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Service Manual - Amalgamated Pumping Supplies

1. Model S20 Non Metallic Design Level 2 Page 23 Pilot Valve Assembly Drawing Pilot Valve Assembly Parts List Item Part Number Description Qty 2 095 093 000 Pilot Valve Assembly 1 2 A 095 092 001 Body Pilot Valve 1 2 B 135 033 506 Bushing 2 2 C 675 055 115 Ring Spiral Retaining 2 2 D 770 049 175 Spacer 5 2 E 917 001 374 Wiper 6 2 F 775 033 506 Spool Pilot 1 M Js fin COs IG C9 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 24 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Insert the safety clip item 1 N from Air Distribution Valve assembly drawing into the smaller unthreaded holes in the end cap item 1 C from air distribution valve assembly drawing Step 1 See PUMP ASSEMBLY DRAWING Using a wrench or socket remove the four capscrews items 9 and four flat washers items 42 Remove the air inlet cap item 8 and air inlet gasket item 21 The pilot valve assembly item 2 can now be removed for inspection or service Step 2 Disassembly of the pilot valve Remove the pilot valve spool item 2 F Wipe clean and inspect for dirt scratches or wear Replace the spool if necessary Remove the two retaining rings items 2 C from each end of the pilot valve body using clip ring pilers Remove the two pilot valve
2. Connection Drain Port Model S20 Non Metallic Design Level 2 Page 9 IMPORTANT SAFETY INFORMATION 4 IMPORTANT Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty 44 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 4 WARNING Before maintenance or repair shut off the com pressed 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 A WARNING In the event of diaphragm rupture pumped material may enter the air end of the pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition WARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly 4 WARNING When used f
3. 17mm 100 psi or 231 ft of water 36 US gallon 1 36 liter PN10 50mm DIN Flange O to 568 liters per minute design 7 bar or 70 meters A CAUTION Operating temperature limitations are as follows Operating Temperatures Maximum Minimum 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 Polypropylene UHMW PE For specific applications always consult the Warren Rupp Chemical Resistance Chart SANDPIPER pumps are designed to be powered only by compressed air 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 1 Explanation of Pump Nomenclature 20 Non Metallic Design Level 2 Ball Valve Check Diaphragm Check Non Wetted Shipping Model Pump Pump Valve Design Wetted CheckValve Valve Material Porting Pump Pump Kit Weight Brand Size Type Level Material Materials Seat Options Options Style Options Options Ibs kg S20B2P1PQAS000 S 20 B 2 P 1 P Q A S 0 00 117 53 S20B2K1KQAS000 S 20 B 2 K 1 K Q A S 0 00 117 53 S20B2P2PQAS000 S 20 B 2 P 2 P
4. 031 140 002 Air Valve Assembly w PTFE coated Hardware 1 22 360 091 360 Gasket Inner Chamber 2 031 141 000 Air Valve Assembly No Encapsulated Muffler 1 23 360 092 360 Gasket Pilot Valve 1 2 095 093 000 Pilot Valve Assembly 1 24 360 093 360 Gasket Main Air Valve 1 3 050 038 354 Ball Check 4 25 518 132 520 Manifold 2 050 038 600 Ball Check 4 518 132 520E Manifold 50mm DIN 2 4 114 021 156 Intermediate Assembly 1 518 132 552 Manifold 2 114 021 307 Intermediate Assembly 1 518 132 552E Manifold 50mm DIN 2 114 021 309 Intermediate Assembly 1 26 545 008 110 Nut Hex 1 2 13 32 114 021 332 Intermediate Assembly 1 545 008 308 Nut Hex 1 2 13 32 5 115 132 080 Bracket Mounting 2 27 545 009 110 Nut Hex 5 8 11 16 115 132 305 Bracket Mounting 2 545 009 308 Nut Hex 5 8 11 16 115 132 306 Bracket Mounting 2 28 560 001 360 O ring 2 115 132 333 Bracket Mounting 2 29 612 179 520 Assembly Outer Diaphragm Plate 2 6 132 019 360 Bumper Diaphragm 2 612 179 552 Assembly Outer Diaphragm Plate 2 7 135 032 506 Bushing Plunger 2 30 612 158 150 Assembly Inner Diaphragm Plate 2 8 165 099 156 Cap Air Inlet 1 31 620 017 115 Plunger Actuator 2 165 099 307 Cap Air Inlet 1 32 670 046 520 Retainer Ball 4 165 099 309 Cap Air Inlet 1 670 046 552 Retainer Ball 4 165 099 332 Cap Air Inlet 1 33 685 050 120 Rod Diaphragm 1 9 170 052 115 Capscrew Hex HD 3 8 16 x 2 25 4 34 685 053 115 Rod Support 2 170 052 308 Capscrew Hex HD 3 8 16 x 2 25 4 685 053 308 Rod Support 2 1
5. item 19 is designed to fit snugly over the exterior of the standard TPE diaphragm item 18 The molded directional arrows on the overlay diaphragm must point vertically Follow the same procedures described for the standard diaphragm for removal and installation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S20 Non Metallic Design Level 2 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 3
6. 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 17 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 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 S20 Non Metallic Design Level 2 Page 29 Dual Port Option Drawing 1 ANSI STYLE FLANGE CONNECTION FOUR 2 62 HOLES ON A 63 88 BOLT CIRCLE 1 ANSI STYLE FLANGE CONNECTION FOUR 8 62 HOLES ON A 03 88 BOLT CIRCLE Model S20 Non Metallic Design Level 2 Page 30 9 03 520 202 000 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 20 are designed to mate with standard 125 ANSI style 4 bolt 2 pipe flanges Dual porting of both suction and discharge ends of the pump Converting th
