S20 Metallic · Design Level 1
Contents
1. 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 Group before performing this procedure Any model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S20 Metallic Design Level 1 Page 8 Recycling Many components of SandPIPER Metallic AODD pumps are made of recyclable materials see chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed M2 c b T5 Pump complies with EN2. 17 is a bonded PTFE Santoprene design Follow the same procedures described for the standard diaphragm for removal and installation uniRupp Il DIAPHRAGM SERVICING Bonded PTFE with intergral plate The uniRupp Il diaphragm has a treaded stud installed in the intergral 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 diapragm rod only until the inner plate contacts the rod Do not tighten A small amount of grease may be applied between the inner plate and the diaphragm to facilitate assembly Insert the diaphragm rod assembly into the pump and install the outer chamber Turn the pump over and thread the second daiphragm inner plate onto the diaphragm rod Turn the diapragm 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 A IMPORTANT Read these instructions completely before in Stallation 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 S20 Metallic Design Level 1 Page 21 ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed air supply
3. 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 items 11 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly item 4 can now be removed Step 2 Inspect the actuator plungers See ILLUSTRATION AT RIGHT The actuator plungers items 32 can be reached through the pilot valve cavity in the intermediate assembly item 5 Remove the plungers item 32 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 27 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go To remove the bushings item 7 first remove the retaining rings item 33 by using a flat screwdriver NOTE It is recommended that new retaining rings be installed 520 273 000 7 03 Rev D Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 20 air inlet cap item 8 and capscrews item 11 Connect the air supply to the pump The pump is now ready for operation ACTUATOR PLUNGER SERVICING Model S20 Metallic Desi
4. l om i e 1 Terminal d Power Negative Positive BET D Sa 4 gt zm pm pe pm pm l l l l l l l H m l Ol l l L wm mn vm el Een Cd Model S20 Metallic Design Level 1 Page 19 Diaphragm Service Drawing Diaphragm Service Drawing uniRupp Diaphragm with Overlay Non Overlay Service Drawing AVAILABLE FOR FIELD CONVERSION IN KITS Kit 475 218 157 Kit 475 218 110 Kit 475 219 157 2 uniRupp Diaphragms 2 uniRupp Diaphragms 2 uniRupp Diaphragms 2 Aluminum Inner Plates 2 Aluminum Inner Plates 2 Cast Iron Inner Plates 2 Aluminum Outer Plates 2 Stainless Steel Outer Plates 2 Aluminum Outer Plates Kit 475 219 010 Kit 475 219 157 Kit 475 219 110 2 uniRupp Diaphragms 2 uniRupp Diaphragms 2 uniRupp Diaphragms 2 Cast Iron Inner Plates 2 Cast Iron Inner Plates 2 Cast Iron Inner Plates 2 Cast Iron Outer Plates 2 Aluminum Outer Plates 2 Stainless Steel Outer Plates 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 20 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump assembly drawing and the diaphragm servicing illustration Using a 9 16 wrench or socket remove the 16 capscrews item 9 hex nuts and lockwashers t
5. no kit options AA SP Stroke Indicator Pins 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 2 Performance Curve S20 Metallic Design Level 1 L N M A Tr O 520 273 000 1 00 90 80 70 60 50 40 30 20 10 7 03 Rev D Liters per minute Capacity Model S20 Metallic Design Level 1 Page 3 OBR ON OO Cp METERS Sch Wu SCFM M hr S20 Metallic Performance Curve 20 34 Performance based on water at ambient temperature 700 5 gt 40 68 G Displacement per Stroke 42 gallons SA A 60 102 1 59 liters 80 Flow Capacity 0 to150 gallon per minute PSI 0 to 567 liters per minute 1 R x X UN X N S 4 06 BS x t 100 170 it SES A x S H Po 2 72 Bar N N 20 Ki N Es SS 20 PSI Gas Sr T ar Air ney E S 2 x Sie 10 Ure me Ko lt 5 0 20 40 60 100 120 140 160 U S Gallons per minute 100 200 400 500 600 NPSHR Dimensions S20 Metallic Dimensions in Inches Dimensional Tolerance 1 8 VIEW 51 3 16 Discharge Port 2 NPT 2 3 8 Suction Port 2 NPT Encapsulated Muffler 1 NPT Exhaust Port For Optional Muffler Styles or Piping Exhaust Air In Submerged Applications Air Inlet 3 4 NPT 520 273 000 7 03 Rev D VIEW DIMENSION Encapsulated Muffler 12 19 32 Both Suction And Discharge Ports Are Available With 2 B
6. produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e 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 520 273 000 7 03 Rev D What to Check Undersized 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 the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspec
