Model S1F Non-Metallic Design Level 3 - Tri-Ark
Contents
1. 11 Composite Repair Parts Drawing sessies recente bna ter exe nena cu en RR nu cen 12 Overlay Option Drawing 12 Composite Repair Parts List n cei neret enm ree er i set be i e ancients 13 RuppGUARD Spill Prevention Option for Virgin PTFE Equipped Pumps 14 RuppGUARD Spill Prevention Repair Parts List 14 RuppGUARD Spill Prevention Concept sssssssssseeeeeeeenennnennennetnnn then 15 RuppGUARD Spill Prevention Option Diaphragm Servicing 15 Filling RuppGUARD Chambers with Liquid esssescsseeeeeeeeeeeeneeneennnntnnnnn 15 RuppGUARD Spill Prevention Option for TPE Equipped Pumps eee 16 RuppGUARD Spill Prevention Repair Parts List 16 RuppGUARD Spill Prevention Concept with TPE Diaphragms 17 RuppGUARD Spill Prevention Option with TPE Diaphragm 17 Air Distribution Valve Assembly Drawing sessi 18 Main Air Valve Assembly Parts List tenete then ains 18 U S Patent A 400 210 CE 5 996 627 6 241 487 Air Distribution Valve SErviCiNgi 19 Air Distribution Valve with Stroke Indicator Options2. 20 Air Distribution Valve with Stroke Indicator Parts List 20 Air Distribution Valve with Stroke Indicator Servicing esssseeeeenne 21 Solenoid Shifted Air Valve Drawing sesssesseseeeeeneneetentnetnnennn tnnt tnntnnt tnra 22 Solenoid Shifted Air Valve List ener rect ice etre ternera dei cina a Cenni 22 Solenoid Shifted Air Distibution Valve Option 28 Pilot Valve Assembly Drawing sesseeseeeeeeeeennenennnne nennen nennen reset etnies 24 Pilot Valve Assembly Parts 5 seres itinere ede eet ct Re 24 Pilot Essen 25 Diaphragm Service Drawing Non Overlay ssssssssseseneeeneeneennenneeee nennen 26 Diaphragm Service Drawing with 26 S Toc 0 27 27 Purrping azardous EIquids etr ect ere s ee ete eere tot erecti 28 Converting the pump for piping the exhaust 28 Exhaust Conversion DFawirig cett tatnen a a ras ni sana EUR RA
3. If you prefer to substitute another liquid to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 50 Replace 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 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve 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 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill prevention chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber 6 Loosely reinstall one boss plug item 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to b
4. conduit 1 59 170 029 330 Capscrew Hex HD 5 16 18 x 1 50 4 60 618 051 150 Plug 2 For Explosion Proof Solenoid Valve Connector not required for explosion proof coil coil is integral with valve 56 893 098 001 Solenoid Valve NEMA 7 9 24VDC 1 893 098 002 Solenoid Valve NEMA 7 9 24VAC 12VDC 1 893 098 003 Solenoid Valve NEMA 7 9 120VAC 1 893 098 004 Solenoid Valve NEMA 7 9 220VAC 1 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 22 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 the Warren Rupp Solenoid Rate Controller Batch Control or 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 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
5. in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 17 Air Distribution Valve Assembly Drawing S1F Design Level 3 AIR VALVE ASSEMBLY PARTS LIST Part Number Description Qty 031 140 000 Air Valve Assembly 1 031 139 000 Sleeve and Spool Set 1 095 094 551 Body Air Valve 1 132 029 552 Bumper 2 165 096 551 Muffler 1 1 165 115 552 2 1 530 028 550 Muffler 1 1 560 020 360 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 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 18 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 5 16 Allen wrench remove the four hex socket capscrews item 13 and four flat washers item 42 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of
6. 28 Converted Exhaust Illustration 28 Modular Check Valve Servicing ssssssssssssssseseeeene cece nennen tnnt ennetnetnr tnnt 29 Modular Check Valve 2 2 rn ertet terit fr inerte nea te eer eet cts 29 Dual Port Option Drawings aee erepti er ee ea nie RE Te ERE EE 30 Dual Porting Options acte 31 Dual porting of both suction and discharge ends of the pump 31 Single porting of the suction and dual porting of the pump discharge 31 Dual porting of the suction and single porting of the pump 31 RuppTech Leak Detection Options Drawing RuppTech Electronic Leak Detector Installation RuppTech Mechanical Leak Detector Installation 32 RuppTech Pulse Output Kit Drawing 0 0 00 eee eee ee sneer 33 RuppTech Pulse Output Kit 38 Exhaust Port or Auxiliary Muffler Setup 33 Integral Muffler Setup creuit teet eti t ed eec ERE HER 33 Optional Muffler configurations Drawing sesssseesseeseeneeeennnennenntnntne 34 Warren Rupp Inc A Unit of IDEX Corporation B
7. Metallic Design Level 3 Page 15 RuppGUARD Option For Equipped Pumps Drawing S1F SPILL PREVENTION REPAIR PARTS LIST FOR TPE EQUIPPED PUMPS Item Part Number Description Qty 438 170 114 115 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Prevention 2 196 159 520 Chamber Spill Prevention 2 46 518 180 520 Manifold Spill Prevention 2 Replace 518 179 520 518 180 552 Manifold Spill Prevention 2 Replace 518 179 552 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Plug Boss 4 618 031 308 Plug Boss 4 52 835 005 110 4 835 005 308 4 53 860 056 606 Tube Sight 2 54 866 060 110 Connector Tube 4 55 286 092 354 Diaphragm Pumping 2 18 286 108 600 Diaphragm Overlay is not used 2 Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing Note Item 55 The diaphragm is to be installed with the convex side facing N toward the outer chambers 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 16 RuppGUARD FOR TPE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pum
