Manual - Amalgamated Pumping Supplies
Contents
1. the rubber diaphragm rod bumper is installed on the rod behind each inner diaphragm The pilot valve Air Inlet Installed diaphragm 520 012 000 3 04 Models SA3 A amp SA4 A Page 3 Rev B plate Re torque the 6 socket head capscrews that secure the diaphragm between the plates to 30 foot Ibs 40 67 Newton meters torque reading 2 Caution should be used while reassembling the check valves The valves are designed for some preload over the retainer and the 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 valve face mate without gap This is important for dry primes However after priming action has started valves will function due to differential pressure without concern or trouble TROUBLE SHOOTING PROBLEM Pump cycles but will not pump Note higher suction lifts require faster cycling speed for priming POSSIBLE CAUSES A Air leak in suction line B Excessive suction lift C Check valve not closing D Leakage at joint of suction manifold or elbow flange E Suction line plugged F Diaphragm ruptured PROBLEM Pump will not cycle Note Always disconnect air supply to relieve air pressure before disassembling any portion of pump POSSIBLE CAUSES A Discharge hose or line plugged or discharge head requirement greater than air pressure Disconnect2. 330 Capscrew Hex Head 8 52 900 003 330 Washer Lock 8 53 618 004 330 Pipe Plug 2 54 196 004 155 Chamber Outer 2 55 312 015 155 Elbow Suction 2 56 312 016 155 Elbow Discharge 2 57 518 014 156 Manifold 2 58 286 018 365 Diaphragm 2 286 018 360 Diaphragm 2 286 018 354 Diaphragm 2 286 018 357 Diaphragm 2 59 338 011 356 Flap Valve 4 338 011 354 Flap Valve 4 338 011 357 Flap Valve 4 338 008 360 Flap Valve 4 338 008 365 Flap Valve 4 60 570 002 365 Pad Hinge Not Used With Santoprene 4 570 002 360 Pad Hinge Not Used With Santoprene 4 61 722 007 010 Seat Flap Valve Angle 4 722 007 115 Seat Flap Valve Angle 4 62 618 003 330 Pipe Plug 2 64 132 022 360 Bumper 2 Not Shown 031 019 156 Main Air Valve Assembly 1 includes items 10 11 13 14 15 amp 16 901 035 115 Washer Flat 8 used w Santoprene Flaps SA4 A Type 3 65 545 009 330 Hex Nut 8 66 900 007 330 Lock Washer 8 67 807 005 330 Stud 8 68 360 036 426 Flange Gasket 2 69 334 037 010 Adapter Flange 2 Not Shown 770 020 080 Spacer Foot 4 901 006 330 Washer Flat used w foot spacer 8 Repair Parts shown in bold face darker type are more likely to need replacement after extended periods of normal use They are readily available from most Warren Rupp distributors The pump owner may prefer to maintain a limited inventory of these parts in his own stock to reduce re pair downtime to a minimum IMPORTANT When ordering repair parts always furnish pump model number serial numb
3. 5 156 Plate Diaphragm Outer 2 e ioe Gast AIMN Aloy 380 22 685 008 120 Rod Diaphragm 1 ETA Aay Saa 23 807 01 7 330 Stud 8 162 Brass Yellow Screw Machine Stock 24 170 024 330 Capscrew Hex Head 8 166 _Bronze SAE 66D 25 170 045 330 Capscrew Hex Head 4 ice A A 27 545 008 330 Nut Hex 24 ERSAN 28 547 006 330 Nut Stop 2 331 Chrome Plated Steel 29 900 006 330 Washer Lock 12 oe ees S 30 901 023 330 Washer Flat 2 oS eee Brass 31 901 013 180 Washer Sealing 2 340r Nickel eaa 32 172 001 330 Capscrew Socket 12 354 Injection Molded 203 40 Santoprene 33 360 013 379 Gasket Seat 4 355 Thermoplastic Elastomer 360 013 384 Gasket Seat 4 hae 34 360 01 4 379 Gasket Flange 4 358 Polyurethane 360 014 384 Gasket Flange 4 cee ee 35 670 006 115 Retainer Flap Valve 4 erry eh aca aa ara 670 043 110 Retainer Flap Valve w Santoprene 4 Sore all Oa CaaS EEY 36 807 016 330 Stud 12 365 Neoprene Rubber Color coded GREEN 37 170 023 330 Capscrew Hex Head 4 371 Phthane ruftane a 38 545 007 330 N ut Hex 20 List continued next page 39 807 018 110 Stud 8 Models SA3 A amp SA4 A Page 6 Rev B 520 012 000 3 04 ITEM TOTAL NO PARTNUMBER DESCRIPTION RQD 40 901 011 180 Washer Sealing 12 41 547 002 110 Nut Stop 8 42 334 020 000 Flange Follower 4 43 360 021 000 Gasket 4 44 170 066 330 Capscrew 36 45 901 006 330 Flat Washer 12 46 115 020 080 Foot Mounting 2 47 115 021 080 Foot Mounting 2 48 530 036 000 Muffler Exhaust 1 51 170 012
4. Material may remain from the old gasket Old material not cleaned from this area may cause air leakage after reassembly Take care that the bumper stays in place allowing the HAZARD WARNING POSSIBLE EXPLOSION HAZARD can result if 1 1 1 Trichloroethane Methylene Chloride or other Halogenated Hydrocarbon solvents are used in pressurized fluid systems having Aluminum or Galvanized wetted parts Death serious bodily injury and or property damage could result Consult with the factory if you have questions concerning Halogenated Hydrocarbon solvents Models SA3 A amp SA4 A Page 2 Rev B 520 012 000 3 04 sleeve to press in all the way Reinstall the spool the opposite end cap gasket and bumper 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 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
