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1. Model HDF2 Page 5 A NOTE ABOUT 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 lubrica tion 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 consumedatits 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 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
2. 31655 31655 31655 31655 31655 55 SS CI CI 316SS I z lt z 2 lt m lo lz la 2 lt 2 2 lt 2 2 lt gt lt gt lt HZ lt 2 lt 2 lt 2 lt z 2 z lt Mm gt 2 lt Z 2 2 lt 22 2 lt See CF 8M Materials information above i A Compressed Fibre DC Die Cast PS Plated Steel SS I Stainless Steel seat with EPDM O Ring Meanings of AL Aluminum H Hytrel S Santoprene T PTFE Nitrile Stainless Steel Urethane Abbreviations B Nitril EPDM SS Stainless Steel U Ureth Cl Cast Iron N Neoprene V FKM Fluorocarbon F FDAAccepted White Nitrile Most types available in dual port design See price book or consult factory for details Hytrel is a registered tradename of E I du Pont Santoprene is a registered tradename of Exxon Mobil Corp 16 5 26 5 Il 3 1 Gc T5 Il 3 2 G c T5 Il 1 Dc T100 C Il 2D c T100 C All models including pumps equipped with Aluminum IM2c wetted and midsection parts Models equipped with Cast Iron or Stainless Steel wetted See page 18 for ATEX Explanation of Type Examination parts and Cast Iron midsection parts See page 18 for
3. 12 Composite Repair Paris EISE 13 14 Composite Repair 15 CE Declaration of Conformity 16 CE Declaration fo Conformity ATEX 2 ccccccccccececeeeeeeeeeeesseseeesseeeeeeneeeneneneeee 17 Explanation of ATEX 2 2 12 5 4 4 enean am aranea 18 Warren Rupp Inc A Unit of IDEX Corporation 800 N Main St Mansfield Ohio 44902 USA Telephone 419 524 8388 Fax 419 522 7867 warrenrupp com hdf2dl6sm rev0515 Copyright 2015 Warren Rupp Inc All rights reserved BEDS WARREN RUPP A WARREN RUPP PUMP BRAND Quality System Heavy Duty Flap Valve ISO 9001 Certified Environmental H D F 2 Type 6 Management System E ISO 14001 Certified C Air Operated Double Diaphragm Pump See pages 17 amp 18 ENGINEERING PERFORMANCE for ATEX ratings amp CONSTRUCTION DATA FLUID amp METERING INTAKE DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS HANDLING HEADS UP TO 2 NPT F 0 to 140 gallons per minute No lube no stall Up to 2 50mm 125 psi or 289 ft of water 0 to 530 liters per minute design 8 8 Kg cm or 88 meters AIRG ONSOME TON MODEL HDF2 Performance Curve SCFM M3 hr Performance based on the following elastomer fitted pump flooded suction water at ambient conditions The use of other materials and var
4. 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 S05 S1F 15 S20 S30 SB1 SB25 SE ST1 ST25 ST1 ST40 U1F G05 G1F G15 G20 and G30 Surge Suppressors all types Marking II 2 G Ex ia c IIC T5 Gb 11 3 2 Ex ia c IIC T5 Gc Gb Il 2 D Ex ia c IIIC T100 C Db Il 2 G Ex mb IIC T5 Gb Il 3 2 G Ex mb IIC T5 Gc Gb I 2 D Ex tDa 21 IP65 T100 C Db Il 1 GcT5 Il 3 1 Gc T5 Il 1 Dc T100 C IM1c IM2c 2 6 5 Il 3 2 G c T5 Il 2 Dc T100 C I2 G T5 3 2 G T5 Il 2 D T100C EC Type Certificate No Pumps 09 0071 X Type Certificate No Pumps KEMA 09 0072 X Type Certificate No Suppressors KEMA 09 0073 09 0071 X 0344 09 0071 0344 09 0071 09 0072 0344 09 0072 09 0073 Listed In 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0071 X 09 0072 09 0072 09 0072 09 0072 09
5. 0073 09 0073 09 0073 Non Conductive Fluids No Yes Yes No Yes Yes Pumps marked with equipment Category II 3 1 G internal 3 G external 1 G 1D M1 and M2 when used for non conductive fluids The pumps are Category II 1 G when used for conductive fluids Pumps and surge suppressors are Category 1 2 G when pumping conductive fluids When non conductive fluids are pumped models with non conductive diaphragms that have a fluid contact surface area above 400cm are restricted to Category II 3 G internally and Category II 2 G for external surfaces The following models are restricted ST1 1 2 ST40 15 and S20 ATEX compliant Nonmetallic equipped with Synthesis One Piece Bonded PTFE diaphragms 15 S20 G15 and G20 Metallic equipped with Synthesis One Piece Bonded PTFE diaphragms 530 and G30 Metallic HDB1 1 2 and HDB2 equipped with Synthesis One Piece Bonded PTFE diaphragms HDB3 HDB4 HDF3 HDF3M HDF4 and HDF4M TA3 and TA80 IEC WR DofC ATEX V rev0515
