Model S05 Non-Metallic Design Level 2
Contents
1. 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 356 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 s05nmdl2sm REV0708 180 305 306 307 308 309 310 330 331 332 333 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 Material Codes The Last 3 Digits of Part Number Copper Alloy Carbon Steel Black Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF 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 Urethane Rubber Some Applications Compression Mold Urethane Rubber Nitrile Rubber Color coded RED FDA Accepted Nitrile FKM Fluorocarbon Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN F2. See page 2 for ATEX ratings U S Patent 400 210 5 996 627 6 241 487 Solenoid Shifted Air Valve Drawing eseeeeseeseesieeerereeitetretnretnntnrtnetnntnnstnnennenne 18 Solenoid Shifted Air Valve Parts List ceccecseeeseeeeeeeeeeeseeeeeneeseaeeeaeeseaeeseeeeeaeensas 18 Solenoid Shifted Air Distribution Valve Option 19 Intermediate Assembly Drawing Parts List and Servicing seseeeseeseeeeeeeeeeeeee 20 Check Valve Drawing and Gerviclng ne 21 Diaphragm Service Drawing Non Owerlany 22 Diaphragm Service Drawing with Overlay cceeceseeeeseeeeeesneeeeaeeeeeeteneeeeeeeeaees 22 Diaphragm Servicing BEE 23 Overlay Diaphragm Servicing ccceeceeeeeeeeeeeeceeeeeeeeeseeeeaeeeeeeteaeeseeeeeeseeeeeaeetaas 23 Dual Port Option Drawing dE EENS eioi i oe eai i 24 Dual Porting Options nsciis eea died t e E asri eke 25 Dual porting of both suction and discharge ends of the pump ssssssseserrerren 25 Single porting of the suction and dual porting of the pump discharge 25 Dual porting of the suction and single porting of the pump discharge eeseesen 25 Single Port Suction Repair Parts List eceeceeseeeeeeeneeeeeeeeeeeseaeeeeeseaeeseeeeeaeesaas 26 Single Port Discharge Repair Parts List cccecceeeceseeeseeeeeeeeeeeeeeeeeeeeeeeeeeaeenaas 26 Dual Port Suction and Discharge Repair Parts Ulet 26 Pumping Hazardous Uiouide A 27 Converting the pump for piping the exhaust ai
3. 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling s05nmdl2sm REV0708 What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and 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 p
4. PTFE Seats and PTFE Seals WETTED END KIT One Piece Bonded PTFE Nitrile Diaphragm PTFE Balls PTFE Seats DIAPHRAGM CONFIGURATION DETAIL TET H THE DIAPHRAGMS FOR BOTH CONFIGURATIONS SHOWN ABOVE ARE TO BE INSTALLED WITH CONVOLUTIONS FACING TOWARDS CENTER OF PUMP s05nmdl2sm REV0708 Model S05 Non Metallic Page 11 X ATEX Compliant I 1 J 15 286 095 360 Diaphragm 2 Composite Repair Parts List 286 116 000 Diaphragm One Piece 2 Item Part Number Description Qty 46 286 096 600 Diaphragm Overlay 2 1 031 166 000 Air Valve Assembly 1 17 312 106 520 Elbow Suction 2 031 166 002 Air Valve Assembly with PTFE Coated Hardware 1 A 312 106 521 Elbow Suction 2 031 166 003 Air Valve Assembly with Conductive Polypropylene 1 312 106 542 Elbow Suction 2 AA 031 167 000 Air Valve Assembly with Stroke Indicator Pins 1 312 106 552 Elbow Suction 2 031 167 002 Air Valve Assembly 1 312 106 557 Elbow Suction 2 with Stroke Indicator Pins and PTFE Coated Hardware 18 312 112 520 Elbow Discharge 2 031 168 000 Air Valve Assembly 1 312 112 521 Elbow Discharge 2 031 168 002 Air Valve Assembly Conductive Polypropylene 1 312 112 542 Elbow Discharge 2 031 169 000 Air Valve Assembly no muffler with Stroke Indicator Pins 1 312 112 552 Elbow Discharge 2 031 194 000 High Temperature 1 312 112 557 Elbow Discharge 2 031 194 002 High Temperature Conductive Polypropylene 1 19 360 099 360 Gasket Spacer use w TPE Diaphragms Only 2 031 1
5. 308 Nut Flanged 5 16 18 36 171 064 308 Capscrew Flanged 5 16 18 X 1 50 12 26 560 001 360 O ring 2 12 171 066 115 Capscrew Flanged 1 4 20 X 1 25 8 27 612 091 520 Plate Outer Diaphragm 2 171 066 308 Capscrew Flanged 1 4 20 X 1 25 8 612 091 542 Plate Outer Diaphragm 2 13 171 075 115 Capscrew Flanged 5 16 18 X 88 4 612 091 552 Plate Outer Diaphragm 2 171 075 308 Capscrew Flanged 5 16 18 X 88 4 28 612 177 330 Plate Inner Diaphragm 2 14 196 178 520 Chamber Outer 2 612 221 330 Plate Inner Diaphragm use with 286 116 000 2 A 196 178 521 Chamber Outer 2 29 620 019 115 Plunger Actuator 2 196 178 542 Chamber Outer 2 30 675 042 115 Ring Retaining 2 196 178 552 Chamber Outer 2 31 685 056 120 Rod Diaphragm 1 A 196 178 557 Chamber Outer 2 32 720 012 360 Seal Diaphragm Rod 2 15 286 095 354 Diaphragm 2 33 720 045 600 Seal Manifold 4 286 095 357 Diaphragm 2 34 722 099 600 Seat Check Valve 4 s05nmdl2sm REV0708 Model S05 Non Metallic Page 12 Air Distribution Valve Assembly Drawing E Item Part Number Description Qty 1 031 166 000 Air Valve Assembly 1 1 A 095 106 551 Body Air Valve 1 1 B 031 132 000 Sleeve and Spool Set 1 1 C 560 101 360 O Ring 8 1 E 165 122 551 End Cap 2 1 F 560 026 360 O Ring 2 1 G 675 062 115 End Cap Retainer 2 1 H 530 031 550 Muffler 1 1 l 165 109 551 Muffler Cap 1 1 J 710 011 115 Self Tapping Screw 4 For Pumps with Virgin PTFE coated hardware 1 031 166 002 Air Valve Assembly 1 1 G 675 0
6. 557N 518 138 520 518 138 520E A518 138 521 A518 138 521E 518 138 542 518 138 542E 518 138 552 518 138 552E A518 138 557 A4518 138 557E 544 005 115 544 005 308 Description Capscrew Flanged 5 16 18 x 1 25 Capscrew Flanged 5 16 18 x 1 25 Elbow 1 2 NPT replaces 312 112 520 Elbow 1 2 NPT replaces 312 112 521 Elbow v2 NPT replaces 312 112 542 Elbow 1 2 NPT replaces 312 112 552 Elbow 2 NPT replaces 312 112 557 Manifold installed in bottom position NPT Manifold installed in bottom position BSP Tapered Manifold installed in bottom position NPT Manifold installed in bottom position BSP Tapered Manifold installed in bottom position NPT Manifold installed in bottom position BSP Tapered Manifold installed in bottom position NPT Manifold installed in bottom position BSP Tapered Manifold installed in bottom position NPT Manifold installed in bottom position BSP Tapered Nut Flanged 5 16 18 Nut Flanged 5 16 18 eg e ee ee eet Zoe SINGLE PORT DISCHARGE REPAIR PARTS LIST 10 hi 17 23 171 063 115 171 063 308 171 064 115 171 064 308 312 106 520N A4312 106 521N 312 106 542N 312 106 552N AX312 106 557N 518 138 520 518 138 520E A518 138 521 A4518 138 521E 518 138 542 518 138 542E 518 138 552 518 138 552E 518 138 557 518 138 557E s05nmdl2sm REV0708 Capscrew Flanged 5 16 18 x 1 25 Capscrew Flanged 5 16 18 x 1 25 Capscrew Flanged HD 5 16 18
7. balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool shifts to the opposite end of the valve body the pressure to the chambers s05nmdl2sm REV0708 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 pu
8. if necessary Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft clean cloth and inspect for scratches or abrasive wear s05nmdl2sm REV0708 Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B Note The sleeve and spool set is match ground to a specified clearance Sleeves and spools cannot be interchanged STEP 3 Reassembly of the air distribution valve Install one end cap with o rings items 1 E 1 C and 1 F into one end of the air valve body item 1 A Insert one end cap retainer item 1 G into the two smaller holes align with groove in the end cap and push until the closed end of the retainer is below the flat surface of the valve body Remove the new sleeve and spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 C 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 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 end cap on the opposite end Install the remaining end cap with o rin
9. s05nmdl2sm REV0708 Model S05 Non Metallic Page 3 Dimensions S05 Non Metallic Dimensions in Inches Dimensional tolerance t s 10 1 8 Discharge Port Le H el 5 1 16 1 2 NPT Internal fig el 1 NPT External 1 3 4 FS Manifold Can Rotate 90 DAO From Vertical Centerline l Standard Encapsulated Muffler C Air Inlet 1 4 NPT 3 8 NPT Exhaust Port For Optional 3 j Jee Muffler Styles or Piping Exhaust Air 9 9716 D E In Submerged Applications 10 11 16 O O 11 5 16 FRONT VIEW 5 1 2 SIDE VIEW 1 16 E H H H 1 7 8 Suction Port 1 3 4 3 2 1 16 Ye NPT Internal 1 3 8 1 NPT External Bolt Pattern is Symmetrical About Centerlines Both Suction And Discharge Ports are Available in Ye BSP Tapered Internal 1 BSP Tapered External BOTTOM VIEW DIMENSION Standard Pump 4 1 16 7 1 16 Pulse Output Kit 4 1 16 7 1 16 Mesh Muffler 5 3 4 8 3 4 Sound Dampening Muffler 5 3 4 8 3 4 Metal Muffler 4 PLACES s05nmdl2sm REV0708 Model S05 Non Metallic Page 4 Metric Dimensions S05 Non Metallic Dimensions in millimeters Dimensional tolerance 3mm 05 16 4 PLACES s05nmdl2sm REV0708 258mm 129mm FRONT E Get CR Bolt Pattern Is Encapsulated Muffler 3 8 NPT Exhaust Port el For Optio
10. supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump composite repair parts drawing and the diaphragm servicing illustration Using a 1 2 wrench or socket remove the 16 capscrews items 9 amp 10 and flanged nuts that fasten the elbows items 17 and 18 to the outer chambers items 14 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a 1 2 wrench or socket remove the 16 capscrews items 11 and 13 and flanged nuts that fasten the outer chambers diaphragms and intermediate item 4 together Step 3 Removing the diaphragm assemblies Use a 3 4 19mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 32 by turning counterclockwise Insert a 6 32 set screw into the smaller tapped hole in the inner diaphragm plate item 28 Insert the protruding stud and the 6 32 fastener loosely into a vise Use a s05nmdl2sm REV0708 3 4 wrench or socket to remove the outer diaphragm plate item 27 by turning counterclockwise Inspect the diaphragm item 15 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise onto the stud Insert the loose asse
11. 344 under Document 203040000 IMPORTANT SAFETY INFORMATION 4A 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 AA 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 AA 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 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 See page 31 A WARNING This pump is pressurized internally with air pressure during operation Always make certain that all b
12. 518 138 521E 518 138 542 518 138 542E 518 138 552 518 138 552E 518 138 557 518 138 557E 544 005 115 544 005 308 115 144 305 115 144 306 171 068 115 171 068 308 A ATEX Compliant Description Capscrew Flanged 5 16 18 x 1 25 Capscrew Flanged 5 16 18 x 1 25 Capscrew Flanged HD 5 16 18 X 1 50 Capscrew Flanged HD 5 16 18 X 1 50 Elbow 1 2 NPT replaces 312 106 520 Elbow 1 2 NPT replaces 312 106 521 Elbow 1 2 NPT replaces 312 106 542 Elbow 1 2 NPT replaces 312 106 552 Elbow 1 2 NPT replaces 312 106 557 Elbow 1 2 NPT replaces 312 112 520 Elbow 2 NPT replaces 312 112 521 Elbow 1 2 NPT replaces 312 112 542 Elbow 2 NPT replaces 312 112 552 Elbow 2 NPT replaces 312 112 557 Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Manifold none required Nut Flanged 5 16 18 20 Nut Flanged 5 16 18 20 Bracket Free Standing replaces 115 140 115 2 Bracket Free Standing replaces 115 140 115 2 Capscrew Flanged 5 16 18 X 1 63 8 Capscrew Flanged 5 16 18 X 1 63 8 Q lt NNNNNNNNNN P P oo o Zeg st ng eet A Lotte r e Quantities change from Composite Repair Parts List Model S05 Non Metallic Page 26 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter
