Operation Manual - Fluid Systems Incorporated
Contents
1. Solenoid Connector Before wiring remove terminal block from ug conduit connector IL 4A 4 Vai 4A Pd d ee LL LL E icc apicc adr d 4A Myra enne Berg eee Se ea 71 Wiring Diagram 3rd Terminal for ground 2 Terminal Neutral 1 Terminal A Negative Power Positive a zi Model 15 Non Metallic Page 21 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER 4 095 110 558 4 A 095 095 558 4 B 55 052 000 4 C 560 033 360 4 D 775 055 000 4 E 560 023 360 4 F 675 037 080 Valve Body 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 1 2 wrench or socket remove the four capscrews item 9 Remove the air inlet cap item 7 and air inlet gasket item 21 The pilot valve assembly item 2 can now be removed for inspection and service s15nmdl3sm REVO908 DESCRIPTION Pilot Valve Assembly Sleeve With O rings O ring Sleeve Spool With O rings O ring Spool Retaining Ring QTY MA O STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 D2. iii 24 Pilot Valve Assembly evt aedes Uta es tau Ex Vu Uu ERAT 24 Pilot Valve Servicing c etapa E TAS M Pub ED Ed 24 Pumping Hazardous Equidem nein cease tus Ur de ape 25 Converting the pump for piping the exhaust aif 25 Exhaust Conversion 25 Converted Exhaust 25 Modular GheckValve Servicing adele 26 Modular Check Valve Drawing 26 Dual POU Option Draw GO iaia as ausa EUR e aliena RR eta 27 Dual cepe PTT 27 Dual Porting of both suction and discharge ends of the pump 27 Single Porting of the suction and dual porting of the pump discharge 27 Dual Porting of the suction and single porting of the pump discharge 27 Detection Options Drawing sS soe bs Potuit XAR Stet fu at dev ovas 28 Electronic Leak Detector Installation 28 Mechanical Leak Detector Installationi alia ale 28 Pulse Qutp t Kit DAWNO sis E aoe tcc 29 Pulse Output KiE so t c EM 29 Optional Muffler Configurations E E a 30 Grounding he Pimp 31 CE D
3. 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 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 six self tapping screws item 1 J Hemove the muffler cap and muffler items 1 D and 1 F The 1 NPT molded threads in the air distribution valve body item 1 B Piping or hose may now be installed s15nmdl3sm REV0908 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the m
4. 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 553 555 556 557 558 559 5 0 580 590 591 592 600 601 602 603 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 Il 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 Balls and seals Santoprene Diaphragm and Check Balls EPDM Seats EPDM Santoprene Delrin and Hytrel are registered tradenames of E l DuPont Gylon is a registered tradena
5. Ball Retainer Ball Ring Retainer Rod Diaphragm Seal U Cup Seal Check Valve Assembly Seal Manifold Seat Check Valve Seat Check Valve Washer Flat 5 16 Washer Flat 5 16 Washer Flat 1 2 Washer Flat 1 2 Washer Flat 3 8 Washer Flat 3 8 Muffler Muffler Muffler Note ATEX Compliant lt GC CO MINNNNNNNNNN EFRS HIN AINN sb SISODODISISIASIAA V0ME NISANNNN Model S15 Non Metallic Page 13 Spill Containment Option 15 Spill Containment Repair Parts List ITEM PART NUMBER DESCRIPTION QTY 1 031 146 000 Air Valve Assembly 1 replaces 031 140 000 031 147 000 Air Valve Assembly 1 replaces 031 141 000 170 102 115 Capscrew Hex HD 1 2 13x 6 00 16 replaces 170 095 115 170 102 308 Capscrew Hex HD 1 2 13x 6 00 16 196 189 520 Chamber Spill Prevention 2 196 189 552 Chamber Spill Prevention 2 286 120 600 Diaphragm Pumping 2 518 198 520 Manifold 2 replaces 518 197 520 518 198 520E Manifold 40mm DIN 2 replaces 518 197 520E item 23 518 198 552 Manifold 2 replaces 518 197 552 518 198 552E Manifold 40mm DIN 2 replaces 518 197 552E item 23 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 560 078 611 O Ring 8 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 Note 618 025 110 Plug Boss 4 Items 41 618 025 308 Plug Boss 4 the diaphragms 618 031 110 Threaded Bushing 4 are to be installed 618 031 308 Threaded Bushing 4 with the concave 835 005 110 Tee Pipe 4