6. N SERVICE amp OPERATING MANUAL PI Original Instructions PE SA RUPP PUMP BRAND Model H DF2 sx eom Npes Table of Contents Engineering Data and Performance 2 222 4 4 4 1 Explanation of Pump Nomenclature aia pukua a ai 2 Temperature Limitations and Dimensions 0 1 3 Principle of Operation PREPRNCRR ERE 4 Installation and Start Up esios rset reenen ve ve eae Paat EEEE 4 Air SUPPI 4 Air nlet S uiae see ec eee 4 tr 5 ESADS Plus Externally Serviceable Air Distribution System 6 AIM EX NAUSI wa Rad DR ba FRU E DUM UE MED Mi 7 Between USCS Me 7 huge 7 Diaphragm Servicing EE 7 POSS OO RE oo o Dm 8 x5 7 P 8 PIS Valve PC WON Mc 8 Service Instructions Troubleshooting nannaa sanan 9 Warranty Recommended 2 242111 9 erre diese The m 10 Important Safety Information iisuv lt 3J lt tj tZJsa ato ssa mannaa saas terree knee aan aon ak rare naa 11 Et 11 riz cT T
7. 2 334 014 010 FLANGE SUCTION DUAL PORTED ONLY 2 334 014 110 FLANGE SUCTION DUAL PORTED ONLY 2 334 014 156 FLANGE SUCTION DUAL PORTED ONLY 2 hdf2dl6sm rev0515 Model HDF2 Page 13 25 26 38 312 013 010 312 013 110 312 013 156 334 015 010 334 015 156 338 005 360 338 005 363 338 005 364 338 005 365 338 005 366 338 010 354 338 010 356 338 010 357 360 010 425 360 041 379 360 048 425 518 001 010 518 001 110 518 001 157 530 036 000 545 007 330 547 002 110 560 001 360 560 020 360 560 022 360 570 001 360 570 001 363 570 001 364 570 001 365 570 001 366 570 009 360 570 009 363 570 009 364 570 009 365 612 047 330 612 008 330 612 096 110 618 003 330 618 003 110 620 011 114 670 005 110 675 013 360 675 013 363 675 013 364 675 013 365 675 013 366 685 007 120 720 004 360 722 070 360 722 070 363 722 070 364 722 070 365 770 005 330 807 018 110 900 005 330 900 006 330 900 006 330 902 003 000 560 046 360 hdf2dl6sm rev0515 ELBOW DISCHARGE ELBOW DISCHARGE ELBOW DISCHARGE FLANGE DISCHARGE DUAL PORTED ONLY FLANGE DISCHARGE DUAL PORTED ONLY FLAP VALVE FLAP VALVE FLAP VALVE FLAP VALVE FLAP VALVE FLAP VALVE FLAP VALVE FLAP VALVE GASKET END CAP GASKET VALVE BODY GASKET VALVE BODY MANIFOLD MANIFOLD MANIFOLD MUFFLER NUT HEX 7 16 14 ALUMINUM ONLY NUT STOP O RING O RING O RING PAD HINGE FLAP VALVE PAD HINGE FLAP VALVE PAD HINGE FLAP VALVE PAD HINGE FLAP V
8. Certificate ATEX Explanation of EC Type Certificate hdf2dl6sm rev0515 Model HDF2 Page 2 Maximum and Minimum Temperatures are the limits for which H H H these materials can be operated Temperatures coupled with M a ter I a s a n d D I m en s I ns H D F 2 pressure affect the longeviy of pedes Operating Temperatures Maximum life should not be expected at the extreme limits of the temperature ranges Materials acim m Nitrile FDA White Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid 190 F 10 F resistance Should not be used with highly polar solvents 88 C 23 C like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons EPDM Shows very good water and chemical resistance Has poor resistance to oil and solvents but is fair in 280 F 40 F ketones and alcohols 138 C 40 C NEOPRENE All purpose Resistant to vegetable oils Generally not affected by moderate chemicals fats 200 F 10 F greases and many oils and solvents Generally 93 C 23 C attacked by strong oxidizing acids ketones esters nitro hydrocarbons and chlorinated aromatic hydrocar bons 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 350 F 40 F aromatic and halogenated hydrocarbons acids animal 177 C 40 C and v