13. 62 308 End Cap Retainer 2 1 J 710 011 308 Self Tapping Screw 4 Includes all other items used on 031 166 000 above For Pumps with alternate Mesh or Sound Dampening Mufflers or Piped Exhaust 1 031 168 000 Air Valve Assembly 1 Includes all items used on 031 166 000 above minus 1 H 1 1 and 1 J MAIN AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 166 003 Air Valve Assembly 1 1 A 095 106 559 Body Air Valve 1 1 B 031 132 000 Sleeve and Spool Set 1 1 C 560 101 360 O Ring 8 1 E 165 122 551 End Cap 2 1 F 560 026 360 O Ring 2 1 G 675 062 115 End Cap Retainer 2 1 H 530 031 550 Muffler 1 1 1 165 109 559 Muffler Cap 1 1 J 710 011 115 Self Tapping Screw 4 For Pumps with alternate Mesh Muffler or Piped Exhaust 1 031 168 002 Air Valve Assembly 1 Includes all items used on 031 166 003 above minus 1 H 1 l and 1 J For pumps with High Temperature Options 1 031 194 000 Air Valve Assembly 1 1 B 031 175 000 Sleeve and Spool Set 1 Includes all the other items on 031 168 000 above 1 031 195 000 Air Valve Assembly 1 1 031 175 000 Sleeve and Spool Set 1 Includes on other items on 031 166 000 above Ex A ATEX Compliant s05nmdl2sm REV0708 Model S05 Non Metallic Page 13 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump STEP 1 See COMPOSITE REPAIR PARTS DRAWING Using a 3 8 wrench or s
14. 95 000 High Temperature 1 20 360 100 379 Gasket Air Inlet 1 031 195 003 High Temperature Conductive Polypropylene 1 21 360 101 360 Gasket Pilot Valve 1 2 050 027 354 Ball Check 4 22 360 102 360 Gasket Air Valve 1 050 027 357 Ball Check 4 23 518 138 520 Manifold NPT 2 050 027 360 Ball Check 4 518 138 520E Manifold BSP Tapered 2 050 022 600 Ball Check 4 518 138 521 Manifold NPT 2 3 095 091 000 Pilot Valve Assembly 1 518 138 521E Manifold BSP Tapered 2 4 114 023 551 Bracket Intermediate 1 518 138 542 Manifold NPT 2 114 023 559 Bracket Intermediate 1 518 138 542E Manifold BSP Tapered 2 5 115 140 115 Bracket Mounting 2 518 138 552 Manifold NPT 2 115 140 308 Bracket Mounting 2 518 138 552E Manifold BSP Tapered 2 6 132 034 360 Bumper Diaphragm 2 518 138 557 Manifold NPT 2 7 135 036 506 Bushing Plunger 2 518 138 557E Manifold BSP Tapered 2 8 165 110 551 Cap Air Inlet 1 24 530 023 000 Muffler with metal mesh element 1 165 110 559 Cap Air Inlet 1 Not available for Conductive Polypropylene or PVDF 9 171 062 115 Capscrew Flanged 5 16 18 X 1 00 12 530 024 000 Muffler with porous plastic element 1 171 062 308 Capscrew Flanged 5 16 18 X 1 00 12 Not available for Conductive Polypropylene or PVDF 10 171 063 115 Capscrew Flanged 5 16 18 X 1 25 24 530 035 000 Muffler 1 171 063 308 Capscrew Flanged 5 16 18 X 1 25 24 25 544 005 115 Nut Flanged 5 16 18 36 11 171 064 115 Capscrew Flanged 5 16 18 X 1 50 12 544 005
15. ING Declaration of Conformity Warren Rupp Inc 800 North Main Street Mansfield Ohio certifies that Air Operated Double Diaphragm Pumps Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic Containment Duty Gas UL High Pressure W Submersible and Tranquilizers comply with the European Community Directive 98 37 EC Safety of Machinery This product has used EN 809 Pumps and Pump Units for Liquids Common Safety Requirements harmonized standard to verify conformance AE eseou October 20 2005 Signature of authorized person Date of issue David Roseberry Engineering Manager Printed name of authorized person Title CE Declaration of Conformity
16. SERVICE amp OPERATING MANUAL SANDPIPERs A WARREN RUPP PUMP BRAND Model S05 Non Metallic Design Level 2 Table of Contents Engineering Data and Temperature Limitations AA 1 Explanation of Pump Nomenclature AN 2 Performance Curves icc citael sien e dEEE EE edn el et eae 3 Run Le A Metric DIM NSIONS EEN 5 Principle of Pump Operation 6 Installation and Start Up 0 0 cceeecceeeeeeeeeeeeeceeeeeeeseaeeseeeeeeeesaeseaeeseeeeeeseeeeeieeseaeeeeeee 6 ELE eege iesen eee geegent eege e 6 Air Valve Lubrication wis aiac eit een E tsi da et le dca ieee 6 Air Line Mettes i4i itd ieee eee deed ege ae ei e 6 Air Inlet and Priming seirinin na n a en ee 6 Between USES eege eine E iets EE E et een Ea EN 6 InStallation Ie EE H lge ee ue WEE 8 Warranty EE 8 Important Safety Information ceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeseeeeaeeseeeeeieeseaeeeeeee Material Codes eise a tin eee te ee eae Composite Repair Parts Drawing Overlay Option Drawing Muffler Option Drawing eeeseeseeseeeseesiesessrrsresrrseresen 11 Available Service and Conversion Kits A 11 Composite Repair Parts List 12 Air Valve Assembly Drawing and Parts List AN 13 Air Valve Assembly Servicing cccceeceeeeeeseeeeeeceeeeeaeeeeeecaeeeeeseaeesaeeeaeeseeeeeaeenaas 14 Air Valve with Stroke Indicator Assembly Drawing and Parts Uert 15 Air Valve with Stroke Indicator Assembly Gervicng 16 Pilot Valve Servicing Assembly Drawing and Parts Ulet 17
17. X 1 50 Capscrew Flanged HD 5 16 18 X 1 50 Elbow 2 NPT replaces 312 106 520 Elbow 2 NPT replaces 312 106 521 Elbow 1 2 NPT replaces 312 106 542 Elbow 1 2 NPT replaces 312 106 552 Elbow 1 2 NPT replaces 312 106 557 Manifold installed in top position NPT Manifold installed in top position BSP Tapered Manifold installed in top position NPT Manifold installed in top position BSP Tapered Manifold installed in top position NPT Manifold installed in top position BSP Tapered Manifold installed in top position NPT Manifold installed in top position BSP Tapered Manifold installed in top position NPT Manifold installed in top position BSP Tapered Qty 16 E ooo sas e ost MM MM 28 28 A wh RO On e i sch b mb sch i nnn MM MAMM A 25 37 38 544 005 115 544 005 308 115 144 305 115 144 306 171 068 115 171 068 308 Nut Flanged 5 16 18 28 Nut Flanged 5 16 18 28 Bracket Free Standing replaces 115 140 115 Bracket Free Standing replaces 115 140 115 Capscrew Flanged 5 16 18 X 1 63 Capscrew Flanged 5 16 18 X 1 63 aon hy DUAL PORT SUCTION AND DISCHARGE REPAIR PARTS LIST Item 10 11 17 18 23 25 37 38 Part Number 171 063 115 171 063 308 171 064 115 171 064 308 312 106 520N A312 106 521N 312 106 542N 312 106 552N A4312 106 557N 312 112 520N A312 112 521N 312 112 542N 312 112 552N A312 112 557N 518 138 520 518 138 520E A518 138 521 A