7. 17 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 52 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S20 Non Metallic Design Level 2 Page 15 RuppGUARD Option for TPE Equipped Pumps Drawing 20 Spill Prevention for TPE Equipped Pumps 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 45 170 092 115 Capscrew Hex HD 1 2 13 x 4 00 8 170 092 308 Capscrew Hex HD 1 2 13 x 4 00 8 Suction replaces 170 068 115 Manifold 46 170 108 115 Capscrew Hex HD 1 2 13 x 5 50 8 replaces 170 095 115 170 108 308 Capscrew Hex HD 1 2 13 x 5 50 8 replaces 170 095 115 47 196 149 520 Chamber Spill Prevention 2 196 149 552 Chamber Spill Prevention 2 48 286 081 354 Diaphra
8. DIA BOLT CIRCLE 64mm SUCTION PORT 2 STANDARD 1254 FLANGE CONFIGURATION SIDE VIEW E BOLT PATTERN P zoo IS SYMMETRICAL m ABOUT CENTERLINES LT mM ER AIR INLET E Pulse Output Kit 3 4 NT 3M Muffler BOITOM VIEW Mesh Muffler Note Porting Flanges are also avaible with PN10 50mm DIN bolting configuration 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 5 Dimensions S20 Non Metallic with RuppGUARD Spill Prevention Dimensions in Inches Dimensional tolerance 1 8 14 11 16 BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES DISCHARGE PORT 2 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4 DIA BOLT CIRCLE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER M 10 7 8 1 1 16 11 7 16 12 7 8 520 202 000 9 03 BOTTOM VIEW 2 1 2 AIR INLET 3 4 STYLES OR PIPING EXHAUST AIR IN SUBERGED APPLICATIONS SUCTION PORT 2 STANDARD 1254 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4 DIA BOLT CIRCLE 4 1 16 MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE SAC QAO y Dimension Standard Pump Pulse Output Kit 12 11 16 14 1 16 129 16 1811 16 813 16 14 15 16 3M Muffler
9. Drawing Discharge Manifold Suction Manifold Note All of the diaphragms are to be installed with the concave side facing toward the outer chambers Flat side of spill prevention chamber item 47 to face outer chamber item 17 520 202 000 9 03 20 Spill Prevention Repair Parts List for Virgin PTFE Equipped Pumps 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 45 170 092 115 Capscrew Hex HD 1 2 13 x 4 00 8 replaces 170 068 115 170 092 308 Capscrew Hex HD 1 2 13 x 4 00 8 replaces170 068 115 46 170 108 115 Capscrew Hex HD 1 2 13 x 5 50 8 47 48 49 50 51 52 53 54 170 108 308 196 149 5207 196 149 5527 286 076 600 518 134 520 518 134 520E 518 134 552 518 134 552E 538 022 110 538 022 308 560 078 611 618 003 110 618 003 308 618 025 110 618 025 308 618 031 110 618 031 308 770 057 600 770 057 552 835 005 110 835 005 308 860 055 606 866 060 110 170 111 115 replaces 170 095 115 Capscrew Hex HD 1 2 13 x 5 50 replaces 170 095 115 Chamber Spill Prevention Chamber Spill Prevention Diaphragm Pumping Manifold replaces 518 132 520 Manifold 50mm DIN Manifold replaces 518 130 552 Manifold 50mm DIN Nipple Pipe Nipple Pipe O Ring Plug Pipe Plug Pipe Plug Boss Plug Boss Plug Boss Plug Boss Spacer Manifold S
10. J Painted Aluminum PTFE Leak Detection see i Explosion Proof Coil Q Epoxy Coated Aluminum S Standard BARA E2 Solenoid Kit with 24VAC 12VDC K PTFE Coated Aluminum V RuppGUARD with Visual Coil L PTFE Coated Aluminum with Leak Detection E3 Solenoid Kit with 24VAC12VDC PTFE Coated Hardware Explosion Proof Coil R Epoxy Coated Aluminum with E4 Solenoid Kit with 110VAC Coil PTFE Coated Hardware 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 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 2 Performance Curve Model S20 Non Metallic Design Level 2 07 GEM IM S20 Non Metallic Performance Curve S A Performance based on water at ambient temperature 7r 100 90 6 80 5t 70 a 60 O o 50 80 136 ka TS 3 o LL O Z 2 30 9 1 20 6 1 95 161 5 15 45 10 43 5 41 5 0 0 20 40 60 80 100 120 140 160 U S Gallons per minute ep eDaily rire unes 100 200 300 400 500 600 Liters per minute Capacity 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 3 Dimensions S20 Non Metallic Dimensions in Inches Dimensional tolerance s DISCHARGE PORT 2 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED 4 1 16 ON A 4 3 4 DIA BOLT CIRCLE MANIFOLD CAN ROTATE 90 FROM VER
11. Mesh Muffler Note Porting Flanges are also avaible with PN10 40mm DIN bolting configuration Model S20 Non Metallic Design Level 2 Page 6 Metric Dimensions S20 Non Metallic with RuppGUARD Spill Prevention DISCHARGE PORT 2 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4 DIA BOLT CIRCLE 103mm MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER SYTLE OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS LS SUCTION PORT P E 2 STANDARD 125 FLANGE CONFIGURATION E 3 4 DIA 4 HOLES EQUALLY SPACED 4 3 4 DIA BOLT CIRCLE aui i 99 16 TYP 8 PLACES 276mm Standard Pump Pulse Output Kit BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES BOTTOM VIEW 225mm 380mm 65mm AIR INLET 3 4 NPT Note Porting Flanges are also avaible with PN10 50mm DIN bolting configuration Model S20 Non Metallic Design Level 2 Page 7 520 202 000 9 03 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 t
12. a PLC The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the Air Distribution Valve Assembly when the threaded exhaust port or an auxiliary muffler is being used See the individual kits listed on the Pump Repair Parts List for further information Exhaust Port or Auxiliary Muffler Setup gt A PULSE OUTPUT KIT PULSE OUTPUT KIT 520 202 000 9 03 Integral Muffler Setup MUFFLER CAP Model S20 Non Metallic Design Level 2 Page 33 ADAPTER PLATE
