HDF1 HF25 Metal Pump Manual - Best Prices SandPIPER Pumps in
Contents
1. AWARNING Airborne particles and loud noise hazards Wear ear and eye protection RECYCLING Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 11 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed hdfidlism rev0411 Models HDF1 amp HDF25 Page 9 GROUNDING THE PUMP To be fully groundable the pumps must be Take action to prevent static sparking Fire or explosion can result ATEX Compliant Refer to pump data sheet especially whenshnandling ammabile for ordering liquids The pump piping valves containers or other miscellaneous equipment must be grounded One eyelet is fastened to the pump hardware One eyelet is installed to a true earth ground Requires a 5 16 or 8mm maximum diameter bolt This 8footlong 244 centimeters Ground Strap part number 920 025 000 can be ordered as a service item To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required or in the absence of local codes an industry or nationally recognized code having jurisdiction over specific installations hdf1dl1sm rev0411 Models HDF1 amp HDF25 Page 10 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 180 3052. 17 196 043 157 Chamber Inner AL Center 1 196 090 010 Chamber Inner CI Center 1 18 196 199 156 Chamber Outer 2 196 199 010 Chamber Outer 2 196 199 110 Chamber Outer 2 19 255 012 335 Coupling Pipe 3 4 NPT 1 20 286 008 354 Diaphragm 2 286 008 356 Diaphragm 2 286 008 360 Diaphragm 2 286 008 363 Diaphragm 2 286 008 364 Diaphragm 2 286 008 365 Diaphragm 2 21 312 119 156 Elbow Suction 2 312 119 010 Elbow Suction 2 312 119 110 Elbow Suction 2 22 312 120 156 Elbow Discharge 2 312 120 010 Elbow Discharge 2 312 120 110 Elbow Discharge 2 23 338 014 354 Flap Valve 4 338 014 356 Flap Valve 4 hdf1dl1sm rev0411 Models HDF1 amp HDF25 Page 12 ITEM NO PART NUMBER DESCRIPTION TY 338 014 360 Flap Valve 4 338 014 363 Flap Valve 4 338 014 364 Flap Valve 4 338 014 365 Flap Valve 4 24 350 002 360 Foot Rubber 4 25 360 056 379 Gasket 1 26 360 057 360 Gasket 1 27 360 058 360 Gasket 1 28 518 205 156 Manifold 2 518 205 156 E Manifold 2 518 205 010 Manifold 2 518 205 010 E Manifold 2 518 205 110 Manifold 2 518 205 110 E Manifold 2 29 530 036 000 Muffler 1 30 542 001 330 Nut Square 1 31 545 004 330 Nut Hex 5 16 18 14 32 547 002 110 Nut Stop 12 33 560 001 360 O Ring 2 34 560 038 360 O Ring 8 560 038 363 O Ring 8 560 038 364 O Ring 8 560 038 365 O Ring 8 35 560 040 360 O Ring 2 36 560 198 360 O Ring 4 560 198 363 O Ring 4 560 198 364 O Ring 4 560 198 365 O Ring 4 37 570 018 360 Pad Hinge 4 570 018 363 Pad Hinge 4 570 018 364
3. 306 307 308 309 310 313 330 331 332 333 335 336 337 340 342 351 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 Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 1351 Almag 35 Aluminum 356 T6 Aluminum 356 T6 Aluminum Die Cast Aluminum Alloy 380 Aluminum Alloy SR 319 Anodized Aluminum Brass Yellow Screw Machine Stock Cast Bronze 85 5 5 5 Bronze SAE 660 Bronze Bearing Type Oil Impregnated Die Cast Zinc Copper Alloy Carbon Steel Black Epoxy Coated Carbon Steel Black PTFE Coated Aluminum Black Epoxy Coated Stainless Steel Black PTFE Coated Aluminum Black PTFE Coated PVDF Coated Aluminum White Epoxy 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 Food Grade Santoprene Color NATURAL
4. 7 the air line from the pump The discharge line may be pressurized and must be bled of its pressure AWARNING In the event of diaphragm rupture pumped material may enter the air end of the pump and be discharged into the atmosphere If pumping a product which is hazardous or toxic the air exhaust must be piped to an appropriate area for safe disposition AWARNING Take action to prevent static Sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded See page 10 A WARNING This pump is pressurized internally with air pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly 4 WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly AWARNING 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