18. ace of the check balls must seat flush to the surface of the inner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary RE ASSEMBLE THE CHECK VALVE Place a check ball item 2 in the ball cage of either the discharge elbow or the outer chamber Install a check valve seat in the counter on each end of the chamber Refasten the elbows to the chamber A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S05 Non Metallic Page 21 Diaphragm Service Drawing Diaphragm Orientation Install diaphragm and spacer as shown above s05nmdl2sm REV0708 Diaphragm Service Drawing with Overlay SS SS Sr A VW Za Oe 0 Lei s aS LN BE YN Li A h as Diaphragm Orientation Install diaphragm and overlay as shown above Diaphragm Service Drawing with One Piece Bonded Diaphragm Orientation Install diaphragm 286 116 000 only as shown above Model S05 Non Metallic Page 22 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
19. ailure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S05 Non Metallic Page 23 Dual Port Option Drawing ER R 2 d Ly bi us 00 pD o o 2d oa ge 1 o K4 S CSI S TE INN A 5 GER E Yo r J PsN ou Or Y gg S TN A A je D 5 RS SA MEG y m Q Mi W6 d 5 Ze e LX gd 5 Ko LET E S EN e oF S a z and Single or Dual Port Discharge AE BX EE Wee AE 2X SY Sh Model S05 Non Metallic Page 24 Illustration for Single Port Suction with Dual Port Discharge s05nmdl2sm REV0708 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 are possible because the porting flange of the elbows items 17 amp 18 are designed to mate with NPT or 1 2 BSP Tapered connection 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 and manifolds items 33 and 23 from pump assembly drawing from the pump The discharge elbows and suction elbows can be rotated 90 increm
20. ation of Pump Nomenclature S05 Non Metallic Design Level 2 Ball Valve Diaphragm Check Valve Materials Non Wetted Material Options Shipping Weight Ibs kg Kit Options Wetted Material Porting Options Pump Options S05B2P1TPNSOOO S05B2P2TPNSOOO SO5B2PUTPNSOOO S05B2K1TPNSOOO S05B2K2TPNS000 S05B2KUTPNS000 S05B2N1TPNSOOO SO05B2N2TPNSOOO SO5B2NUTPNSOOO Note Models listed in the table are for reference only See nomenclature below for other models 21212 Z Z Z 2 Pump Brand Diaphragm Check Valve Materials Porting Options Kit Options Kit Options continued S SANDPIPER 1 Santoprene Santoprene N NPT Threads A 00 None A E7 Solenoid Kit with 220VAC Pump Size 2 Virgin PTFE Santoprene B BSP Tapered Threads P0 10 30VDC Pulse Output Kit Explosion Proof Coil 05 1 2 Backup Virgin PTFE 1 Dual Porting NPT P1 Intrinsically Safe 5 30VDC A E8 Solenoid Kit with 110VAC 50 Hz B Nitrile Nitrile 2 Top Dual Porting NPT 110 120VAC 220 240 VAC Explosion Proof Coil Check Valve Type U Polyurethane Polyurethane 3 Bottom Dual Porting NPT Pulse Output Kit A E9 Solenoid Kit with 230VAC 50 Hz B Solid Ball Z One Piece Bonded PTEE 4 Dual Porting BSP Tapered P2 110 120 or 220 240VAC Explosion Proof Coil Design Level 5 Top Dual Porting BSP Tapered Pulse Output Kit SP Stroke Indicator Pins 2 Design Level Check Valve Seat 6 Bottom D
21. cludes all items used on Composite Repair Parts List except as shown Item Part Number Description Qty 4 114 023 551 Bracket Intermediate 1 35 893 099 000 Solenoid Valve NEMA4 1 36 219 001 000 Solenoid Coil 24VDC 1 219 004 000 Solenoid Coil 24VAC 12VDC 1 219 002 000 Solenoid Coil 120VAC 1 219 003 000 Solenoid Coil 240VAC 1 37 241 001 000 Connector conduit 1 241 003 000 Conduit Connector with 1 Suppression Diode DC Only 38 171 065 115 Capscrew Flanged 1 4 20 x 1 00 4 39 618 050 150 Plug Replaces Item 7 2 IEC EEX m T4 Ab APPROVED For Explosion Proof Solenoid Coils used in North America and outside the European Union 36 219 009 001 Solenoid Coil 120VAC 60 Hz 1 219 009 002 Solenoid Coil 240VAC 60 Hz 1 219 009 003 Solenoid Coil 12VDC 1 219 009 004 Solenoid Coil 24VDC 1 219 009 005 Solenoid Coil 110VAC 50 Hz 1 219 009 006 Solenoid Coil 230VAC 50 Hz 1 Item 37 Conduit Conductor is not required Il 2G EEx m c T5 Il 2D c IP65 T100 C d For Explosion Proof Solenoid Coils used in the European Union 36 219 011 001 Solenoid Coil 12 VDC 3 3W 0 531A 0 014A 1 219 011 002 Solenoid Coil 24 VDC 3 3W 0 531A 0 014A 1 219 011 003 Solenoid Coil 110 120 VAC 3 4W 0 212A 0 015A 1 219 011 004 Solenoid Coil 220 240 VAC 3 4W 0 212A 0 015A 1 Item 37 Conduit Conductor is not required Special Conditions For Safe Use A fuse corresponding to its rated current max 271 according IEC 60127 2 1
22. d As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard SANDPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION BEFORE WIRING THE SOLENOID make certain it is compatible with your system voltage s05nmdl2sm REV0708 Solenoid Connector Before wiring remove terminal block from conduit connector A 2 Terminal Neutral Wiring l Diagram 3rd Terminal for ground 1 Terminal Power Positive Negative Model S05 Non Metallic Page 19 Intermediate Assembly Drawing INTERMEDIATE REPAIR PARTS LIST Item Part Number Description Qty 4 114 023 551 Bracket Intermediate 1 114 023 559 Bracket Intermediate 1 7 135 036 506 Bushing Plunger 2 26 560 001 360 O Ring 2 29 620 019 115 Plunger Actuator 2 30 675 042 115 Ring Retaining 2 Note It is recommended that when plunger components are serviced new retaining rings be installed s05nmdl2sm REV0708 Intermediate Assembly Servicing ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed air supply bleed the pressure from the pump and disconnect t