13. bushings items 2 B five spacers items 2 D and six spool wipers items 2 E by pushing gently from other end of the pilot valve body Inspect the wipers for cuts and or wear Replace any wipers as necessary 520 202 000 9 03 Step 3 Re assembly of the pilot valve First install a spiral retaining ring to one end of the pilot valve body 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 retaining ring using clip ring pilers 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 4 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 plu
14. can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARD OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 53 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet end components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional TPE pumping diaphragms item 48 These diaphragms are installed with the natural concave curve toward the outer chamber 520 202 000 9 03 items 17 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 replac
15. 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 1420 ml 48 01 fl 0z It is important that the exact amount of fluid is used Too little or too much fluid causes premature diaphragm failure and erratic pumping 6 Loosely reinstall one boss plug item 53 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly install the safety clip 8 Loosen the top boss plug on the filled chambers This allows fluid in the chamber to purge trapped air from the chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 56 is in the vertical position Loosen the pipe plug item 52 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item
16. 0 170 055 115 Capscrew Hex HD 1 2 13 x 2 50 16 35 720 010 375 Seal Diaphragm Rod 2 170 055 308 Capscrew Hex HD 1 2 13 x 2 50 16 36 720 038 600 Seal Manifold Spacer 8 11 170 068 115 Capscrew Hex HD 1 2 13 x 1 75 8 37 720 041 600 Seal Check Valve Assembly 8 170 068 308 Capscrew Hex HD 1 2 13 x 1 75 8 38 722 075 520 Seat Check Valve 4 12 170 095 115 Capscrew Soc HD 1 2 13 x 3 00 8 722 075 552 Seat Check Valve 4 170 095 308 Capscrew Soc HD 1 2 13 x 3 00 8 39 770 056 520 Spacer Manifold 4 13 170 110 115 Capscrew Soc HD 5 8 11 x 3 00 16 770 056 552 Spacer Manifold 4 170 110 308 Capscrew Soc HD 5 8 11 x 3 00 16 40 901 046 115 Washer Flat 1 2 60 14 171 004 115 Capscrew Flat HD 1 2 13 X 1 25 6 901 046 308 Washer Flat 1 2 60 15 171 053 115 Capscrew Soc HD 3 8 16 X 2 75 4 41 901 047 115 Washer Flat 5 8 32 171 053 308 Capscrew Soc HD 3 8 16 X 2 75 4 901 047 308 Washer Flat 5 8 32 16 196 148 156 Chamber Inner 2 42 901 048 115 Washer Flat 3 8 8 196 148 307 Chamber Inner 2 901 048 308 Washer Flat 3 8 8 196 148 309 Chamber Inner 2 43 538 035 555 Nipple Pipe 1 NPT Close 1 196 148 332 Chamber Inner 2 44 530 027 000 Muffler 1 17 196 150 520 Chamber Outer 2 196 150 552 Chamber Outer 2 18 286 074 354 Diaphragm 2 NOT SHOWN 19 286 075 600 Diaphragm Overlay 2 535 069 000 Nameplate 20 312 102 520 Elbow 4 312 102 552 Elbow 4 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 13 RuppGUARD Option for Virgin PTFE Equipped Pumps
17. 0 Non Metallic Design Level 2 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 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 20 from pump composite repair parts drawing Use a 9 6 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 17 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 3 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 520 202 000 9 03 Remove the remaining check valve
18. 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 24 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 S20 Non Metallic Design Level 2 Page 19 Air Valve Assembly Drawing with Stroke Indicator Option 20 Design Level 2 Note Stroke Indicator is standard on RuppGUARD Spill Prevention models Pilot Valve Assembly Parts List Item Part Number Description Qty 1 031 146 000 Air Valve Assembly 1 1 A 031 143 000 Sleeve and Spool Set w Pins 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 165 098 147 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 Scr
19. Q A S 0 00 151 68 S20B2K2KQAS000 S 20 B 2 K 2 K Q A S 0 00 151 68 S20B2PSPQAVOOO S 20 B 2 P 3 P Q A V 0 00 148 67 S20B2K3KQAVOOO S 20 B 2 K 3 K Q A V 0 00 189 86 S20B2P4PQAVOOO S 20 B 2 P 4 P Q A V 0 00 148 67 S20B2K4KQAVOOO S 20 B 2 K 4 K Q A V 0 00 189 86 Pump Brand Diaphragm Check Valve Materials Porting Options Pump Options Kit Options S SANDPIPER 1 Santoprene Santoprene A ANSI Flange 0 None 00 2 None 2 PTFE Santoprene Backup PTFE D DIN Flange 1 3M Muffler P0 0 30VDC Pulse Output Kit Pump Size 3 PTFE Pumping PTFE Santoprene 7 Dual Porting ANSI 2 Mesh Muffler P1 Intrinsically Safe 10 30VDC 20 2 Backup Driver PTFE 8 Top Dual Porting ANSI 3 High temperature Air Valve Pulse Output Kit Check Valve Type oF lng Pumping Santoprene 9 Bottom Dual Porting ANSI w Encapsulated Muffler P2 110 120 or 220 240VAC B Ball nversanoprene 4 High temperature Air Valve Pulse Output Kit Check Valve Seat w 3M Muffler P3 Intrinsically Safe 110 120VAC Design Level K PVDF RuppGUARD with Electronic 5 High temperature Air Valve Pulse Output Kit 2 Design Level 2 P Polypropylene Ka AN w Mesh Muffler P4 Intrinsically Safe 220 240VAC E RuppGUARD with Electronic Pulse Output Kit Wetted Material Non Wetted Material Options Leak Detection 220V E0 Solenoid Kit with 24VDC Coil K PVDF i i TM wi i A Painted Aluminum M RuppGUARD with Mechanical E1 Solenoid Kit with 24VDC P Polypropylene Pai i B ypropy
