S1F non-metallic-TOC svc man level 2.p65
Contents
1. 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 Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Department before performing this procedure A model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your loc2. SIDE VIEW 5 5 8 10 1 4 Pulse Output Kit 7 3 8 12 BOITOM VIEW Mesh Muffler 8 9 16 11 5 32 Sound Dampening Muffler 18 7 8 13 7 16 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 4 Metric Dimensions S1F Non Metallic Dimensions in Millimeters Dimensional tolerance 3mm VAN tij DS 44mm 13mm TYP 4 PLACES NN mn le 77 E Ss BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES IL 4 B 7 97 16 4 PLACES AIR INLET 22mm k 1 2 520 199 000 1 01 STANDARD ENCAPSULATED MUFFLER EH AIR IN SUBMERGED Ye APPLICATIONS E 7 N PT FRONT VIEW P C DISCHARGE PORT 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 BOLT CIRCLE 1 2 EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST SUCTION PORT 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 DIA BOLT CIRCLE DIMENSION Standard Pump MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE SIDE VIEW Pulse Output Kit Mesh Muffler BOTTOM VIEW Sound Dampening Muffler Model S1F Non Metallic Design Level 2 Page 5 Dimensions S1F Non Metallic with RuppGuard Spill Prevention DISCHARGE PORT 1 STANDARD 125 FLANGE CONFIGU
3. 1 F amp 1 J 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 20 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 316 Allen wrench remove the four hex socket capscrews item 13 and four flat washers item 43 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 520 199 000 1 01 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one bumper item 1 and one end cap item 1 E with an o ring item
4. cavitating the fluid by fast cycling What to Check Undersized suction line 520 199 000 1 01 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 inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a surge suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections
5. AIR EXHAUST PIPING MUFFLER LT LIQUID J LEVEL SUCTION LINE Illustration 3 1 DIAMETER AIR EXHAUST PIPING Model S1F Non Metallic Design Level 2 Page 26 MODULAR CHECK VALVE SERVICING Before servicing the check valves first shut off the suction line and then the discharge line to the pump Next shut off the compressed air supply bleed air pressure from the pump and disconnect the air supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the modular check valve remove the elbows items 18 from pump composite repair parts drawing Use a Wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seen in the cavities of the outer chamber items 14 Next remove the check valve seal item 39 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 33 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats items 40 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chamfers The spherical surface of the check balls must seat flush to the surface of the i
6. Unit 1 Surge Suppressor Pipe Connection Limited to Style Optional 100 psi Gauge NEM Flexible p Connection TM 2 FT DISCHARGE dk et Drain Port Flexible Connection TOP Filter Regulator Tofte DIAPHRAGM Air Shut Off Valve Air Dryer SC AIR INLET Flexible Style Optional Gauge Shut Off Valve l 1 _ I 1 uU N Connection Drain Port Model S1F Non Metallic Design Level 2 Page 9 IMPORTANT SAFETY INFORMATION 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 WARNING Before maintenance or repair shut off the com pressed air line bleed t
7. ad i tlt ee vc ps 31 WARREN RUPP INC A Unit of IDEX Corporation PO 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com 520 199 000 1 01 Copyright 2000 Warren Rupp Inc All rights reserved WARREN RUPP SanoPIPER SA e Quality System CE l F Non Metallic 109001 Certified IN Design Level 2 Environmental VES B ll V I Management System 15014001 Certified aive Other U S Patents Alr Powered Applied for Double Diaphragm Pump Mud AJ is DEK Air Inlet Side View Air Exhaust Side View ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE x CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 1 ANSI Flange O to 45 gallons per minute No lube no stall Up to 25 in 100 psi or 231 ft of water 17 gallon 64 liter or 0 to 170 liters per minute design 7 bar or 70 meters PN10 25mm DIN Flange CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum Optimum Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex 50 to 212 F life Excellent abrasion resistance 10 C to 100 C PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with Teflon molten alkali metals turbulent liquid or gaseous fluorine and a few fluo
8. 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 BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to prevent damage Product remaining in the pump between uses could dry out or settle out This could cause problems with the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases Model S1F Non Metallic Design Level 2 Page 8 WARREN RUPP Available from Warren Rupp Surge Suppressor 2 020 050 000 Filter Regulator 3 020 050 001 Lubricator 4 020 047 007 Air Dryer 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 520 199 000 Air Exhaust SUCTION 1 01 Pipe Connection INSTALLATION GUIDE Top Discharge Ball Valve