23. e body Remove the new sleeve and spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 C 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 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 end cap on the opposite end Install the remaining end cap with o rings and retainer Fasten the air valve assembly item 1 and gasket item 23 to the pump using the four hex flanged capscrews item 12 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 S05 Non Metallic Page 14 Air Valve with Stroke Indicator Assembly Drawing Parts List MAIN AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 167 000 Air Valve Assembly 1 1 A 095 106 559 Body Air Valve 1 1 B 031 134 000 Sleeve and Spool Set 1 1 C 560 101 360 O Ring 8 1 D 132 030 552 Bumper 2 1 E 165 123 147 End Cap 2 1 F 560 029 360 O Ri
24. ents see arrows and optional positioning in the Dual Porting Drawing 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 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 and manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing NOTE See Repair Parts List on next page s05nmdl2sm REV0708 A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S05 Non Metallic Page 25 SINGLE PORT SUCTION REPAIR PARTS LIST Item 10 18 23 25 Part Number 171 063 115 171 063 308 312 112 520N A312 112 521N 312 112 542N 312 112 552N AX312 112
25. ews items 11 and 13 and flanged nuts Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 9 amp 10 and flanged nuts The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 16 is designed to fit snugly over the exterior of the standard TPE diaphragm item15 ONE PIECE DIAPHRAGM SERVICING Bonded PTFE with integral plate The One Piece diaphragm has a threaded stud installed in the integral plate at the factory The inner diaphragm plate has a through hole instead of a threaded hole Place the inner plate over the diaphragm stud and thread the first diaphragm inner plate onto the diaphragm rod only until the inner plate contacts the rod Do not tighten A small amount of grease may be applied between the inner plate and the diaphragm to facilitate assembly Insert the diaphragm rod assembly into the pump and install the outer chamber Turn the pump over and thread the second diaphragm inner plate onto the diaphragm rod Turn the diaphragm until the inner plate contacts the rod and hand tighten the assembly Continue tightening until the bolt holes align with the inner chamber holes DO NOT LEAVE THE ASSEMBLY LOOSE A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference F
26. gs and retainer Fasten the air valve assembly item 1 and gasket item 23 to the pump using the four hex flanged capscrews item 12 Connect the compressed air line to the pump The pump is now ready for operation IMPORTANT Remove the safety clip The pump will not function properly until it is removed 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 S05 Non Metallic Page 16 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PARTNUMBER DESCRIPTION QTY 3 A 3 095 091 000 Pilot Valve Assembly 1 3 A 095 087 551 Valve Body 1 3 B 755 051 000 Sleeve With O rings 1 3 C 560 033 360 O ring Sleeve 6 3 D 775 055 000 Spool With O rings 1 3 E 560 023 360 O ring Spool 3 3 F 675 037 080 Retaining Ring 1 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 STEP 1 See pump assembly drawing Using a 7 16 wrench or socket remove the four capscrews item 12 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly
27. he air supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 3 8 wrench or socket remove the four capscrews items 12 Remove the air inlet cap item 8 and air inlet gasket item 20 The pilot valve assembly item 3 can now be removed Step 2 Servicing the actuator plungers See PUMP ASSEMBLY DRAWING The actuator plungers items 29 can be reached through the stem cavity of the pilot valve in the intermediate bracket item 4 To service bushings o rings and retaining rings see Intermediate Drawing Remove the plungers items 29 from the bushings item 7 in each end of the intermediate cavity Inspect for wear or damage Replace plunger as needed Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 20 air inlet cap item 8 and capscrews items 12 Connect the air supply to the pump The pump is now ready for operation PLUNGER BUSHING O RING AND RETAINING RING SERVICING To service the plunger bushing components first remove the two retaining rings items 30 using a small flat screwdriver Note It is recommended that new retaining rings be insta
28. item 3 can now be removed for inspection and service s05nmdl2sm REV0708 STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 3 D Wipe clean and inspect spool and o rings for dirt cuts or wear Replace the o rings and spool if necessary Remove the retaining ring item 3 F from the end of the sleeve item 3 b and remove the sleeve from the valve body item 3 A Wipe clean and inspect sleeve and o rings for dirt cuts or wear Replace the o rings and sleeve if necessary STEP 3 Re assembly of the pilot valve Generously lubricate outside diameter of the sleeve and o rings Then carefully insert sleeve into valve body Take CAUTION when inserting sleeve not to shear any o rings Install retaining ring to sleeve Generously lubricate outside diameter of spool and o rings Then carefully insert spool into sleeve Take CAUTION when inserting spool not to shear any o rings Use BP LS EP 2 multipurpose grease or equivalent STEP 4 Re install the pilot valve assembly into the intermediate Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate Re install the gasket air inlet cap and capscrews Connect the air supply to the pump The pump is now ready for operation Model S05 Non Metallic Page 17 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST In
29. lled Next remove the two plunger bushings items 7 Inspect the bushings for wear or scratches Replace the bushings as necessary Inspect the two o rings 26 for cuts and or wear A IMPORTANT Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S05 Non Metallic Page 20 Check Ball Valve Drawing s05nmdl2sm REV0708 MODULAR CHECK BALL 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 17 and 18 from pump composite repair parts drawing Use a 1 2 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 Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats items 34 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chamfers The spherical surf