7. 106 363 560 106 364 560 106 365 720 060 608 530 033 000 DESCRIPTION Manifold Suction 2 BSPT Manifold Discharge Manifold Discharge 2 BSPT Manifold Discharge Manifold Discharge 2 BSPT Manifold Discharge Manifold Discharge 2 BSPT Nut Hex 3 8 16 Nut Hex 3 8 16 Nut Hex 7 16 14 Nut Hex 7 16 14 O Ring Plate Inner Diaphragm Assembly Plate Inner Diaphragm Assembly Plate Outer Diaphragm Assembly Plate Outer Diaphragm Assembly Plate Outer Diaphragm Assembly Plate Inner Diaphragm used with 286 085 650 or 286 020 604 Plate Inner Diaphragm used with 286 085 650 or 286 020 604 Plate Outer Diaphragm Assembly use with 286 085 650 or 286 020 604 Plate Outer Diaphragm Assembly use with 286 085 650 or 286 020 604 Plate Outer Diaphragm Assembly use with 286 085 650 or 286 020 604 Plunger Actuator Ring Retaining Rod Diaphragm Seal Diaphragm Rod Seat Check Ball Seat Check Ball Seat Check Ball Seat Check Ball Seat Check Ball seals required see item 28 Seat Check Ball seals required see item 28 Seat Check Ball seals required see item 28 Seat Check Ball Washer Lock Washer Lock Washer Flat 5 16 Washer Flat 5 16 Washer Flat 3 8 Sroke Indicator Only Washer Flat 3 8 Sroke Indicator Only Seal O Ring See item 34 Seal O Ring See item 34 Seal O Ring See item 34 Seal O Ring See item 34 Seal O Ring See item 34 Metal Muffler fo
8. 114 303 Stainless Steel 115 302 304 Stainless Steel 117 440 C Stainless Steel Martensitic 120 416 Stainless Steel Wrought Martensitic 123 410 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 149 2024 T4 Aluminum 150 6061 T6 Aluminum 151 6063 T6 Aluminum 152 2024 T4 Aluminum 2023 T351 154 Almag 35 Aluminum 155 EE 356 T6 Aluminum 156 356 T6 Aluminum 157 Die Cast Aluminum Alloy 380 158 Aluminum Alloy SR 319 159 3342 Anodized Aluminum 162 Brass Yellow Screw Machine Stock 165 Cast Bronze 85 5 5 5 166 Bronze SAE 660 170 Bronze Bearing Type Oil Impregnated 520 273 000 7 03 Rev D Material Codes The Last 3 Digits of Part Number TS ex Die Cast Zinc 180 Copper Alloy 305 Carbon Steel Black Epoxy Coated 306 Carbon Steel Black PTFE Coated 307 Aluminum Black Epoxy Coated 308 Stainless Steel Black PTFE Coated 309 Aluminum Black PTFE Coated 310 Kynar Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminum Electroless Nickel Plated 333 Carbon Steel Electroless Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 353 Geolast Color Black 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 355 Thermal Plastic 35
9. 16 X 2 Capscrew Hex Hd 7 16 14 X Capscrew Hex Hd 7 16 14 X Capscrew Hex Hd 5 16 18 X Capscrew Hex Hd 5 16 18 X Capscrew Soc Hd 3 8 16 X 2 Stroke Indicator Only Capscrew Soc Hd 3 8 16 X 2 50 Stroke Indicator Only Capscrew Hex HD 3 8 16 X 1 00 Capscrew Hex HD 3 8 16 X 1 00 Capscrew Soc Hd 7 16 14 X 1 25 Capscrew Soc Hd 7 16 14 X 1 25 Chamber Outer Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Overlay Diaphragm uniRupp Diaphragm Diaphragm Diaphragm Diaphragm Gasket Air Valve Gasket Pilot Valve Gasket Air Inlet Gasket Inner Chamber Manifold Suction Manifold Suction 2 BSPT Manifold Suction Manifold Suction 2 BSPT Manifold Suction 50 AA O aa NMA NNYNNYNYNYNYNYNYNNOMOAR A RPRADZZDIANNAAAIANARARRRAAAAH Y ITEM 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 46 PART NUMBER 518 145 110E 518 146 156 518 146 156E 518 146 010 518 146 010E 518 146 110 518 146 110E 545 005 115 545 005 330 545 007 115 545 007 330 560 001 360 612 192 157 612 192 010 612 194 157 612 194 010 612 194 110 612 195 157 612 195 010 612 039 010 612 097 110 612 039 157 620 020 115 675 042 115 685 058 120 720 004 360 722 040 360 722 040 363 722 040 364 722 040 365 722 040 080 722 040 110 722 040 150 722 040 600 900 005 115 900 005 330 901 038 115 901 038 330 901 048 115 901 048 330 560 106 360 560
10. 2 Filled PTFE 603 Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated Viton 632 Neoprene Hytrel 633 Viton PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE Viton PTFE 638 PTFE Hytrel PTFE 639 Buna N TFE 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene Delrin Viton and Hytrel are registered tradenames of E 1 DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Warren Rupp SandPIPER PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Model S20 Metallic Design Level 1 Page 10 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 11 Composite Repair Parts Drawing Available Service And Conversion Kits 476 227 000 AIR END KIT Use With Aluminum Centers Seals O ring Gaskets Retaining Rings Air Valve Sleeve and Spool Set and Pilot Valve Assembly 476 170 000 AIR END KIT Air