9. from the top port of the outer chamber item 14 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 52 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation 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 S1F Non Metallic Design Level 2 Page 15 RuppGUARD Option for TPE Equipped Pumps Drawing Note Item 48 The diaphragm is to be installed with the concave side facing toward the outer chambers 520 199 000 1 01 S1F Spill Prevention for TPE Equipped Pumps Repair Parts List Item Part Number Qty 45 46 49 50 51 52 53 54 55 56 57 58 17 48 38 55 170 114 115 170 114 308 196 159 552 196 159 600 518 137 520 518 137 520E 518 137 552 518 137 552E 538 022 110 538 022 308 560 078 611 618 003 110 618 003 308 618 025 110 618 025 308 618 031 110 618 031 308 770 066 520 770 066 542
10. items Ferritic Malleable Iron Music Wire Carbon Steel AISI B 1112 Alloy 20 Alloy Type 316 Stainless Steel Alloy Type 316 Stainless Steel Electro Polished Alloy C Hastelloy equivalent Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 Almag 35 Aluminum 356 T6 Aluminum 956 T6 Aluminum Die Cast Aluminum Alloy 380 Aluminum Alloy SR 319 Anodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc Copper Alloy Carbon Steel Gray Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Gray Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated Kynar Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Rupplon Uretha
11. 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 it touches the bumper on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 21 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 S1F Non Metallic Design Level 2 Page 19 Air Valve Assembly Drawing with Stroke Indicator Option S1F Design Level 2 Pilot Valve Assembly Parts List Item Part Number Description Qty 1 031 157 000 Air Valve Assembly 1 1 A 031 152 000 Sleeve and Spool Setw Pins 1 1 B 095 085 551 Body Air Valve 1 1 C 132 031 552 Bumper 2 1 D 165 106 551 Cap Muffler 1 1 E 165 105 147 Cap End 2 1 F 530 030 550 Muffler 1 1 G 560 103 360 O Ring 8 1 H 675 055 115 Ring Retaining 2 1 J 710 015 115 Screw Self Tapping 6 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O Ring 2 For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 158 000 Air Valve Assembly 1 includes all items on 031 157 000 minus 1 D
12. 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the small unthreaded hole in the end cap Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 21 to the pump Connect the compressed air line to the pump The pump is now ready for operation 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 S1F Non Metallic Design Level 2 Page 21 Pilot Valve Assembly Drawing 520 199 000 1 01 Pilot Valve Assembly Parts List Item 3 3 A 3 B 3 C 3 D 3 E 3 F Part Number De
13. 5 5 SIG 20 34 90 7 8 850 6 7 25 42 5 80 bt 200 PSI 5 7 NN 5 44 5 50 5 44 Bar gt 59 5 60 1 oO 4 60 PSI 77 40 68 JAMBES I k i T 3 40 145 76 5 H u r S 2 30 d 30 9 1 R 25 7 6 20 mr 20 16 1 PSI 1 36 Bar ag Do 15 14 5 pl ee cese f eme AS 5 10 15 20 25 30 35 40 45 U S Gallons per minute UM ke MER 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 Liters per minute Capacity 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 3 Dimensions S1F Non Metallic Dimensions in Inches Dimensional tolerance 1 17 9 16 8 25 32 I 3p ill at Teal ET TyTN 1 x an R AmA A BOLT PATTERN IS df I e SYMMETRICAL H j A ABOUT CENTERLINES gt l 07 16 TYP E L 4 PLACES AIR INLET 1 2 NPT STANDARD ENCAPSULATED MUFFLER FRONT VIEW ISCHARGE PORT 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE 1 2 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS SUCTION PORT 1 STANDARD 1254 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 DIA BOLT CIRCLE 9 15 16 DIMENSION Standard Pump
14. 770 066 552 835 005 110 835 055 308 860 056 606 866 060 110 286 093 600 286 092 354 720 056 600 720 057 600 770 064 520 770 064 552 Description Capscrew Hex Hd 3 8 16 x 4 25 replace 170 020 115 qty 16 of 32 Capscrew Hex Hd 3 8 16 x 4 25 replace 170 020 115 qty 16 of 32 Chamber Spill Prevention Chamber Spill Prevention Manifold Spill Prevention replace 518 136 520 Manifold 25mm DIN Manifold Spill Prevention replace 518 136 552 Manifold 25mm DIN Nipple Pipe Nipple Pipe O Ring Plug Pipe Plug Pipe Plug Boss Plug Boss Plug Boss Plug Boss Spacer Manifold used w overlay Spacer Manifold used w overlay Spacer Manifold used w overlay Tee Pipe Tee Pipe Tube Sight Connector Tube Diaphragm Overlay is not used Diaphragm Pumping Replaces 286 094 600 Seal Manifold Replaces 720 044 600 Seal Manifold PVDF only Replaces 720 044 600 Spacer Manifold Replaces 770 062 520 Spacer Manifold Replaces 770 062 552 Note The diaphragm is to be installed with the concave side facing toward the outer chambers See drawing 16 16 2 2 2 NN MPNANDAHAARAHRAHRAHRAHOAAD 4 4 4 4 Model S1F Non Metallic Design Level 2 Page 16 RuppGUARDT FOR TPE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It al