9. re start In freezing temperatures the pump must be drained between uses in all cases FLAP VALVE SERVICING Valve inspection requires removal of 3 8 hex nuts 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 DIAPHRAGM SERVICING Diaphragms can be inspected or the diaphragm assembly removed without removing the suction and discharge flanges Remove 8 nuts around the chamber flange and the housing assembly will pull off Flap valves can be inspected for proper seating at this point as well as the diaphragm Use care to keep foreign matter from behind the diaphragm The opposite dia phragm may be inspected by the same procedure If either diaphragm has to be replaced follow closely these steps Pull the outer diameter of one diaphragm off the 8 capscrews NOTE One side only On the free diaphragm assembly use a 3 8 allen wrench to turn the assembly diaphragm plates and screw loose from the shaft Once the assembly has turned it will turn out by hand by use of the diaphragm Now the opposite diaphragm assembly and the drive shaft will pull free from the capscrews and pump intermediate assembly The interior components consisting of sleeve bearings rod seals and pilot
10. valve actuator bushings are now accessible for service if required Hold the shaft in a clamping device making sure to protect surface of shaft so as not to scratch or mar it in any way The diaphragm assembly will turn loose To disassemble the components turn a 1 4 20 capscrew by hand into the tapped hole in the inner plate This keeps the plate from turning while the socket head capscrew is removed To do this place assembly in a vise so the two protruding ends of screws are loose in the vise jaws about 3 4 apart Turn the center screw loose from the back plate and the assembly will come apart REASSEMBLY All procedures for reassembling the pump are the reverse of the previous instructions with further instructions as shown 1 The diaphragm assemblies are to be installed with the natural bulge outward or toward the head of the center screw Make sure both plates are installed with outer radii against the diaphragm After all components are in position in a vise and hand tight set a torque wrench for 480 inch pounds 40 ft pounds 54 23 Newton meters or 600 inch pounds 50 ft pounds 67 79 Newton meters for Santoprene using a 3 8 allen head socket After each diaphragm sub assembly has been completed thread one assembly into the shaft held near the middle in a vise having soft jaws to protect the finish making sure the stainless steel washer is in place on the capscrew Make sure 1 4 20 mounting screw has been removed and that t
11. 60 033 360 O RING 4 C 560 023 360 4 D 675 037 080 4 E 755 025 000 4 F 715 026 000 O RING SPOOL RETAINING RING SLEEVE PILOT VALVE SPOOL PILOT VALVE 5 114 002 010 INTERMEDIATE 114 002 156 INTERMEDIATE 6 115 158 080 BRACKET LEG 7 115 159 080 BRACKET LEG 8 132 002 360 BUMPER DIAPHRAGM PLATE 9 132 014 358 BUMPER AIR VALVE 10 135 016 162 BUSHING THREADED W O RING 560 001 360 11 165 011 010 CAP END 165 011 157 CAP END ee euer Lee e pr E 12 170 023 330 12 170 023 330 CAPSCREW HEX HEAD ALUMINUM ONLY CAPSCREW HEX HEAD CAST IRON AND STAINLESS STEEL 16 13 170 024 330 CAPSCREW HEX HD 7 16 14 X 1 8 14 170 026 330 CAPSCREW HEX HEAD 3 8 16 X 3 1 2 2 15 170 032 330 CAPSCREW HEX HEAD 1 4 20 X 3 4 8 16 170 035 330 CAPSCREW HEX HD 7 16 14 X 1 1 2 ALUMINUM ONLY 8 17 170 045 330 CAPSCREW HEX HEAD 5 16 18 X 1 1 4 4 18 170 052 330 CAPSCREW HEX HEAD 3 8 16 X 2 1 2 2 19 170 061 330 CAPSCREW HEX HEAD 3 8 16 X 2 16 20 171 002 110 CAPSCREW SOCKET HEAD 2 171 002 330 CAPSCREW SOCKET HEAD 2 21 196 001 010 CHAMBER INNER 2 196 001 157 CHAMBER INNER 2 22 196 002 010 NS CHAMBER OUTER 2 196 002 110 NS CHAMBER OUTER 2 196 002 157 NS CHAMBER OUTER 2 23 286 007 354 DIAPHRAGM 2 286 007 356 DIAPHRAGM 2 286 007 360 DIAPHRAGM 2 286 007 363 DIAPHRAGM 2 286 007 364 DIAPHRAGM 2 286 007 365 DIAPHRAGM 2 286 007 366 DIAPHRAGM 2 24 312 012 010 ELBOW SUCTION 2 312 012 110 ELBOW SUCTION 2 312 012 156 ELBOW SUCTION