8. PTFE Hardware 1 20 312 113 520 Elbow Suction 2 031 157 000 Air Valve Assembly With Stroke Indicator Option 1 312 113 552 Elbow Suction 2 031 158 000 Air Valve Assembly No Muffler w Stroke Indicator 1 21 360 093 360 Gasket Air Valve 1 2 050 042 354 Ball Check 4 22 360 103 360 Gasket Pilot Valve 1 050 042 600 Ball Check 4 23 360 104 360 Gasket Air Inlet 1 3 070 006 170 Bushing With 114 024 307 309 2 24 360 107 360 Gasket Inner Chamber With 114 024 551 2 4 095 096 558 Pilot Valve Assembly 1 360 105 360 Gasket Inner Chamber With 114 024 307 309 2 5 114 024 551 Intermediate Assembly 1 25 518 179 520 Manifold 2 114 024 307 Intermediate Assembly 1 518 179 552 Manifold 2 114 024 309 Intermediate Assembly 1 26 545 005 115 Nut Hex 3 8 16 32 6 132 035 360 Bumper Diaphragm 2 545 005 308 Nut Hex 3 8 16 32 7 135 034 506 Bushing Plunger 2 27 545 008 115 Nut Hex 1 2 13 16 8 165 125 551 Cap Air Inlet 1 545 008 308 Nut Hex 1 2 13 16 165 125 307 Cap Air Inlet 1 28 560 001 360 O ring 2 165 125 309 Cap Air Inlet 1 29 612 200 157 Inner Diaphragm Plate 2 9 170 020 115 Capscrew Hex HD 3 8 16 x 2 00 16 612 200 082 Inner Diaphragm Plate 2 170 020 308 Capscrew Hex HD 3 8 16 x 2 00 16 30 612 204 520 Outer Diaphragm Plate 2 10 170 030 115 Capscrew Hex HD 1 2 13 x 2 00 16 612 204 552 Outer Diaphragm Plate 2 170 030 308 Capscrew Hex HD 1 2 13 x 2 00 16 31 620 020 115 Plunger Actuator 2 11 170 052 115 Capscrew Hex HD 3 8 16 x 2 25 16
9. pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 16 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 15 to the pump using the capscrews items 11 hex nuts and flat washers On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 34 as far as possible and still allow for alignment of the bolt holes in the diaphragm with the bolt pattern in the inner chamber The molded directional arrows on the diaphragm must point vertically Fasten the remaining outer chamber item 15 to the pump using the capscrews items 11 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 9 hex nuts and flat washers The pump is now ready to be re installed connected and returned to operation OVERLAY DIAPHRAGM SERVICING The PTFE overlay diaphragm item 18 is designed to fit snugly over the exterior of the standard TPE diaphragm item 17 The molded directional arrows on the overlay diaphragm must point vertically Folow the same procedures described for the standard diaphragm for removal and installation A IMPORTANT Read these instructions c
10. the RuppGUARD Spill Prevention Chambers when installing leak detectors For pumps 530 028 550 Enclosed Muffler Electronic Leak Detector Installation P 9 612 186 552 Kit 032 037 000 100VAC 50Hz x 110 120VAC 50 60Hz SELF MAPPING SCREWS or 220 240VAC 50 60Hz Kit 032 045 000 12 32VDC For pumps with Alternate Mufflers To install electronic leak detectors remove the bottom 14 NPT pipe plug on the visual sight tube item 53 Insert leak detector into the 14 pipe tee item 52 Leak Detection Option B Mechanical Follow instructions found elsewhere in this manual Filling the RuppGUARD Spill Prevention Chambers when installing leak detectors Mechanical Leak Detector Installation Kit 031 023 110 To install mechanical leak detectors remove the bottom NPT pipe plug on the visual sight tube item 53 Insert leak detector into the 14 pipe tee item 52 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 32 RuppTech Pulse Output Kit Drawing PULSE OUTPUT KIT OPTION This pump can be fitted with a Pulse Output Kit This converts the mechanical strokes of the pump to an electrical signal which interfaces with the RuppTech Stroke Counter Batch Controller or user control devices such as a PLC The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the Air Distribution Valve Assembly when the threaded exhaust port or an auxiliar
11. the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to stratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 520 199 000 7 02 Inspect the inner diameter of the sleeve part of item 1 A for dirt scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve 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 asse
12. the solenoid the pump cycles much like a standard SandPIPER pump with one exception This option provides a way to precisely control and monitor pump speed BEFORE INSTALLATION Before wiring the solenoid make certain it is compatible with your system voltage 520 199 000 7 02 cue 4 Solenoid Connector Wiring dh Diagram 211 3rd Terminal Before wiring f r grounds E remove terminal CMT Blook fror conduit Y D NU Neutral Positive A Negative M 4 KL SS r MN ee ee J L Model S1F Non Metallic Design Level 3 Page 23 Pilot Valve Assembly Drawing PILOT VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 4 095 096 558 Pilot Valve Assembly 4 A 095 095 558 Body Pilot Valve 1 4 B 135 037 506 Bushing 2 4 C 675 057 115 Ring Spiral Retaining 2 770 065 175 Spacer 5 775 041 506 Spool Pilot 1 917 003 374 Wiper 6 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 24 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supp
13. 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 50 Replace 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 15 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 50 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve 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 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill containment chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber The volume of fluid is 1198 ml 40 49 fl 2 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 50 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the s