5. SERVICE AND OPERATING MANUAL Ry ANDPIPE A WARREN RUPP PUMP BRAND x l2gDbT5 CE 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 flap swing check 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 head 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 may require a back pressure regulating device This will maximize diaphragm life Alternate pressuring and exha
6. darker 1 070 006 170 Bearing Sleeve 2 type are more likely to need replacement 2 114 002 156 Bracket Intermediate 1 after extended periods of normal use They 3 720 004 360 Seal U Cup 2 are readily available from most Warren 4 135 008 000 Bushing Threaded ee eee with O Ring 560 001 360 w o 5 620 004 114 Plunger Actuator r 2 repair downtime to a minimum a A R EPA PEA ee yalye IMPORTANT When ordering repair parts 6 B 755 025 000 Sleeve without O Ring 1 eee ee a pe ey 6 C 560 033 360 O Ring Sleeve 4 YF 6 D 775 026 000 Spool without O Ring 1 AERIAL CODES 6 E 560 023 360 O Ring Spool 2 RI 6 F 675 037 080 Retaining Ring 1 The Last 3 Digits of Part Number 7 360 041 379 Gasket Valve Body 1 aa rer sub assembly and some purchased 8 560 001 360 O Ring 2 012 Powered Metal 9 paged 56 Body Valve 1 ve erie ae Iron 10 132 014 358 Bumper Valve Spool 2 025 Music Wire 11 165 011 157 Cap End 2 Oyo 12 360 048 425 Gas ket Valve Body 1 i dcr TE Sie S a Electro Polished 13 360 010 425 Gasket End Cap 2 112 Allloy C 14 560 020 360 O Ring 6 1 T ain ener Steel Hand Polished 15 031 01 2 000 Sleeve amp Spool Set 1 MTO ee SEa Martensitic 16 170 032330 Capscrew HexHead Bae anes Ste Wovgh Maron 17 132 002 360 Bum per Diaph ragm Plate 2 148 Hardcoat Anodized Aluminum 18 196 003 155 Chamber Inner 2 Or eoe TE ALN 19 560 022 360 O Ring 2 151 6063 T6 Aluminum 20 612 014 000 Plate Diaphragm 2 ecaimegss manne 21 612 01
7. discharge line to check B Spool in air distribution valve not shifting Remove end cap and check spool must slide freely C Diaphragm ruptured Air will escape out discharge line in this case D Blockage in diaphragm chamber preventing movement Shut off air supply and reopen after pressure is relieved E Plugged or dirty exhaust muffler PROBLEM Uneven discharge flow Indicates one chamber not operating properly POSSIBLE CAUSES A Check valve not sealing properly in one chamber B Diaphragm failure in one chamber C Air leak at suction manifold joint or elbow flange one side For additional information see the Warren Rupp Troubleshooting Guide WARRANTY This pump is warranted for a period of five years against defective material and workmanship Failure to comply with the recommendations stated in this manual voids all factory warranty RECOMMENDED WARREN RUPP ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE Tranquiilizer Surge Suppressor For nearly pulse free flow Warren Rupp Air Dryer For clean dry compressed air 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 WARNING This unit is pressurized i
8. ely self priming from a dry start for suction lifts of 20 feet 6 096 meters or less For suction lifts exceeding 20 feet of liquid fill the chambers with liquid prior to priming 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 3 4 19mm 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 Models SA3 A Type 7 SA4 A Type 3 A IMPORTANT A Read these instructions completely before installation and start up It is the responsibility of the purchaser to retain this manual for reference Failure to comply with the recommendations stated in this manual will damage the pump and void factory warranty WARNING amp 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 5 BEFORE OPERATION Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Retorque loose fasteners to prevent leakage Follow recommended tor
9. er and type number MATERIAL CODES The Last 3 Digits of Part Number Continued from previous page 375 Fluorinated Nitrile 378 High density Polypropylene 379 Conductive Nitrile 384 Conductive Neoprene 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 505 Acrylic Resin Plastic 520 Injection Molded PVDF Natural Color 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene 551 Polypropylene 552 Unfilled Polypropylene 555 Polyvinyl Chloride 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 PTFE virgin material Tetrafluoroethylene TFE 601 Virgin PTFE Bronze and moly filled 602 Filled Virgin PTFE 603 Blue Gylon 604 Virgin PTFE 606 Virgin PTFE 608 Conductive PTFE 610 Virgin PTFE Encapsulated Silicon 611 Virgin PTFE Encapsulated Viton 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 Rulon Ilis a registered tradename of Dixion Industries Corporation Hastelloy C is a registered tradename of Cabot Corp Ryton is a registered tradename of Phillips Chemical Company Valox is a registered tradename of General Electric Company Warren Rupp Rupplon SANDPIPER PortaPump Tranquili