15. ANT 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 S1F Non Metallic Design Level 2 Page 29 Leak Detection Options Drawing For pumps with 530 030 550 ENCLOSED MUFFLER 710 014 330 Self tapping Screws Qty of 4 For pumps with 612 187 552 ALTERNATE MUFFLERS Mounting Plate 612 186 552 uu Mounting Plate 710 009 115 Self tapping Screws Gty of 4 520 199 000 1 01 RuppTech LEAK DETECTION OPTION A ELECTRONIC Follow instructions found elsewhere in this manual Filling the RuppGUARD Spill Prevention Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 033 000 110VAC Kit 032 034 000 220VAC To install electronic leak detectors remove the bottom 1 4 NPT pipe plug on the visual sight tube item 56 Insert leak detector into the 14 pipe tee item 55 LEAK DETECTION OPTION B MECHANICAL Follow instructions found elsewhere in this manual Filling the RuppGUARD Spill Prevention Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical leak detectors remove the bottom 1 4 NPT pipe plug on the visual sight tube item 56 Insert leak detector into he 1 4
16. METRICAL ABOUT CENTERLINES DIMENSION 07 16 206mm Standard Pump 4 PLACES Pulse Output Kit Mesh Muffler Sound Dampening Muffler AIR INLET BOITOM VIEW 1 2 NPT 44mm 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 7 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air andis 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally m
17. PTFE Pumping PTFE Santoprene 7 Dual Porting ANSI 2 Mesh Muffler P1 Intrinsically Safe 10 30VDC Pulse Output Kit H Backup Driver PTFE 8 Top Dual Porting ANSI 3 High temperature Air P2 110 120 or 220 240VAC Pulse Output Kit Check Valve Type CheckValve Seat 9 Bottom Dual Porting ANSI Valve w Encapsulated P3 Intrinsically Safe 110 120VAC Pulse Output Kit B Ball K PVDF Pump Style Muffler P4 Intrinsically Safe 220 240VAC Pulse Output Kit Design Level N Nylon D RuppGUARD with 4 High temperature Air SP Stroke Indicator Pins 2 Design Level 2 P Polypropylene Electronic Leak Detection Valve w 3M Muffler 110V 5 High temperature Wetted Material E RuppGUARD with AirValvew Mesh Muffler K PVDF Non Wetted Material Options Electronic Leak Detection N Nylon A Painted Aluminum 220V J Painted Aluminum PTFE M RuppGUARDTM with Mechanical P Polypropylene Rupp D wi echanical Q Epoxy Coated Aluminum Leak Detection S Standard K PTFE Al Gpated Aluminum V RuppGUARD with Visual L PTFE Coated Aluminum with PTFE Leak Detection Coated Hardware R Epoxy Coated Aluminum with PTFE Coated Hardware 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 2 Performance Curve Model S1F Non Metallic Design Level 2 c i lt MY hr S1F Non Metallic Performance Curve ET s Performance based on water at ambient temperature 71 199 700 s 15 2
18. RATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 2 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS FRONT VIEW SIDE VIEW SUCTION PORT 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 DIA BOLT CIRCLE 1 2 TYP DOE 4 PLACES DIMENSION PO SYMMETRICAL Standard Pump 5 5 8 10 1 4 ABOUT CENTERLINES 07 16 TYR E F 1 8 Pulse Output Kit 7 3 8 12 4 PLACES ee Mesh Muffler 6 9 16 11 1 8 Sound Dampening Muffler 18 7 8 13 7 16 AIR INLET BOTTOM VIEW _ 7 8 1 2 NPT 1 3 4 da 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 6 Metric Dimensions S1F Non Metallic with RuppGuard Spill Prevention DISCHARGE PORT SEN 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 2 EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLIGATIONS FRONT VIEW SIDE VIEW SUCTION PORT 1 STANDARD 125 FLANGE CONFIGURATION 5 8 DIA 4 HOLES EQUALLY SPACED ON A 3 1 8 DIA BOLT CIRCLE BOLT PATTERN IS SYM
19. SERVICE amp OPERATING MANUAL San PIPER Model SIF Non Metallic Design Level 2 Table of Contents Engineering Data and Temperature Limitations aaiaaaaiaaaansansansannaasnanaannnnnnnnnnnansannna 1 Explanation of Pump Nomenclature 2 2aaaasaaaaasaaasaaaanasnnaanansannansnnnnnnnannannnnannnnnnnnnsnnnnnnanaa 2 Performance Curve Model S1F Non Metallic Design Level 2 3 Dimensions S1F Non Metallic aaanaaaanaasasanaasanansanannanannnnnnnnnannnnnannnnnannnnnannnnsnsanansnnansannana 4 Metric Dimensions S1F Non Metallic sese nnne 5 Dimensions S1F Non Metallic with Spill Prevention een 6 Metric Dimensions S1F Non Metallic with Spill 7 Principle of Pump Operation essent nennen 8 Installation nd Start Up iiit t riri pnt tn ie erect coe d jaaa da kl dpt 8 Air Supply 8 Air Valve Lubrication rrt tnnt nre rin tinte 8 Ar ENG Mostue su co fte no 8 Air Inlet and Priming irt ttr neret rtt cri eri ner been 8 Between USCS 8 Installation Guide cm sssdunv s ssk das Auris tause 9 Important Safety Information 5 ine rn dusti vanl sa te t etes Ke
20. TFE Coated Stainless Steel Capscrews Hex Nuts Washers and Support Rod For use with RuppGUARD Spill Prevention Options RuppTech PULSE OUTPUT KITS For use with 530 007 000 and 530 025 000 Mufflers Muffler Option Drawing AQ X K 2 m U HET X N AN d LX N 7 WE v N gt 2 NE IN 4 5 ai 0 8 G2 G2 OG or piped exhaust C 475 198 016 DC Kit p 475 198 017 DC Intrinsically Safe Kit J VE 475 198 018 110 120VAC or 220 240VAC Kit fp N TT 475 198 019 110 120VAC Intrinsically Safe Kit MA 475 198 020 220 240VAC Intrinsically Safe Kit K 44 For use with encapsulated 530 030 550 Muffler Overlay Option Drawing 4j R e 7 475 198 011 DC Kit z 28 475 198 012 DC Intrinsically Safe Kit 475 198 013 110 120VAC or 220 240VAC Kit 475 198 014 110 120VAC Intrinsically Safe Kit S 475 198 015 220 240VAC Intrinsically Safe Kit Ne G RuppTech ELECTRONIC LEAK DETECTOR KITS 032 033 000 110VAC 032 034 000 220VAC 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 12 Composite Repair Parts List ITEM PARTNUMBER DESCRIPTION QTY ITEM PART NUMBER DESCRIPTION QTY 1 031 155 000 Air Valve Assembly 1 21 360 096 360 Gasket Air Vale 1 031 155 002 Air Valve Assembly w PTFE coated Hardware 1 22 360 097 360 Gasket Inner Chamber 2 031 156 000 Air Valve Assembly No Enca