11. 3 Rev D M2 c b T5 Il 2GD b T5 U S Patent 5 996 627 6 241 487 Other U S Patents Applied for CE SOLIDS HANDLING Up to 25 in 6mm Maximum 190 F 88 C 212 F 100 C 170 F 77 C 212 F 100 C 212 F 100 C 212 F 100 C 150 F 65 C Definite reduction in service life SANDPIPER Design Level 1 Ball Valve Air Powered Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA DISPLACEMENT STROKE 42 Gallon 1 59 liter HEADS UPTO 125 psi or 289 ft of water 8 6 Kg cm or 86 meters Operating Temperatures inimum Optimum 10 F 50 to 140 F 23 C 10 to 60 C 10 F 50 to 212 F 23 C 10 to 100 C 10 F 50 to 130 F 23 C 10 to 54 C 10 F 50 to 212 F 23 C 10 to 100 C 35 F 50 to 212 F 37 C 24 to 100 C 32 F 75 to 212 F 0 C 24 to 100 C 40 F 40 C Minimal reduction in service life at ends of range Model S20 Metallic Design Level 1 Page 1 Explanation of Pump Nomenclature 20 Metallic Design Level 1 Ball Valve Diaphragm Non Wetted Design Wetted Check Valve Material Porting Pump Kit Level Material Materials Options Options Options Options 20B1ABBANSO00 E B 1 A B B A N S 0 S20B1AEEANS000 5 B 1 A E E A N S 0 S20B1AGTANSOOO S B 1 A G T A N S 0 20B1ANNANSOOO
12. 6 Hytrel 357 Injection Molded Polyurethane 358 Urethane Rubber Some Applications Compression Mold 359 Urethane Rubber 360 Buna N Rubber Color coded RED 361 Buna N 363 Viton Flurorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile 368 Food Grade EPDM 370 Butyl Rubber Color coded BROWN 371 Philthane Tuftane 374 Carboxylated Nitrile 375 Fluorinated Nitrile 378 High Density Polypropylene 379 Conductive Nitrile 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 502 Conductive Acetal ESD 800 503 Conductive Acetal Glass Filled 505 Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF Natural color 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene Bb Glass Filled Polypropylene 552 ivi Unfilled Polypropylene 553 Unfilled Polypropylene 555 Polyvinyl Chloride 556 Black Vinyl 558 Conductive HDPE 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 PTFE virgin material Tetrafluorocarbon TFE 601 PTFE Bronze and moly filled 60
13. 809 Pumping Il 2GD b T5 Directive and Directive 98 37 EC Safety of Machinery and ATEX 100a Directive CE 94 9 EC Equipment for use in Potentially Explosive Environments 520 273 000 7 03 Rev D Important Safety Information A IMPORTANT Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual 4 WARNING Before maintenance or repair shut off the com pressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure WARNING In the event of diaphragm rupture pumped material may enter the air end of the pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition AA 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 equipmen
14. S B 1 A N N A N S 0 20B1A1EANSO000 S B 1 A 1 E A N S 0 20B1AVTANSOOO E B 1 A V T A N S 0 20B1IBBANSOOO 5 B 1 B B A N 5 0 S20B1IEEANSOOO S B 1 E E A N S 0 20B1IGTANSOOO S B 1 G T A N S 0 S20B1INNANSOOO S B 1 N N A N S 0 20B111EANSOO0 S B 1 1 E A N S 0 S20B1IVTANSOOO gt B 1 V T A N S 0 20B1IEEANSO00 S B 1 E E A N Ei 0 20B1SBBANSO00 S B 1 S B B A N S 0 20B1SGTANSOOO S B 1 S G T A N S 0 20B1SNNANSOOO S B 1 S N N A N 5 0 S20B1S1EANS000 S B 1 S 1 E A N S 0 S20B1SVTANSOOO S B 1 S V T A N Ei 0 Pump Brand Diaphragm Check Valve Materials Check Valve Seat Cont Porting Options 5 High temperature Air Valve S SandPIPER 1 Santoprene Santoprene S Stainless Steel N NPT Threads w Mesh Muffler Pump Size a ae le Ve Ge B BSPT Tapered Threads 6 Metal Muffler AA 20 2 E EPDM EPDM Pump Style Kit Options Check Valve Type l EPDM Santoprene Non Wetted Material Options S Standard 00 None B Ball G PTFE Neoprene PTFE A Painted Aluminum Pump Options DO 0 30VDC Pulse Output Kit Design Level i EE I Cast on 0 None P1 ce 10 30VDC 1 Design Level pa d Painted Aluminum WPTEE 15 Sound e P2 110 120 or 220 240VAC Wetted Material Check Valve Seat Y Se SE w GE Air Valve Pulse O utput Kit Se Ss SE Stainless Steel Hardware w Encapsulated Muffler P Pie CuI EH Si E Garbon Sto Emer High oper A Vane _ Ps KSE 220 240VAC N Neoprene AA Note ATEX compliant pumps must be ordered with a metal muffler and
15. SANDPIPER A WARREN RUPP PUMP BRAND Model S20 Metallic Design Level 1 Table of Contents Engineering Data and Temperature Limitations 0 0 0 0 eeeeseseeeeesneeeeeneeeeeneeees 1 Explanation of Pump Nomenclature AAA 2 Performance Curve uu cecceeeceeseeeeeeeeeeeeeneeseeeeeaeeseaeeeaeesnaeesaeeseeeseaeeseaeeeeesiaeeneeetnaees 3 lu Ee A Metric DIMGNSIONS srein een eee nie cee aa a atte deed 5 Principle of PUMP Operation ceeceeeceeeeeceeeeeceeeeeeeeeeeaeeseeeeeaeeteaeseaeessaeeeeeeeaees 6 Installation ANd Gart Up 6 Tele EE 6 Air Valve GUD RICAtOni iison adaon aaa Eaa a ea Eed 6 Aimane Moisture EE 6 Air Inlet and Priming ET 6 Between USOS eerste ig ieaiaia anp aaae E ia paaa etek dade aaa EARE 6 Installation Guide AA 7 TroubIGSHOOUNG WEE 8 Warranty EE 8 FRECYCIING EE 9 Important Safety Information 2 0 eeeeeeeeeeeeeeeeeeeeeeeeeneeseaeeeeeseaeeeeeseeeeseeeseaeeeaeees 9 IER e EE 10 Composite Repair Parts Drawing eecceesceeeeeeeeeeeeeeeeeeeteeeeeeeeneeeeeeseaeeeaeete 12 Available Service and Conversion Kits cceeseesceeeeeeeeeeeeneeeeeeeeeeesseeeeaeeeeees 12 Composite Repair Parts List cecceeceeeeeeeneeeeeeeeeeeeeeeeeaeeeeeeeeaeesneeseeeseeeeeeene 13 Air Valve Drawing Parts List Service Instructions Cast Iron Centers Only 14 Air Valve Drawing Parts List Service Instructions Aluminum Centers Only 15 Air Valve w Stroke Indicator Drawing and Parts List 2 cecceceeceesee
