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1. 48 pb025nmdl3sm rev0814 219 009 001 219 009 002 219 009 003 219 009 004 219 009 005 219 009 006 NO wech wesch wesch zech zech wh vc vc sesch wesch sesch zech zech _ vc zech sesch wesch ASSEMBLY INSTRUCTIONS Must Be Performed Prior To Start Up The tee item 51 nipple item 50 fitting item 53 and tubing item 52 have been pre assembled at the factory Thread this assembly into the air inlet cap item 9 Be careful not to over tighten Push the free end of the tubing into the fitting item 49 which is attached to the valve Page 10 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION Warren Rupp s solenoid shifted air distribution valve option utilizes electrical signals to precisely control your SANDPIPER s speed The solenoid coil is connected to a customer supplied control Compressed air provides the pumping power while electrical signals control pump speed pumping rate OPERATION The Solenoid Shifted SANDPIPER has a solenoid operated air distribution valve in place of the standard SANDPIPER s pilot operated air distribution valve Where a pilot valve is normally utilized to cycle the pumps 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 chamb
2. Ai DISCHARGE PORT i 8 ch eg A Ten m EXHAUST VIEW SUCTION PORT 1 2 NPT EXTERNAL N7 1 4 NPT INTERNAL 8 TYP SLOT AIR INLET PORT w 1 4 NPT INTERNAL THREADS BOTTOM VIEW a INLET VIEW Dimension A 8 0 pbO025nmdl3sm rev0814 Page 3 Metric Dimensions PB Non Metallic DISCHARGE PORT 1 2 NPT EXTERNAL THREADS 1 4 NPT INTERNAL THREADS n OPTIONAL HORIZONTAL AT DISCHARGE PORT 17mm 196mm EXHAUST VIEW SUCTION PORT 1 2 NPT EXTERNAL 1 44 NPT INTERNAL 10mm TYP SLOT Cal 7 Nz WE AIR INLET PORT 1 4 NPT INTERNAL THREADS BOTTOM VIEW INLET VIEW Dimension A 8 Pulse Output Kit 178 140 pbO025nmdl3sm rev0814 Page 4 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 centres of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is dis charged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stro
3. 37 38 39 40 ITEM PART NO 612 146 520 A 612 146 502 612 146 552 200 057 115 100 002 115 945 027 337 196 145 520 A 196 145 502 196 145 552 720 032 600 722 073 520 722 073 506 122 073 552 050 033 354 050 033 356 050 034 600 A 312 095 520 312 095 502 312 095 552 706 023 115 544 004 115 A 312 096 520 312 096 502 312 096 552 720 033 600 41 518 127 520 518 127 502 518 127 552 42 518 128 520 518 128 502 518 128 552 43 360 086 360 54 920 025 000 Item not shown 706 025 115 DESCRIPTION Plate Outer Diaphragm Plate Outer Diaphragm Plate Outer Diaphragm Clamp V Band T Bolt Nut Hex 1 4 28UNF Chamber Outer Chamber Outer Chamber Outer Seal Check Valve Seat Check Valve Seat Check Valve Seat Check Valve Ball Check Ball Check Ball Check Elbow Suction Elbow Suction Elbow Suction Screw Machine 10 32UNF x 1 Long Nut Hex Flange 10 32UNF Elbow Discharge Elbow Discharge Elbow Discharge Seal Manifold Manifold Horizontal Optional Discharge Manifold Horizontal Optional Discharge Manifold Horizontal Optional Discharge Manifold Vertical Manifold Vertical Manifold Vertical Gasket Sealing Grounding Cable Conductive Acetal Units Only Screw Machine 10 32UNF x 88 Long QTY RNUNNAROHNNNARARARRANNNNNNNNYND NNS Nanan To be fully groundable the pumps must be ATEX Compliant Refer to pump data
4. F 82 C 0 C Conductive Acetal 190 F 20 F 88 C 29 C For specific applications always consult the Warren Rupp Chemical Resistance Chart Maximum and Minimum Temperatures are the limits for which these l 7 l materials can be operated Temperatures coupled with pressure affect the CAUTION Nonmetallic pumps and plastic components are not UV stabilized Ultraviolet longevity of diaphragm pump components Maximum life should not be radiation can damage these parts and negatively affect material properties Do not expose expected at the extreme limits of the temperature ranges to UV light for extended periods of time _ Performance based on the following elastomer fitted pump flooded suction water at ambient conditions o The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 T 4 1 7 AIR CONSUMPTION SCFM M hr O HEAD 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 U S Gallons per minute 0 2 4 6 8 10 12 14 16 Liters per minute SANDPIPER pumps are designed to be powered only by compressed air pb025nmdl3sm rev0814 Page 1 Explanation of Pump Nomenclature Your Model Pump Pump Pump Size Discharge Diaphragm Design XXX A Model XX A XXXXXX XX Pump Series P Plastic Pump Design B Gold Ball Pump Size and Options 1 4 1 4 NPT P1 Intrinsically Safe ATEX Compliant Pulse Output PO 10 30VDC Pulse Output Option P2 110 120 or 220 240VAC
5. HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 GIE 15 S20 S30 SB1 SB25 ST1 ST40 G15 G20 and G30 without the above listed options no aluminum parts Il 2 Gc T5 Il 3 2 G c T5 Il 2 D c T100 C Pump types DMF2 DMF3 HDB1 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 GIE 15 S20 S30 SB1 SB25 SE ST1 ST25 ST1 ST40 U1F G05 G1F G15 G20 and G30 I2 G15 Il 3 2 G T5 Il 2 D T100 C Surge Suppressors all types EC Type Certificate No Pumps KEMA O9ATEX0071 X Type Certificate No Pumps KEMA O9ATEX0072 X Type Certificate No Suppressors KEMA O9ATEX0073 Pumps marked with equipment Category II 3 1 G internal 3 G eternal 1 G 1D M1 and M2 when used for non conductive fluids The pumps are Category II 2 G when used for conductive fluids Pumps and surge suppressors marked with equipment Category II 3 2 internal 3 G external 2 G 2D when used for non conductive fluids The pumps are Category II 2 G when used for conductive fluids KEMA O9ATEX0071 X KEMA 09ATEX0071 X CE 0344 KEMA 09ATEX0071 X KEMA 09ATEX0072 X CE 0344 KEMA 09ATEX0072 X CE KEMA 09ATEX0073 CE Listed In KEMA O9ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0073 KEMA 09ATEX0
6. Pulse Output Option EO Integral Solenoid 24VDC Coil E1 Integral Solenoid 24VDC Explosion Proof Coil E2 Integral Solenoid 24VAC 12VDC Coil E3 Integral Solenoid 12VDC Explosion Proof Coil E4 Integral Solenoid 110VAC Coil E5 Integral Solenoid 110VAC Explosion Proof Coil E6 Integral Solenoid 220VAC Coil E7 Integral Solenoid 220VAC Explosion Proof Coil E8 Integral Solenoid 115VAC 50Hz Explosion Proof Coil E9 Integral Solenoid 230VAC 50Hz Explosion Proof Coil Your Serial ATEX Detail 1 Ex tistcers External Muffler ll 1D c T100 C A Mie I M2 c Il 2G c T5 Conductive Acetal models ONLY with Ex Il 3 2 G c T5 Integral Muffler Il 2D c T100 C pb025nmdl3sm rev0814 Conductive Acetal models ONLY with Metal XX Discharge Porting Position T Top H Horizontal Suction and Discharge V Vertical Discharge VV Vertical Suction and Discharge Diaphragm Check Valve Materials S Santoprene T Virgin PTFE U Santoprene Diaphragms PTF E Ball Design Level 3 Construction P Polypropylene Wet End and Center K PVDF Wet End and Polypropylene Center CA Conductive Acetal Wet End and Center 2 Ex Il 2G Ex ia c IIC T5 Il 3 2 G Ex ia c IIC T5 Il 2D Ex c ia 20 IP67 T100 C Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option P1 Page 2 Dimensions PB Non Metallic DISCHARGE PORT 1 2 NPT EXTERNAL THREADS 1 4 NPT INTERNAL THREADS EE 7 gt
7. chambers to the intermediate housing Remove the diaphragm assembly outer plate diaphragm inner plate by turning the assembly counterclockwise using a 1 2 1 27 cm wrench on the outer plate lugs If a socket is used it must be a six point socket The interior components consisting of the shaft seal and pilot valve assembly are now accessible for service Procedures for reassembling the diaphragms are the reverse of the above Install the diaphragm with the natural bulge outward Install the outer diaphragm plate on the outside of the diaphragm and make certain that the large radius side of the inner plate is toward the diaphragm Tighten the outer diaphragm plate to approximately 30 in Ibs 3 39 Newton meters Torque while allowing the diaphragm to turn freely with plates Use a wrench on the outer diaphragm plate of the pb025nmdl3sm rev0814 phragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid p
8. 073 KEMA 09ATEX0073 Non Conductive Fluids No Yes Yes No Yes Yes FLUID amp METERING Ten EE Pe a