30. lls and seals Santoprene Diaphragm and Check Balls EPDM Seats EPDM Santoprene Delrin and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Warren Rupp SANDPIPER PortaPump Tranquilizers and SludgeMaster are registered tradenames of Warren Rupp Inc Model S05 Non Metallic Page 10 Composite Repair Parts Drawing DIRECTION OF DIAPHRAGMS Available Service And Conversion Kits 476 219 000 476 220 000 476 202 360 476 202 354 476 202 357 476 202 654 476 202 659 AIR END KIT Seals O ring Gaskets Retaining Rings Air Valve Assembly and Pilot Valve Assembly AIR END KIT Air Valve with Stroke Indicator Pin Seals O ring Gaskets Retaining Rings Air Valve Assembly Pilot Valve Assembly WET END KIT Nitrile Diaphragms Nitrile Check Balls PTFE Seats and PTFE Seals WET END KIT Santoprene Diaphragms Nitrile Spacer Gaskets Santoprene Check Balls PTFE Seats and PTFE Seals WET END KIT Polyurethane Diaphragms Nitrile Spacer Gaskets Santoprene Check Balls PTFE Seats and PTFE Seals WET END KIT Santoprene Diaphragms PTFE Overlay Diaphragm PTFE Check Balls
31. mbly with the above 6 32 fastener back into the vise Use a torque wrench to tighten the diaphragm assembly together to 90 in Ibs 10 17 Newton meters 120 in Ibs Santoprene 13 56 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 31 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 intermediate item 4 Fasten the outer chamber item 14 to the pump using the capscrews items 11 and 13 and flanged nuts On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 31 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber Install diaphragms with convolutions facing towards center of pump See sectional view on previous page Fasten the remaining outer chamber item 14 to the pump using the capscr
32. mped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 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 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 P
33. nal Muffler Styles or Piping Exhaust Air In 243mm Submerged Applications VIEW Symmetrical About Centerlines 166mm 143mm 92mm BOTTOM Discharge Port 1 2 NPT Internal 1 NPT External Standard 287mm OT Suction Port 1 2 NPT Internal 1 NPT External 35mm Both Suction And Discharge Ports are Available in Ye BSP Tapered Internal 1 BSP Tapered External VIEW DIMENSION Standard Pump Pulse Output Kit A 103mm 44mm Manifold Can Rotate 90 From Vertical Centerline Air Inlet 1 4 NPT SIDE VIEW B 179mm Mesh Muffler Sound Dampening Muffler Metal Muffler Model S05 Non Metallic Page 5 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by compressed air and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform 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
34. ng 2 1 G 675 062 115 End Cap Retainer 2 1 H 210 008 330 Safety Clip 1 1 l 530 031 550 Muffler 1 1 J 165 109 559 Muffler Cap 1 1 K 710 011 115 Self Tapping Screw 4 For Pumps with Virgin PTFE coated hardware 1 031 167 002 Air Valve Assembly 1 1 G 675 062 308 End Cap Retainer 2 1 J 710 011 308 Self Tapping Screw 4 Includes all other items used on 031 166 000 above For Pumps with alternate Mesh Muffler or Piped Exhaust A 031 169 000 Air Valve Assembly 1 Includes all items used on 031 167 000 above minus 1 H 1 I and 1 J x ATEX Compliant sO05nmdl2sm REV0708 Model S05 Non Metallic Page 15 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed pressure from the pump and disconnect the air supply line from the pump STEP 1 See COMPOSITE REPAIR PARTS DRAWING Using a 3 8 wrench or socket remove the four hex flanged capscrews item 12 Remove the air valve assembly from the pump STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two end cap retainers item 1 G by inserting a small flat screwdriver into the two slotted grooves on the valve body and gently lifting the retainers out Next remove the two end caps item 1 E by grasping the pull tab with finger and thumb or pliers and tugging Inspect the two o rings items 1 C and 1 F on each end cap for wear or cuts Replace the o rings
35. ning Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 023 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element A OPTION 6 530 035 000 Metal Muffler screws directly into the Air Body Option 0 Option 6 Option 1 and 2 x A Note Pumps are only ATEX compliant when ordered with wetted material options C or V non wetted material option C pump options 0 6 or 7 and Kit options 00 or P1 s05nmdl2sm REV0708 Model S05 Non Metallic Page 29 Grounding The Pump To be fully groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet end is fastened to the pump hardware The other end is installed to a true earth ground s05nmdl2sm REV0708 O This optional 8 foot long 244 centimeters Ground Strap 920 025 000 is available for easy ground connection 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 Model S05 Non Metallic Page 30 AULUIOJUOTD jo UOISlIgIer FLUID amp METER