14. 32 670 048 520 Retainer Ball 4 170 052 308 Capscrew Hex HD 3 8 16 x 2 25 16 670 048 552 Retainer Ball 4 12 170 069 115 Capscrew Hex HD 5 16 18 x 1 75 4 33 675 042 115 Ring Retainer 2 170 069 308 Capscrew Hex HD 5 16 18 x 1 75 4 34 685 058 120 Rod Diaphragm 1 13 171 053 115 Capscrew Soc HD 3 8 16 x 2 50 4 35 720 004 360 Seal Diaphragm Rod 2 14 171 015 115 Capscrew Soc HD 3 8 16 x 88 8 36 720 044 600 Seal Manifold Spacer 4 171 015 308 Capscrew Soc HD 3 8 16 x 88 8 37 720 047 600 Seal Check Valve 8 171 059 115 Capscrew Soc HD 7 16 14 x 1 25 8 38 722 079 520 Seat Check Valve 4 With 114 024 307 309 722 079 552 Seat Check Valve 4 171 059 308 Capscrew Soc HD 7 16 14 x 1 25 8 39 901 009 115 Washer Flat 5 16 64 With 114 024 307 309 901 009 308 Washer Flat 5 16 64 15 196 157 520 Chamber Outer 2 40 901 038 115 Washer Flat 5 16 4 196 157 552 Chamber Outer 2 901 038 308 Washer Flat 5 16 4 16 196 177 551 Chamber Inner 2 41 901 046 115 Washer Flat 1 2 32 196 177 307 Chamber Inner 2 901 046 308 Washer Flat 1 2 32 196 177 309 Chamber Inner 2 42 901 048 115 Washer Flat 3 8 4 17 286 107 354 Diaphragm 2 901 048 308 Washer Flat 3 8 4 Not Shown 535 069 000 Nameplate 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 13 RuppGUARD Option For Virgin PTFE Equipped Pumps Drawing S1F SPILL PREVENTION REPAIR PARTS LIST FOR VIRGIN PTFE EQUIPPED PUMPS Item Part Number Description Qty 43 170 114 115 Capsc
15. A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 21 to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 21 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 56 893 097 000 Solenoid Valve NEMA4 1 57 219 001 000 Solenoid Coil 24 1 219 004 000 Solenoid Coil 24VAC 12VDC 1 219 002 000 Solenoid Coil 120VAC 1 219 003 000 Solenoid Coil 240VAC 1 58 241 001 000 Connector
16. 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 service evaluation Warranty Refer to the enclosed Warren Rupp Warranty Certificate Model S1F Non Metallic Design Level 3 Page 11 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 217 000 AIR END KIT For Polypropylene Center Section Seals O rings Gaskets Retaining RIngs Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 169 558 AIR END KIT For Aluminum Center Section Seals O rings Gaskets Retaining RIngs Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 218 000 AIR END KIT Stroke Indicator Option For Polypropylene Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assemlby 476 170 558 AIR END KIT Stroke Indicator Option For Aluminum Center Section Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assemlby 476 197 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and PTFE Seals 476 197 654 WETTED END KIT Santoprene Diaphragms PTFE Over
17. ING CONFIGURATION FITS TO EITHER 1 ANSI 1254 FLANGE CONNECTION OR 25mm DIN FLANGE CONNECTION my MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATE MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS e FRONT VIEW ane K ORNS AD SIDE VIEW SUCTION PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1250 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION 14mm TYP 4 PLACES BOLT PATTERN IS N SYMMETRICAL 1 3 5 1 102mm DIMENSION U LI A e Standard Pump Pulse Output Kit Mesh Muffler Sound Dampening Muffler 19mm AIR INLET 1 2 NPT BOTTOM VIEW 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 7 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 i
18. SERVICE amp OPERATING MANUAL TI Model S1F Non Metallic Design Level 3 Table of Contents Engineering Data and Temperature Limitations ssssssseeeeeeneenee 1 Explanation of Pump Nomenclature ssssssesseeeeeeeeneeneen nennen nene nnne nennen nennen 2 Performance Curve Model S1F Non Metallic Design Level 3 Dimensions S1F Non Metallic 24 Metric Dimensions S1F Non Metallic cessent nennen tnnt 5 Dimensions S1F Spill Prevention 6 Metric Dimensions S1F Spill Prevention 7 Principle of Pump OperaltiOni n tries tere etr ete hr pe entem teet tene Ee t vetet teo ea 8 Installation and Start up ses 8 Air SUDDIV vo needs 8 Air Valve ecu MH 8 Airline Moisture 255555 8 Air Inlet and Priming ent contente lebe tete tote ese 8 Between Uses 8 Installation 0462 9 Important Safety Information eie ete tt delent tede tine ip vd eed a eau 10 Material CodeS sira 10 Troubleshooting et ger dera dr qr v e bee n de Ad 11 WV ITN rca pies cee
19. System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling 520 199 000 7 02 Whatto Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING Whatto Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connections to pump Corrective Action Install flexible connectors and a surge suppressor What to Check Blocked air exhaust muffler Corrective Action Remove muffler screen clean or de ice and reinstall Refer to the Air Exhaust section of your pump SERVICE MANUAL What to Check Pumped
20. ad 520 199 000 O 7 02 70 60 50 40 30 20 10 Liters per minute Capacity SCFM Non Metallic Performance Curve 5 8 5 15 25 5 Performance based on water at ambient temperature 10017 ORS 20 34 EN 80 25 42 5 EL ix 80 Psi 5 b 5 5 ki gt t 37 P 35 59 5 E 40 68 2d PSI 4 0g Bar 5 45 76 5 T 2m x Qo 40 Ps x EN LL 2 755 2 1 2 Bary 1 30 9 7 i ia 25 7 6 4 gt 20 06 20 PST 1365 ME S 15 14 5 2Air Inlet Press eue T i 10 13 M XX we t8 o Ot hc 5 1 5 0 5 10 15 20 25 30 35 40 45 50 55 U S Gallons per minute 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Model S1F Non Metallic Design Level 3 Page 3 Dimensions S1F Non Metallic Dimensions in Inches Dimensional tolerance 1 MANIFOLD CAN ROTATE ISCHARGE PORT 90 FROM VERTICAL 9 16 x 11 16 SLOTTED BOLTING CENTERLINE CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR pour PNIO 25mm DIN FLANGE CONNECTION STANDARD ENCAPSULATED MUFFLER rains 1 EXHUST PORT FOR OPTIONAL 7 SN N MUFFLER STYLES OR PIPING O INIA e p EXHAUST AIR IN SUBMERGED 1 e