16. SP Connection Pulse Output Kit 13 31 32 Aluminum 1311 16 263 16 Stainless Steel 1313 16 265 16 Mesh Muffler 15 1 8 Sound Dampening Muffler 15 1 8 Metal Muffler 1411 16 Model S20 Metallic Design Level 1 Page 4 Metric Dimensions S20 Metallic Dimensions in Millimeters Dimensional Tolerance 3mm FRONT VIEW 60mm Encapsulated Muffler 1 NPT Exhaust Port For Optional Muffler Styles or Piping Exhaust Air In Submerged 128mm Applications Suction Port 2 NPT DIMENSION Encapsulated Muffler 148mm Discharge Port 2 NPT SIDE VIEW Both Suction and Discharge Ports Are Available With 2 BSP Tapered Connection Pulse Output Kit Aluminum 625mm 47mm 8mm 3 4 NPT Stainless Steel 629mm 51mm 12mm 351mm Mesh Muffler Sound Dampening Muffler 520 273 000 7 03 Rev D Metal Muffler Model S20 Metallic Design Level 1 Page 5 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform
17. TER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 mie MUFFLER LA 1 DIAMETER AIR EXHAUST PIPING MUFFLER LA LIQUID F LEVEL SUCTION LINE Illustration 3 Se 1 DIAMETER AIR EXHAUST PIPING Model S20 Metallic Design Level 1 Page 25 RuppTech Leak Detection Options Drawing Note Pumps equipped with these options are not ATEX compliant 520 273 000 RuppTech ELECTRONIC LEAK DETECTOR Kit 032 037 000 100VAC 50Hz or110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC CONFIGURATION A To be used with the Encapsulated muffler option You will need to mount the terminal box directly to the muffler cap on the air valve using the 2 710 014 330 self tapping screws Then insert the leak detectors into the bottom port in the inner chambers CONFIGURATION B To be used with either of the muffler options or if your exhaust is piped away You will need to mount the terminal box to the 612 185 552 mounting plate using the 2 710 014 330 self tapping screws Then mount the mounting plate directly to the air valve body using the 4 710 009 115 self tapping screws Then insert the leak detectors into the bottom port in the inner chambers MECHANICAL LEAK DETECTOR Kit 031 023 110 Insert
18. 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 equipment This device removes water from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 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 pre
19. Valve with Stroke Indicator Pin Seals O ring Gaskets Retaining Rings Air Valve Sleeve and Spool Set and Pilot Valve Assembly 476 042 360 WET END KIT Buna Diaphragms Balls and Seats 476 042 656 WET END KIT Santoprene Diaphragms Balls and EPDM Seats 476 042 365 WET END KIT Neoprene Diaphragms Balls and Seats 476 042 633 WET END KIT Viton Diaphragms PTFE Balls and PTFE Seats 476 042 635 WET END KIT Neoprene Diaphragms PTFE Overlay PTFE Balls and PTFE Seats 476 042 364 WET END KIT EPDM Diaphragms Balls and Seats 475 216 000 MIDSECTION CONVERSION KIT Replaces Aluminum Midsection With Cast Iron Components Ait Inlet Cap Intermediate Bracket Inner Chamber and Inner Diaphragm Plates Hardware Kits 475 200 330 Zinc Plated Capscrews Washers and Hex Nuts 475 200 115 Stainless Steel Capscrews Washers and Hex Nuts Pulse Output Kits For use with 530 010 000 or piped exhaust 475 198 001 DC Kit 475 198 002 DC Intrinsically Safe Kit 475 198 003 110 120VAC or 220 240VAC Kit 475 198 004 110 120VAC Intrinsically Safe Kit 475 198 005 220 240VAC Intrinsically Safe Kit For use with encapsulated 530 028 550 muffler 475 198 006 DC Kit 475 198 007 DC Intrinsically Safe Kit 475 198 008 110 120VAC or 220 240VAC Kit 475 198 009 110 120VAC Intrinsically Safe Kit 475 198 010 220 240VAC Intrinsically Safe Kit Electronic Leak Detector Kits 032 037 000 100 120 220 290 VAC de e F P 032 045 000 12 32 VDC Note Pumps equip
20. alve body item 1 A 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 Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews Fasten the air valve assembly item 1 and gasket 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 in Stallation 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 S20 Metallic Design Level 1 Page 15 Air Valve with Stroke Indicator Assembly Drawing Parts List 520 273 000 7 03 Rev D NOTE CHECK GAP AFTER ASSEMBLY TO INSURE COMPLETE INSTALLATION OF RETAINING RING Note Pumps equipped with this valve assembly are not ATEX compliant AIR VALVE ASSEMBLY PARTS LIST Part Number 031 146 000 031 143 000 095 094 551 132 029 552 165 096 551 165 098 147 530 028 550 560 020 360 675 044 115 710 015 115 210 008 330 560 001 360 S 3 SETSEEEEEEER i sch mh h sch sch ch ch sch sch h ech Description Air Valve Assembly Sleeve and Spool Set Body Air Valve Bumper Cap Muffler Cap End Muffler O Ring Ring Retaining Scre