12. A NOTE ABOUT 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 lubrica tion 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 consumedatits 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 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 SYS
13. ALVE PAD HINGE FLAP VALVE PAD WEAR PAD WEAR PAD WEAR PAD WEAR PLATE INNER DIAPHRAGM PLATE OUTER DIAPHRAGM PLATE OUTER DIAPHRAGM SS UNITS ONLY PLUG PIPE 1 4 PLUG PIPE 1 4 STAINLESS STEEL ONLY PLUNGER ACTUATOR RETAINER FLAP VALVE RING SEALING RING SEALING RING SEALING RING SEALING RING SEALING ROD DIAPHRAGM SEAL U CUP SEAT FLAP VALVE SEAT FLAP VALVE SEAT FLAP VALVE SEAT FLAP VALVE SPACER ALUMINUM ONLY STUD 1 4 20 WASHER LOCK 3 8 WASHER LOCK 7 16 ALUMINUM WASHER LOCK 7 16 WASHER SEALING O RING STAINLESS STEEL UNITS ONLY NN AZFNoONKRARANARAR ARR ANNANNNNNNNAAARANDANABMANNNAANARAARRARANNNNDND Model HDF2 Page 14 2010 Warren Rupp Inc All rights reserved SANDPIPER is a registered tradename of Warren Rupp Inc Printed in U S A hdf2di6sm rev0515 Model HDF2 Page 15 WARREN RUPP Declaration of Conformity Manufacturer Warren Rupp Inc 800 N Main Street Mansfield Ohio 44902 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 EN809 1998 A1 2009 Pumps and Pump Units for Liq
14. RATION This flap swing 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 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 re
15. 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 Unfilled 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 Fi
16. SERVICEABLE AIR DISTRIBUTION SYSTEM Please refer to the exploded view drawing and parts list in the Service Manual sup plied 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 set should be removed from the valve body for cleaning and further inspection Remove the spool from the sleeve Using an arbor press or benc
17. TEM Please refer to the exploded view drawing and parts list in the Service Manual sup plied 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 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 mand
18. egetable oils Hot water or hot aqueous solutions over 70 F will attack FKM Urethane Shows good resistance to abrasives Has poor resistance to most solvents and oils 66 44 0 C Santoprene Injection molded thermoplastic elastomer with no fabric layer Long mechanical flex life Excel 275 F 40 F lent abrasion resistance CF 8M Stainless Steel equal to or exceeding ASTM specification A743 for corrosion resistant iron chro mium iron chromium nickel and nickel based alloy castings for general applications Commonly referred to as 316 Stainless Steel in the pump industry For specific applications always consult Chemical Resistance Chart Technical Bulletin This pump also available in dual port design See price book or consult factory for details Dimensions are 1 8 Figures in parenthesis millimeters 2 62 2 NPT SUCTION PORT 1 20 30 516 OPTIONAL VERTICAL SUCTION 19 87 PORT 1505 17 68 449 2 NPT DISCHARGE PORT 10 25 3 4 NPT AIR INLET 11 00 as 279 226 2 NPT F Suction and Discharge NPT F Air Inlet Port NPT F Air Exhaust Port not shown 3 4 NPT EXHAUST 356 hdf2dl6sm rev0515 Model HDF2 Page 3 N SERVICE AND OPERATING MANUAL SANDPIPER A WARREN RUPP PUMP BRAND Model HDF2 Type 6 S 17 amp 18 IEzX ep C Heavy Duty F lap Valve PRINCIPLE OF PUMP OPE
19. h 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 Re install one end cap gasket and bumper 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 You may have to clean the surfaces of the valve body where the end caps mount Material may remain from the old gasket Old material not cleaned from this area may cause air leakage after reassembly Take care hdf2dl6sm rev0515 Model HDF2 Page 6