36. ocket remove the four hex flanged capscrews item 12 Remove the air valve assembly from the pump STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two end cap retainers item 1 G by inserting a small flat screwdriver into the two slotted grooves on the valve body and gently lifting the retainers out Next remove the two end caps item 1 E by grasping the pull tab with finger and thumb or pliers and tugging Inspect the two o rings items 1 C and 1 F on each end cap for wear or cuts Replace the o rings if necessary Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft clean cloth and inspect for scratches or abrasive wear s05nmdl2sm REV0708 Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminants Remove the sleeve if needed and replace with a new sleeve and spool set item 1 B Note The sleeve and spool set is match ground to a specified clearance Sleeves and spools cannot be interchanged STEP 3 Reassembly of the air distribution valve Install one end cap with o rings items 1 E 1 C and 1 F into one end of the air valve body item 1 A Insert one end cap retainer item 1 G into the two smaller holes align with groove in the end cap and push until the closed end of the retainer is below the flat surface of the valv
37. olded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance Nylon Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures PVDF Generally reserved for applications requiring the highest purity strength and resistance to solvents acids amp bases Polypropylene Generally rugged and usually resistant to many chemicals solvents Rugged and often stiffer than other plastics economical Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons For specific applications always consult the Warren Rupp Chemical Resistance Chart SANDPIPER pumps are designed to be powered only by compressed air s05nmdl2sm REV0708 HEADS UP TO DISPLACEMENT STROKE 100 psi or 231 ft of water 026 Gallon 098 liter 7 bar or 70 meters Operating Temperatures Maximum Minimum 275 F 40 F 135 C 40 C 180 F 32 F 82 C UC 220 F 35 F 104 C 37 C 250 F O F 121 C 18 C 180 F 32 F 82 C UC 190 F 10 F 88 C 23 C Model S05 Non Metallic Page 1 Explan
38. olting 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 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 WARNING Airborne particles and loud noise hazards Wear ear and eye protection Model S05 Non Metallic Page 9 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 Assembly sub assembly and some purchased items Cast Iron Powered Metal Ductile Iron 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 Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic
39. ompliant when ordered with kit option A1 A2 A3 or AA Note See page 18 for Special Conditions For Safe Use Note Pump models equipped with these explosion proof solenoid kit options E1 E3 E5 E7 E8 or E9 are certified and approved by the above agencies They are NOT ATEX compliant Model S05 Non Metallic Page 2 Performance Curve S05 Non Metallic Design Level 2 MODEL S05 Non Metallic Performance Curve Performance based on the following elastomer fitted pump flooded suction water at ambient conditions a D The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 D Aa 3 SCFM M hr 2 3 5 7 100 E gt 7 4 7 ORS AEE 6 ar 8 13 5 80 ES GR 10 17 D 79 Li EFS 12 20 oc Bar 7 i KR i a E 24 Ek 60 t 7 Z CH 4 60 p h N N lt Si 4 08 y 16 27 ul 50 T Bar N x x x ES t e I X Si S S UI 3 40 D S x N Q N gt Ld im P ne X H S N 5 X 5 A R X E S 2 72 D s S SK SOON 2 4 30 a x s 30 9 1 Ze Saal Ze oh 25 7 6 N N N 20 i S 3 20 6 1 Wees B Sei W 15 14 5 ar A s D 10 Air Inlet Pressu 10 43 5 11 5 0 0 L L L L L L L L L L L L L L L L L L L L L L L L L L L L L c a E So a So 6 E EE EE o A d2 E 44 gt de 4e U S Gallons per minute be i el pS ee ee RES 0 10 20 30 40 50 60 Liters per minute CAPACITY
40. ood Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 553 555 556 557 558 559 570 580 590 591 592 600 601 602 603 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 Conductive PVDF Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive Polypropylene Conductive HDPE Glass Filled Conductive Polypropylene Rulon II Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon 604 606 607 608 610 611 632 633 634 635 637 638 639 643 644 650 654 656 661 PTFE PTFE Envelon Conductive PTFE PTFE Integral Silicon PTFE Integral FKM Neoprene Hytrel FKM Fluorocarbon PTFE EPDM PTFE Neoprene PTFE PTFE FKM Fluorocarbon PTFE PTFE Hytrel PTFE Nitrile TFE Santoprene EPDM Santoprene PTFE Bonded Santoprene and PTFE Santoprene Diaphragm PTFE Overlay Ba
41. or a motor protecting switch with short circuit and thermal instantaneous tripping set to rated current shall be connected in series to each solenoid as short circuit protection For very low rated currents of the solenoid the fuse of lowest current value according to the indicated IEC standard will be sufficient The fuse may be accommodated in the associated supply unit or shall be separately arranged The rated voltage to the fuse shall be equal to or greater than the stated rated voltage of the magnet coil The breakage capacity of the fuse link shall be as high as or higher than the maximum expected short circuit current at the location of the installation usually 1500 A A maximum permissible ripple of 20 is valid for all magnets of direct current design s05nmdl2sm REV0708 Model S05 Non Metallic Page 18 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 pump s air distribution valve an electric solenoid is utilize
42. 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 Any model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S05 Non Metallic Page 8 RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed Il 2GD T5 CE s05nmdl2sm REV0708 Pump complies with EN809 Pumping Directive Directive 98 37 EC Safety of Machinery and Directive 94 9 EC EN13463 1 Equipment for use in Potentially Explosive Environments For reference to the directive certificates visit www warrenrupp com The Technical File No AX1 is stored at KEMA Notified Body 0