9. 19 503 530 022 550 165 073 551 A 165 073 503 545 003 115 449 021 551 A 449 021 503 720 031 359 685 046 120 755 038 000 560 066 360 675 047 115 775 038 000 560 029 374 612 147 150 286 069 354 286 069 356 286 070 600 Composite Repair Parts List DESCRIPTION Body Main Air Valve Body Main Air Valve Sleeve amp Spool Set O Rings Cap End with O Ring Cap End with O Ring Ring Retaining Gasket Valve Body Gasket Valve Body Conductive Acetal Only Cap Air Inlet Cap Air Inlet Washer Flat 1 4 Capscrew Hex Head 1 4 20 5 Long Gasket Intermediate Bracket Gasket Intermediate Bracket Conductive Acetal Only Intermediate Bracket Intermediate Bracket Muffler Cap Air Exhaust Cap Air Exhaust Nut Hex 1 4 20UNC Insert Gland Insert Gland Seal K R Rod Diaphragm Sleeve Pilot Valve with O rings O rings Ring Retaining Pilot Valve Sleeve Spool Pilot Valve with O rings O rings Plate Inner Diaphragm Diaphragm Diaphragm Diaphragm on external 1 2 NPT porting threads A Grounding The Pump One eyelet end is fastened to the pump hardware pb025nmdl3sm rev0814 One eyelet is installed to a true earth ground Requires a 5 16 or 8mm maximum diameter bolt QTY ch sch Jf CO sech RD NO HO CO gt RO RO RO NO OD OD VP NP HMO HR a mo oa os oS for Conductive Acetal Pumps only A Ex 27 28 29 30 31 32 33 34 35
10. 333 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 540 541 542 544 550 551 552 A CAUTION The air exhaust should be piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure Air Exhaust Material Codes Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Compression Mold Urethane Rubber Nitrile Rubber Color coded RED Nitrile FKM Fluorocarbon Color coded YELLOW EPDM Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene INSTALL
11. ATION GUIDE Top Discharge Ball Valve Unit Surge Dampener Limited to Pipe Connection Style Optional Valve SUCTION B TU CODE LJ Gauge Shut Off ai DISCHARGE DIAPHRAGM PUMP Flexible Connection Drain Port pb025nmdl3sm rev0814 Flexible Ir O 553 555 556 557 559 570 580 590 591 592 600 601 602 603 604 607 606 610 611 632 633 634 635 637 638 639 643 644 656 Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Unfilled Conductive Polypropylene Glass Filled Conductive Polypropylene Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE Envelon PTFE PTFE Encapsulated Silicon PTFE Encapsulated FKM Neoprene Hytrel FKM PTFE EPDM PTFE Neoprene PTFE PTFE FKM PTFE PTFE Hytrel PTFE Nitrile TFE Santoprene EPDM Santoprene PTFE Santoprene Diaphragm and Check Balls EPDM Seats Delrin and Hytrel are registered tradenames of E l DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Exxon Mobil Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Rupplon SANDPIPER PortaPump Tranquilizer and
12. ERFORMANCE CURVE Pump is cavitating the fluid by fast cycling What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommenda tions 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 inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a 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 dia phragm 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 connect
13. Fax 419 522 7867 e warrenrupp com pb025nmdl3sm rev0814 deen el SANDPIPER A WARREN RUPP PUMP BRAND Quality System Model PB 4 ISO 9001 Certified 2 See pages 2 13 and 14 Environmental Man Ex Orea Ty p e 3 agement System ISO 14001 Certified CE ef e Air Operated 3 Sr Double Diaphragm Pump IREX I o y Engineering Performance amp Construction Data INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 14 NPT internal 0 to 4 gallons per minute No lube no stall Up to air 1mm 100 psi or 231 ft of water L i NPT external 0 to 15 liters per minute design 7 bar or 70 meters 01 US Gallons 04 liters A CAUTION Operating temperature limitations are as follows i Operating Temperatures Materials Maximum Minimum Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life 275 F 40 F Excellent abrasion resistance 135 C 40 C Hytrel Good on acids bases amines and glycols at room temperatures only 220 F 20 F 104 C 29 C Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically 220 F e with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such S ES i as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures 104 C 37 C PVDF 250 F 0 F 121 C 18 C Polypropylene 180 F 32