21. al Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S1F Non Metallic Design Level 2 Page 11 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 191 000 476 193 000 476 145 354 476 145 654 476 146 655 476 184 655 476 146 354 476 184 354 HARDWARE KITS 475 175 308 475 176 308 AIR END KIT Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly AIR END KIT for Stroke Indicator Option Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pitot Valve Assembly WETTED END KIT Santoprene Diaphragms Santoprene Balls and PTFE Seals WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms TFE Balls and TFE Seals WETTED END KIT for Polypropylene RuppGuard Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals WETTED END KIT for PVDF RuppGUARD Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals WETTED END KIT for Polypropylene RuppGUARD Santoprene Diaphragms Santoprene Pumping Diaphragms Santoprene Check Balls amp PTFE Seals WETTED END KIT for PVDF RuppGUARD Santoprene Diaphragms Santoprene Pumping Diaphragms Santoprene Check Balls amp TFE Seals P
22. any remaining liquid from the pump Step 1 See the pump composite repair parts drawing and the diaphragm servicing illustration Using a wrench or socket remove the 16 capscrews items 9 hex nuts and washers that fasten the elbows items 18 to the outer chambers items 14 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a As wrench or socket remove the 16 capscrews items 9 hex nuts and washers that fasten the outer chambers diaphragms and inner chambers items 15 together Step 3 Removing the diaphragm assemblies Use a 1 35mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 35 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 31 Insert the protruding stud and the 1 4 20 fastener loosely into a vise Use a 13 s wrench or socket to remove the outer diaphragm 520 199 000 1 01 plate item 30 by turning counterclockwise Inspect the 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 Use a torque wrench to tighten the diaphragm assemb
23. d re install the plungers in to the bushings Push the plungers in as far as they will go Step 5 Re install the pilot valve ssembly 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 19 air inlet cap item 8 capscrews and washers items 11 and 43 Connect the air supply to the pump Remove the safety clip item 1 F from the end cap item 1 D 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 S1F Non Metallic Design Level 2 Page 23 Diaphragm Service Drawing Diaphragm Service Drawing Non Overlay with Overlay Du IG KS B a S E 4 f ON S gt Su LASS PI BG Z LAN A QP NY SN S VA W 9 Y Y al AV R FT 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 24 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
24. dename 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 Rupplon SandPIPER SandPIPER II PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 10 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is
25. e pilot valve body Inspect the wipers for cuts and or wear Replace any wipers as necessary 520 199 000 1 01 Step 3 Re assembly of the pilot valve First install a spiral retaining ring to one end of the pilot valve body Spread the spiral and insert one end into the groove in the pilot valve body Twist the ring in a clockwise motion until the full ring is snapped into the groove Install one bushing making sure the step side faces toward the wiper Apply a light coating of grease to the outside diameter of each wiper Next gently push in the wipers and spacers until they are against the installed retaining ring in the opposite end of the pilot valve body Install the remaining bushing making sure the step side faces the wiper Install the remaining spiral retaining ring using the same method described Apply a light coating of grease to the inner diameter of each wiper Also apply a light coating of grease to the outer diameter of the pilot valve spool and gently push the spool through each wiper Step 4 Inspect the actuator plungers See PUMP ASSEMBLY DRAWING The actuator plungers items 32 can be reached through the stem cavity of the pilot valve in the intermediate assembly item 4 Remove the plungers items 32 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 29 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring an