21. 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 Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 125 psi 8 6 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 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
22. ed and returned to operation METALLIC SEATS Two o rings or conductive PTFE seals item 40 are required for metallic seats 520 273 000 7 03 Rev D Check Valve Drawing with Non Metallic Seats with Metallic Seats Model S20 Metallic Design Level 1 Page 23 Optional Muffler Configurations Drawing Note the pump is built with a metal muffler for static electric dissipation to meet ATEX requirements The options shown on this page are not ATEX compliant CONFIGURATION A 530 028 550 Encapsulated Muffler uses 1 165 096 551 Cap and 4 710 015 115 Self Tapping Screw plastic valves or 4 706 026 330 Machine Screws Aluminum Valves to hold it in place CONFIGURATION B 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element CONFIGURATION C 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element Configuration A Configuration B and C 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 24 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials o
23. f construction are compatible with the liquid being pumped The air exhaust must be piped above the liquid level See illustration 2 at right Piping used for the air exhaust must not be smaller than 1 2 54 cm diameter Reducing the pipe size will restrict air flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the exhaust higher than the product source to prevent siphoning spills See illustration 3 at right CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Remove the muffler item 46 The air distribution valve item 1 has 1 NPT threads for piped exhaust 520 273 000 7 03 Rev D IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded 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 conductive and physically supported Failure to support these connections could also result in damage to the air distribution valve body Air Valve Assembly On ATEX compliant units the pump comes equipped with a standard metal muffler CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAME
24. f the sleeve part of item 1 A for dirt scratches or other contaminants Remove the sleeve if needed and replace 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 o rings item 1 G and 1 M into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the smaller unthreaded hole in the endcap Remove the new sleeve and 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 rings and retaining ring Fasten the air valve assembly item 1 and gasket item 19 to the pump Connect the compressed air line to the pump Remove the safety clip The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failu
25. gn Level 1 A IMPORTANT Read these instructions completely before in Stallation 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 Page 22 CHECK VALVE SERVICING Before servicing the check valve components 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 check valve components remove the manifold item 23 or item 24 not shown Use a 9 16 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 36 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled reconnect
26. hat fasten the manifolds items 23 amp 24 to the outer chambers item 14 Step 2 Removing the outer chambers Using a 11 16 and a 5 8 wrench or socket remove the 16 capscrews item 10 and hex nuts that fasten the outer chambers diaphragms and inner chambers together Step 3 Removing the diaphragm assemblies Use a 1 16 27mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 34 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 28 or 30 Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use a 11 16 wrench or socket to remove the outer diaphragm plate item 29 or 31 by turning counter clockwise Inspect the 520 273 000 7 03 Rev D diaphragm item 16 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 onto the stud Insert the loose assembly with the above 1 4 20 fastener back into the vise Use a torque wrench to tighten the diaphragm assembly together to 480 in Ibs 54 23 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clam
