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1. Assembly sub assembly and some purchased Items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable Iron 025 Music Wire 080 CarbonSteel AISI B 1112 100 Alloy 20 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel Electro Polished 112 Alloy C 113 Alloy Type 316 Stainless Steel Hand Polished 114 303 Stainless Steel 115 302 304 Stainless Steel 117 440 C Stainless Steel Martensitic 120 416 Stainless Steel Wrought Martensitic 123 410 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 149 2024 T4 Aluminum 150 6061 T6 Aluminum 151 6063 T6 Aluminum 152 2024 T4 Aluminum 2023 T351 154 Almag 35 Aluminum 155 or 156 356 T6 Aluminum 157 Die Cast Aluminum Alloy 380 158 Aluminum Alloy SR 319 159 Anodized Aluminum 162 Brass Yellow Screw Machine Stock 165 Cast Bronze 85 5 5 5 166 Bronze SAE 660 170 Bronze Bearing Type Oil Impregnated 180 Copper Alloy 310 Kynar Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Electroless Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 355 Thermoplastic Elastomer 356 Hytrel 357 Rupplon Urethane Rubber Color coded PURPLE 358 Rupplon Urethane Rubber Color coded PURPLE Some
2. ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE e Tranquilizer Surge Suppressor For nearly pulse free flow Warren Rupp Air Dryer For clean dry compressed air WarrenRupp 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 A IMPORTANT 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 Model PB 2 A Type 3 Page 4 520 041 000 2 99 WARREN RUPP IDEX CORPORATION REPAIR PARTS LIST and DRAWING SondPIPER Model PB A Type 3 ITEM TOTAL NO PART NUMBER DESCRIPTION RQD 1 095 056 551 Spool Valve Body 1 2 031 036 000 Sleeve amp Spool Set 1 3 560 026 360 O Ring 8 4 165 046 356 End Cap 2 5 675 046 115 Retaining Ring 2 6 165 044 551 Valve Cap 1 7 360 066 360 Valve Body Gasket 1 8 360 065 360 Valve Cap Gasket 1 9 031 054 000 Pilot Valve Assembly 1 9A 560 066 360 O Ring Sleeve 6 9B 755 032 162 Sleeve 1 9C 775 024 115 Spool 1 9D 560 001 360 O Ring Spool 6 9E 675 047 115 Ring Retainer 1 10 170 053 115 Hex Head Capscrew 6 170 019 115 Hex Head Capscrew 6 Teflon Wetted
3. Applications Compression Mold 359 Urethane Rubber 360 Buna N Rubber Color coded RED 361 Buna N 363 Viton Fluorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 370 Butyl Rubber Color coded BROWN 371 Philthane Tuftane List continued next page WARREN RUPP INC A Unit of IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA 419 524 8388 Fax 419 522 7867 520 041 000 2 99 Model PB 2 A Type 3 Page 5 ITEM TOTAL NO PART NUMBER DESCRIPTION RQD 31 560 071 611 O Ring 4 560 071 360 O Ring 4 32 722 046 110 Seat 4 722 046 552 Seat 4 722 046 520 Seat 4 722 046 542 Seat 4 722 046 606 Seat 4 722 063 552 Seat 4 33 050 022 600 Check Valve Ball 4 050 027 354 Check Valve Ball 4 050 027 356 Check Valve Ball 4 050 027 360 Check Valve Ball use with seat 4 722 063 552 050 027 365 Check Valve Ball use with seat 4 722 063 552 34 312 042 552 Discharge Elbow 2 312 042 520 Discharge Elbow 2 312 042 542 Discharge Elbow 2 312 042 606 Discharge Elbow 2 35 312 043 552 Suction Elbow 2 312 043 520 Suction Elbow 2 312 043 542 Suction Elbow 2 312 043 606 Suction Elbow 2 36 518 067 552 Manifold 2 518 067 520 Manifold 2 518 067 542 Manifold 2 518 067 606 Manifold 2 37 710 011 115 Self Tapping Screw 8 38 170 063 115 Hex Head Capscrew 6 170 001 115 Hex Head Capscrew 6 Teflon Wetted Pumps Only 39 901 037 115 Washer 12 40 518 101 552 Manifol
4. icing of the air exhaust can occur under certain temperature and humidity conditions Use of a Warren Rupp Air 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 Need for inspection or service is usually indicated by poor priming unstable cy cling reduced performance or the pump s cycling but not pumping Remove the twelve capscrews securing the manifold assemblies to the outer chambers Inspect the surfaces of both check valve and seat for wear or damage that could prevent proper sealing If pump is to prime properly valves must seat air tight DIAPHRAGM SERVICING Remove the two V Band clamps securing the outer chambers to the intermediate housing Remove the diaphragm assembly outer plate diaphragm inner plate by turning the assembly counterclockwise using a 4 1 91 cm wrench on the outer plate lugs If a socket is used it must be a six point socket The interior components consisting of the shaft seal and pilot valve assembly are now accessible for service Procedures for reassembling the diaphragms are the reverse of the above Dur
5. 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 wt 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 supple ment 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 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 repl
6. 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 Figure 6 Disassembling the pilot valve Figure 7 Pilot valve with o rings 520 041 000 2 99 Model PB 2 A Type 3 Page 3 PILOT VALVE ACTUATOR The pilot valve spool item 9C contains 6 o rings item 9D This spool moves through the sleeve item 9B Check condition of o rings for cuts or gouges before re assembly Apply a light coating of grease to the o rings when inserting into the sleeve Insert spool into sleeve from chamfered side The o ring on the end should be installed after the spool is in place install last Make sure the sleeve is locked into the intermediate bracket item 16 with retainer ring item 9E Fig 7 TROUBLESHOOTING 1 Pump will not cycle A Check to make sure the unit has enough pressure to operate and that the air inlet valve is open B Check the discharge line to insure that the discharge line is neither closed nor blocked C If the spool in the air distribution valve is not shifting check the main spool It must slide freely D Excessive air leakage in the pump can prevent cycling This condition will be evident Air leakage into the discharge line indicates a ruptured diaphragm Air leakage from the exhaust po