26. e possible because the porting flange of the elbows items 18 are designed to mate with standard 125 ANSI style 4 bolt 1 pipe flanges Dual porting of both suction and discharge ends of the pump Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals spacers and manifolds items 38 41 and 23 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows and optional positioning in the Dual Porting Drawing 520 199 000 1 01 Single porting of the suction and dual porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing Dual porting of the suction and single porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds spacers and manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing IMPORT
27. he pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure A 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 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 A WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly A 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 A WARNING Airborne particles and loud noise hazards Wear ear and eye protection MATERIAL CODES The Last 3 Digits of Part Number 000 ss Assembly sub assembly and some purchased
28. item 43 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to stratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 520 199 000 1 01 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A STEP 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve
29. ka EE E a RR EN 10 Material C0des 21 2222 12220 522sada askasashanssnana s asananda anna anna ana snadasngakasabaa a ansnd ananndanga nna ana da anidir 10 Troubleshooting ss 1 EORR Atena Ge dude aa Eee E KR AER AY RO 11 Composite Repair Parts enne enne nnne 12 Overlay Option Drawing Composite Repair Parts List RuppGUARD Spill Prevention Option for Virgin PTFE Equipped Pumps 14 RuppGUARD Spill Prevention Repair Parts List aa aiaaaaiasaaiasasassasassasassasassnsassanana 14 RuppGUARD Spill Prevention Concept a aaaaaaaaaaasaaaasasassasassasasnnsasansasansannanansanannnnanani 15 RuppGUARD Spill Prevention Option Diaphragm Servicing 15 Filling RuppGUARD Chambers with Liquid a aaiaiaaaaiasasaasasassasasassassnsassnsasansasannansanansanani 15 RuppGUARD Spill Prevention Option for Equipped Pumps 16 RuppGUARD Spill Prevention Repair Parts List RuppGUARD Spill Prevention Concept with TPE Diaphragms RuppGUARD Spill Prevention Option with TPE Diaphragm U S Patent 400 210 5 996 627 CE Air Distribution Valve Assembly Drawing Main Air Valve Assembly Part
30. ket Air Inlet 1 901 046 308 Washer Flat 1 2 32 20 360 095 360 Gasket Pilot Valve 1 NOT SHOWN 535 069 000 Nameplate 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 13 S1F Spill Prevention Repair Parts List for Virgin PTFE Equipped RuppGUARD Option for Item 48 The diaphragm is to be installed with the convex side facing toward the outer chambers SS j 520 199 000 1 01 Pumps 4 4 Item Part Number Description Virgin PTFE Equipped 45 170 114 115 Capscrew Hex Hd 3 8 16 x 4 25 16 replace 170 020 115 qty 16 of 32 Pumps Drawing 170 114 308 Capscrew Hex Hd 3 8 16 x 4 25 16 replace 170 020 115 qty 16 of 32 46 196 159 552 Chamber Spill Prevention 2 196 159 600 Chamber Spill Prevention 2 48 286 094 600 Diaphragm Pumping 2 49 518 137 520 Manifold Spill Prevention 2 replace 518 136 520 518 137 520E Manifold 25mm DIN 2 518 137 542 Manifold Spill Prevention 2 replace 518 136 542 518 137 542E Manifold 25mm DIN 2 518 137 552 Manifold Spill Prevention 2 replace 518 136 552 518 137 552E Manifold 25mm DIN 2 50 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 51 560 078 611 O Ring 8 52 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 53 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 54 618 031 110 Plug Boss 4 618 031 308 Plug Boss 4 56 835 005 110 Tee Pipe 4 835 055 308 Tee Pipe 4 57 860 056 606 Tube Sight 2 58 866 060 110 Connector Tube 4 38 720 056 600 Sea
31. l Manifold Replaces 720 044 600 4 720 057 600 Seal Manifold PVDF only 4 Replaces 720 044 600 Note i 55 770 064 520 Spacer Manifold Replaces 770 062 520 4 770 064 552 Spacer Manifold Replaces 770 062 552 4 Note The diaphragm is to be installed with the convex side facing toward the outer chambers See drawing Model S1F Non Metallic Design Level 2 Page 14 RuppGUARD FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARD OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 53 from each spill prevention chamber After the fluid from the spill p
32. l S1F Non Metallic Design Level 2 Page 17 Air Distribution Valve Assembly Drawing S1F Design Level 2 Main Air Valve Assembly Parts List Item Part Number Description Qty 1 031 155 000 Main Air Valve Assembly 1 1 A 031 151 000 Spool Assembly 1 1 B 095 085 551 Body Air Valve 1 1 132 031 353 2 1 D 165 106 551 Cap Muffler 1 1 E 165 117 552 Cap End 2 1 F 530 030 550 Muffler 1 1 G 560 103 360 O Ring 8 1 H 675 055 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 6 For pumps equipped with PTFE Coated Hardware 1 031 155 002 Air Valve Assembly 1 Includes all items used on 031 155 000 except 1 H 675 055 308 Ring Retaining 2 1 J 710 019 308 Screw Selftapping 6 For pumps equipped with PTFE coated hardware option 1 031 156 000 Air Valve Assembly 1 Includes all items used on 031 155 000 minus items 1 D 1 F amp 1 J For pumps with alternate Mesh or Sound Dampening mufflers or piped exhaust 1 031 156 002 Air Valve Assembly 1 Includes all items used on 031 156 000 except 1 H 675 055 308 Ring Retaining 2 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 18 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 316 Allen wrench remove the four hex socket capscrews item 13 and four flat washers