27. of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the e O type of equipment required O O 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 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 28 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 Warren Rupp Inc 800 North Main Street P O Box 1568 Mansfield OH 44902 USA Models Air Operated Double Diaphragm Metallic Pumps Series G SA SB S ST and U under Sandpiper and Marathon Brands SANDPIPER MARATHON PIE DATE APPROVAL TITLE 8 May 2003 Rev B 23 October 2003 Jason Awad V P Engineering
28. ped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 6 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 34 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 Fasten the outer chamber item 14 to the pump using the capscrews item 9 and hex nuts 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 34 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 15 Fasten the remaining outer chamber item 14 to the pump using the capscrews items 10 hex nuts and lockwashers Step 6 Re install the manifolds to the pump using the capscrews item 10 hex nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 16 is designed to fit over the exterior of the standard TPE diaphragm item 18 uniRupp DIAPHRAGM SERVICING The uniRupp diaphragm item
29. ped with these components are not ATEX compliant 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 12 ITEM Oo OND oO BW me ey fk N Oo 13 14 15 16 17 18 19 20 21 22 23 520 273 000 PART NUMBER 031 146 000 031 147 000 031 173 000 031 183 000 031 179 000 050 017 354 050 017 360 050 017 363 050 017 364 050 017 365 050 018 600 070 006 170 095 110 558 095 110 110 114 024 157 114 024 010 132 035 360 135 034 506 165 116 157 165 116 010 170 052 115 170 052 330 170 060 115 170 060 330 170 069 115 170 069 330 171 053 115 171 053 330 170 006 115 170 006 330 171 059 115 171 059 330 196 167 156 157 196 167 010 196 167 110 196 168 157 196 168 010 286 020 604 286 085 650 286 007 360 286 007 363 286 007 364 286 007 365 360 093 379 360 103 379 360 104 379 360 105 379 518 145 156 518 145 156E 518 145 010 518 145 010E 518 145 110 7 03 Rev D DESCRIPTION Air Valve Assembly Stroke Indicator Only Air Valve Assembly Stroke Indicator Only Air Valve Assembly Air Valve Assembly Air Valve Assembly Cast Iron Centers Only Ball Check Ball Check Ball Check Ball Check Ball Check Ball Check Bushing Pilot Valve Assembly Pilot Valve Assembly Cast Iron Centers Only Intermediate Bracket Intermediate Bracket Bumper Diaphragm Bushing Plunger Cap Air Inlet Assembly Cap Air Inlet Assembly Capscrew Hex Hd 3 8 16 X 2 Capscrew Hex Hd 3 8
30. plied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate AIR OPERATION The Solenoid Shifted SandPIPER has a solenoid operated air distribution valve in place of the standard SandPIPER s pilot operated air distribution valve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard SandPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage 520 273 000 7 03 Rev D l l l l l l l l l l l l l L Solenoid Connector l Before wiring remove terminal e block from conduit connector a a a a a a a EE 7 a ae Ne ew Ee pe aw eee a q Wiring Diagram E n ES 3rd Terminal for ground A i
31. r damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B M2 c b T5 Il 2GD b T5 AIR VALVE ASSEMBLY PARTS LIST Use w Aluminum centers only Item Part Number Description Qty 1 031 183 000 Air Valve Assembly 1 1 A 095 109 157 Body Air Valve 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 Hex Head Capscrew 1 4 20 x 75 8 AIR VALVE ASSEMBLY PARTS LIST Use w Cast Iron centers only Item Part Number Description Qty 1 031 179 000 Air Valve Assembly 1 1 A 095 109 110 Body Air Valve 1 1 B 031 139 000 Sleeve and Spool Set 1 1 C 132 029 357 Bumper 2 1 D 560 020 379 O Ring 10 1 E 165 127 110 Cap End 2 1 F 170 032 115 Hex Head Capscrew 1 4 20 x 75 8 Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the v
32. r other muffler options see pg 24 Note Pumps equipped with these valve assemblies are not ATEX compliant Model S20 Metallic Design Level 1 O ch sch sch sch sch sch sch 4 or ee eer eG O amp O oO PBRABRABRHABRNYMHDMDY N N N N NNNNMNNP kk nk QO AA ARAL Page 13 Air Valve Servicing Assembly Drawing amp Parts List Use With Aluminum Centers Only AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 19 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that 520 273 000 7 03 Rev D fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the bumpers as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches o
33. r wear Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B Note Pumps equipped with this valve assembly are not ATEX compliant AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 173 000 Air Valve Assembly 1 1 A 095 109 157 Body Air Valve 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 Hex Head Capscrew 1 4 20 x 75 8 1 G 530 028 550 Muffler 1 1 H 165 096 551 Muffler Cap 1 1 J 706 026 330 Machine Screw 4 Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D 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 A 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 Carefully insert the sleeve into the bumper and end cap with o rings and fasten with the remaining hex capscrews Fasten the air valve a