5. 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 375 378 379 384 405 408 425 426 440 465 500 501 502 503 505 506 520 521 540 541 542 544 550 551 552 555 556 Geolast Color BLACK Injection Molded 3203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Color BLUE Injection Molded Polyurethane Color GREEN Urethane Rubber Color NATURAL Some Applications Compression Mold Urethane Rubber Color NATURAL Nitrile Rubber Color Coded RED Nitrile FKM Fluorocarbon Color Coded YELLOW E P D M Rubber Color Coded BLUE Neoprene Rubber Color Coded GREEN Food Grade Nitrile Color WHITE Food Grade EPDM Color GRAY Butyl Rubber Color Coded BROWN Philthane Tuftane Carboxylated Nitrile Fluorinated Nitrile High Density Polypropylene Conductive Nitrile Color Coded RED amp SILVER Conductive Neoprene Color Coded GREEN amp SILVER Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Color BLACK Conductive Acetal Glass Filled Color BLACK Color Coded YELLOW Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Color NATURAL Injection Molded Conductive PVDF Color BLACK Color Coded LIGHT GREEN Nylon Nylon Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Color BLACK Unfill
6. Pad Hinge 4 570 018 365 Pad Hinge 4 38 570 019 360 Pad Wear 2 570 019 363 Pad Wear 2 570 019 364 Pad Wear 2 570 019 365 Pad Wear 2 39 612 022 330 Plate Diaphragm Inner 2 40 612 108 157 Assembly Diaphragm Plate 2 612 101 082 Assembly Diaphragm Plate 2 612 101 110 Assembly Diaphragm Plate 2 41 618 003 330 Plug Pipe 1 4 3 42 620 007 114 Plunger Actuator 2 43 670 053 110 Retainer 4 44 675 040 360 Ring Sealing 2 45 675 042 115 Ring Retaining 2 46 675 065 360 Ring Sealing 4 675 065 363 Ring Sealing 4 675 065 364 Ring Sealing 4 675 065 364 Ring Sealing 4 47 685 039 120 Rod Diaphragm 1 48 706 013 330 Screw Machine 4 49 720 010 375 Seal U Cup 2 50 720 066 360 Seal Seat 4 720 066 363 Seal Seat 4 720 066 364 Seal Seat 4 720 066 365 Seal Seat 4 51 722 101 110 Seat Flap 4 52 807 018 110 Stud 1 4 20 8 53 900 004 330 Washer Lock 5 16 32 54 901 005 330 Washer Flat 3 8 4 55 901 012 180 Washer Sealing 2 56 901 035 330 Washer Flat 7 hdfidlism rev0411 Models HDF1 amp HDF25 Page 13 Composite Repair Drawing CAST IRON MID SECTION ASSEMBLY CONFIGURATION amp SANDPIPER and Tranquilizer are registered tradenames of Warren Rupp Inc 2010 Warren Rupp Inc All rights reserved Printed in U S A GNeverseize is a registered tradename of Loctite hdf1dl1sm rev04 11 Models HDF1 amp HDF25 Page 14 n1ILLLJOJUO JO UOIHeJe 3erg WARREN RUPP INC Declaration of Conformity Manufacturer Warren Rup
7. X KEMA Quality B V Utrechtseweg 310 6812 AR Arnhem The Netherlands SANDPIPER Tranquilizer A WARREN RUPP INC BRAND DATE APPROVAL TITLE 27 MAY 2010 David Roseberry Engineering Manag r FLUID amp METERING WARREN RUPP INC EC Declaration of Conformity ATEX Summary of Markings Pump types S1F S15 S20 and S30 provided with the pulse output option Pump types S1F S15 S20 and S30 provided with the integral solenoid option Pump types HDB175 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 S1F S15 S20 S30 SB1 SB25 ST1 ST40 G15 G20 and G30 without the above listed options no aluminum parts Pump types DMF2 DMF3 HDB1 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M PB S05 S1F 15 S20 S30 SB1 SB25 SE ST1 ST25 ST175 ST40 U1F G05 G1F G15 G20 and G30 Surge Suppressors all types DIET TIT Il 2 G Ex ia c IIC T5 Il 3 2 G Ex ia c IIC T5 Il 2 D Ex c iaD 20 IP67 T100C Il 2 G EEx mc II T5 Il 3 2 G EEx m c II T5 II 2 D c IP65 T100 C Il 1 Gc T5 Il 3 1 Gc T5 Il 1 Dc T100 C IM1c IM2c I2 GcT5 Il 3 2 G c T5 Il 2 Dc T100 C II 2 G T5 Il 3 2 G T5 Il 2 D T100C EC Type Certificate No Pumps KEMA O9ATEX0071 X Type Certificate No Pumps KEMA O9ATEXO0072 X Type Certificate No Suppressors KEMA O9ATEX0073 KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X CE 0344 KEMA O9ATEXO0071 X KEMA O9ATEX0072 X CE 0344 KEMA O9ATEX0072 X
8. avoid damage PILOT VALVE ACTUATOR Bushings for the pilot valve actuators are held in the inner chambers with retaining rings An o ring is behind each bushing Ifthe plunger has any sideways motion check o rings and bushing for deterioration or wear The plunger may be removed for inspection or replacement First remove the air distribution valve body and the pilot valve body from the pump The plungers can be located by looking into the intermediate It may be necessary to use a fine piece of wire to pull them out The bushing can be turned out through the inner chamber by removing the outer chamber assembly Replace the bushings if pins have bent TROUBLESHOOTING For additional information see the Warren Rupp Troubleshooting Guide PROBLEMe e e e e e e e e e e e POSSIBLE CAUSES Pump cycles but will not pump A Air leak in suction line Note higher suction lifts require faster Excessive suction lift cycling speed for priming Flap valve not seating properly Suction line or strainer plugged Diaphragm ruptured PROBLEMe e e e e e e e e e e e POSSIBLE CAUSES B C D Leakage at joint of suction manifold or elbow flange E F Pump will not cycle Note Always A disconnect air supply to relieve air pressure before disassembling any portion of pump B Discharge hose or line plugged or discharge head requirement greater than air supply pressure Disconnect discharge line to check Spool in air distribution