6. Design Level 3 Ball Valve S15B3P1PPAS000 S15B3K1KPAS000 515B3P2PPAS000 S15B3K2KPAS000 S15B3PGPPASO000 S15B3KGKPASO00 S15B3C1PCAS000 Diaphragm Check Valve Materials Check Non Wetted Note Models listed in the table are for reference only See nomenclature below for other models Pump Brand S SANDPIPER Pump Size 15 1 1 2 Check Valve Type B Ball Design Level 3 Design Level 3 Wetted Material K PVDF P Polypropylene A C Conductive Polypropylene 1 x II 2GD T5 Note Pumps are only ATEX compliant when ordered with wetted material option C non wetted material option C pump option O 6 Diaphragm Check Valve Materials 12 Santoprene Santoprene 2 PTFE Santoprene Backup PTFE 6 PTFE Pumping PTFE Neoprene Backup Driver PTFE B Nitrile Nitrile C FKM PTFE G PTFE Neoprene Backup PTFE N Neoprene Neoprene U Urethane Urethane Z One Piece Bonded PTFE Check Valve Seat K PVDF P Polypropylene A Non Wetted Material Options C Carbon Filled Conductive Polypropylene P 40 Glass Filled Polypropylene 1 40 Glass Filled Polypropylene w PTFE Coated Hardware 2 Il 2G Ex ia c IIC T5 Il 2D c iaD 20 IP67 T100 C Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option P1 or 7 and kit option O s15nmdl3sm REVO908 Porting Options A ANSI Flange D DIN Flange 7 Dual Porting ANSI 8 Top Dual Porti
7. STANDARD 1254 FLANGE CONFIGURATION 6 62 4 HOLES EQUALLY SPACED ON A 5 88 BOLT CIRCLE AIR INLET 3 4 NPT s15nmdl3sm REVO908 STANDARD ENCAPSULTATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGRED APPLICATIONS DISCHARGE PORT 1 1 2 STANDARD 1254 FLANGE CONFIGURATION 62 4 HOLES EQUALLY SPACED ON A 5 88 BOLT CIRCLE 9 00 13 00 330 6 88 175 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE ARE c Sims Zn ANALI Y m p OPTIONAL THREADED 1 NPT SOUND DAMPENING OR BRASS MESH MUFFLER A ez i ty wre a Y ab 4 1 METAL MUFFLER FOR ATEX COMPLIANT PUMPS et N 15 12 Y 25 19 14 35 i P 640 564 _ b SANA ZA 350 3 56 89 90 ISa e OPTIONAL THREADED 1 Gee ALY WI E lt 4 Note Porting Flanges are also available with PN10 40mm DIN Bolting Configuration Model S15 Non Metallic Page 4 Dimensions 15 Non Metallic with Spill Containment Dimensions in Inches in Millimeters DISCHARGE PORT Dimensional tolerance 1 8 1 3mm 15 00 1 1 2 NOD 125E FLANGE SCONGICURATION 4 62 4 HOLES EQUALLY SPACED ON A 35 88 BOLT CIRCLE 27 62 MANIFOLD ROTATE 90 FROM VERTICAL CENTERLINE ANDA A A MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGRED APPL
8. 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 4 F from the end of the sleeve item 4 B and remove the sleeve from the valve body item 4 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 15 Non Metallic Page 22 Diaphragm Service Drawing with Overlay N oN 24 Pin Field conversion kit 475 256 000 available for conversion from PTFE Overlay to One Piece bonded Diaphragm Part Description Qty 286 114 000 One Piece Diaphragm 2 612 22
9. side facing 835 005 308 Tee Pipe 4 toward the outer 860 055 606 Tube Sight 2 866 060 110 Connector Tube 4 chambers s15nmdl3sm REVO908 Model S15 Non Metallic Page 14 SPILL CONTAINMENT CONCEPT The spill containment 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 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 containment chambers This can be done by removing the bottom plug item 46 from each spill containment chamber After the fluid from the spill containment chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill containment option has two additional virgin PTFE pumping diaphragms item 41 The
10. 3 8 16 x1 25 Chamber Outer Chamber Outer Chamber Outer Chamber Inner Chamber Inner Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm One Piece Bonded PTFE Diaphragm Overlay Elbow Discharge Elbow Discharge Elbow Discharge QTY nd GC RANMNHIANMNH HAHAHAHAHA ek MINNNNNNNNNNNNNNQDDASIALADDI ITEM PART NUMBER 18 312 115 520 312 115 552 312 115 557 19 360 093 360 20 360 103 360 21 360 104 360 360 104 379 22 360 107 360 23 518 197 520 518 197 520E 518 197 552 518 197 552E 518 197 557 518 197 557E 24 545 008 110 545 008 308 25 560 001 360 26 612 195 157 612 227 150 27 612 225 520 612 225 552 28 620 004 115 29 670 045 520 670 045 552 30 675 042 115 31 685 063 120 32 720 004 360 33 720 035 600 34 720 037 600 35 722 074 520 722 074 552 36 901 038 115 901 038 308 37 901 046 115 901 046 308 38 901 048 115 901 048 308 NOT SHOWN 535 010 000 530 027 000 A 530 033 000 DESCRIPTION Elbow Suction Elbow Suction Elbow Suction Gasket Main Air Valve Gasket Pilot Valve Gasket Air Inlet Cap Gasket Air Inlet Cap Conductive Models Only Gasket Inner Chamber Manifold Manifold 40mm DIN Manifold Manifold 40mm DIN Manifold Manifold 40mm DIN Nut Hex 1 2 13 Nut Hex 1 2 13 O Ring Inner Plate Diaphragm Inner Diaphragm Plate One Piece Bonded Option Outer Plate Diaphragm Outer Plate Diaphragm Plunger Actuator Retainer
11. 65 9 fl oz 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 46 to the filled spill containment 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 48 is in the vertical position Loosen the pipe plug item 45 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 item13 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 45 allowing the fluid to purge any remaining trapped air Reinstall th