21. afety 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 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 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 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non
22. any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARD OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional virgin PTFE pumping diaphragms item 45 These diaphragms are installed with 520 199 000 7 02 the natural convex curve toward the outer chamber items 14 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING RuppGUARD CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY If you prefer to substitute another liquid to prevent system 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
23. e X Unpainted Aluminum 12 40 Glass Filled Polypropylene with PTFE hardware Porting Options U Universal Fits ANSI and DIN 7 Dual Porting ANSI 8 Top Dual Porting ANSI 9 Bottom Dual Porting ANSI Pump Style D RuppGUARD with Electronic Leak Detection 110V E RuppGUARD with Electronic Leak Detection 220V RuppGUARD with Mechanical Leak Detection S Standard V RuppGUARD with Visual Leak Detection Pump Options 0 None 1 Sound Dampening Muffler 2 Mesh Muffler 3 High temperature Air Valve w Encapsulated Muffler 4 High temperature Air Valve w Sound Dampening Muffler 5 High temperature Air Valve w Mesh Muffler Kit Options 00 None P0 0 30VDC Pulse Output Kit P1 Intrinsically Safe 10 30VDC Pulse Output Kit P2 110 120 or 220 240VAC Pulse Output Kit P3 Intrinsically Safe 110 120VAC Pulse Output Kit P4 Intrinsically Safe 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 E3 Solenoid Kit with 24VAC 12VDC Explosion Proof Coil E4 Solenoid Kit with 110VAC Coil E5 Solenoid Kit with 110VAC Explosion Proof Coil E6 Solenoid Kit with 220VAC Coil E7 Solenoid Kit with 220VAC Explosion Proof Coil SP Stroke Indicator Pins 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 2 Performance Curve Model S1F Non Metallic Design Level 3 He
24. e 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 52 is in the vertical position Loosen the pipe plug item 49 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 15 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 49 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated
25. er INLET 1 2 NPT 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 5 Dimensions S1F Non Metallic with RuppGUARD Spill Prevention Dimensions in Inches Dimensional tolerance 1 BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES 4 AIR INLET 1 2 NPT BOTTOM VIEW JISCHARGE PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1250 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD ENCAPSULATE MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS 7 m b O VVA FS Jf FRONT VIEW 17 1 8 S ANY SNO 2 e 9 N SUCTION PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION DIMENSION Standard Pump MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE 2 20 3 4 SIDE VIEW 5 5 8 10 1 4 Pulse Output Kit 7 3 8 12 Mesh Muffler 8 9 16 11 1 8 Sound Dampening Muffler 8 9 16 11 1 8 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 6 Metric Dimensions S1F Non Metallic with RuppGUARD Spill Prevention Dimensions in Millimeters Dimensional tolerance 3mm DISCHARGE PORT 14mm x 17mm SLOTTED BOLT
26. fluid in air exhaust muffler Corrective Action Disassemble pump chambers Inspect for diaphragm rupture orloose 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 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
27. freezing temperatures the pump must be completely drained between uses in all cases Model S1F Non Metallic Design Level 3 Page 8 WARREN RUPP Available from Warren Rupp INSTALLATION GUIDE Top Discharge Ball Valve Unit Pipe Connection 520 199 000 Style Optional 1 DAO5 Surge Suppressor 00 2 020 049 000 Filter Regulator Gauge 8 020 049 001 Lubricator Flexible Connection 4 Air Dryer Thea FT DISCHARGE M A CAUTION tt The air exhaust should be 1 piped to area for safe disposition of the product Drain Port being pumped in the event T T of a diaphragm failure Flexible Connection Air Shut Off Pipe Connection Valve Style Optional TOP Air Exhaust Filter Regulator Air Dryer Gauge DISCHARGE DIAPHRAGM imd Shut Off PUMP 18 valve A AIR INLET one ONG SUCTION p ud Connection Drain Port 7 02 Model S1F Non Metallic Design Level 3 Page 9 Important Safety Information m Assembly sub assembly and some purchased items Cast Iron Powered Metal IMPORTANT WARNING Music Wire Read these safety warn
28. in any remaining fluid from the pump The pump can now be removed for service To access the modular check valve remove the elbows items 19 and 20 from pump composite repair parts drawing Use s wrench or socket to remove the fasteners Once the elbows are removed the modular check valves can be seen the cavities of the outer chamber items 15 Next remove the check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Disassemble the component parts of each modular check valve Inspect the check valve retainer item 32 for cuts abrasive wear or embedded materials Replace as needed Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats items 38 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 520 199 000 7 02 Remove the remaining check valve seal item 37 Inspect the seal for cuts or pinched areas Replace seal as needed Re assemble the modular check valve The seat should fit snugly into the retainer Place a check valve seal item 37 into the cavity of the outer chamber item 15 Make sure the chamfer side of the seal faces