34. re to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S20 Metallic Design Level 1 Page 17 Solenoid Shifted Air Valve Drawing Note Pumps equipped with Integral Solenoid Valves are not ATEX compliant SOLENOID SHIFTED AIR VALVE PARTS LIST Includes all items used on Composite Repair Parts List except as shown Item Part Number Description Qty 41 893 097 000 Solenoid Valve NEMA4 1 42 219 001 000 Solenoid Coil 24VDC 1 219 004 000 Solenoid Coil 24VAC 12VDC 1 219 002 000 Solenoid Coil 120VAC 1 219 003 000 Solenoid Coil 240VAC 1 43 241 001 000 Connector conduit 1 241 003 000 Conduit Connector with 1 Suppression Diode DC Only 44 170 029 330 Capscrew Hex HD 5 16 18 x 1 25 4 45 618 051 150 Plug 2 For Explosion Proof Solenoid Valve Connector not required for explosion proof coil coil is integral with valve 41 893 098 001 Solenoid Valve NEMA 7 9 24VDC 1 893 098 002 Solenoid Valve NEMA 7 9 24VAC 12VDC 1 893 098 003 Solenoid Valve NEMA 7 9 120VAC 1 893 098 004 Solenoid Valve NEMA 7 9 220VAC 1 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 18 SOLENOID SHIFTED 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 the Warren Rupp Solenoid Rate Controller Batch Control or a customer sup
35. reeeees 16 M2 c b T5 II 2GD b T5 U S Patent 5 996 627 6 241 487 Other U S Patents Applied for Air Valve w Stroke Indicator Servicing c eccecceceeceeeeeeeeseeeeeeeeeeereaeenteaes 17 Solenoid Shifted Air Viave Drawing cecceccsceeceeceseeseesceeeestecteeeereeetersenenneaes 18 Solenoid Shifted Air Valve Parts List 18 Solenoid Shifted Air Valve Option ccccccecceceeseeseeceeeeeeceeceeteeeeeseeeeeeaeeaneaes 19 Diaphragm Service Drawing with Overlay cecceeeeseeeeeeeeseeeeeneetseeeeneeteeeeeaes 20 Diaphragm Service Drawing Non Overlay c ceeccessceeeseeseeeeeeeeeeeeeeeeeeeeeaes 20 Diaphragm Service Drawing UNIRUPP cecceeeeeeeeeeceeeeeeeeeeeeeeeteeeeaeeaees 20 Diaphragm Servicing cecceeeceeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeseaeeeneeseaeeeeesneeesieeseaeeeaes 21 Overlay Diaphragm Servicing cceccceeeeeseeseeeeeeeeeeeeeeeeeeeeeeeeseaeeeaeessaeeeeeenaees 21 Actuator Plunger Servicing e cccecceeseeeeeeeeeeeeeeeeeaeesaeeseaeeseeeeaeesaeeteaeeeeeseneees 22 Check Valve Servicing eccececceeeeeeeeeeneeeeeeeeaeeeeaeeeaeesaeeeaeeseeesaeeseeeeeneeseaeeeneeee 23 Check Valve Drawing cecceccceeeeeceeeeeeneeeeeeseaeeseeeeeaeesaeeseeesaeeeaeesneeeeeeseaeeeeeees 23 Optional Muffler Configurations c ccccccceseeseeseeeceeeeeeeeeeeceeeereeeeereestertaneaes 24 Optional Muffler Configuration Drawing s seesssesesrees
36. reeerirtsrenerernrtrenrernrnnene 24 Pumping Hazardous Liquid AAA 25 Converting Pump for Piping Exhaust Air 25 Converted Exhaust Illustration cc ceecceeeeeneeeeeeeeneeceeeeeaeeseeeeeaeeseeeeeneeeeaeeeeees 25 RuppTech Leak Detection Options amp Drawing c seceeeeeeeeseereeeeees 26 RuppTech Electronic Leak Detector Installation cccceceeseeeeeeeeeees 26 RuppTech Mechanical Leak Detector Installation cecceceeceeteteeeeeeees 26 RuppTech Pulse Output Kit Drawing s ssesssesessesirierststnrernrirtrrntnrnrnrrnrnrnnnenene 27 RuppTech Pulse Output Kit Options cecceceecceseeeeeeeeeeeeeeeteeeeeeeeeeeaeeaes 27 Grounding the PUMP EE 28 Note Not ATEX compliant WARREN RUPP INC A Unit of IDEX Corporation PO Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 e www warrenrupp com 520 273 000 7 03 Rev D Copyright 2003 Warren Rupp Inc All rights reserved WARREN RUPP Quality System IS0O9001 Certified Environmental Management System 1S014001 Certified Air Inlet Side View Air Exhaust Side View IDEX CORPORATION INTAKE DISCHARGE PIPE SIZE CAPACITY AIRVALVE 2 NPT internal 2 BSPT Tapered internal No lube no stall Oto 150 gallons per minute 0 to 567 liters per minute design A CAUTION Operating temperature limitations are as follows Materials Buna General purpose oil resi
37. ssembly item 1 and gasket 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 in Stallation 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 S20 Metallic Design Level 1 Page 14 Air Valve Servicing Assembly Drawing amp Parts List AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 19 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that 520 273 000 7 03 Rev D fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the o rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B from the sleeve Be careful not to scratch o