33. ly together to 20 ft Lbs 27 11 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 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 35 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 15 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 14 to the pump using the capscrews items 9 hex nuts and flat washers On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 35 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber The molded directional arrows on the diaphragm must point vertically Fasten the remaining outer chamber item 14 to the pump using the capscrews items 9 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to
34. mp 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 CONVERTINGTHE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Use a 8 Torx or flat screwdriver to remove the six self tapping screws item 1 L Remove the muffler cap and muffler items 1 E and 1 G The 1 2 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed 520 199 000 1 01 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be physically supported Failure to support these connections could also result in damage to the air distribution valve body Exhaust Conversion Drawing CONVERTED EXHAUST LLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 MUFFLER 1 DIAMETER
35. ne Rubber Color coded PURPLE Some Applications Compression Mold Urethane Rubber Buna N Rubber Color coded RED Buna N Viton Flurorel Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile 9375 Fluorinated Nitrile 378 High Density Polypropylene 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre Blue Gard rin 570 nductive Acetal ESD 800 nductive Acetal Glass Filled BOD s Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF Natural color 540 Nylon 541 25 55 Nylon Nylon lon Injection Molded lyethylene 551 Glass Filled Polypropylene 552 Unfilled Polypropylene 553 illed Polypropylene 555 Polyvinyl Chloride 556 Black Vinyl 570 Rulon Il 580 Ryton 590 Valox ua Nylatron G S Nylatron NSB Virgin PTFE PTFE Bronze and moly filled Filled PTFE Blue Gylon Virgin PTFE Envelon Injected molded PFA Encapsulated Silicon Encapsulated Viton Neoprene Hytrel Viton Teflon EPDM Teflon PTFE Viton TFE Hytrel Delrin Viton 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 tra
36. ng the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber The volume of fluid is 1198 ml 40 49 fl 02 It is important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug item 53 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 56 is in the vertical position Loosen the pipe plug item 52 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components
37. nner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary 520 199 000 1 01 Remove the remaining check valve seal item 39 Inspect the seal for cuts or pinched areas Replace seal as needed Re assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 39 into the cavity of the outer chamber item 14 Make sure the chamfer side of the seal faces out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 39 Make sure the chamfer side of the seal faces the chamfer on the check valve seat or retainer The pump can now reassembled reconnected and returned to operation Modular Check Valve Drawing Model S1F Non Metallic Design Level 2 Page 27 1 ANSI STYLE FLANGE CONNECTION FOUR 62 HOLES ON A 3 12 BOLT CIRCLE 1 ANSI STYLE FLANGE CONNECTION FOUR 62 HOLES ON A 3 12 BOLT CIRCLE Dual Port Option Drawing Model S1F Non Metallic Design Level 2 Page 28 1 01 520 199 000 DUAL PORTING OPTIONS Several dual porting options are possible The pump can be converted to a dual port arrangement on both the suction and the discharge ends The porting can be configured to a single suction and a dual discharge The porting can be changed to a dual suction and a single discharge The above changes ar
38. ounted 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 520 199 000 1 01 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 connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump ai
39. pi item 1 Model S1F Non Metallic Design Level 2 Page 30 RuppTech Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the 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 Integral Muffler Setup Muffler Setup MUFFLER CAP PULSE OUTPUT KIT CYA ia FS ADAPTER PLATE PULSE OUTPUT KIT 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 31