29. ings d This pump is pressurized su Carbon Steel AISI B 1112 and instructions in this internally with air pressure Alloy 20 manual completely before 48 Alloy 316 Stainless Steel 4 during operation Always Alloy Type 316 Stainless Steel Electro Polished installation and start up ji i Oy ainless Steel Electro Polished make certain that all bolting i f th It is th Alloy C Hastelloy equivalent Eu o e pump is in good condition and that Alloy Type 316 Stainless Steel Hand Polished responsibility of the purchaser to retain this all of the correct bolting is reinstalled during 303 Stainless Steel manual for reference Failure to comply with assembly s 302 304 Stainless Steel the recommendations stated in this manual will 440 C Stainless Steel Martensitic damage the pump and void factory warranty 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum E 2024 T4 Aluminum 4 6061 T6 Aluminum WARNING 6063 T6 Aluminum 2024 T4 Aluminum 2023 7351 When used for toxic or Almag 35 Aluminum Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nytrile Fluorinated Nitrile High Density Polypropylene 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 Re
30. inlet cap item 8 capscrews and washers items 12 and 40 Connect the air supply to the pump Remove the safety clip item 1 F from the end cap item 1 D The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 25 Diaphragm Service Drawing Diaphragm Service Drawing Non Overlay with Overlay 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 26 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 As wrench or socket remove the 16 capscrews items 9 hex nuts and washers that fasten the elbows items 19 and 20 to the outer chambers items 15 Remove the elbows with the manifolds and spacers attached Step 2 Removing the outer chambers Using a As wrench or socket remove the 16 capscrews items 11 hex nuts and washers that fasten the outer chambers diaphragm
31. lay Diaphragms TFE Balls and TFE Seals 476 198 655 WETTED END KIT For Polypropylene RuppGUARD Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 476 198 354 WETTED END KIT For Polypropylene RuppGUARD Santoprene Diaphragms Santoprene Pumping Diaphragms Santoprene Ckeck Balls and PTFE Seals HARDWARE KITS RuppTech PULSE OUTPUT KITS For Use With 530 010 000 Mufflers or Piped Exhaust 475 198 001 DC Kit i 475 198 002 DC Intrinsically Safe Kit veray 475 198 003 110 120 VAC or 220 240 Kit 475 198 004 110 120 VAC Intrinsically Safe Kit 475 198 005 220 240 VAC Intrinsically Safe Kit For Use With Encapsulated 530 028 550 Muffler 475 198 006 DC Kit 475 198 007 DC Intrinsically Safe Kit 475 198 008 110 120 VAC or 220 240 Kit 475 198 009 110 120 VAC Intrinsically Safe Kit 475 198 010 220 240 VAC Intrinsically Safe Kit RuppTech ELECTRONIC LEAK DETECTOR KITS 032 037 000 110 VAC 220 VAC 032 045 000 12 32 VDC 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 12 Composite Repair Parts List Item Part Number Description Qty Item Part Number Description Qty 1 031 155 000 Air Valve Assembly 1 18 286 108 600 Diaphragm Overlay 2 031 155 002 Air Valve Assembly w PTFE Coated Hardware 1 19 312 104 520 Elbow 2 031 156 000 Air Valve Assembly No Encapsulated Muffler 1 312 104 552 Elbow 2 031 156 002 Air Valve Assembly No Muffler
32. ly bleed the pressure from the pump and disconnect the air supply line from the pump Insert the safety clip item 1 F from Air Distribution Valve assembly drawing into the smaller unthreaded holes in the end cap item 1 D from air distribution valve assembly drawing Step 1 See PUMP ASSEMBLY DRAWING Using a wrench or socket remove the four capscrews items 12 and four flat washers items 40 Remove the air inlet cap item 8 and air inlet gasket item 23 The pilot valve assembly item 4 can now be removed for inspection or service Step 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 E Wipe clean and inspect for dirt scratches or wear Replace the spool if necessary Remove the two spiral retaining rings items 4 C from each end of the pilot valve body by inserting the tip of a small flat screw driver under the notch in the retaining ring Lift and push the ring clockwise in a circular motion Remove the two pilot valve bushings items 4 B five spacers items 4 D and six spool wipers items 4 F by pushing gently from other end of the pilot valve body Inspect the wipers for cuts and or wear Replace any wipers as necessary 520 199 000 7 02 Step 3 Re assembly of the pilot valve First install a spiral retaining ring to one end of the pilot valve body Spread the spiral and insert one end into the groove in the pilot valve body Twist the ring in a clockwise motion un
33. mbly item 1 and gasket item 21 to the pump Connect the compressed air line to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 19 Air Valve Assembly Drawing With Stroke Indicator Option S1F Design Level 3 520 199 000 7 02 AIR VALVE ASSEMBLY PARTS LIST Item 1 1 A 1 B 1 C Part Number 031 146 000 031 143 000 095 094 551 132 029 552 165 096 551 165 098 147 530 028 550 560 020 360 675 044 115 710 015 115 210 008 330 560 001 360 Description Air Valve Assembly Sleeve and Spool Set Body Air Valve Bumper Cap Muffler Cap End Muffler O ring Ring Retaining Screw Self tapping Clip Safety O ring lt N For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 147 000 Air Valve Assembly Includes all items used on 031 140 000 minus items 1 D 1 F amp 1 J 1 Model S1F Non Metallic Design Level 3 Page 20 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and di
34. mp INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping System A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump 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