12. HOLES ON A 93 88 BOLT CIRCLE s15nmdl3sm REVO908 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 are designed to mate with a 1 1 2 ANSI Flange 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 from the pump The discharge elbows can be rotated in 90 increments and the suction elbows can be rotated in 180 increments see 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 di
13. for applications requiring the highest purity strength and resistance to solvents acids amp bases 250 F 121 C Polypropylene Generally rugged and usually resistant to many chemicals solvents Rugged and often stiffer than other plastics economical 180 F 32 F 92 C 0 C Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used 190 F 10 F with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons 88 C 23 C Neoprene All purpose Resistant to vegetable oil Generally not affected by moderate chemicals fats greases and many 200 F 10 F oils and solvents Generally attacked by strong oxidizing acids ketones esters Nitro hydrocarbons and chlorinated aromatic hydrocarbons GE 23 C FKM Fluorocarbon Shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated 350 F 40 F hydrocarbons acids animal and vegetable oils Hot water or hot aqueous solutions over 70 F will attack FKM 177 40 Urethane Shows good resistance to abrasives Has poor resistance to most solvents and oils 150 F 66 C 0 C SANDPIPER pumps are designed to be powered only by compressed air For specific applications always consult the Warren Rupp Chemical Resistance Chart s15nmdl3sm REV0908 Model S15 Non Metallic Page 1 Explanation of Pump Nomenclature 15 Non Metallic
14. 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 s15nmdl3sm REVO908 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 red
15. 7 150 Plate Inner Diaphragm 2 s15nmdl3sm REV0908 Diaphragm Service Drawing Non Overlay Model S15 Non Metallic Page 23 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump composite repair parts drawing and the diaphragm servicing illustration Using a wrench or socket remove the 16 capscrews items 8 hex nuts and washers that fasten the elbows items 17 to the outer chambers items 13 Remove the elbows with the manifolds attached Step 42 Removing the outer chambers Using a wrench or socket remove the 16 capscrews items 10 hex nuts and washers that fasten the outer chambers diaphragms and inner chambers items 14 together Step 43 Removing the diaphragm assemblies Use a 1 38mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 31 by turning counterclockwise Inspect the diaphragm item 15 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary s15nmdl3sm REVO908 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
16. AY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 16 is designed to fit over the exterior of the standard diaphragm item 15 Follow the same procedures described for the standard diaphragm for removal and installation One Piece Bonded DIAPHRAGM SERVICING Bonded PTFE with integral plate The one piece bonded diaphragm item 15 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 dia phragm rod only until the inner plate contacts the rod Do not tighten A small amountof grease may be applied between the inner plate and the diaphragm to facilitate assembly 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 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 Model 15 Non Metallic Page 24
17. Explosion Proof Coil SP Stroke Indicator Pins 1 Solenoid Kit with 12 VDC Explosion Proof Coil A2 Solenoid Kit with 24 VDC Explosion Proof Coil A3 Solenoid Kit with 110 120 VAC 50 60 Hz Explosion Proof Coil A4 Solenoid Kit with 220 240 VAC 50 60 Hz Explosion Proof Coil C IEC EEX m T4 SP APPROVED 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 Note See page 20 for Special Conditions For Safe Use Model S15 Non Metallic Page 2 Performance Curve Model 515 Non Metallic Design Level 3 a lt 7 O HEAD s15nmdl3sm REV0908 MODEL S15 Non Metallic Performance Curve Performance based on the following elastomer fitted pump flooded suction water at ambient conditions The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 SCFM M hr pot LLL LL LLL M 43 Gallons 1 63 Liters Flow Capacity 0 100 Gallons Per Min 0 378 Lilters Per Min Displacement Per Stroke 10 20 30 40 50 60 70 80 90 100 U S Gallons per minute 20 100 150 200 250 300 350 Liters per minute CAPACITY METERS N Model S15 Non Metallic Page 3 Dimensions S15 Non Metallic Dimensions in Inches Dimensional tolerance 1 8 in Millimeters 3mm SUCTION PORT 1 1 2