40. psulated Muffler 1 23 518 136 520 Manifold 2 031 156 002 Air Valve Assembly No Muffler PTFE Hardware 1 518 136 520E Manifold 25mm DIN 2 031 157 000 Air Valve Assembly With Stroke Indicator Option 1 518 136 542 Manifold 2 031 158 000 Air Valve Assembly No Muffler w Stroke Indicator 1 518 136 542E Manifold 25mm DIN 2 2 050 042 354 Ball Check 4 518 136 552 Manifold 2 050 042 600 Ball Check 4 518 136 552E Manifold 25mm DIN 2 3 095 090 000 Pilot Valve Assembly 1 24 530 007 000 Muffler Mesh not shown 1 4 114 022 157 Intermediate Assembly 1 530 025 000 Muffler Sound Dampening 1 114 022 307 Intermediate Assembly 1 25 538 011 555 Nipple Pipe 1 114 022 309 Intermediate Assembly 1 26 545 004 115 Nut Hex 5 16 18 8 114 022 332 Intermediate Assembly 1 545 004 308 Nut Hex 5 16 18 8 5 115 139 080 Bracket Mounting 2 27 545 005 115 Nut Hex 3 8 16 40 115 139 305 Bracket Mounting 2 545 005 308 Nut Hex 3 8 16 40 115 139 306 Bracket Mounting 2 28 545 008 110 Nut Hex 1 2 13 16 115 139 333 Bracket Mounting 2 545 008 308 Nut Hex 1 2 13 16 6 132 032 360 Bumper Diaphragm 2 29 560 001 360 O ring 2 7 135 034 506 Bushing Plunger 2 30 612 170 520 Assembly Outer Diaphragm Plate 2 8 165 107 157 Cap Air Inlet 1 612 170 542 Assembly Outer Diaphragm Plate 2 165 107 307 Cap Air Inlet 1 612 170 552 Assembly Outer Diaphragm Plate 2 165 107 309 Cap Air Inlet 1 31 612 171 157 Plate Inner Diaphragm 2 165 107 332 Cap Air Inlet 1 32 620 018 115 Plunger Actua
41. r 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 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
42. rawing 26 Converted Exhaust Illustration 4 2 nrc te ecc E a a Hala 26 Modular Check Valve Servicing a iaiaainiasasasaasasaasasansasansansansasnnnnsannnsannnnnnanannanansanansananian 27 Modular Check Valve Drawing cniin dini Baldas kia g an bekke 27 Dual Port Option Drawing As Dual Porting Options 2 nein mee Fert tenere err gen GA tereti ic dde Dual porting of both suction and discharge ends of the pump 29 Single porting of the suction and dual porting of the pump 29 Dual porting of the suction and single porting of the pump discharge 29 Leak Detection Options Drawing crei eere eter bt iin beats vak 30 RuppTech Electronic Leak Detector Installation ee 30 Mechanical Leak Detector Installation a2iaaaaaiaasaasaasa ssassansassansansaanaanannannnaanannaannnnna 30 RuppTech Pulse Output Kit Drawing a iaaaaaasasaaaasasassasassasanansasannnsannnnnnnnsnnnansannnsannnnana 31 RuppTech Pulse Output Kit Option asaaiasasanaasasassasasaasasansanansanannnsannnsannnsanansanansanansanana 31 Exhaust Port or Auxiliary Muffler Setup seen 31 Integral Muffler Setup ncc ertet pedit er eet ed
43. revention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional virgin PTFE pumping diaphragms item 48 These diaphragms are installed with the natural convex curve toward the outer chamber items 520 199 000 1 01 14 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING RuppGUARD CHAMBERSWITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 53 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 9 fastening the discharge manifold and elbows to the outer chambers items 14 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 53 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 F into the smaller unthreaded hole in one end cap item 1 D This locks the valve spool to one side keepi
44. ro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures PVDF 50 F to 212 F 10 C to 100 C Polypropylene Nylon For specific applications always consult Chemical Resistance Chart Technical Bulletin Definite reduction in service life Minimal reduction in service life at ends of range SandPIPER II pumps are designed to be powered only by compressed air 520 199 000 1 01 Model S1F Non Metallic Design Level 2 Page 1 Explanation of Pump Nomenclature S1F Non Metallic Design Level 2 Ball Valve Check Diaphragm Check Non Wetted Shipping MODEL Pump Pump Valve Design Wetted Check Valve Valve Material Porting Pump Pump Kit Weight Brand Size Type Level Material Materials Seat Options Options Style Options Options Ibs kg S1FB2P1PAAS000 S 1F B 2 P 1 P A A S 0 00 53 24 S1FB2P2PAAS000 S 1F B 2 P 2 P A A S 0 00 53 24 S1FB2K1KAAS000 S 1F B 2 K 1 K A A S 0 00 65 29 S1FB2K2KAAS000 S 1F B 2 K 2 K A A S 0 00 65 29 S1FB2P3PAAV000 S 1F B 2 P 3 P A A V 0 00 58 26 S1FB2K3KAAV000 S 1F B 2 K 3 K A A V 0 00 77 35 Pump Brand Diaphragm Check Valve Materials Porting Options Pump Options Kit Options S SandPIPER II 1 Santoprene Santoprene A ANSI Flange 0 None 00 None Pump Size 2 PTFE Santoprene Backup PTFE D DIN Flange 1 3M Muffler P0 0 30VDC Pulse Output Kit ipe Full Flow 3
45. s List rrsnronrnrnrnrnonvnnnvnnnrnnnvnnnnrnvnrnenvennvennrnnvvernnnnenrsenrennvensenne Air Distribution Valve Servicing a aaaaaasaaaasasansasansasannnnannnnannnnnnanannanannanannnnnnnnnannnsnnnnsnnnnna Air Distribution Valve with Stroke Indicator Options a aaiaaaasssassssasassasasaasasansanansananaai 20 Air Distribution Valve with Stroke Indicator Parts List 2 auaasasaasasassasasassasassasansasanana 20 Air Distribution Valve with Stroke Indicator Servicing ia aaiaiaaaasasassasassasasaasasansasanansana 21 Pilot Valve Assembly Drawing 2 2saaadaaaaasaanansanannnndannnannnnananaananndannnnannnnnnanannnannnnnannnnannnaa 22 Pilot Valve Assembly Parts i 22 Pilot Valve Servicing aaiaaaaaaiasasaasasansasanannannnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnsanansanansanansananannasannana 23 Diaphragm Service Drawing Non Overlay rrrrrnrrnvnnnernrnvvrrnrnrvennennvennrrsvennrenvernrrssnenerneesnn 24 Diaphragm Service Drawing with Overlay aaaaiaaaaiasasaasasassasassnsassnsassnsasansansannansanaannanani 24 Diaphragm Servicing Overlay Diaphragm Service PUMPING Hazardous trato atro etr etr eren tr eret edes 26 Converting the pump for piping the exhaust air a aaiaiaaaniasaasasasassasassasassasansasansasanaasana 26 Exhaust Gonversion D