10. nternally with air pressure during operation Always disconnect air supply before disassembling and ALWAYS reassemble ALL original bolting before operating IMPORTANTA 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 Models SA3 A amp SA4 A Page 4 Rev B 520 012 000 3 04 Grounding The Pump NTEN N 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 One eyelet is fastened to the pump hardware This 8 foot long 244 centimeters Ground Strap part number 920 025 000 can be S ordered as a service item Dal mA Nea ih 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 juristiction over specific installations 520 012 000 3 04 Models SA3 A amp SA4 A Page 5 Rev B SERVICE AND OPERATING MANUAL Models SA3 A Type 7 x l2aDbT5 CE SA4 A Type 3 ITEM TOTAL NO PARTNUMBER DESCRIPTION RQD eta DPIPE A WARREN RUPP PUMP BRAND Repair Parts shown in bold face
11. onditions Use of a Warren Rupp Extractor Dryer unit 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 CHECK VALVE SERVICING For flap valve inspection or replacement remove the flange bolts securing the suction and discharge elbows and loosen Dresser type couplings The flap valves are exposed for inspection or servicing upon removal of elbows DIAPHRAGM SERVICING Diaphragms are serviced by removing the outer diaphragm chambers which are secured with 12 bolts After removing the outer chamber unbolt the diaphragm plate by removing 6 socket head capscrews Allen wrench required To remove the diaphragm rod remove the inner diaphragm plate secured by a nut on the end of the diaphragm rod The opposite diaphragm and rod can then be removed as a unit The interior components consisting of sleeve bearings rod seals and pilot valve actuator bushings are now accessible for service if required REASSEMBLY All procedures for reassembling the pump are the reverse of the above with these further instructions 1 Install the diaphragms with their natural bulge outward Make certain that
12. ques stated in the card attached to the new pump DANGER Before doing any maintenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all other openings and connections Be certain the air supply is locked out or made non operational so that it cannot be started while work is being done on the pump Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death CAUTION amp 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 A caution Before maintenance or repair shut off the compressed air line bleed the pressure and disconnect the air line from the pump The discharge line may be pressurized and must be bled of its pressure When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARREN RUPP INC A Unit of IDEX Corporation e P O Box 1568 Mansfield Ohio 44901 1568 USA e 419 524 8388 Fax 419 522 7867 520 012 000 3 04 Models SA3 A amp SA4 A Page 1 Rev B increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be clo
13. r drying equipment This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem Externally Serviceable Air Distribution System Please 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 at the number shown below To receive the correct manual you must specify the MODEL and TYPE information found on the name plate of the pump Models with 1 suction discharge or larger and METAL center sections 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 four hex head capscrews each end on the end caps of 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 supply 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
14. sed 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 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 compressed 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 available from Warren Rupp to supplement a plant s ai
15. 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 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 Press the set into the valve body easily without shearing the o rings Re install one end cap gasket and bumper on the valve body Using the arbor press or bench vise that was used in disassembly press the sleeve back into the valve body You may have to clean the surfaces of the valve body where the end caps mount
16. 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 avoid damage PILOT VALVE ACTUATOR Bushings for the pilot valve actuators are threaded into the intermediate bracket from the outside 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 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 Reducing 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 c
17. usting 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 the 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 pulsation in flow This pump was tested at the factory prior to shipment and is ready for operation It is complet
18. zer and SludgeMaster are registered tradenames of Warren Rupp Inc 520 012 000 3 04 Models SA3 A amp SA4 A Page 7 Rev B MOTE 544 4 Typa J Tra SA A conp s the seria sa ihe shindand 343 4 ach che addicean ot tha adaple Teenie hardway lighted A eae terra dwulahlg in Kit 2004 Warren Rupp Inc All rights reserved Warren Rupp and SANDPIPER are registered tradenames of Warren Rupp Inc Printed in U S A Models SA3 A amp SA4 A Page 8 Rev B 520 012 000 3 04
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