18. ICATIONS A z Po pe sis De va OPTIONAL THREADED 1 NPT SOUND DAMPENING OR BRASS MESH MUFFLER SUCTION PORT 1 1 2 STANDARD 1257 FLANGE CONFIGURATION 17 44 9 62 4 HOLES EQUALLY SPACED ON 93 88 BOLT CIRCLE OPTIONAL THREADED 1 NPT METAL MUFFLER FOR BAC A Du SU vis ATEX COMPLIANT PUMPS af ss 4 K 2 Note Porting Flanges are also available with PN10 40mm DIN bolting configuration AIR INLET 3 4 NPT s15nmdl3sm REV0908 Model S15 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 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
19. SERVICE amp OPERATING MANUAL SANDPIPER A WARREN RUPP PUMP BRAND Model S15 Non Metallic Design Level 3 Table of Contents Engineering Data and Temperature 1 Explanation of Pump Nomenclature 2 Performance Curve Model S15 Non Metallic Design Level 3 Dimensions S15 Non MetalliC nennen nnne nnns 4 Dimensions 15 Non Metallic with Spill 5 Principle of Pump daB s RE b ended sub cud asi 6 Irstallation and Start agraria bau Bav ceeds 6 AF SUP release 6 Alr Yawe LUDNCAON E 6 A ENE eai neri it N RIA Ri A raise 6 Air Alet and a ala E a 6 USES atei aiar 6 Mstallaton Guden uM a M EM a M ME E 7 aie riesi 8 Importantareb Informati soe etse bv ee tere autas Ri 8 CodeS eT PD e ai ie ren a Man 9 Icejtjol erereiila o m tme T E 10 etr CE e 10 Composite Repair Parts Drawing nne 12 Repair Parts Servicing oes rir acer euren vene eee hanh oes ree dva e deum edid deua sat ous 12 Composite Aepall Parts EISE Ea 13 Spill Containment ODIOM dai 14 Spill Containme
20. actory warranty Model 15 Non Metallic Page 17 Air Valve Assembly Drawing with Stroke Indicator Option S15 Design Level 3 AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty Note Stroke Indicator is standard on Spill Containment models Ai 031 146 000 Air Valve Assembly 1 1 A 031 143 000 Sleeve and Spool Set w Pins 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 559 Cap Muffler 1 1 E 165 098 147 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self Tapping 4 1 K 210 008 330 Clip Safety 1 1 M 560 029 360 O Ring 2 For Pumps with PTFE Coated Hardware 1 031 146 002 Air Valve Assembly 1 1 J 710 015 308 Screw Self Tapping 4 includes all other items on 031 146 000 above For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust Ai 031 147 000 Air Valve Assembly 1 includes all items 031 146 000 minus 1 0 1 F amp 1 4 x Note ATEX Compliant s15nmdl3sm REV0908 Model S15 Non Metallic Page 18 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 16 Allen wrench remove the four hex socket capscrews item 11 and four flat washers item 38 Remove the air valve assembl
21. ays be flushed clean prior to disassembly 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 S15 Non Metallic Page 8 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 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 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 Almag 35 Alumi
22. bly Model 15 Non Metallic Page 12 Composite Repair Parts List ITEM PART NUMBER 1 NO CO 10 11 12 13 14 15 16 17 031 140 000 Ad 031 140 001 031 140 002 A 031 141 000 031 141 001 031 141 002 095 110 558 050 036 354 050 036 357 050 036 360 050 036 365 050 036 600 114 024 551 A 114 024 559 132 035 360 135 034 506 165 118 551 A 165 118 559 170 055 115 170 055 308 170 069 115 170 069 308 170 092 115 170 092 308 171 053 115 171 053 308 171 078 115 196 187 520 196 187 552 A 196 187 557 196 188 551 A 196 188 559 286 005 354 286 005 357 286 005 360 286 005 363 286 005 365 286 114 000 286 119 600 312 101 520 312 101 552 A 312 101 557 s15nmdl3sm REVO908 DESCRIPTION Air Valve Assembly Air Valve Assembly Air Valve Assembly w PTFE coated Hardware Air Valve Assembly No Integral Muffler Air Valve Assembly No Integral Muffler Air Valve Assembly No Integral Muffler PTFE Coated Hardware Pilot Valve Assembly Ball Check Ball Check Ball Check Ball Check Ball Check Intermediate Assembly Intermediate Assembly Bumper Diaphragm Bushing Plunger Air Inlet Cap Assembly Air Inlet Cap Assembly Capscrew Hex HD 1 2 13 x 2 50 Capscrew Hex HD 1 2 13 x 2 50 Capscrew Hex HD 5 16 18 x 1 75 Capscrew Hex HD 5 16 18 x 1 75 Capscrew Hex HD 1 2 13 x 4 00 Capscrew Hex HD 1 2 13 x 4 00 Capscrew Soc HD 3 8 16 x 2 75 Capscrew Soc HD 3 8 16 x 2 75 Capscrew Flat HD
23. ce 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 The other end is installed to a true earth ground A 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 s15nmdl3sm REV0908 Model S15 Non Metallic Page 31 mn1ILLLJOJUO JO UOI18eJej3a WARREN RUPP FLUID amp METERING 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 T series G series U series EH and SH High Pressure W series SMA and SPA Submersibles and Tranquilizer Surge Supressors comply with the European Community Directive 98 37 EC Safety of Machinery This product has used Harmonized Standard EN 809 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance Signature of authorized person Date of issue David Roseberry Engineering Manager Printed name of authorized person Title August 6 2008 Revision level A Date of revision Declaration of Conformity