9. rings on the sleeve for nicks tears or abrasions Damage of this sort could happen during assembly or servicing A sheared or cut o ring can allow the pump s compressed air supply to leak or bypass within the air valve assembly causing the pump to leak compressed air from the pump air exhaust or not cycle properly This is most noticeable at pump dead head or high discharge pressure conditions Replace any of these o rings as required or set up a routine preventive maintenance schedule to do so on a regular basis This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent inspecting for signs of wear or damage and replacing worn components To re install the sleeve and spool set lightly lubricate the o rings on the sleeve with an o ring assembly lubricant or lightweight oil such as 10 wt air line lubricant Re install one end cap and retaining ring see safety warning on the valve body Using the arbor press or bench vise that was used in disassembly carefully press the sleeve back into the valve body without shearing the o rings Re install the spool opposite end cap and retaining ring see safety warning on the valve body After inspecting and cleaning the gasket surfaces on the valve body and intermediate reinstall the valve body on the pump using new gaskets Tighten the four hex head capscrews evenly and in an alternating cross pattern at 150 in Ibs 16 94 Newton meters hdf
10. valve face mate without gap This is important for dry prime However after priming action has started valves will function due to differential pressure without concern or trouble DIAPHRAGM SERVICING Remove the eight bolts securing the elbows to the chamber Remove the four nuts and four capscrews securing the outer diaphragm chamber flange and remove the chamber Loosen the capscrew securing the diaphragm and plate to the rod by leaving the diaphragm engaged with the capscrews around the outer flange preventing rotation of the rod DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEAL During reassembly make certain that the rubber bumper is on the rod on each side Install the diaphragm with the natural bulge outward as indicated on the diaphragm Install the outer plate on the outside of the diaphragm Place the sealing washer between the inner diaphragm plate and the end of the rod Tighten the capscrew to approximately 25 ft Ibs 33 9 Newton meters Torque while allowing diaphragm to turn freely with plates Except for EPDM Rubber use a lightweight oil between plates and diaphragm when doing this procedure For EPDM water can be used Use a wrench on the Hex of the opposite side to keep the rod from rotating If the opposite chamber is assembled the rod need not be held The Flap Valves can also be inspected for proper seating at this point hdf1dl1sm revO4 11 Models HDF1 amp HDF25 Page 6 A
11. 80DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L380DC AL380 L380DC AL380 Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al gt gt gt gt gt gt gt gt gt gt gt gt gt YS S S S S E L380DC AL380 DS gt gt gt gt gt 2 gt gt gt gt gt gt YS S S S S S gt C ojo O O O O O O O O O O O O O O O Ol O O O O O O O O Meaning of Abbreviations zI o c zj o zijmr o c zi ojzirjoj z jo z imo e z uj zir o cjz o c Ir o e zj mo cjr o c zi oj cir o z juo c Tm o z uj cir o cjz i o U U U U U U U D D U D 0 0 AL Aluminum DC Die Cast N Neoprene S Sanotprene U Urethane B Nitrile H Hytre PE Conductive HDPE SS Stainless Steel V FKM CI Cast Iron EPDM PS Plated Steel ll1GcT5 Models equipped with Cast Iron or Stainless l2 GcT5 All models including pumps equipped with Aluminum Il 3 1 Gc T5 Steel wetted parts and Cast Iron midsection Il 3 2 Gc T5 wetted and midsection parts ll 1 Dc T1000C parts See page 17 for ATEX Explanation of ll2DcT1000C See