20. SERVICE amp OPERATING MANUAL Model S20 Non Metallic Design Level 2 Engineering Data and Temperature Limitations 1 Explanation of Pump Nomenclature sessseesessseeeseeeeneeee nennen enne 2 Performance Curve Model S20 Non Metallic Design Level 2 3 Dimensions S20 Non Metallic ecceeeceseeeeeeeeeeeeeceeeeeeeeeeaeeeesaeeeeseseeeeeeseesaeeaesaeseseeseaeeaeeateas 4 Metric Dimensions S20 Non Metallic esee 5 Dimensions S20 Non Metallic with Spill Prevention senen 6 Metric Dimensions S20 Non Metallic with Spill Prevention sesser 7 Principle of Pump Operation Installation and Stan Up iiti citet ec ient atcp rr nace enixa erect te tibl cec 8 Air Valve lubrication cineri etre etie rnit ote rini rien rd t Ego 8 Air EIneMOISIUIG fears irr entsteht 8 Air Inlet and PRIMING e didani 8 Between AN NAAN UNANG teins AE EESAN 8 instalation Guide 2 tn ANN M bm Eie tt n a nene RGR 9 Important Safety Information ssssssseseeeeeneeneenenee ener 10 Material Cod6es iniri osi iaai daa in Yun iov Tea Peg 10 Troubleshootilig 23 eorr eet tr ber Ferte eben De di E EE VERUS 11 Warranty siisii Composite Repair Parts Drawing enne nennen 12 Overlay Option Drawi
21. Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 476 142 655 WETTED END KIT for PVDF RuppGUARD Santoprene Diaphragms PTFE Overlay Diaphragms PTFE Pumping Diaphragms PTFE Balls and PTFE Seals 031 141 000 ASSEMBLY AIR VALVE without Encapsulated Muffler Muffler Cap and six screws HARDWARE KITS 475 170 308 PTFE Coated Stainless Steel Capscrews Hex Nuts Washers and Support Rod 475 171 308 For use with RuppGUARD Spill Prevention Options RuppTech PULSE OUTPUT KITS For use with 530 010 000 and 530 032 000 Mufflers or piped exhaust 475 198 001 DC Kit 475 198 002 DC Intrinsically Safe Kit 475 198 003 110 120VAC or 220 240VAC Kit 475 198 004 110 120VAC Intrinsically Safe Kit 475 198 005 220 240VAC 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 120VAC or 220 240VAC Kit 475 198 009 110 120VAC Intrinsically Safe Kit 475 198 010 220 240VAC Intrinsically Safe Kit RuppTech ELECTRONIC LEAK DETECTOR KITS 032 037 000 100VAC 50Hz or 110 120VAC 50 60Hz or 220 240VAC 50 60Hz 032 045 000 12 32VDC 520 202 000 9 03 Muffler Option Drawing Overlay Option Drawing Model S20 Non Metallic Design Level 2 Page 12 Composite Repair Parts List ITEM PARTNUMBER DESCRIPTION QTY ITEM PART NUMBER DESCRIPTION QTY 1 031 140 000 Air Valve Assembly 1 21 360 090 360 Gasket Air Inlet 1
22. TICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER EE STYLES OR PIPING EXHAUST 0 5 AIR IN SUBMERGED APPLICATIONS FRONT VIEW f SUCTION PORT 2 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4 DIA BOLT CIRCLE 4 5 8 69 16 8 PLACES SIDE VIEW Dimension A B Standard Pump 6 9 16 12 11 16 BOLT PATTERN IS SYMMETRICAL ABOUT CENTERLINES 10 7 8 Pulse Output Kit 12 9 16 18 11 16 3M Muffler 4 1 16 15 1 4 Mesh Muffler 12 9 16 18 11 16 1 1 16 E 1 13 16 11 7 16 12 7 8 A N AIR INLET 3 4 NPT BOTTOM VIEW Note Porting Flanges are also avaible with PN10 50mm DIN bolting configuration 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 4 Metric Dimensions S20 Non Metallic Dimensions in Millimeters Dimensional tolerance 3mm DISCHARGE PORT 2 STANDARD 125 FLANGE CONFIGURATION 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4 DIA BOLT CIRCLE I 103mm MANIFOLD CAN ROTATE 90 FROM VERTICAL CENTERLINE STANDARD ENCAPSULATED MUFFLER 1 NPT EXHAUST PORT FOR OPTIONAL MUFFLER STYLE OR PIPING EXHAUST AIR IN SUBMERGED APPLICATIONS lii Tana TI FRONT VIEW ee a em 3 4 DIA 4 HOLES EQUALLY SPACED ON A 4 3 4
23. alve are designed to operate WITHOUT lubrication This is the preferred mode of operation There may be instances of personal preference or poor quality air supplies when lubrication of the compressed air supply is required The pump air system will operate with properly lubricated compressed air supply Proper lubrication requires the use of an air line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of air the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing or freezing of the exhaust air causing the pump to cycle erratically or stop operating Water in the air supply 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 sett
24. asten the elbows items 20 to the outer chambers items 17 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 4 12 hex nuts and washers that fasten the outer chambers diaphragms 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 33 by turning counterclockwise Insert a 1 4 20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate item 30 Insert the protruding stud and the 1 4 20 fastener 520 202 000 9 03 loosely into a vise Use a 13 s wrench or socket to remove the outer diaphragm plate item 29 by turning counterclockwise Inspect the diaphragm item 18 for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary Step 4 Installing the diaphragms Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm Thread the inner plate clockwise onto the stud Use a torque wrench to tighten the diaphragm 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 dia
25. 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 Remove the muffler 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 520 202 000 9 03 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 EN MUFFLER 1 DIAMETER AIR EXHAUST PIPING MUFFLER LT LIQUID _ LEVEL SUCTION LINE Illustration 3 1 DIAMETER AIR EXHAUST PIPING Model S2