38. stant Shows good solvent oil water and hydraulic fluid resitance Should not be used with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hyrdrocarbons EPDM Shows very good water and chemical resistance Has poor resistance to oil and solvents but is fair in ketones and alcohols 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 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 fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures Viton Shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids animal and vegrtable oils Hot water or hot aqueous solutions over 70 F will attack Viton Polpropylene For specific applications always consult Chemical Resistance Chart Technical Bulletin SandPIPER pumps are designed to be powered only by compressed air 520 273 000 7 0
39. t must be grounded See page 28 A WARNING 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 WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly AA WARNING Before doing any main tenance 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 WARNING Airborne particles and loud noise hazards Wear ear and eye protection Model S20 Metallic Design Level 1 Page 9 000 Assembly sub assembly and some purchased items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable Iron 025 Music Wire 080 Carbon Steel AISI B 1112 100 Alloy 20 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel Electro Polished 112 Alloy C Hastelloy equivalent 113 Alloy Type 316 Stainless Steel Hand Polished
40. t 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 Warren Rupp Tranquilizer Surge Suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section 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
41. the leak detectors into the bottom part in the inner chambers 7 03 Rev D Configuration B To Control Box Configuration A Leak Detectors Model S20 Metallic Design Level 1 Page 26 RuppTech Pulse Output Kit Drawing amp Options Note Pumps equipped with Pulse Output Kits are not ATEX compliant RuppTech 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 RuppTech 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 Distribution Valve Assembly when the threaded exhaust port or an auxiliary muffler is being used See the individual kits listed on the Pump Repair Parts List for further information Exhaust Port or Auxiliary Muffler Configuration B amp C Pulse Output Kit 520 273 000 7 03 Rev D Integral Muffler Configuration A S KOS DPD Pulse Output Kit Model S20 Metallic Design Level 1 Page 27 Grounding The Pump The eyelet end is fastened to the pump hardware The clamp end is installed to a true earth ground ae This 8 foot long 244 centimeters Ground Strap part number 920 025 000 2 can be ordered as a service item 7 To reduce the risk
42. 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 one end of the valve body inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool 520 273 000 7 03 Rev D shifts to the opposite end of the valve body the pressure to the chambers 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
43. vent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model S20 Metallic Design Level 1 Page 6 WARREN TYPICAL INSTALLATION GUIDE RUPP For Metallic Pumps Available from Warren Rupp Surge PERRA Pipe Connection CO TA1 or TA25 Tranquilizer a de Style Optional 020 050 000 Filter Regulator 8 020 050 001 Lubricator Gauge Flexible Shut Off Valve Air Dryer Connection 1 A CAUTION Gg The air exhaust should be EL piped to an area for safe DISCHARGE disposition of the product Eege being pumped in the event S be S R of a diaphragm failure l Drain Port Flexible Connection Air Shut Off Pipe Connection Valve Style Optional f TOP Air Exhaust Air Dryer Gauge WW DISCHARGE DIAPHRAGM 1 Shut Off O Valve AIR INLET O Y Flexible SUCTION pn EC Connection EE Li j i Drain Port 520 273 000 7 03 Rev D Model S20 Metallic Design Level 1 Page 7 TROUBLESHOOTING Possible Symptoms e Pump will not cycle e Pump cycles but
44. w Self Tapping Clip Safety O Ring Qty For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 147 000 Air Valve Assembly 1 includes all items on 031 146 000 minus 1 D 1 F amp 1 J Model S20 Metallic Design Level 1 Page 16 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air 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 COMPOSITE REPAIR PARTS DRAWING Using a 5 16 Allen wrench remove the four hex socket capscrews item 12 and four flat washers item 39 Remove the air valve assembly from the pump Remove and inspect gasket item 19 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o ring items 1 G and 1 M for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cut wear or abrasion Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 520 273 000 7 03 Rev D Inspect the inner diameter o
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