY This pump is warranted for a period of five years against defective material and workmanship Failure to comply with the recommendations stated in this manual voids all factory warranty RECOMMENDED WARREN RUPP ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE e Tranquilizer Surge Suppressor For nearly pulse free flow e Warren Rupp Filter Regulator For modular installation and service convenience e Warren Rupp Speed Control For manual or programmable process control Manual adjustment or 4 20mA reception For more detailed information on these accessories contact your local Warren Rupp Factory Authorized Distributor or Warren Rupp corporate headquarters 2004 Warren Rupp Inc All rights reserved SandPIPER and Tranquilizer are registered tradenames of Warren Rupp Inc Neverseize is a registered tradename of Loctite Printed in U S A 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 5 Grounding The Pump Nice N Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids
12. ceed 125 psi 8 61 bar Connect the pump air inlet a to an air supply of sufficient capacity and pressure required for desired performance Ja KO When the air line is solid piping use a short length of flexible hose not less than 3 4 19mm in diameter between pump and piping to eliminate strain to pipes Use of a Warren Rupp Filter Regulator is the air line is recommended AIR INLET amp PRIMING For start up open an air valve approximately 1 4 to 1 2 turn After the unit primes an air valve can be opened to increase flow as desired If opening the valve increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be closed slightly For the most efficient use of compressed air and the longest diaphragm life throttle the air inlet to the lowest cycling rate that does not reduce flow AIR EXHAUST If a diaphragm fails the pumped liquid or fumes can enter the air end of the pump and be exhausted into the atmosphere When pumping hazardous or toxic materials pipe the exhaust to an appropriate area for safe disposition This pump can be submerged if materials of construction are compatible with the liquid The air exhaust must be piped above the liquid level Piping used for the air exhaust must not be smaller than 1 2 54 cm Reducing the pipe size will restrict air flow and reduce pump performance When the product source is at a higher level than the pump flooded suction
13. dcap and new retaining rings Tighten the four capscrews to eliminate air leakage Tighten at 150 in Ibs 16 9 newton meters Reinstall the body on the intermediate bracket with new gaskets A NOTE ABOUT AIR VALVE LUBRICATION The SandPiper pump s pilot and main air valve assemblies 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 supplies Proper lubrication of the compressed air supply would entail the use of an air line lubricator available from Warren Rupp set to deliver one drop of 10 wt non detergent oil for every 20 SCFM of air the pump consumed at its point of operation Consult the pump s published Performance Curve to determine this It is important to remember to inspect the sleeve and spool set routinely It should move back and forth freely This is most important when the air supply is lubricated If a lubricator is used oil accumulation will over time collect any debris from the compressed air This can prevent the pump from operating properly 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 This can be addressed by using a point of use air dryer to supplement a plant s air
14. drying equipment This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem ESADS Externally Serviceable Air Distribution System Please refer to the exploded view drawing and parts list in the Service Manual supplied with your pump If you need replacement of additional copies contact your local Warren Rupp Distributor or the Warren Rupp factory Literature Department at the number shown below To receive the correct manual you must specify the MODEL and TYPE information found on the name plate of the pump Models with 1 suction discharge or larger and METAL center sections The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head capscrews The valve body assembly is removed from the pump by removing these four hex head capscrews With the valve body assembly off the pump access to the sleeve and spool set is made by removing four hex head capscrews each end on the end caps of the valve body assembly With the end caps removed slide the spool back and forth in the sleeve The spool is closely sized to the sleeve and must move freely to allow for Pilot valve _ Pilot valve body spool plungers Bushings retaining rings and o rings 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 3 proper pump operation An accumulation of oil dirt or other contaminants from the pump s air supply or from a failed diaphragm