35. nd optional positioning in the Dual Porting Drawing 520 199 000 7 02 SINGLE PORTING OF THE SUCTION AND DUAL PORTING OF THE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing DUAL PORTING OF THE SUCTION AND SINGLE PORTING OFTHE PUMP DISCHARGE To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds spacers and manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 31 RuppTech Leak Detection Options Drawing 710 014 330 Self tapping Screws Qty of 2 RuppTech LEAK DETECTION OPTION A ELECTRONIC Follow instructions found elsewhere in this manual Filling
36. oated repair shut off the com pump suction discharge Zinc Plated Steel pressed air line bleed the piping and all other openings and connections doe bum pressure and disconnect Be certain the air supply is locked out or made us ol LN k iP 4 the air line from the pump 2 E arbon Steel Electroless Nickel Plate _ pump non operational so that it cannot be started while Galvanized Steel The discharge line may be pressurized and work is being done on the pump Be certain that Zinc Plated Yellow Brass must be bled of its pressure approved eye protection and protective clothing Silver Plated Steel are worn all times in the vicinity of the pump Nickel Plated Failure to follow these recommendations may Filled Nylon 7 ma Geolast Color Black result in serious injury or death Injection Molded 4203 40 Santoprene Duro 40D id RED Delrin Viton and Hytrel are registered tradenames of ermal Plastic E l DuPont WARNING Hytrel Gylon is a registered tradename of Garlock Inc Injection Molded Pol th In the event of diaphragm Rupplon Urethane Rubber Color coded Nylatron is a registered tradename of Polymer Corp rupture pumped material AW ARNIN G PURPLE Some Applications Compression Mold Santoprene is a registered tradename of Monsanto Corp may enter the air end of the Urethane Rubber Kynar is a registered tradename of ATOFINA Chemicals Inc pump and be discharged B
37. olded threads in the air distribution valve body item 1 B Piping or hose may now be installed 520 199 000 7 02 IMPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible hose or connection between the pump and any rigid plumbing This reduces stresses on the molded plastic threads of the air exhaust port Failure to do so may result in damage to the air distribution valve body Any piping or hose connected to the pump s air exhaust port must be physically supported Failure to support these connections could also result in damage to the air distribution valve body Exhaust Conversion Drawing CONVERTED EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE Illustration 2 200 MUFFLER 1 DIAMETER AIR EXHAUST PIPING MUFFLER L LIQUID _ LEVEL SUCTION LINE Illustration 3 1 DIAMETER AIR EXHAUST PIPING Model S1F Non Metallic Design Level 3 Page 28 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 Dra
38. ompletely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S1F Non Metallic Design Level 3 Page 27 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 83 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 1 Remove the muffler cap and muffler items 1 E and 1 G The 1 NPT m
39. operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing or freezing of the exhaust air causing the pump to cycle erratically or stop operating Water in the air supply can be reduced by using a point of use air dryer to supplement the user s air drying equipment This device removes water from the compressed air supply and alleviates the icing or freezing problems AIR INLET AND PRIMING To start the pump open the air valve approximately 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
40. out Insert the modular check valve into the outer chamber with the retainer facing up Install a check valve seal item 37 Make sure the chamfer side of the seal faces the chamfer on the check valve seat or retainer The pump can now reassembled reconnected and returned to operation Modular Check Valve Drawing Model S1F Non Metallic Design Level 3 Page 29 Dual Port Option Drawing o Gg 27 RSs a S 919 TX i uu 7 m 7 TAM OE VE 9 WS SENS Model S1F Non Metallic Design Level 3 Page 30 7 02 520 199 000 DUAL PORTING OPTIONS Several dual porting options are possible The pump can be converted to a dual port arrangement on both the suction and the discharge ends The porting can be configured to a single suction and a dual discharge The porting can be changed to a dual suction anda single discharge The above changes are possible because the porting flange of the elbows items 19 and 20 are designed to mate with standard 125 ANSI style 4 bolt 1 pipe flanges DUAL PORTING OF BOTH SUCTION AND DISCHARGE ENDS OF THE PUMP Converting the pump from the standard single suction and discharge porting configuration to dual porting at each end is easy Simply remove the manifold seals spacers and manifolds items 36 and 24 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows a
41. ox 1568 Mansfield Ohio 44901 1568 USA Tel 419 524 8388 Fax 419 522 7867 www warrenrupp com 520 199 000 7 02 WARREN RUPP Quality System 1809001 Certified Environmental Management System 15014001 Certified Air Exhaust Side View Air Inlet Side View IDEX CORPORATION INTAKE DISCHARGE PIPE SIZE 1 ANSI Flange or PN10 25mm DIN Flange CAPACITY AIRVALVE 0 to 45 gallons per minute No lube no stall 0 to 170 liters per minute design A CAUTION Operating temperature limitations are as follows Materials Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures PVDF Polypropylene For specific applications always consult Chemical Resistance Chart Technical Bulletin SandPIPER II pumps are designed to be powered only by compressed air Santoprene is a registered tradename of Monsanto Corporation amp SandPIPER Il and Warren Rupp are registered tradenames of Warren Rupp Inc SanoPIPER S1F Non Metallic U S Patent 6 006 627 Design Level 3 400 210 diners Patents Ball Va Ive Applied for Air Po