26. chamber This can be seen by watching the column of fluid in the sight tube When fluid appears at the top of the port quickly tighten the boss plug Fluid loss of 1 to 2ml is acceptable 9 Tilt the pump so the uppermost pipe tee item 56 is in the vertical position Loosen the pipe plug item 52 This will allow trapped air to purge through the pipe tee When fluid appears at the tee opening reinstall the pipe plug NOTE If all air is not purged using this procedure remove the check valve components from the top port of the outer chamber item 17 Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm Loosen the pipe plug item 52 allowing the fluid to purge any remaining trapped air Reinstall the plug 10 Repeat steps 5 through 9 to fill opposite spill prevention chamber 11 Reinstall the check valve components discharge manifold and elbows to the pump The pump is now ready for operation A IMPORTANT Read these instructions completely before in Stallation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S20 Non Metallic Design Level 2 Page 17 Air Distribution Valve Assembly Drawing 20 Design Level 2 Main Air Valve Assembly Parts Li
27. ck 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 service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model S20 Non Metallic Design Level 2 Page 11 Composite Repair Parts Drawing AVAILABLE SERVICE AND CONVERSION KITS 476 174 000 AIR END KIT Seals O rings Gaskets red Rings Air Valve Sleeve amp Spool Set and Pilot Valve Assembly 476 175 000 AIR END KIT for Stroke Indicator Option Seals O rings Gaskets Retaining Rings Air Valve Sleeve amp Spool Set and Pitot Valve Assembly 476 139 354 WETTED END KIT Santoprene Diaphragms Santoprene Balls and TFE Seals 476 139 654 WETTED END KIT Santoprene Diaphragms PTFE Overlay Diaphragms TFE Balls and TFE Seals 476 142 354 WETTED END KIT for Polypropylene RuppGuard
28. d components can now be removed See diaphragm servicing section for detailed instructions The spill prevention option has two additional virgin PTFE pumping diaphragms item 48 These diaphragms are installed with the natural concave curve toward the 520 202 000 9 03 outer chamber items 17 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 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 53 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 17 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 53 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 N into the smaller unthreaded hole in one end cap item 1 D This locks the valve spool to one side keeping the pump from shifting 5 Face the side
29. ded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Rulon Il 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 Delrin Viton and Hytrel are registered tradenames of E I DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto Corp Rulon Il is a registered tradename of Dixion Industries Corp Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co Warren Rupp Rupplon SANDPIPER PortaPump Tranquilizer RuppGUARD RuppTech and SludgeMaster are registered tradenames of Warren Rupp Inc 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 10 TROUBLESHOOTING Possible Symptoms e Pump will not cycle e Pump cycles but produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceed
30. e the liquid in the pump after disassembly or liquid loss 1 Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs items 53 Replace the bottom two boss plugs after the fluid is drained 2 Remove the eight capscrews item 10 fastening the discharge manifold and elbows to the outer chambers items 17 The discharge manifolds and elbows can now be removed 3 Remove the top two boss plugs items 53 The spill prevention chambers are filled through the exposed ports 4 Apply air pressure to the air distribution valve Install safety clip item 1 N into the smaller unthreaded hole in one end cap item 1 D This locks the valve spool to one side keeping the pump from shifting 5 Face the side of the pump with the installed safety clip If the safety clip is installed in the top end cap fill the left spill prevention chamber If the safety clip is installed on the bottom end cap fill the right spill prevention chamber 6 Loosely reinstall one boss plug item 53 to the filled spill prevention chamber 7 Shut off air supply Remove safety clip Adjust the air line regulator so that air pressure slowly fills the pump The diaphragm expands forcing the fluid in the chamber to be slowly displaced When the pump shifts to the opposite side quickly 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
31. e 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 39 and 25 from pump assembly drawing from the pump The discharge and suction elbows can be rotated at 90 increments see arrows and optional positioning in the Dual Porting Drawing 520 202 000 9 03 Single porting of the suction and dual porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual discharge porting arrangement remove the only the discharge manifolds spacers and manifold seals Position the discharge elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing Dual porting of the suction and single porting of the pump discharge To convert the pump from the standard single suction and single discharge porting configuration to a dual suction porting arrangement remove the only the suction bottom manifolds spacers and manifold seals Position the suction elbows in the desired direction at 90 increments See arrows and optional positioning in the Dual Porting Drawing 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 t