7. 1 Polypropylene 552 Unfilled Polypropylene 553 Unfilled Polypropylene 555 Polyvinyl Chloride 570 Rulon Il 580 Ryton 590 Valox 591 Nylatron G S 592 Nylatron NSB 600 Teflon virgin material Tetrafluoroethylene TFE 601 Teflon Bronze and moly filled 602 Filled Teflon 603 Blue Gylon 604 Teflon 606 Teflon 610 Teflon Encapsulated Silicon 611 Teflon Encapsulated Viton Delrin Teflon 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 Il is 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 Rupplon SandPIPER PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Model PB 2 A Type 3 Page 6 520 041 000 2 99 Note Install Item 9 into the chamfered end of item 16 1999 Warren Rupp Inc All rights reserved SandPIPER is a registered tradename of Warren Rupp Inc Printed in U S A 520 041 000 2 99 Model PB 2 A Type 3 Page 7
8. Pumps Only 11 360 074 360 Gasket Spacer 2 12 286 034 604 Overlay Diaphragm 2 13 560 073 611 O Ring 4 560 073 360 O Ring 4 14 170 080 115 Hex Head Capscrew 4 15 901 038 115 Flat Washer 4 16 114 010 551 Intermediate Bracket 1 18 165 064 551 Muffler Cap 1 19 710 013 115 Self Tapping Screw 6 20 530 021 550 Muffler 1 21 685 042 120 Diaphragm Rod 1 22 720 021 359 Rod Seal 2 23 612 092 150 Inner Diaphragm Plate 2 24 132 021 360 Bumper 2 25 200 045 115 V Band Clamp Assembly 2 Includes Items 26 amp 27 26 100 001 115 Tee Bolt 2 27 545 022 337 Hex Nut 2 28 286 033 354 Diaphragm 2 286 033 356 Diaphragm 2 286 033 360 Diaphragm 2 286 033 363 Diaphragm 2 286 033 364 Diaphragm 2 286 033 365 Diaphragm 2 29 612 091 552 Outer Diaphragm Plate 2 612 091 520 Outer Diaphragm Plate 2 612 091 542 Outer Diaphragm Plate 2 612 091 606 Outer Diaphragm Plate 2 30 196 058 552 Outer Chamber 2 196 058 520 Outer Chamber 2 196 058 542 Outer Chamber 2 196 058 606 Outer Chamber 2 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 number and type number MATERIAL CODES The Last 3 Digits of Part Number 000
9. WARREN RUPP IDEX CORPORATION PLEASE NOTE The photos 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 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 dia phragms 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 dis charge 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 exhausting of the diaphragm chamber is performed by means of an exte
10. acement 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 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 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 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 his point inspect the o rings on the sleeve for nicks tears or abrasions Damage of this sort could happen during assem
11. bly or servicing A sheared or cut o ring can allow the pump s compressed air suppiy to leak or bypass within the air valve assembly causing the pump to leak compressed alr from the pump air exhaust or not cycle properly This is most noticeable at pump dead head or high discharge pres sure conditions Replace any of these o rings as required or set up a routine preven tive maintenance schedule to do so on a regular basls This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent in specting 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 lightweignt 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 and retaining ring on the valve body Using the arbor press or bench vise that was used in disassembly press the sleeve back into the valve body Re install the spool keeping the counter bored end toward you and install the spring opposite end cap and retaining ring on the valve body After inspecting and cleaning the gasket surfaces on the valve body and intermediate re install the valve body on the pump using new gaskets Tighten the four hex head capscrews evenly and in an alternating cross pattern at 70 in lbs 7 9 Newton meters CAUTION Before maintenance or repair
12. d Dual Port 1 2 Optional Not Shown 535 015 000 Name Plate 1 710 010 115 Self Tapping Screw 031 043 551 Air Valve Body Assembly 1 Incl Items 1 2 3 4 5 547 002 115 Stop Nut Used to hold suction and 12 1 Standard production on non overlay models but also required on overlay discharge elbow to the outer chambers models if disassembly has occurred for repair 2 Use only with 050 027 360 or 050 027 365 ball valves 3 Available as kit only order 475 130 000 If muffler needs to be piped to area of safe disposition order exhaust cap kit 475 107 000 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 number and type number MATERIAL CODES The Last 3 Digits of Part Number Continued from previous page 375 Fluorinated Nitrile 378 High density Polypropylene 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 55