15. een the plates and diqohragm when doing this procedure Use a wrench on the capscrew of the opposite side to keep the rod from rotating If the opposite chamber is assembled the rod need not be held When reassembling the outer chambers and the manifold the bolts securing the manifold flange to the chamber should be snugged prior to tightening the chamber bolts The sleeve and spool set is located in the valve body which is held onto the intermediate bracket by four 4 capscrews Loosening the four 4 hex head capscrews allows the valve body to come out of place Once the valve body is off the pump remove the retaining ring holding the endcap on the body to inspect the spool and sleeve set The spool of the air distribution valve is closely sized to the sleeve The spool must slide freely in the sleeve Accumulation of dirt and contaminants may prevent the spool from moving freely It may stick ina position that prevents the pump from cycling Clean all parts before reassembly Use a safety solvent and air oil to keep the parts from oxidizing Any nicks on the spool should be removed with a fine stone or crocus cloth When removing the stainless steel sleeve carefully press it out of the body preferably using an arbor press Reinstall it into the body until it bottoms out against the opposite endcap Use new o rings when reinstalling and apply a light coating of grease or o ring lube before placing in the valve body Reinstall the spring en
16. ely self priming from a dry start for suction lifts of 5 7 feet 1 5 2 meters or less For suction lifts exceeding 10 feet of liquid fill the chambers with liquid prior to priming CHAMBER PORTING SA1 A with bottom chamber porting of check valve manifolding is recommended for general portable pumping applications low head transfer pumping and for pumping solids laden liquids which tend to settle out For low flow high pressure applications and for pumping highly viscous liquids top porting of chamber to check valve manifold is recommended Model SA1 A SandPIPER with flap type valves can be arranged in either bottom chamber porting or top chamber porting of check valve manifold simply by rotating outer diaphragm chambers 180 and reversing the flap valves and seats in the manifold so they Model SA1T A Model SAZ5A Type 4 A IMPORTANT A 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 A WARNING A 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 6 AX BEFORE OPERATION Before pump operation inspect all gasketed fasteners for looseness caused by
17. enter 1 IMPORTANT Wh d i i 900 005 330 Washer Lock CI Center 6 ee AE 6 901 005 330 Washer Flat 4 ee 7 542 001 330 Nut Square 1 l 8 095 051 558 Body Spool Valve 1 9 031 039 000 Sleeve amp Spool Set 1 MATERIAL CODES 10 165 038 356 Cap End 2 The Last 3 Digits of Part Number 11 675 043 115 Ring Retainer 2 000 Assembly sub assembly 12 560 058 360 O Ring 8 and some purchased Items 13 360 057 360 Gasket 1 DE Powered Metal 14 095 074 000 Assembly Pilot Valve 1 ee eee 14 A 095 071 551 Valve Body 1 025 _ Music Wire 14 B 755 025 000 Sleeve without O Ring 1 mee eee ae AISI B 1112 14 C 560 033 360 O Ring Sleeve 4 110 Alloy Type 316 Stainless Steel 14 D 775 014 000 Spool without O Ring 1 earn lg 316 Stainless Steel Electro Polished a AllO 14 E 960 023 360 O Ring Spool 4 113 Alloy Type 316 Stainless Steel Hand Polished 14 F 675 037 080 Retaining Ring 1 a ane ves ainiess otee 15 360 056 360 Gasket 1 117 440 C Stainless Steel Martensitic 16 114 007 157 Bracket Intermediate AL Center 1 120 416 Stainless Steel Wrought Martensitic 17 114012010 Bracket Intermediate CI Center E e Ring 149 2024 T4 Aluminum 18 675 040 360 Ring Sealing AL Center 2 fey es oer iain 19 720 010 375 Seal U Cup 2 152 2024 T4 Aluminum 2023 7351 Kaa SU ee 2 e ie 2 2 od lap ragm 157 Die Cast Aluminum Alloy 380 22 901 012 180 Washer Sealing 2 ie 23 170 034 330 Capscrew Hex Head 2 162 Brase Yelow Screw Machine Stok 24 900
18. he suction and discharge lines higher than the check valves and pouring liquid into the unit through the suction inlet When priming at high suction lifts or with long suction lines operate the pump at maximum cycle rate 3 Low performance A Capacity is reduced as the discharge pressure increases as indicated on the performance curve Performance capability varies with available inlet air supply Check air pressure at the pump inlet when the pump is operating to make certain that adequate air supply is maintained B Check vacuum at the pump suction Capacity is reduced as vacuum increases Reduced flow rate due to starved suction will be evident when cycle rate can be varied without change in capacity This condition will be more prevalent when pumping viscous liquids When pumping thick heavy materials 10 000 SSU limit the suction line must be kept as large in diameter and as short as possible to keep suction loss minimal C Low flow rate and slow cycling rate indicate restricted flow through the discharge line Low flow rate and fast cycling rate indicate restriction in the suction line or air leakage into suction NOTE Bottom chamber porting on the SA1 A pump for thick liquids may create an air trap in the outer liquid chamber causing reduced displacement and low capacity performance Use of air vent lines from the top of the chamber back to the liquid source will correct this Converting to top chamber porting will eliminate any possi