46. scription Qty 095 090 000 Pilot Valve Assembly 095 084 551 Body Pilot Valve 1 135 037 506 Bushing 2 675 057 115 Ring Spiral Retaining 2 770 065 175 Spacer 5 775 041 506 Spool Pilot 1 917 003 374 Wiper 6 Model S1F Non Metallic Design Level 2 Page 22 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Insert the safety clip item 1 F from Air Distribution Valve assembly drawing into the smaller unthreaded holes in the end cap item 1 D from air distribution valve assembly drawing Step 1 See PUMP ASSEMBLY DRAWING Using a wrench or socket remove the four capscrews items 11 and four flat washers items 43 Remove the air inlet cap item 8 and air inlet gasket item 19 The pilot valve assembly item 3 can now be removed for inspection or service Step 2 Disassembly of the pilot valve Remove the pilot valve spool item 3 E Wipe clean and inspect for dirt scratches or wear Replace the spool if necessary Remove the two spiral retaining rings items 3 from each end of the pilot valve body by inserting the tip of a small flat screw driver under the notch in the retaining ring Lift and push the ring clockwise in a circular motion Remove the two pilot valve bushings items 3 B five spacers items 3 D and six spool wipers items 3 F by pushing gently from other end of th
47. so helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARDT OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 53 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional TPE pumping diaphragms item 48 These diaphragms are installed with the natural concave curve toward the outer chamber items 520 199 000 1 01 14 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING RuppGUARD CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system contamina
48. tall the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 56 is in the vertical position Loosen the pipe plug item 52 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 14 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 52 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before 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 Mode
49. the pump using the capscrews items 9 hex nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 17 is designed to fit snugly over the exterior of the standard TPE diaphragm item 16 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation A IMPORTANT Read these instructions completely before 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 S1F Non Metallic Design Level 2 Page 25 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the air end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust air must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The air exhaust must be piped above 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 pu
50. tion consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 53 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 9 fastening the discharge manifold and elbows to the outer chambers items 14 The discharge manifolds and eloows can now be removed 3 Remove the top two boss plugs items 53 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 F into the smaller unthreaded hole in one end cap item 1 D This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill prevention chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber 6 Loosely reinstall one boss plug item 53 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly ins
51. tor 2 9 170 020 115 Capscrew Hex HD 3 8 16 x 2 00 32 33 670 048 520 Retainer Ball 4 170 020 308 Capscrew Hex HD 3 8 16 x 2 00 32 670 048 542 Retainer Ball 4 10 170 066 115 Capscrew Hex HD 1 2 13 x 2 25 16 670 048 552 Retainer Ball 4 170 066 308 Capscrew Hex HD 1 2 13 x 2 25 16 34 675 042 115 Ring Retainer 2 11 170 085 115 Capscrew Hex HD 5 16 18 x 2 00 4 35 685 054 120 Rod Diaphragm 1 170 085 308 Capscrew Hex HD 5 16 18 x 2 00 4 36 685 055 115 Rod Support 2 12 171 015 115 Capscrew Soc HD 3 8 16 x 88 6 685 055 308 Rod Support 2 13 171 057 115 Capscrew Soc HD 5 16 18 x 2 25 4 37 720 012 360 Seal Diaphragm Rod 2 171 057 308 Capscrew Soc HD 5 16 18 x 2 25 4 38 720 044 600 Seal Manifold Spacer 8 14 196 157 520 Chamber Outer 2 39 720 047 600 Seal Check Valve 8 196 157 542 Chamber Outer 2 40 722 079 520 Seat Check Valve 4 196 157 552 Chamber Outer 2 722 079 542 Seat Check Valve 4 15 196 160 157 Chamber Inner 2 722 079 552 Seat Check Valve 4 196 160 307 Chamber Inner 2 41 770 062 520 Spacer Manifold 4 196 160 309 Chamber Inner 2 770 062 542 Spacer Manifold 4 196 160 332 Chamber Inner 2 770 062 552 Spacer Manifold 4 16 286 091 354 Diaphragm 2 42 901 009 115 Washer Flat 5 16 72 17 286 093 600 Diaphragm Overlay 2 901 009 308 Washer Flat 5 16 72 18 312 104 520 Elbow 4 43 901 038 115 Washer Flat 5 16 8 312 104 542 Elbow 4 901 038 308 Washer Flat 5 16 8 312 104 552 Elbow 4 44 901 046 115 Washer Flat 1 2 32 19 360 094 360 Gas
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