14. SERVICE amp OPERATING MANUAL Original Instructions SANDPIPER a ba A WARREN RUPP PUMP BRAND Model PB 4 E CE T e 3 Ex See pages 2 13 and 14 Foi i E y DH for ATEX ratings d move hia l Air Operated Double Diaphragm Pump Table of Contents Engineering Data and Temperature Limitations 1 Performance Curve cccceceeeceeeeeeeeseeeeeeeeeeeeeeeetseeeeeeeeetaeess 1 Explanation of Pump Nomenclature cccceeeceeeeeeeeeees 2 DEN e EE 3 Metric Blue Lal LE 4 Principle of Pump Operaton 5 Check Valve Gernvicnmg 5 Diaphragm Servicing BEE 5 TROUDIGSNOOUING E 6 EI NM ota cee E E E E E 6 Keen Le EEN 6 Important Safety Information ccccccccseceseeeseeeeeeeeseeeseees 6 Mat rial COdES ee 7 Installation Guide T Composite Repair Parts Drawing cccccceecsseeseeteeeeeeeees 8 Available Service and CGonmversonkts 8 Composite Repair arts 9 Grounding the Humpe 9 Solenoid Shifted Option Drawimng 10 solenoid Shifted Air Valve Parts st 10 Solenoid Shifted Options cc ccececcsecceseceeeseeseeeeseeeeeenees 11 Solenoid Connector Drawimg 11 CE Declaration of Conformity Machinery 0008 12 CE Declaration of Conformity ATES ees 13 Explanatiion of ATEX Markings o nnaneannennennnnnnnnnnnnnnnnnnnnne 14 Warren Rupp Inc A Unit of IDEX Corporation e 800 N Main St Mansfield Ohio 44902 USA Telephone 419 524 8388
15. SludgeMaster are registered tradenames of Warren Rupp Inc Pipe Connection Style Optional Gauge Shut Off Valve Flexible Connection Filter ees C Siem DISCHARGE Ei Drain Port Air Shut Off Valve Air Dryer We neg IC PTL FE O AIR INLET 3 2 Page 7 Wy pud JV sjeg 9 supesydeq u dozue zy DU pP R M sjeg 9 supesydeq JdLld Wy pua pepe sjeg 9 supesydeq 1974H Wy Puy Deag u dozue zy PUZ pepo aua AdoudAjod Ul UM AOJSUEI IEd AGAd HUN J JSUEIL led Ajuo jejeoV BA ONpUOD WY UOISIOAUOD sneyxa Iy WY UOISIOAUOD sneyxa Iy A quiassy aNIEN IO AjUO II SAIIONPUOD Ajquiassy Apog dajeA 1y ule Ajquiassy Apog dajeA 1y ule 000 621 9LV VVO LLL OLV 009 Z1LL 9LV 9G LLL OLD VSE LLL OLV CGG 6V1 GLV OCS 671 SLV 000 79 94 000 Gt L 94 000 LOL LEO 09 Z0L LEO LSS ZOL LE0O sry Alossaa0y 9 321S Page 8 pb025nmdl3sm rev0814 ITEM PART NO 1 095 077 551 095 077 503 2 031 106 000 3 560 101 360 6 165 074 551 165 074 503 7 675 051 115 8 360 085 360 360 085 379 9 165 072 551 165 072 503 10 901 037 115 11 170 103 115 12 360 084 360 13 14 15 16 17 18 19 20 21 22 23 24 25 26 use in place of four 706 023 115 machine screws with horizontal manifold item 41 on port side only when a pipe couple is installed AA 360 084 379 114 019 551 A 114 0
16. air end of the pump and be discharged into the atmosphere If A WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves 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 44 WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly Airborne particles and loud noise hazards Wear ear and eye protection 4 WARNING Use safe practices when lifting A WARNING Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so 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 RECYCLING Many components of Warren Rupp Metallic AODD pumps are made of recyclable materials see chart on page 9 for material specifications We encourage pump user to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed Page 6 Th
17. e Last 3 Digits of Part Number 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 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 123 410 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminium 149 2024 T4 Aluminium 150 6061 T6 Aluminium 151 6063 T6 Aluminium 152 2024 T4 Aluminium 2023 T351 154 Almag 35 Aluminium 155 356 T6 Aluminium 156 356 T6 Aluminium 157 Die Cast Aluminium Alloy 380 158 Aluminium Alloy SR 319 159 Anodized Aluminium 162 Brass Yellow Screw Machine Stock 165 Cast Bronze 85 5 5 5 166 Bronze SAE 660 170 Bronze Bearing Type Oil Impregnated 175 Die Cast Zinc 180 Copper Alloy 305 Carbon Steel Gray Epoxy Coated 306 Carbon Steel Black PTFE Coated 307 Aluminium Gray Epoxy Coated 308 Stainless Steel Black PTFE Coated 309 Aluminium Black PTFE Coated 310 PVDF Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminium Electroless Nickel Plated WARREN RUPP Available from Warren Rupp 1 DAOS Non Metallic Surge Dampener 2 020 049 000 Filter Regulator 3 Air Dryer