42. ping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARD OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 50 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional TPE pumping diaphragms item 55 These diaphragms are installed with the natural 520 199 000 7 02 concave curve toward the outer chamber items 15 from the pump assembly drawing The molded directional arrows on the diaphragms must point vertically FILLING RuppGUARD CHAMBERS WITH LIQUID THE CHAMBERS ARE FILLED WITH WATER AT THE FACTORY
43. rew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 170 114 308 Capscrew Hex HD 3 8 16 x 4 50 16 Replace 170 052 115 44 196 159 552 Chamber Spill Prevention 2 196 159 520 Chamber Spill Prevention 2 45 286 094 600 Diaphragm Pumping 2 46 518 180 520 Manifold Spill Prevention 2 Replace 518 179 520 518 180 552 Manifold Spill Prevention 2 Replace 518 179 520 47 538 022 110 Nipple Pipe 4 538 022 308 Nipple Pipe 4 48 560 078 611 O ring 8 49 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 50 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 51 618 031 110 Plug Boss 4 618 031 308 Plug Boss 4 52 835 005 110 Tee Pipe 4 835 005 308 Tee Pipe 4 53 860 056 606 Tube Sight 2 54 866 060 110 Connector Tube 4 Note The Diaphragm is to be installed with the convex side facing toward the outer chamber See drawing Note Item 45 The diaphragm is to be installed with the convex side facing toward the outer chambers 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 14 RuppGUARD FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before
44. s and inner chambers items 16 together Step 3 Removing the diaphragm assemblies Use a 13 5 35mm wrench or six pointed socket to remove the diaphragm assemblies outer plate diaphragm and inner plate from the diaphragm rod item 34 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 29 Insert the protruding stud and the 1 4 20 fastener 520 199 000 7 02 loosely into a vise Use a 1 s wrench or socket to remove the outer diaphragm plate item 30 by turning counter clockwise Inspect the diaphragm item 17 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 ofthe diaphragm Thread the inner plate clockwise onto the stud Use a torque wrench to tighten the diaphragm assembly together to 20 ft Lbs 27 11 Newton meters Allow a minimum of 15 minutes to elapse after torquing then re torque the assembly to compensate for stress relaxation in the clamped assembly Step 5 Installing the diaphragm assemblies to the pump Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the one diaphragm assembly clockwise into the tapped hole atthe end of the diaphragm rod item 34 until the inner diaphragm plate is flush to the end of the rod Insert rod into
45. s discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing exhausting of the diaphragm chamber is performed by an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool 520 199 000 7 02 shifts to the opposite end of the valve body the pressure to the chambers is reversed The air distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the air distribution valve spool while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pu
46. sconnect the air supply line from the pump Step 1 See Composite Repair and Parts Drawing Using a 5 1 Allen wrench remove the four hex socket capscrews item 13 and four flat washers item 42 Remove the air valve assembly item 1 from the pump Remove and inspect gasket item 21 for cracks or damage Replace gasket if needed Step 2 Disassembly of the air valve To access the internal air valve components first remove the two retaining rings item 1 K from each end of the air valve assembly using clip ring pliers Next remove the two end caps item 1 E Inspect the o rings item 1 G for cuts or wear Replace the o rings if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear Inspect the inner diameter of the Sleeve part of item 1 A for dirt 520 199 000 7 02 scratches or other contaminates Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set item 1 A Step 3 Reassembly of the air valve Install one bumper item 1 C and one end cap item 1 E with an o ring item 1 G into one end of the air valve body item 1 B Install one retaining ring item 1 H into the groove on the same end Insert the safety clip item 1 K through the small unthreaded hole in the end cap Remove the new sleeve an spool set item 1
47. se VAN FRONT VIEW 7 APPLICATIONS 20 3 4 A 52 v IS ZS 57 pe d Les SIDE VIEW Tunt ui SUCTION PORT 9 16 x 11 16 SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION 5 1 8 Em TAN O N UF 2 BOLT PATTERN IS SYMMETRICAL ABOUT 9 16 wwe ON CENTERLINES DIMENSION Standard Pump 5 5 8 10 1 4 201 4 7 8 Pulse Output Kit 7 3 8 12 Mesh Muffler 8 9 16 11 5 32 Sound Dampening Muffler 8 9 16 11 5 32 INLET 1 2 NPT 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 4 Metric Dimensions S1F Non Metallic Dimensions in Millimeters Dimensional tolerance x3mm MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE JISCHARGE PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 125 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION STANDARD ENCAPSULATED MUFFLER 1 NPT EXHUST PORT FOR OPTIONAL MUFFLER STYLES OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS 223 FRONT VIEW SIDE VIEW SUCTION PORT 14mm x 17mm SLOTTED BOLTING CONFIGURATION FITS TO EITHER 1 ANSI 1258 FLANGE CONNECTION OR PNIO 25mm DIN FLANGE CONNECTION 130mm FA 111 AIAN BOLT PATTERN IS imm e TT Od Mhl JAIRU Poringa or 4 PLACES to2mn 1 4 DIMENSION Standard Pump Pulse Output Kit Mesh Muffler Sound Dampening Muffl