43. r 27 Exhaust Conversion Drawing esseeseseesseserrsitsttsttsttstttstnstrnttnstnntinttnstnntnetnntenenn 27 Converted Exhaust Wlustraton tennen nennennnennennne 27 Pulse Output Kit Drawing 00 eeeeeeeeeceeeeseeeeeeeeeeaeeeeeesseeeeaeeseeeeseeeeaeeseeteeeseeeeeaees 28 PulSe Output Kit Option EE 28 due ele 29 Grounding The PUMP RE 30 CE Declaration of Conformity ccceecceeeceeeeeeeneeeeneeeeeeteaeeseeeeeaeeseaeeeaeeseaeeseeeeeaeesaas 31 WARREN RUPP INC e A Unit of IDEX Corporation e P O Box 1568 Mansfield Ohio 44901 1568 USA e Telephone 419 524 8388 e Fax 419 522 7867 e www warrenrupp com s05nmdl2sm REV0708 Copyright 2008 Warren Rupp Inc All rights reserved WARREN RUPP Quality System 1S09001 Certified Environmental Management System 1S014001 Certified FLUID amp METERING INTAKE DISCHARGE PIPE SIZE 1 2 NPT Internal or 1 2 BSP Tapered 1 NPT External or 1 BSP Tapered 0 to 14 gallons per minute 0 to 52 liters per minute No lube no stall design U S Patent 5 996 627 6 241 487 Other U S Patents Applied for CE See page 2 for ATEX ratings SOLIDS HANDLING Up to 125 in 8mm SANDPIPERs A WARREN RUPP PUMP BRAND SO5 Non Metallic Design Level 2 Ball Valve Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA A CAUTION Operating temperature limitations are as follows MATERIALS Santoprene Injection m
44. rained between uses in all cases Model S05 Non Metallic Page 6 WARREN _ INSTALLATION GUIDE RUPP Top Discharge Ball Valve Unit 1 Available from Warren Rupp Dampene f Pipe Connection GE Style Optional T DAOS Surge Dampener 00 p ae 2 020 049 000 Filter Regulator Gauge Air Dryer Flexible Shut Off Valve Connection Ome z nA DISCHARGE EE A CAUTION ot th The air exhaust should be piped to an area for safe disposition of the product Drain Port being pumped in the event of a diaphragm failure Flexible Connection Air Shut Off Pipe Connection Valve Style Optional TOP Air Exhaust Filter Regulator Air Dryer a Gauge Weare DIAPHRAGM ES Shut Off PUMP Valve SE AIR INLET i Flexible SUCTION E N Connection Wf Li Like Drain Port s05nmdl2sm REV0708 Model S05 Non Metallic Page 7 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
45. roper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing or freezing of the exhaust air causing the pump to cycle erratically or stop operating Water in the air supply can be reduced by using a point of use air dryer to supplement the user s air drying equipment This device removes water from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 1 2 to 3 4 turn After the pump primes the air valve can be opened to increase air flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient air flow to pump flow ratio BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be flushed after each use to 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 d
46. ses 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 Air Valve Assembly CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA SAFE AIR EXHAUST DISPOSAL AREA MUFFLER 1 DIAMETER AIR EXHAUST PIPING Illustration 1 MUFFLER geg 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Se Ed Illustration 2 MUFFLER E 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE Illustration 3 Model S05 Non Metallic Page 27 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 Stroke Counter Batch Controller or user control devices such as a PLC See the individual kits listed on the Pump Repair Parts List for further information s05nmdl2sm REV0708 Model S05 Non Metallic Page 28 Optional Muffler Configurations Drawing A OPTION 0 530 031 550 Integral Muffler uses 1 Cap and 4 706 027 115 Machine Screw to hold it in place OPTION 1 530 024 000 Sound Dampe
47. 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 3 8 diameter Reducing the pipe size will restrict air flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the exhaust higher than the product source to prevent siphoning spills See illustration 3 at right CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR The following steps are necessary to convert the pump to pipe the exhaust air away from the pump Use a 8 Torx or flat screwdriver to remove the four self tapping screws item 1 J Plastic Valves Use a Phillips screwdriver to remove four machine screws item 1 1 Aluminum Valves Remove the muffler cap and muffler The air distribution valve body has 3 8 NPT threads for installation of alternate mesh or sound dampening mufflers or piped exhaust s05nmdl2sm REV0708 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stres
48. ual Porting BSP Tapered E0 Solenoid Kit with 24VDC Coil Ai Senat Kit with 12 VDC T Virgin PTFE Pump Style A Eis Solenoid Kit with 24VDC Explosion Proof Coil Wetted Material Explosion Proof Coil K PVDF Non Wetted Material Options S Standard Xp OSION T TOOT SOl e A2 Solenoid Kit with 24 VDC N Nyl P Polypropylene F E2 Solenoid Kit with 24VAC 12VDC Coil Explosion Proof Coil Nylon Pump Options E3 Solenoid Kit with 12VD id Kit wi P Polypropylene 1 Polypropylene w PTFE Coated A 0 None 3 So enoi it wit 2 C A3 Solenoid Kit with 110 120 VAC c Conductive Polypropylene Hardware 7 Explosion Proof Coil 50 60 Hz Explosion Proof Coil A V Conductive Bones A C Conductive Polypropylene SE E4 Solenoid Kit with 110VAC Coil Ad Solenoid Kit with 220 240 VAC AA E5 Solenoid Kit with 110VAC 50 60 Hz Explosion Proof Coil A 6 Metal Muffler A 7 Metal Muffler with Grounding Cable 2 II 2G Ex ia c IIC T5 Il 2D c iaD 20 IP67 T100 C Explosion Proof Coil E6 Solenoid Kit with 220VAC Coil 1 amp 08 SB Gy ee 4 SEN IEC EEX m T4 SP APPROVED s05nmdl2sm Note Pumps are only ATEX compliant when ordered with wetted material option C or V non wetted material option C pump option 0 6 or 7 and kit option 0 REV0708 Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option P1 Note Pumps ordered with the options listed in 1 to the left are ATEX c
49. ump Corrective Action Install flexible connectors and a Warren Rupp Tranquilizer Surge Suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Corrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions 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
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