24. clockwise onto the stud Use a torque wrench to tighten the diaphragm assembly together to 480 in Lbs 54 23 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 5 is installed over the diaphragm rod Thread the stud of 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 Fasten the remaining outer chamber item 13 to the pump using the capscrews items 10 hex nuts and flat washers and tighten Make sure the bumper item 5 is installed over the diaphragm rod Thread the stud of the other diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 31 make sure the 2nd diaphragm assembly is tight enough that the inner plate is flush to the end of the rod The bead of the end of the diaphragm should fit into the groove of the inner chamber Fasten the remaining outer chamber item13 to the pump using the capscrews items 10 hex nuts and flat washers Step 6 Re install the elbow manifold assemblies to the pump using the capscrews items 8 hex nuts and flat washers Ref pg 12 The pump is now ready to be re installed connected and returned to operation OVERL
25. d areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 29 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 3 for wear abrasion or cuts on the spherical surface The check valve seats items 35 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 inner chamfer on the check valve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary s15nmdl3sm REVO908 Remove the remaining check valve seal item 33 Inspect the seal for cuts or pinched areas Replace seal as needed He assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 33 into the cavity of the outer chamber item 13 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 33 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 S15 Non Metallic Page 26 Dual Port Option Drawing 1 1 2 ANSI STYLE FLANGE CONNECTION FOUR 9 65
26. e 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 local Warren Rupp Distributor or factory Technical Services Group for a serv
27. e plug 10 Repeat steps 5 through 9 to fill opposite spill containment 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 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 S15 Non Metallic Page 15 Air Distribution Valve Assembly Drawing z AIR VALVE ASSEMBLY PARTS LIST S15 Design Level 3 Item Part Number Description Qty 1 031 140 000 Air Valve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 B 095 094 551 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 551 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ring 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 141 000 Air Valve Assembly 1 Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J A AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031 140 001 Air Valve Assembly 1 1 A 031 139 000 Sleeve and Spool Set 1 1 B 095 094 559 Body Air Valve 1 1 C 132 029 552 Bumper 2 1 D 165 096 559 Cap Muffler 1 1 E 165 115 552 Cap End 2 1 F 530 028 550 Muffler 1 1 G 560 020 360 O Ri
28. eclaration of dll lara 32 Copyright 2008 Warren Rupp Inc All rights reserved WARREN SANDPIPER A WARREN RUPP PUMP BRAND See page 2 for ATEX ratings 1 i Non Metallic Design Level 3 Ball Valve Quality System 1509001 Certified Environmental Management System SO14001 Certified U S Patent _ 5 851 109 5 996 627 Air Operated 400 210 co Double Diaphragm Pump Applied for FLUID amp METERING ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 1 1 2 ANSI Flange or O 100 US Gallons per minute No lube no stall Up to 47in 12mm 100 psi or 231 ft of water 43 US gallons 1 63 liter PN10 40mm DIN Flange O 378 liters per minute design 7 bar or 70 meters A CAUTION Operating temperature limitations are as follows Operating Temperatures Materials Maximum Minimum Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance 40 C Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals 220 F turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily 104 C liberate free fluorine at elevated temperatures PVDF Generally reserved
29. g the fluid by fast cycling s15nmdl3sm REVO908 What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Hestricted 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 Plus 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 What to Check Obstructed check valv