19. iaphragm fails the pumped product or fumes can enter the air side of the pump This side is exhausted through the exhaust port muffler When the product is a hazardous or toxic material the exhaust should be piped to an appropriate area for safe disposition When the product source is at a higher level than the pump flooded suction the exhaust should be piped to a higher level than the product to prevent spills caused by siphoning A SAFETY WARNING A To assure proper pump function and safe installation of the retaining ring check the gap G dimension for full installation into the valve body grooves gt 232 G Dimensions between lugs 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 4 2 Pump cycles but will not pump A Suction side of pump pulling in air Check the suction line for air leaks and be sure that the end of the suction line is submerged Check flange bolting Check valve flanges and manifold to chamber flange joints B Make certain the suction line or strainer is not plugged Restriction at the suction is indicated by a high vacuum reading when a vacuum gauge is installed in the suction line C Check valves may not be seating properly To check remove the suction line and cover the suction port with your hand If the unit does not pull a good suction vacuum the check valves should be inspected for proper seating D Static suction lift may be too high Priming can be improved by elevating t
20. ings An o ring is behind each bushing If the plunger has any sideways motion check o rings and bushings for deterioration wear The plunger may be removed for inspection or replacement First remove the air distribution valve body and the pilot valve body from the pump The plungers can be located by looking into the intermediate It may be necessary to use a fine piece of wire to pull them out The bushing can be turned out through the inner chamber by removing the outer chamber assembly Replace the bushings if pins have bent TROUBLE SHOOTING 1 Pump will not cycle A Check to make sure the unit has enough pressure to operate and that the air inlet valve is open B Check the discharge line to insure that the discharge line is neither closed nor blocked C It the spool in the air distribution valve is not shifting check the main spool It must slide freely D Excessive air leakage in the pump can prevent cycling This condition will be evident Air leakage into the discharge line indicates a ruptured diaphragm Air leakage from the exhaust port indicates leakage in the air distribution valve See further service instructions E Blockage in the liquid chamber can impede movement of diaphragm IMPORTANT Q 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 CAUTION If a d
21. me of Warren Rupp Inc Printed in U S A Discharge 520 004 000 1 04 Model SA1 A SA25A Type 4 Page 9 WARREN RUPP IDEX CORPORATION Declaration of Conformity ATEX 100a In accordance with Directive 94 9 EC Annex VIII Equipment intended for use in potentially explosive environments Technical File is stored at KEMA Notified Body 0344 under document number 203040000 Manufacturer Applicable Standard Warren Rupp Inc 94 9 EC 800 North Main Street For potentially explosive environments P O Box 1568 Group l Category M2 Mansfield OH 44902 USA Group II Category 2 GD Models Air Operated Double Diaphragm Metallic Pumps Series G SA SB S ST and U under SANDPIPER and MARATHON Brands SANDPIPER A WARREN RUPP PUMP BRAND ARATHO A WARREN RUPP PUMP BRAND DATE APPROVAL TITLE UG 8 May 2003 Jason Awad VP Engineering Rev B 23 October 2003
22. pipe the exhaust higher than the product source to prevent siphoning spills Freezing or icing of the air exhaust can occur under certain temperature and humidity conditions Use of an air dryer should eliminate most icing problems Air Inlet Check exhaust muffler for ice buildup air B ETW E z N U S E S contaminants When used for materials that tend to settle out or transform to solid form the pump should be completely 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 ax ne valves and diaphragms at re start In freezing temperatures the pump must be drained between uses in all cases CHECK VALVE SERVICING Need for inspection or service is usually indicated by poor priming unstable cycling reduced performance or the pump s cycling but not pumping Remove the six flange bolts securing the inlet and outlet flanges to the manifold Inspect the surfaces of both check valve and seat for wear or damage that could prevent proper sealing If pump is to prime properly valves must seat air tight Flap valve Flap type models can be assembled with the manifold positioned under the diaphragm chamber bottom porting or above top porting Inlet and outlet flange pipe threads run horizontal in either case Flap valves and seats must be reassembled to unit to conform to the IN and OUT markings on the base plate Install the valve se
23. sting of the diaphragm chamber is performed by means of an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet air 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 porting of chambers is reversed The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool while exhausting the other side The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot valve spool This pushes it into position for shifting of the air distribution valve The chambers are manifolded together with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION amp START UP Locate the pump as close to the product being pumped as possible keeping suction line length and number of fittings to a minimum Do not reduce line size For installations of rigid piping short flexible sections of hose should be installed between pump and piping This reduces vibration and strain to the piping system A Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsation in flow This pump was tested at the factory prior to shipment and is ready for operation It is complet
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