32. ew Self Tapping 4 includes all other items on 031 146 000 above For Pumps with Alternate Mesh Sound Dampening Mufflers or Piped Exhaust 1 031 147 000 Air Valve Assembly 1 includes all items on 031 146 000 minus 1 D 1 F amp 1 J 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 20 AIR DISTRIBUTION VALVE WITH STROKE INDICATOR OPTION SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 5 16 Allen wrench remove the four hex socket capscrews item 15 and four flat washers item 42 Remove the air valve assembly from the pump Remove and inspect gasket item 24 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 bumper for cuts wear or abrasions Replace if necessary Remove the spool part of item 1 A from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear 520 202 000 9 03 Inspect t
33. gm Pumping 2 49 518 134 520 Manifold Spill Prevention 2 replaces 518 132 520 518 134 520E Manifold 50mm DIN 2 518 134 552 Manifold Spill Prevention 2 replaces 518 132 552 518 134 552E Manifold 50mm DIN 2 50 538 022 110 Pipe Nipple 4 538 022 308 Pipe Nipple 4 51 560 078 611 O ring 8 52 618 003 110 Plug Pipe 4 618 003 308 Plug Pipe 4 53 618 025 110 Plug Boss 4 618 025 308 Plug Boss 4 54 618 031 110 Plug Boss 4 618 031 308 Plug Boss 4 55 770 057 600 Spacer Manifold 4 770 057 552 Spacer Manifold 4 56 835 005 110 Tee Pipe 4 835 005 308 Tee Pipe 4 57 860 055 606 Tube Sight 2 ae 58 866 060 110 Connector Tube 4 59 170 111 115 Capscrew Hex HD 5 8 11 x 3 25 16 the diaphragms are to be installed with the concave side facing toward the outer chambers Flat side of spill Note The diaphragms are to be replaces 170 110 600 side facing toward the outer chambers See drawing installed with the concave prevention chamber item 47 to face outer chamber item 17 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 16 RuppGUARD FOR TPE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture
34. he 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 Insert the safety clip item 1 K through the small unthreaded hole in the end cap Remove the new sleeve an spool set item 1 A from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 G into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 B align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Push the spool in until the pin touches the safety clip on the opposite end Install the remaining bumper end cap with o ring and retaining ring Fasten the air valve assembly item 1 and gasket item 24 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 refe
35. his manual will damage the pump and void factory warranty Model S20 Non Metallic Design Level 2 Page 31 RuppTech Leak Detection Options Drawing RuppTech LEAK DETECTION OPTION ELECTRONIC Follow instructions found elsewhere in this manual Filling the RuppGUARD Spill Prevention Chambers when installing leak detectors For pumps with 530 028 550 ENCLOSED MUFFLER Electronic Leak Detector Installation Kit 082 037 000 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 14 NPT pipe plug on the visual sight tube item 52 Insert leak detector into the 14 pipe tee item 56 LEAK DETECTION OPTION MECHANICAL Follow instructions found elsewhere in this manual Filling the q 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 52 Insert leak detector into the 14 pipe tee item 56 520 202 000 9 03 Model S20 Non Metallic Design Level 2 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 Rupp Tech Stroke Counter Batch Controller or user control devices such as
36. ibution Valve with Stroke Indicator Servicing ss 21 Solenoid Shifted Air Valve Drawing 22 Solenoid Shifted Air Valve Parts List esessssseeeeeeneneene nennen eene 22 Solenoid Shifted Air Distribution Valve option a 23 Pilot Valve Assembly samaan tan tnnt tn tnnt GANANG KANAN GAGA 24 Pilot Valve Assembly Parts List ren renrtnne enn 24 Pilot Valve Servicing 2 2 c ein erectae i e n ete eddie dieci 25 Diaphragm Service Drawing Non Overlay esses 26 Diaphragm Service Drawing with Overlay sess 26 Diaphragm 5 ree e a LARA aang 27 Overlay Diaphragm Service enini tee ai et ti eee te 27 PUMPING Hazardous inei arre oen erre rer na rn linda n 28 Converting the pump for piping the exhaust air 28 Exhaust Conversion Drawing sess nnne 28 Converted Exhaust Illustration 28 Modular Check Valve Servicing sse nennen nnne 29 Modular Check Valve Drawing eeseesseeeeeeeeeennenneeeneennennen eene nennen enne 29 D l Port Option Drawing ima riri recorte ceca teer p co 30 Dual Porting Options eiim BARAN AA ee teed ERR Eua duas 31 Dual porting of both suction and discharge ends of the pump 31 Single porting of the suction and dual
37. ing 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds air supply pressure Corrective Action Increase the inlet air pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Air supply pressure or volume exceeds system head Corrective Action Decrease inlet air pressure and volume to the pump as calculated on the published PERFORMANCE CURVE Pump is cavitating the fluid by fast cycling 520 202 000 9 03 What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized air line Corrective Action Install a larger air line and connection Refer to air inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check ESADS the Externally Serviceable Air Distribution System of the pump Corrective Action Disassemble and inspect the main air distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and air valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Rigid pipe connectio