12. CE KEMA O9ATEX0073 CE Listed In KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEX0071 X KEMA O9ATEX0071 X KEMA 09ATEXO0071 X KEMA 09ATEXO0071 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA O9ATEX0073 KEMA O9ATEX0073 KEMA O9ATEX0073 Non Conductive Fluids No Yes Yes No Yes Yes IBEX FLUID amp METERING
13. F25 features base plate and rubber feet British Standard Pipe as standard For stationary BSP Tapered threaded bolt down use rubber feet connections can be removed HDF1 1 NPT F SUCTION AND DISCHARGE NPT F AIR INLET PORT NPT F AIR EXHAUST PORT NOT SHOWN HDF25 1 BSP F TAPERED SUCTION AND DISCHARGE NPT F AIR INLET PORT NPT F AIR EXHAUST PORT NOT SHOWN hdfidlism rev0411 Models HDF1 amp HDF25 Page 3 SERVICE amp OPERATING MANUAL o see Original Instructions Euras Model HDF1 Type 1 SANDPIPER A WARREN RUPP PUMP BRAND CE Model HDF25 Type 1 PLEASE NOTE The photos shown in this manual are for general instruction only Your specific model may not be shown Always refer to the parts list and exploded view drawing for your specific model when installing disassembling or servicing your pump PRINCIPLE OF PUMP OPERATION This ball valve pump is powered by compressed air and is a 1 1 pressure ratio design It alternately pressurizes the inner side of one diaphragm chamber while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod to move endwise Air pressure is applied over the entire surface of the diaphragm while liquid is discharged from the opposite side The diaphragm operates under a balanced condition during the discharge stroke which allows the unit to be operated at discharge heads over 200 feet 61 meters of water h
14. IR INLET DISCHARGE j ITO eg 0 E Flexible i Connection Shut Off Drain Port Valve Pipe Connection Style Optional hdf1dl1sm revO4 11 Models HDF1 amp HDF25 Page 5 AIR SUPPLY Air supply pressures cannot exceed 125 psi 8 61 bar Connect the pump air inlet to an air supply of sufficient capacity and pressure required for desired performance When the air line is solid piping use a short length of flexible hose not less than 1 2 12 7 mm in diameter between pump and piping to eliminate strain to pipes AIR INLET amp PRIMING For start up open an air valve approximately 1 2 to 3 4 turn After the unit primes an air valve can be opened to increase flow as desired If opening the valve increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be closed slightly For the most efficient use of compressed air and the longest diaphragm life throttle the air inlet to the lowest cycling rate that does not reduce flow AIR EXHAUST If a diaphragm fails the pumped liquid or fumes can enter the air end of the pump and be exhausted into the atmosphere When pumping hazardous or toxic materials pipe the exhaust to an appropriate area for safe disposition This pump can be submerged if materials of construction are compatible with the liquid The air exhaust must be piped above the liquid level Piping used for the air exhaust must not be smaller than 1 2 54 cm Reduc
15. IR VALVE LUBRICATION The SANDPIPER pump s pilot valve and main air valve assemblies 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 supplies Proper lubrication of the compressed air supply would entail the use of an air line lubricator available from Warren Rupp set to deliver one drop of 10 weight non detergent oil for every 20 SCFM of air the pump consumed at its point of operation Consult the pump s published Performance Curve to determine this It is important to remember to inspect the sleeve and spool set routinely It should move back and forth freely This is most important when the air supply is lubricated If a lubricator is used oil accumulation will over time collect any debris from the com pressed air This can prevent the pump from operating properly 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 This can be addressed by using a point of use air dryer to supplement a plant s air drying equipment This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem ESADS PLUS EXTERNALLY SERVICEABLE AIR DISTRIBUTION SYSTEM P