48. sin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Glass Filled Conductive HDPE Rulon II Ryton Valox Nylatron G S Nylatron NSB Virgin PTFE PTFE Bronze and moly filled Filled PTFE Blue Gylon Virgin PTFE Envelon Injected molded PFA Encapsulated Silicon Encapsulated Viton Neoprene Hytrel Viton PTFE EPDM PTFE PTFE Viton PTFE Hytrel Buna N Santoprene EPDM Santoprene CAUTION Before pump operation aggressive fluids the pump 356 T6 Aluminum inspect all gasketed should always be flushed 2 356 T6 Aluminum Die Cast Aluminum Alloy 380 fasteners for looseness clean prior to disassembly Aluminum Alloy SR 319 caused by gasket creep Anodized Aluminum Re torque loose fasteners Brass Yellow Screw Machine Stock to prevent leakage Follow recommended dun Gast Bronzer do Sue d in thi I Bronze SAE 660 torques stated in this manual Bronze Bearing Type Oil Impregnated Die Cast Zinc WARNING Copper Aloy Carbon Steel Gray Epoxy Coated a Carbon Steel Black PTFE Coated 4 WARNING Before doing any 2 3 Aluminum Gray Epoxy Coated maintenance on the pump be Stainless Steel Black PTFE Coated 1 certain all pressure is Aluminum Black PTFE Coated Before maintenance or completely vented from the Kynar C
49. til the full ring is snapped into the groove Install one bushing making sure the step side faces toward the wiper Apply a light coating of grease to the outside diameter of each wiper Next gently push in the wipers and spacers until they are against the installed retaining ring in the opposite end of the pilot valve body Install the remaining bushing making sure the step side faces the wiper Install the remaining spiral retaining ring using the same method described Apply a light coating of grease to the inner diameter of each wiper Also apply a light coating of grease to the outer diameter of the pilot valve spool and gently push the spool through each wiper Step 4 Inspect the actuator plungers See PUMP ASSEMBLY DRAWING The actuator plungers items 31 can be reached through the stem cavity of the pilot valve in the intermediate assembly item 5 Remove the plungers items 31 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 28 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go Step 5 Re install the pilot valve ssembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity of the intermediate Re install the gasket item 23 air
50. una N Rubber Color coded RED Rulon Il is a registered tradename of Dixion Industries Corp into the atmos ph ere If noise hazards Buna N Hastelloy C is a registered tradename of Cabot Corp pumping a product which is hazardous or toxic se Viton Flurorel Color coded YELLOW Rytonis a registered tradename of Phillips Chemical Co the air exhaust must be piped to an appropriate Wear ear and eye protection s E P D M Rubber Color coded BLUE Valoxis a registered tradename of General Electric Co area for safe disposition 2 Color coded GREEN Warren Rupp Rupplon SandPIPER SandPIPER II PortaPump 00 rade Nitrile Tranquilizer RuppGUARD RuppTech and SludgeMaster Food Grade EPDM tradenames of Warren Rupp Inc Airborne particles and loud 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 10 TROUBLESHOOTING Possible Symptoms Pump will not cycle Pump cycles but produces no flow Pump cycles but flow rate is unsatisfactory Pump cycle seems unbalanced Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check
51. wered CE Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA DISPLACEMENT STROKE 17 gallon 64 liter SOLIDS HANDLING Up to 25 in 6mm HEADS UPTO 100 psi or 231 ft of water 7 bar or 70 meters Operating Temperatures Maximum Minimum Definite reduction in service life Minimal reduction in service life at ends of range Optimum 50 to 212 F 10 C to 100 C 50 F to 212 F 10 C to 100 C 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 1 Explanation of Pump Nomenclature S1F Non Metallic Design Level 3 Ball Valve S1FB3P1PPUSO00 Diaphragm Check Valve Materials Wetted Material Check Non Wetted Material Options Porting Options Shipping Weight Ibs kg Pump Pump Style Options 5 0 51 2 5000 1FB3K1KPUS000 S1FB3K2KPUSOO0 S1FBS3PS3PPUVOOO S1FBS3KS3KPUVOOO S1FBS3PA4PPUVOOO S1FB3KAKPUVOOO S SandPIPER Pump Size 1F 1 Full Flow Check Valve Type B Ball Design Level 3 Design Level 3 Wetted Material K PVDF Polypropylene Diaphragm Check Valve Materials 12 Santoprene Santoprene 2 PTFESantoprene Backup PTFE 3 PTFE Pumping PTFE Santoprene Backup Driver PTFE 4 Santoprene Pumping Santoprene Check Valve Seat K PVDF Polypropylene Non Wetted Material Options Polypropylen
52. y muffler is being used See the individual kits listed on the Pump Repair Parts List for further information Exhaust Port or Auxiliary Integral Muffler Setup Muffler Setup Pulse Output Kit Muffler Cap 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 33 Optional Muffler Configurations Drawing CONFIGURATION A 530 028 550 Encapsulated Muffler uses 1 165 096 551 Cap and 4 710 015 115 Self Tapping Screw to hold it in place CONFIGURATION B 530 010 000 Mesh Muffler screws directly into the Air Valve Body This muffler is equipped with a metal element CONFIGURATION C 530 027 000 Sound Dampening Muffler screws directly into the Air Valve body This muffler is equipped with a porous plastic element CONFIGURATION A CONFIGURATION B AND C 520 199 000 7 02 Model S1F Non Metallic Design Level 3 Page 34
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