38. le 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 S20 Non Metallic Design Level 2 Page 8 WARREN RUPP 520 202 000 Available from Warren Rupp O Surge Suppressor 2 020 050 000 Filter Regulator 3 020 050 001 Lubricator 4 020 047 007 Air Dryer A CAUTION The air exhaust should be piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure Air Exhaust SUCTION 9 03 Pipe Connection INSTALLATION GUIDE Top Discharge Ball Valve Unit 1 Surge Suppressor Pipe Connection Limited to Style Optional 100 psi Gauge NEM Flexible p Connection 2 FT DISCHARGE TA Drain Port Flexible Connection TOP Filter Regulator DISCHARGE DIAPHRAGM Air Shut Off Valve Air Dryer AIR INLET Flexible Style Optional Gauge Shut Off Valve OR I 1 uU
39. 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 Inspect the bumpers for cuts wear or abrasion Replace 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 520 202 000 9 03 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 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 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
40. ng nre ennt trennen tnn 12 Composite Repair Parts LIS Posi ce MADAPA eo eto od c 13 RuppGUARD Spill Prevention Option for Virgin PTFE Equipped Pumps 14 RuppGUARD Spill Prevention Repair Parts List 14 RuppGUARD Spill Prevention Concept 15 RuppGUARD Spill Prevention Option Diaphragm Servicing 15 Filling RuppGUARD Chambers with Liquid 15 RuppGUARD Spill Prevention Option for TPE Equipped Pumps 16 RuppGUARD Spill Prevention Repair Parts 16 RuppGUARD Spill Prevention Concept with TPE Diaphragms 17 RuppGUARD Spill Prevention Option with TPE Diaphragm 17 Air Distribution Valve Assembly Drawing eeseeseeeeneeeeeeneneeennee nennen 18 te U S Patent 400 210 5 996 627 Main Air Valve Assembly Parts List cece ccc cee awnaanaawaaawaaaunaasasasasanasasasaswasanasanasawas 18 Air Distribution Valve Servicing ssssseeeeeneneeneeene nennen nennen nennen 19 Air Distribution Valve with Stroke Indicator Options seee 20 Air Distribution Valve with Stroke Indicator Parts List ss 20 Air Distr
41. ngers 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 21 air inlet cap item 8 capscrews and washers items 9 and 42 Connect the air supply to the pump Remove the safety clip item 1 N from the end cap item 1 C 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 S20 Non Metallic Design Level 2 Page 25 Diaphragm Service Drawing Diaphragm Service Drawing Non Overlay with Overlay 520 202 000 9 03 Model S20 Non Metallic Design Level 2 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 wrench or socket remove the 16 capscrews items 10 hex nuts and washers that f
42. ns 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 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 Che
43. o move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the suction stroke in the opposite chamber Air pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water For maximum diaphragm life keep the pump as close to the liquid being pumped as possible Positive suction head in excess of 10 feet of liquid 3 048 meters may require a back pressure regulating device to maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally 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 520 202 000 9 03 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
44. or toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARNING Before doing any main tenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death WARNING Airborne particles and loud noise hazards Wear ear and eye protection MATERIAL CODES The Last 3 Digits of Part Number 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 Hastelloy equivalent Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 76 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 Almag 35 Aluminum 356 T6 Aluminum 356 T6 Aluminum Die Cast Aluminum Allo
45. pacer Manifold Tee Pipe Tee Pipe Tube Sight Connector Tube Capscrew Hex HD 5 8 11 x 3 25 replaces 170 110 115 N N N N N N Note The diaphragms are to be installed with the concave side facing toward the outer chambers See drawing Model S20 Non Metallic Design Level 2 Page 14 RuppGUARD FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials It also helps to protect the environment With the installation of optional leak detectors either mechanical or electronic the diaphragm rupture can be detected The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment RuppGUARD OPTION DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Next shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump Drain any remaining pumped liquid from the pump Remove the pump before servicing Next drain the fluid from the spill prevention chambers This can be done by removing the bottom plug item 53 from each spill prevention chamber After the fluid from the spill prevention chambers has been drained the wet en