16. SERVICE amp OPERATING MANUAL mm Original Instructions 95 w Model HDF1 Type 1 DPIPERs SANDI CE Model HDF25 Type 1 Table of Contents Engineering Data Temperature Limitations amp Performance Curve 1 Explanation or Pump NormesnclalWre 220222 n Rb Ru 2UDRRE Sn RU RENE RERO ERE 2RR C paEdS 2 DIM NSIONS aessaet a aiee aru ra dude Deua da Lo aw ks pda vu ie De Ra dauuu Gd 3 NENG Mo et SCAM e M Uu REFE 4 Installation and Statellpiisceutes tea caste guspnnaiagutincondsietiedeebebundauusesdiuaswbidemcdtnedaandubn 4 goa METEO 4 istallation Ds M RR E LOT o S ree 5 Air ICD FE UNE NUNN iocos sedens ete rte EE Ea e EE iS 6 AM EXHAUST cceacccdesesnse saa tacendagcn inte ETT 6 Between GOS e e sands 6 g Eu IRR p 6 Diaphragm Servicing cuencas aas aad U nent M tasE S res Eo UIDI PME UN EEES 6 Air Valve L bfiGallOl ou co rer eus Dra ddac aS e raehe E opn Re Ga ea tad usa epe DP Ope dcdUaaqUdRE e ver E bU Pd nenen 7 Recommended Accessories 2 aucccteret ket t aues qued rirse reinaan 7 ESADS Plus Externally Serviceable Air Distribution System 7 Plat VaN AR er nen ee mentite D xL EI IE UEM Le LI E 8 Pilot Valve Actuator crenis leo un ina quac aso Cb pnt ida e buda dua ad CR S Bed iniu ea 8 Service Instructions Troubleshooting auae uae aec tnos citant da eene 8 Waira My oes case a iesbdesh6c d
17. e pump as close to the product being pumped as possible keeping suction line length and number of fittings to a minimum Do not reduce line size For installations of rigid piping short flexible sections of hose should be installed between pump and piping This reduces vibration and strain to the piping system A Warren Rupp Tranquilizer surge suppressor is recommended to further reduce pulsa tion in flow Tighten all fasteners before pump startup This pump was tested at the factory prior to shipment and is ready for operation It is completely self priming from a dry start for suction lifts of 17 feet 5 8 meters or less For suction lifts exceeding 17 feet of liquid fill tne chambers with liquid prior to priming hdfidlism rev0411 Models HDF1 amp HDF25 Page 4 WARREN RUPP Available from Distributor Available from Warren Rupp Air Inlet Line Surge Suppressor AIR EXHAUST INSTALLATION GUIDE Bottom Discharge Flap Valve Unit amp 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 Pipe Connection Style Optional Gauge Shut Off Valve Flexible Connection mo SUCTION Flexible Connection Air Shut Off Drain Port Valve BOTTOM Filter Regulator Air Dryer DISCHARGE DIAPHRAGM PUMP T Gauge A
18. ead Since the diaphragms are connected by a common rod secured by plates to the center of the diaphragms one diaphragm performs the discharge stroke while the other is pulled to perform the suction stroke in the opposite chamber 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 is not recommended For applications with higher suction heads consult the factory Alternate pressuring and exhausting of the diaphragm chamber is performed by means of an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet air pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool shifts to the opposite end of the valve body the porting of chambers is reversed The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool while exhausting the other side The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot valve spool This pushes it into position for shifting of the air distribution valve The chambers are manifolded together with a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION amp START UP Locate th
19. ed Polypropylene Color NATURAL Polyvinyl Chloride Black Vinyl 557 Conductive Polypropylene Color BLACK Color Coded SILVER 558 Conductive HDPE Color BLACK Color Coded SILVER 559 Conductive Polypropylene Color BLACK Color Coded SILVER 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 TFE virgin material Tetrafluorocarbon TFE 601 PTFE Bronze and moly filled 602 Filled PTFE 603 Blue Gylon v 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE Color BLACK 610 TFE Encapsulated Silicon 611 TFE Encapsulated FKM 632 Neoprene Hytrel 633 FKM PTFE 634 EPDM PTFE 635 Neoprene PTFE 637 PTFE FKM PTFE 638 PTFE Hytrel PTFE 639 Nitrile TFE 643 Santoprene EPDM 644 Santoprene PTFE 656 Santoprene Diaphragm and Check Balls EPDM Seats 661 EPDM Santoprene 666 FDA Nitrile Diaphragm PTFE Overlay Balls and Seals 668 PTFE FDA Santoprene PTFE v v Delrin is a registered tradename 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 Exxon Mobil Corp Rulon Il is a registered tradename of Dixion Industries Corp Ryton is a registered tradename of Phillips Chemical Co Valox is a registered tradename of General Electric Co PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc hdfidil1sm rev0411 Model