13. ed as vacuum increases Reduced flow rate due to starved suction will be evident when cycle rate can be varied without change in capacity This condition will be more prevalent when pumping viscous liquids Viscosity is limited to a maximum of 10 000 SSU When pumping thick heavy materials the suction line must be kept as large in diameter and as short as possible to keep suction loss minimal C Low flow rate and slow cycling rate indicate restricted flow through the discharge line Low flow rate and fast cycling rate indicate restriction in the suction line or air leakage into suction D Unstable cycling indicates improper check valve seating on one chamber This condition is confirmed when unstable cycling repeats consistently on alternate exhausts Cycling that is not consistently unstable may indicate partial exhaust restriction due to freezing and thawing of exhaust air Use of an anti freeze lubri cant in an air line lubricator should solve this problem 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 1999 Warren Rupp Inc All rights reserved SandPIPER and Tranquilizer are registered tradenames of Warren Rupp Inc Neverseize is a registered tradename of Loctite Printed in U S A RECOMMENDED WARREN RUPP
14. ing reassembly make certain that the rubber bumper is on the rod on each side Install the diaphragm with the natural bulge outward Install the outer diaphragm plate on the outside of the diaphragm and make cer tain that the large radius side of the inner plate is toward the diaphragm Tighten the outer diaphragm plate to approximately 90 in lbs 10 16 Newton meters Torque while allowing the diaphragm to turn freely with plates Use a wrench on the outer diaphragm plate of the opposite side to keep rod from rotating If the oppo site chamber is assembled the rod need not be held A WARNING A The weight of the air supply line and of the filter must be supported by some means other than the air valve cap Failure to provide support may result in damage to the pump A pressure regulating valve should be installed to prevent pressure from exceeding recommended limits A CAUTION A 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 ae 8 eee Figure 3 Check valve and seat Figure 4 Diaphragm and diaphragm plate Model PB 2 A Type 3 Page 2 520 041 000 2 99 A NOTE ABOUT AIR VALVE LUBRICATION The SandPiper pump s pilot valve and main air valve assemblies are designed to operate WITHOUT lubrication This
15. ir 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 914 19mm in diameter between pump and piping to eliminate strain to pipes AIR INLET amp PRIMING For start up open an air valve approximately 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 3 8 9525 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 Use exhaust kit 475 107 000 to pipe out exhaust Freezing or
16. ows PFA 212 F 100 C Max to 0 F 18 C Min PVDF 200 F 93 C Max to 10 F 13 C Min Nylon 120 F 48 C Max to 32 F 0 C Min Polypro 150 F 65 C Max to 40 F 5 C Min A BEFORE OPERATIONAL Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Retorque loose fasteners to prevent leakage prior to start up Follow recommended torques stated in this manual Figure 1 Air Inlet Capscrews WARREN RUPP INC A Unit of IDEX Corporation P O Box 1568 Mansfield Ohio 44901 1568 USA 419 524 8388 Fax 419 522 7867 520 041 000 2 99 Model PB 2 A Type 3 Page 1 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 supple ment a plant s air drying equipment This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem AIR SUPPLY Air supply pressures cannot exceed 100 psi 6 89 bar Connect the pump a
17. rnally 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 re versed 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 pul sation in flow 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 10 fee
18. rt indicates leakage in the air distribution valve See further service instructions E Blockage in the liquid chamber can impede movement of diaphragm 2 Pump cycles but will not pump A Suction side of pump pulling in air Check the suction line for air leaks and be sure that the end of the suction line is submerged Check flange bolting Check valve flanges and manifold to chamber flange joints B Make certain the suction line or strainer is not plugged Restriction at the suction is indicated by a high vacuum reading when a vacuum gauge is installed in the suction line C Check valves may not be seating properly To check remove the suction line and cover the suction port with your hand If the unit does not pull a good suction vacuum the check valves should be inspected for proper seating D Static suction lift may be too high Priming can be improved by elevating the suction and discharge lines higher than the check valves and pouring liquid into the unit through the suction inlet When priming at high suction lifts or with long suction lines operate the pump at maximum cycle rate 3 Low performance A Capacity is reduced as the discharge pressure increases as indicated on the performance curve Performance capability varies with available inlet air supply Check air pressure at the pump inlet when the pump is operating to make certain that adequate air supply is maintained B Check vacuum at the pump suction Capacity is reduc
19. t 3 05 meters or less For suction lifts exceeding 10 feet of liquid fill the chambers with liquid prior to priming 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 lubrica tion of the compressed air supply would entail the use of an air line lubricator avail able 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 SERVICE AND OPERATING MANUAL SondPIPER Model PB 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 A WARNING Take action to prevent static sparking Fire or explosion can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded A CAUTION A Operating temperature limitations are as foll

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