46. phragm assemblies to the pump Make sure the bumper item 6 is installed over the diaphragm rod Thread the stud of the one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod item 33 until the inner diaphragm plate is flush to the end of the rod Insert rod into pump Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber item 16 Make sure the molded directional arrows on the diaphragm point vertically Fasten the outer chamber item 17 to the pump using the capscrews items 118 12 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 33 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 17 to the pump using the capscrews items 11 amp 12 hex nuts and flat washers Step 6 Re install the elbow spacer manifold assemblies to the pump using the capscrews items 10 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
47. porting of the pump discharge 31 Dual porting of the suction and single porting of the pump discharge 31 Leak Detection Options Drawing RuppTech Electronic Leak Detector Installation Mechanical Leak Detector Installation RuppTech Pulse Output Kit Drawing esseeeeeenneeneneeneneneneenenennnens RuppTech Pulse Output Kit Option essen nennen Exhaust Port or Auxiliary Muffler Setup eessseeeeneeenenennneeneneennnns Integral Muffler Setup esssssseeeeneeene nennen nnne nnne enne 31 WARREN RUPP INC A Unit of IDEX Corporation PO Box 1568 Mansfield Ohio 44901 1568 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com 520 209 000 9 03 Copyright 2003 Warren Rupp Inc All rights reserved SANDPIPER A WARREN RUPP PUMP BRAND 20 Non Metallic WARREN RUPP Quality System IS09001 Certified D esign Level 2 Environmental pres relatos U S Patent Bal I Va Ive ee 5 996 627 Air Powered Other U S Patents Double Diaphragm Pump Applied for IDEX CORPORATION ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 2 ANSI Flange or 0 to 150 US gallons per minute No lube no stall Up to 66 in
48. rence Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty Model S20 Non Metallic Design Level 2 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 60 893 097 000 Solenoid Valve NEMA4 1 61 219 001 000 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 62 241 001 000 Connector conduit 1 63 170 061 115 Capscrew Hex HD 3 8 16 x 1 75 4 64 618 052 506 Plug 2 For Explosion Proof Solenoid Valve Connector not required for explosion proof coil coil is integral with valve 60 893 098 001 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 S P 6 520 202 000 9 03 Model S20 Non Metallic Design Level 2 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 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
49. 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 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 520 202 000 9 03 Solenoid Connector Before wiring remove terminal block from conduit connector 7 L L A et a 1 Wiring Diagram 3rd Terminal for ground _ gt 2 Terminal 1 Terminal Neutral Power Negative Positive i M m L
50. st Item Part Number Description Qty 1 031 140 000 Main Air Valve Assembly 1 1 A 031 139 000 Spool Assembly 1 1 B 095 094 551 Body Air Valve 1 1 132 029 552 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 1 675 044 115 Ring Retaining 2 1 J 710 015 115 Screw Self tapping 4 For pumps equipped with PTFE Coated Hardware 1 031 140 002 Air Valve Assembly 1 Includes all items used on 031 140 000 except 1 J 710 015 308 Screw Self tapping 4 1 H 675 044 308 Retaining Ring 2 For pumps equipped with PTFE coated hardware option 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 For pumps with alternate Mesh or Sound Dampening mufflers or piped exhaust 1 031 141 002 Air Valve Assembly 1 Includes all items used on 031 141 000 except 1 H 675 044 308 Ring Retaining 2 520 202 000 9 03 Model S20 Non Metallic Design Level 2 Page 18 AIR DISTRIBUTION VALVE SERVICING To service the air valve first shut off the compressed air bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See Composite Repair and Parts Drawing Using a 5 1 Allen wrench remove the four hex socket capscrews item 15 and four flat washers item 42 Remove the air valve assembly from the pump Remove and inspect gasket item 24 for cracks or damage Replace gasket if
51. then pushes the end of the pilot valve spool into position to activate the air distribution valve The chambers are connected with manifolds with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible hose should be installed between the pump and the piping The flexible hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow AIR SUPPLY Air supply pressure cannot exceed 100 psi 7 bar Connect the pump 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 v
52. y 380 Aluminum Alloy SR 319 Anodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc Copper Alloy Carbon Steel Gray Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Gray Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated Kynar Coated Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Rupplon Urethane Rubber Color coded PURPLE Some Applications Compression Mold Urethane Rubber Buna N Rubber Color coded RED Buna N Viton Flurorel Color coded YELLOW E P D M Rubber Color coded BLUE Neoprene Rubber Color coded GREEN Food Grade Nitrile Food Grade EPDM 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 Resin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon Nylon Nylon Injection Mol

Service Manual - Amalgamated Pumping Supplies

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