20. esee ic Sie se cae cece cet ae cates ceneceeececeee 8 Important Safety Information ose cscs cdr raneelteensigncsaaeteceateuntetesnecececetelaeenknamecetincatcese 9 crm EE 9 Grounding The PUMP NN E oS Ei 10 Material CodeS croea 11 Composite Isepalr Parts Stieress r ER 12 13 Composite Repair DIAWING icciscssccsscnicaxecacmnacinwiatsacdlsaniticsanidiniadadieccsdsbawneinandsianadaes 14 CE Declaration of Conformity Machinery cese superba ERR E genie 3e toS dtes ics usan ies 15 CE Declaration To Conformity AT EA ego eda et inda pneter Susa ine treu buaea cr 16 Explanation of ATEX GerlliiGalOTisiisadiexheta EF quuetaa dea ues E eau FE Cud 14 Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA Telephone 419 524 8388 Fax 419 522 7867 www warrenrupp com hdf1dl1sm rev04 11 Copyright 2011 Warren Rupp Inc All rights reserved RUPP SANDPIPER A WARREN RUPP PUMP BRAND HDF1 Typet snis HDF25 Type for ATEX ratings Heavy Duty Flap Valve Air Operated Double Diaphragm Pump ENGINEERING PERFORMANCE amp CONSTRUCTION DATA INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE HDF1 1 25 4mm NPT F 0 to 70 gallons per minute No lube no stall 1 25 4mm 125 psi or 289 ft of water 10 Gallon 38 liter HDF25 1 25 4mm BSP Tapered 0 to 265 liters per minute design 8 8 Kg cm or 88 meters Q
21. idil1sm rev0411 RECOMMENDED WARREN RUPP ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE Tranquilizer Surge Suppressor For nearly pulse free flow Warren Rupp Filter Regulator For modular installation and service convenience Warren Rupp Speed Control For manual or programmable process control Manual adjustment or 4 20mA reception For more detailed information on these accessories contact your local Warren Rupp Factory Authorized Distributor or Warren Rupp corporate headquarters or visit www warrenrupp com A SAFETY WARNING A To assure proper pump func tion and safe installation of the retaining ring check the gap G dimension for full installation into the valve body grooves gt 232 G Dimensions between lugs Models HDF1 amp HDF25 Page 7 PILOT VALVE The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing Most problems with the pilot valve can be corrected by replacing the o rings Always grease the spool prior to inserting it into the sleeve If the sleeve is removed from the body reinsertion must be at the chamfered side Grease the o rings to slide the sleeve into the valve body Securely insert the retaining ring around the sleeve When reinserting the pilot valve push both plungers located inside the intermediate bracket out of the path of the pilot valve spool ends to
22. ing the pipe size will restrict air flow and reduce pump performance When the product source is at a higher level than the pump flooded suction pipe the exhaust higher than the product source to prevent siphoning spills Freezing or icing up of the air exhaust can occur under certain temperature and humidity conditions Use of an air dryer should eliminate most icing problems BETWEEN USES When used for materials that tend to settle out or transform to solid form the pump should be completely 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 valves and diaphragms at re start In freezing temperatures the pump must be drained between uses in all cases FLAP VALVE SERVICING Valve inspection requires removal of Capscrews and elbows When the top suction elbows are removed the valve and seat are connected as an assembly When the bottom discharge elbows are removed the valve and seat stay with the outer chamber Visual inspection and cleaning is possible If parts are to be replaced remove the self locking nuts and all parts are accessible Caution should be used while reassembling Flap valves The valves are designed for some preload over the retainer hinge pad This is done to insure proper face contact with the seat After all parts are in place tighten the lock nuts down on the assembly to the point where visual inspection shows that seat and