18. e of issue David Roseberry Engineering Manager Printed name of authorized person Title April 19 2012 Date of revision FLUID amp METERING 4 Revision Level F WARREN RUPP INC EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Equipment intended for use in potentially explosive environments Manufacturer Applicable Standard Warren Rupp Inc EN13463 1 2009 A Unit of IDEX Corportion EN13463 5 2011 800 North Main Street P O Box 1568 Mansfield OH 44902 USA EN 60079 25 2011 For pumps equipped with Pulse Output ATEX Option Quality B V 0344 AODD Pumps and Surge Suppressors For Type Examination Designations see page 2 back AODD Air Operated Double Diaphragm Pumps EC Type Examination Certificate No Pumps KEMA O9ATEX0071 X DEKRA Certification B V 0344 Meander 1051 6825 MJ Arnhem The Netherlands SANDPIPER Tranquilizer A WARREN RUPP INC BRAND DATE APPROVAL TITLE 14 MAY 2014 P lt ra WARREN RUPP INC EC Declaration of Conformity ATEX Summary of Markings Marking Ex ia c IIC T5 G Ex ia c IIC T5 Ex c iaD 20 IP67 T100 C Pump types S1F S15 S20 and S30 provided with the pulse output option EExm c Il T5 2 G EEx mc II T5 D c IP65 T100 C Pump types S1F S15 S20 and S30 provided with the integral solenoid option I1GceTs Il 3 1 G c T5 Il 1 D c T100 C I M1 c M2 c Pump types HDB1 2 HDB40 HDB2
19. er 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 pb025nmdl3sm rev0814 Diagram 2 Terminal Negative r 3 I Solenoid Connector Wiring Before wiring remove terminal l block from conduit I connector i l ya Neutral aT J lt L ae Se I i i L 3rd Terminal for ground UA 1 Terminal Power Positive Page 11 WARREN RUPP INC Declaration of Conformity Manufacturer Warren Rupp Inc 800 N Main Street Mansfield Ohio 44902 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 RS Series y U Series EH and SH High Pressure W Series SMA and SPA Submersibles i 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 N aT Ee October 20 2005 Signature of authorized person Dat
20. er 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 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 capscrews and install onto the pump Slide the muffler item 14 and the exhaust cap item 15 over the capscrews Re install the washers item 10 and hex nuts items 16 onto the four hex capscrews and torque to 30 in Ibs 3 39 Newton meters SERVICING THE PILOT VALVE To remove the pilot valve spool item 23 first remove the end o ring item 24 from one end of spool Slide the spool out of the sleeve and inspect the five remaining o rings items 24 for damage
21. ions 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 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 What to Check Entrained air or vapor lock in one or both pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Department before performing this procedure 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 evaluati
22. iping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A surge Suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient Capacity and pressure required for desired performance 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 Apres sure regulating valve should be installed to insure air supply pressure does not exceed recommended limits opposite side to keep rod from rotating If the opposite chamber is assembled the rod need not be held EXTERNALLY SERVICEABLE MAIN AIR DISTRIBUTION VALVE To service the main air distribution first shut off and disconnect the air supply to the pump Remove the four long hex cap screws and hex nuts on opposite side of pump which fasten the main air valve body item 1 gaskets item 8 and 11 muffler item 14 and caps item 6 and 15 to the pump Once the main air valve body is off the pump remove the retaining rings items 7 that hold
23. ke 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 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 dia 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 sixteen machine screws securing the manifold assemblies to the outer chambers 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 DIAPHRAGM SERVICING Remove the two V Band clamps securing the outer
24. on 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 A IMPORTANT A WARNING A WARNING responsibility Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the 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 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 CAUTION Pump not designed tested or certified to be powered by compressed natural gas Powering the pump with natural gas will void the warranty 44 WARNING Before maintenance or repair shut off the compressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure pb025nmdl3sm rev0814 pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition containers or other miscellaneous equipment must be grounded is reinstalled during assembly In the event of diaphragm rupture pumped material may enter the