30. ice evaluation WARRANTY Hefer to the enclosed Warren Rupp Warranty Certificate Model S15 Non Metallic Page 10 s15nmdl3sm REV0908 Model S15 Non Metallic Page 11 Composite Repair Drawing 476 253 000 476 254 000 476 255 354 476 255 360 476 255 365 476 255 633 476 255 635 476 255 654 476 256 640 476 255 659 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 Pilot Valve Assembly WETTED END KIT Santoprene Diaphragms Santoprene Balls and TFE Seals WETTED END KIT Nitrile Diaphragms Nitrile Balls and PTFE Seals WETTED END KIT Neoprene Diaphragms Neoprene Balls and PTFE Seals WETTED END KIT FKM Diaphragms PTFE Balls and PTFE Seals WETTED END KIT Neoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals WETTED END KIT For Spill Containment Pumps Neoprene Diaphragms PTFE Overlay Diaphragms PTFE Balls and PTFE Seals Wetted End Kit One piece s15nmdl3sm REVO908 S C A 7n SN PEL D ONAN v e O SS SP 72 946 Overlay Option Drawing m ES e KY One Piece Bonded Option Drawing Fluid End Section Assembly Air End Section Assem
31. ion 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 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 4 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 AWARNING 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 AWARNING 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 44 WARNING When used for toxic or aggressive fluids the pump should alw
32. l strokes of the pump to an electrical signal which interfaces with the 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 valve and senses each stroke of the main spool Consult the factory for further information and availability Pulse Output Kits 475 244 001 10 30 VDC 475 244 002 110 220 VAC 475 244 003 10 30VDC 110VAC and 220 VAC s15nmdl3sm REVO908 Model S15 Non Metallic Page 29 Optional Muffler Configurations Drawing OPTION 0 530 028 550 Integral Muffler uses 1 Cap and 4 710 015 115 Self Tapping Screw to hold it in place OPTION 1 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element OPTION 2 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element A OPTION 6 530 033 000 Metal Muffler screws directly into the Air Body A ATEX Compliant Option 0 Option 1 and 2 Option 6 s15nmdl3sm REV0908 Model S15 Non Metallic Page 30 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 This optional 8 foot long 244 centimeters Ground Strap 920 025 000 is available for easy ground connection To redu
33. ls used in North America and outside the European Union SD 52 219 009 001 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 se 219 009 006 Solenoid Coil 230VAC 50 Hz 1 amp O Note Item 53 Conduit Connector is not required d Q Il 2G EEx m c T5 x II 2D IP65 T100 C For Explosion Proof Solenoid Coils used in the European Union 52 219 011 001 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 Note Item 53 Conduit Connector is not required Special Conditions For Safe Use A fuse corresponding to its rated current max 3 l according IEC 60127 2 1 or a motor protecting switch with short circuit and thermal instantaneous tripping set to rated current shall be connected 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
34. me 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 S15 Non Metallic Page 9 TROUBLESHOOTING Possible Symptoms e Pump will not cycle Pump cycles but produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitatin
35. ng ANSI 9 Bottom Dual Porting ANSI Pump Style D with Electronic Leak Detection 110V E with Electronic Leak Detection 220V M with Mechanical Leak Detection S Standard V with Visual Leak Detection Pump Options A 0 None 1 Sound Dampening Muffler 2 Mesh Muffler 3 High temperature Air Valve w Integral Muffler 4 High temperature Air Valve w Sound Dampening Muffler Il 2D c IP65 T100 C Note Pumps ordered with the options listed in 1 to the left are ATEX compliant when ordered with kit option A1 A2 A3 or A4 3 x Il 2G EEx m c T5 4 Pump Options continued 5 High temperature Air Valve w Mesh Muffler A 6 Metal Muffler A 7 Metal Muffler w Grounding Cable Kit Options A 00 None P0 10 30VDC Pulse Output Kit lt gt P1 Intrinsically Safe 5 30VDC 110 120VAC 220 240 VAC Pulse Output Kit P2 110 120 or 220 240VAC Pulse Output Kit E0 Solenoid Kit with 24VDC Coil E1 Solenoid Kit with 24VDC Explosion Proof Coil E2 Solenoid Kit with 24VAC 12VDC Coil A E3 Solenoid Kit with 12VDC Explosion Proof Coil E4 Solenoid Kit with 110VAC Coil Shipping Weight Ibs kg 83 112 51 36 49 112 51 50 51 Kit Options continued E5 Solenoid Kit with 110VAC Explosion Proof Coil E6 Solenoid Kit with 220VAC Coil E7 Solenoid Kit with 220VAC Explosion Proof Coil A E8 Solenoid Kit with 110VAC 50 Hz Explosion Proof Coil A E9 Solenoid Kit with 230VAC 50 Hz