23. lease refer to the exploded view drawing and parts list in the Service Manual supplied with your pump If you need replacement or additional copies contact your local Warren Rupp Distributor or the Warren Rupp factory Literature Department To receive the correct manual you must specify the MODEL and TYPE information found on the name plate of the pump The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head capscrews The valve body assembly is removed from the pump by removing these four hex head capscrews With the valve body assembly off the pump access to the sleeve and spool set is made by removing a retaining ring each end securing the end cap on the valve body assembly With the end caps removed slide the spool back and forth in the sleeve The spool is closely sized to the sleeve and must move freely to allow for proper pump operation An accumulation of oil dirt or other contaminants from the pump s air sup ply or from a failed diaphragm may prevent the spool from moving freely This can cause the spool to stick in a position that prevents the pump from operating If this is the case the sleeve and spool set should be removed from the valve body for cleaning and further inspection Remove the spool from the sleeve Using an arbor press or bench vise with an improvised mandrel press the sleeve from the valve body Take care not to damage the sleeve At this point inspect the o
24. p Inc 800 N Main Street P O Box 1568 Mansfield Ohio 44901 1568 USA certifies that Air Operated Double Diaphragm Pump Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic T Series G Series RS Series U Series EH and SH High Pressure W Series SMA and SPA Submersibles and Tranquilizer Surge Suppressors comply with the European Community Directive 2006 42 EC on Machinery according to Annex VIII This product has used Harmonized Standard EN 809 Pumps and Pump Units for Liquids Common Safety Requirements to verify conformance Em A October 20 2005 Signature of authorized pergon Date of issue David Roseberry Engineering Manager Printed name of authorized person Title MAY 27 2010 Revision Level E Dom PNE FLUID amp METERING Rm1ILLLJOJUO JO UOIHeJe 3en WARREN RUPP INC EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Equipment intended for use in potentially explosive environments Manufacturer Applicable Standard Warren Rupp Inc EN13463 1 2001 A Unit of IDEX Corportion EN13463 5 2003 800 North Main Street P O Box 1568 Mansfield OH 44901 1568 USA EN 60079 25 2004 For pumps equipped with Pulse Output ATEX Option KEMA Quality B V 0344 AODD Pumps and Surge Suppressors For Type Examination Designations see page 2 back AODD Air Operated Double Diaphragm Pumps EC Type Examination Certificate No Pumps KEMA O9ATEX0071
25. page 17 for ATEX Explanation of Type Examination IM1c EC Type Certificate Certificate IM2c Maximum and Minimum Temperatures are the limits for which these materials can be operated Temperatures coupled with pressure affect the longevity of diaphragm pump components Maximum life should not be expected at the extreme limits of the temperature ranges Operating Temperatures Materials Maximum Minimum Nitrile FDA White Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents 190 F 10 F like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons 88 C 23 C EPDM Shows very good water and chemical resistance Has poor resistance 280 F 40 F to oil and solvents but is fair in ketones and alcohols 138 C 40 C NEOPRENE All purpose Resistant to vegetable oils Generally not affected by moderate chemicals fats greases and many oils and solvents Generally 200 F 10 F attacked by strong oxidizing acids ketones esters nitro hydrocarbons and 93 C 23 C chlorinated aromatic hydrocarbons HYTREL Good on acids bases amines and glycols at room temperature 220 F 20 F 104 C 29 C FKM Fluorocarbon shows good resistance to a wide range of oils and solvents especially all aliphatic aromatic and halogenated hydrocarbons acids animal 350 F 40 F and vegetable oils Hot water or hot aqueous solutions over 70 F will at