25. or wear If necessary replace damaged o rings Inspect the inner diameter of pilot valve sleeve item 20 for scratches dirt or other contaminants Replace the sleeve if necessary To remove the sleeve first remove the retaining ring from one end When installing a pilot valve sleeve first lightly grease the six o rings items 21 Insert the sleeve into the chamfered end of bore on the intermediate bracket item 13 Push the sleeve in until the shoulder is flush to intermediate bracket surface and install the retaining ring item 22 To install the pilot valve spool first lightly grease the four interior o rings and insert into the pilot valve sleeve After insert ing the spool into the sleeve install the remaining loose o rings onto spool SERVICING DIAPHRAGM ROD SEALS To service the rod seals item 18 first remove pilot valve then remove the inserts on each of the intermediate brackets item 17 by prying them out with a small flat screwdriver After removing the inserts take the K R rod seals out of the inserts and replace When reinstalling the seals make sure BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump be tween 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 comple
26. sheet for ordering This 8 foot long 244 centimeters Grounding Cable Item 54 is shipped with the eyelet fastened to the pump hardware To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded Page 9 Solenoid Shifted Option Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Includes all items used on Composite Repair Parts List except as shown QTY ITEM 22 44 45 46 47 48 49 50 51 52 53 PART NUMBER DESCRIPTION 675 047 115 755 037 000 360 106 360 241 001 000 893 095 000 219 001 000 219 004 000 219 002 000 219 003 000 866 068 000 538 083 555 835 009 555 860 062 540 866 069 000 Ring Retaining Pilot Plug Sleeve Pilot Plug Sleeve with O rings Gasket Intermediate Bracket Connector conduit Solenoid Valve NEMA 4 Solenoid Coil 24 VDC Solenoid Coil 24 VAC 12 VDC Solenoid Coil 120 VAC Solenoid Coil 240 VAC Tube Fitting Nipple Tee Pipe Tubing Tube Fitting FOR EXPLOSION PROOF SOLENOID VALVE Solenoid Coil 120VAC 60 Hz Solenoid Coil 240VAC 60 Hz Solenoid Coil 12VDC Solenoid Coil 24VDC Solenoid Coil 110VAC 50 Hz Solenoid Coil 230VAC 50 Hz
27. tely drained between uses in all cases Figure 1 Figure 2 the open side of the seals face into the counterbore in the inserts To install the inserts into intermediate bracket simply press the insert into the counterbore in each of the intermediate bracket making sure that the closed side of insert faces out The inserts should be flush to the surface of the intermediate bracket or slightly below the surface when fully installed O Figure 3 99 Figure 4 Page 5 TROUBLESHOOTING Possible Symptoms e Pump will not cycle e Pump cycles but 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 in let air pressure and volume to the pump as calculated on the published P
28. the end caps in place Remove the end caps items 6 to inspect the spool and sleeve Remove the main air spool part of item 2 and inspect for damage or wear Inspect the inside diameter of the main air valve item 2 for dirt scratches or other contaminants Remove and replace the sleeve if needed When reinstalling the sleeve apply a light coating of grease to the six o rings item 3 before inserting the sleeve into the main air valve body Align the holes in the sleeve with the slots in main valve body making sure the sleeve is centered in the bore Clean the main air valve spool lightly grease the o rings and insert into the sleeve flush to one end Reinstall the end caps and retaining rings The main air valve body is now ready to put back on the pump Assemble the air inlet cap item 9 valve body gasket item 8 to the main air valve body making sure the five rect angular slots face the air inlet cap and the intermediate gasket onto the four hex AIR VALVE LUBRICATION The air distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the pre ferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required The pump air system will operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliv

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