36. ng 8 1 H 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 A For Pumps with Metal Mesh Muffler or Piped Exhaust 1 031 141 001 Air Valve Assembly 1 Includes all items used on 031 140 001 minus items 1 D 1 F amp 1 J x A Note ATEX Compliant s15nmdl3sm REV0908 Model S15 Non Metallic Page 16 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 16 Allen wrench remove the four hex socket capscrews item 11 and four flat washers item 38 Remove the air valve assembly from the pump Hemove and inspect gasket item 19 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the two bumpers item 1 C Inspect the bumpers for cuts wear or abrasion Replace if necessary Hemove 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 s15nmdl3sm REVO908 Inspect the inner diame
37. nt Repair Parts List oontra oo obersten iii 14 Spill Containment Concept iii 14 Spill Containment Option Diaphragm Servicing 15 Filling CHAMBERS AIL BEIOHIG alice 15 Air Distribution Valve Assembly Drawing 16 Main Air Valve Assembly Parts List e 16 Air Distribution Valve Servicing susino d VENE ace UE URBE UT 17 Air Distribution Valve with Stroke Indicator Options 18 Air Distribution Valve with Stroke Indicator Parts List i 18 WARREN RUPP INC AUnitof IDEX Corporation Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com s15nmdl3sm REV0908 2 for ATEX ratings U S Patent 5 851 109 5 996 627 400 210 6 Other U S Patents Applied for Air Distribution Valve with Stroke Indicator Servicing 19 Solenoid Shifted Air Valve Drawing 20 Solenoid Shifted Air Valve Parts List 20 Solenoid Shifted Air Distribution Valve Option 21 Diaphragm Service Drawing Non Overlay essen 22 Diaphragm Service Drawing with Overlay sse 22 Diaphragm Servicios un pud vti ete bos Cuts hola 23 Overlay Diaphragm Service re nnnennnn nnn 23 Pilot Valve Assembly Drawing
38. num 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 s15nmdl3sm REVO908 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 3 4 375 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 Food Grade Nitrile Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile 378 379 405 408 425 426 440 465
39. olded 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 ILLUSTRATION AREA PUMP INSTALLATION SAFE AIR EXHAUST DISPOSAL AREA 1 DIAMETER AIR EXHAUST PIPING MUFFLER Illustration 1 a MUFFLER 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION LINE ABER DS Illustration 2 MUFFLER 1 DIAMETER AIR LIQUID EXHAUST PIPING LEVEL SUCTION Illustration 3 Model S15 Non Metallic Page 25 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 17 amp 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 13 Next remove the check valve seal item 33 Inspect the seal for cuts or pinche
40. piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure Surge Suppressor Limited to 100 psi N LI p Flexible Connection Pipe Connection Style Optional Gauge Shut Off Valve DISCHARGE E E Drain Port Flexible Connection Air Shut Off Pipe Connection Valve Style Optional Air Exhaust Filter Regulator Air Dryer Gauge DIAPHRAGM Shut Off PUMP DL Valve tl 1 AAT AIRINLET Flexible UN O Connection SUCTION 7 1 s15nmdl3sm REVO908 2 Model S15 Non Metallic Page 7 RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 9 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed 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 0344 under Document 203040000 s15nmdl3sm REV0908 IMPORTANT SAFETY INFORMATION IMPORTANT Read these safety warnings and instructions in this manual completely before installat
41. s 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 72 to 34 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 S15 Non Metallic Page 6 WARREN RUPP INSTALLATION GUIDE Top Discharge Ball Valve Unit Available from Warren Rupp 1 Surge Suppressor 2 020 051 000 Filter Regulator 3 Air Dryer A CAUTION The air exhaust should be
42. scharge 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 180 increments See arrows and optional positioning in the Dual Porting Drawing Model 15 Non Metallic Page 27 Spill Containment Leak Detection Options Drawing Spill Containment LEAK DETECTION OPTION ELECTRONIC Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Electronic Leak Detector Installation Kit 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC To install electronic leak detectors remove the bottom NPT pipe plug on the visual sight tube item 49 Insert leak detector into the 14 pipe tee item 48 LEAK DETECTION OPTION MECHANICAL Follow instructions found elsewhere in this manual Filling the Spill Containment Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical leak detectors remove the bottom 14 NPT pipe plug on the visual sight tube item 49 Insert leak detector into the 14 pipe tee item 48 TO CONTROL 30 s15nmdl3sm REVO908 LEAK DETECTORS Model S15 Non Metallic Page 28 Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanica
43. se diaphragms are installed with the natural concave curve toward the s15nmdl3sm REVO908 outer chamber items 13 from the pump assembly drawing FILLING CHAMBERS WITH 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 containment chambers by removing the bottom two boss plugs items 46 Heplace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 13 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 46 The spill containment chambers are filled through the exposed ports 4 Install safety clip item 1 K into the smaller unthreaded hole in one end cap item 1 E This locks the valve spool to one side keeping the pump from shifting Apply air pressure to the air distribution valve 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 containment chamber The volume of fluid is 1950 ml
44. 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 2096 is valid for all magnets of direct current design s15nmdl3sm REV0908 Model S15 Non Metallic Page 20 SOLENOID SHIFTED AIR DISTRIBUTION VALVE OPTION The solenoid shifted air distribution valve option utilizes electrical signals to precisely control your pump 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 pump has a solenoid operated air distribution valve in place of the standard pump s pilot operated air distribution valve Where a pilot valve is normally utilized to cycle the pump s air distribution valve an electric solenoid is utilized As the solenoid is powered one of the pump s air chambers is pressurized while the other chamber is exhausted When electric power is turned off the solenoid shifts and the pressurized chamber is exhausted while the other chamber is pressurized By alternately applying and removing power to the solenoid the pump cycles much like a standard 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 s15nmdl3sm REVO908
45. ter of the sleeve part of item 1 A for dirt scratches or other contaminates Hemove 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 end cap item 1 E with an o ring item 1 G and one bumper item 1 C 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 Hemove 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 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 19 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 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 f
46. 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 19 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 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 S15 Non Metallic Page 19 Solenoid Shifted Air Valve Drawing SOLENOID SHIFTED AIR VALVE PARTS LIST Includes All Items Used on Composite Repair Parts List Except as Shown Item Part Number Description Qty 51 893 097 000 Solenoid Valve NEMA4 1 52 219 001 000 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 53 241 001 000 Connector conduit 1 54 170 029 330 Capscrew Hex HD 5 16 18 x 1 50 4 55 618 051 150 Plug 2 IEC EEX m T4 SP APPROVED For Explosion Proof Solenoid Coi
47. uces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air supply line is solid piping use a short length of flexible hose not less than 1 2 13mm in diameter between the pump and the piping to reduce strain to the piping The weight of the air supply line regulators and filters must be supported by some means other than the air inlet cap Failure to provide support for the piping may result in damage to the pump 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 thi
48. y from the pump Hemove and inspect gasket item 19 for cracks or damage Replace gasket if needed STEP 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 H from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Hemove the two bumpers item 1 C Inspect the bumper for cuts wear or abrasions Replace if necessary Hemove 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 s15nmdl3sm REVO908 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Hemove 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 Insert the safety clip item 1 K through the small unthreaded hole in the end cap Hemove 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
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