26. s HDF1 amp HDF25 Page 11 SERVICE amp OPERATING MANUAL o sea Original Instructions Ed uras Model HDF1 Type 1 SANDPIPERs A WARREN RUPP PUMP BRAND C M Oo d e H D F 2 5 Typ e 1 ITEM NO PART NUMBER DESCRIPTION TY 1 031 030 558 Assembly Air Valve 1 1 1 095 051 558 Body Air Valve 1 1 2 031 039 000 Sleeve amp Spool Set 1 1 3 560 058 360 O Ring 8 1 4 165 038 558 Cap End 2 1 5 675 043 115 Ring Retaining 2 2 070 012 170 Bearing Sleeve 2 3 095 074 001 Pilot Valve Assembly 1 3 1 095 071 551 Body Pilot Valve 1 3 2 755 025 000 Sleeve Assembly w O Rings 1 3 2 1 560 033 360 O Ring 4 3 2 2 755 025 162 Sleeve Pilot Valve 1 3 3 775 014 000 Spool Assembly w O Rings 1 3 3 1 775 014 115 Spool Pilot Valve 1 3 3 2 560 023 360 O Ring 4 3 4 675 037 080 Ring Retaining 1 4 114 007 157 Bracket Intermediate AL Center 1 114 012 010 Bracket Intermediate Cl Center 1 5 115 071 330 Bracket Mounting 1 6 132 019 360 Bumper 2 7 132 022 360 Bumper Actuator 2 8 135 034 506 Bushing Plunger 2 9 165 134 157 Cap Air Inlet Ass y AL Center 1 165 134 558 Cap Air Inlet Ass y CI Center 1 10 170 029 330 Capscrew Hex HD 24 11 170 033 330 Capscrew Hex HD 4 12 170 045 330 Capscrew Hex HD 12 13 170 063 330 Capscrew Hex HD 1 14 170 080 330 Capscrew Hex HD 4 15 170 043 330 Capscrew Hex HD AL Center 6 170 006 330 Capscrew Hex HD CI Center 6 16 196 042 157 Chamber Inner AL Center 1 196 084 010 Chamber Inner CI Center 1
27. tack FKM 177 C 40 C Urethane Shows good resistance to abrasives Has poor resistance to most solvents and oils Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excellent abrasion resistance 150 F ie d 66 C 275 F 40 F 135 C 40 C CF 8M Stainless Steel equal to or exceeding ASTM specification A743 for corrosion resistant iron chromium iron chromium nickel and nickel based alloy castings for general applications Commonly referred to as 316 Stainless Steel in the pump industry For saami inii j i hdf1dl1sm rev04 11 Models HDF1 amp HDF25 Page 2 Dimensions HDF1 amp HDF25 SUCTION PORT 1 NPTF HDF1 AIR EXHAUST le PR 1 BSPF HDF2 j 5 3 4 NPTM OPTIONAL 90 PORT ROTATION I AIR INLET 1 2 NPTF DISCHARGE PORT 1 NPTF HDF1 1 BSPF HDF25 4X 5 28 7 MOUNTING HOLE Dimensions are 1 8 Figures in parenthesis millimeters Be E Model HDF1 features Note NPT threaded connections Unit furnished with sub Model HD
28. uality System 1SO9001 Certified Environmental Management System 1SO14001 Certified FLUID amp METERING MODEL HDF1 Performance Curve Performance based on the following elastomer fitted pump flooded suction AIR CONSUMPTION water at ambient temperature Average displacement per pump stroke 10 Gallons 38 Liters SCFM MShr The use of other materials and varying hydraulic conditions may result in deviations in excess of 5 30 40 50 U S Gallons per minute 50 75 100 125 150 175 200 225 250 275 275 Liters per minute CAPACITY hdf1dl1sm rev0411 Models HDF1 amp HDF25 Page 1 Explanation of Pump Nomenclature MATERIALS OF CONSTRUCTION To order a pump or replacement parts first enter the Model Number or followed by the Type Designation listed below in the far left column Manifold amp Outer Inner Outer Inner Intermediate Elbow Chamber Chamber Diaphragm Diaphragm Housing Plate Diaphragm Rod Diaphragm Flap Seat i i Shipping Valve Manifold Wt Ibs Material Seal 356 T6AL 356 T6AL L380DC L380DC AL380 416SS B 356 T6AL 356 T6AL L380DC L380DC AL380 416SS 356 T6AL 356 T6AL L380DC L380DC AL380 4168S N 356 T6AL 356 T6AL L380DC L380DC AL380 416SS V 356 T6AL 356 T6AL L380DC L380DC AL380 416S8 356 T6AL 356 T6AL L380DC L380DC AL380 356 T6AL 356 T6AL L380DC L380DC AL380 L380DC L380DC AL380 L380DC L380DC AL380 L3
29. valve not shifting Remove end cap and check spool must slide freely Diaphragm ruptured Air will escape out discharge line in this case Blockage in diaphragm chamber preventing movement Shut off air supply and reopen after pressure is relieved PROBLEMe e e e e e e e e e e e POSSIBLE CAUSES Uneven discharge flow Indicates one A chamber not operating properly B C Flap valve not sealing properly in one chamber Diaphragm failure in one chamber Air leak at suction manifold joint or elbow flange one side For additional information see the Warren Rupp Troubleshooting Guide WARRANT Y This unit is guaranteed for a period of five years against defective material and workmanship hdf1dl1sm revO4 11 Models HDF1 amp HDF25 Page 8 IMPORTANT SAFETY INFORMATION IMPORTANT Read these safety warnings and instructions in this manual completely before installation and start up of the pump It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty CAUTION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques stated in this manual 4 WARNING Before maintenance or repair shut off the com pressed air line bleed the pressure and disconnect
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