20. he bumper Item 19 on drawing is in place in the shaft Install this sub assembly into the pump and secure by placing the outer chamber housing and capscrews on the end with the diaphragm This will hold the assembly in place while the opposite side is installed Make sure the last diaphragm assem bly is torqued to 30 ft Ibs 40 67 Newton meters before placing the outer diaphragm over the capscrews If the holes in the diaphragm flange do not line up with the holes in the chamber flange turn the diaphragm assembly in the direction of tighten ing to align the holes so that the capscrews can be inserted This final torquing of the last diaphragm assembly will lock the two diaphragm assemblies together Place remaining outer chamber on the open end and tighten down the securing nuts gradually and evenly on both sides 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 as hdf2dl6sm rev0515 Model HDF2 Page 8 sembly to the point where visual inspection shows that seat and 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 PILOT VALVE The pilot valve assembly is accessed by removing the main air distribution valve body from the p
21. ished 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 7351 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 hdf2dl6sm rev0515 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 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Color BLUE Injection Molded Polyurethane Color GREEN Urethane
22. lled 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 Model HDF2 Page 12 Em SERVICE AND OPERATING MANUAL SANDPIPER Model HDF2 IBEX S 16 amp 17 Type FLUID amp METERING Ex for ATEX ratings C H ea vy D u ty F Pp Va I ve A WARREN RUPP PUMP BRAND ITEM PART NUMBER DESCRIPTION 1 031 012 000 SLEEVE amp SPOOL SET 2 070 006 170 BEARING 3 095 043 010 BODY AIR VALVE 095 043 156 BODY AIR VALVE 4 095 073 001 PILOT VALVE ASSEMBLY 4 A 095 070 558 BODY PILOT VALVE 4 B 5
23. lowing the sleeve to press in all the way Reinstall the spool 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 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 conditions Use of an 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
24. 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 dy WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly A WARNING Airborne particles and loud noise hazards Wear ear and eye protection 4 WARNING Use safe practices when lifting Many components of SANDPIPER AODD pumps are made of recyclable materials see chart on page 12 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed hdf2dl6sm rev0515 Model HDF2 Page 11 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 180 305 306 307 308 309 310 313 330 331 332 333 335 336 337 340 342 351 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 Pol
25. p 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 A CAUTION Pump not designed tested or certified to be powered by compressed natural gas Powering the pump with natural gas will void the warranty A 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 RECYCLING Take action to prevent static WARNING sparking Fire or explosion can result especially when handling flammable liguids The pump piping valves containers or other miscellaneous eguipment must be grounded See page 10 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 A WARNING Before doing any main tenance on the pump be certain all pressure is completely vented from the pump suction discharge piping and all
26. rel 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 hdf2dl6sm rev0515 Model HDF2 Page 7 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 gasket and bumper 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 You may have to clean the surfaces of the valve body where the end caps mount 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 al
27. 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 increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be closed slightly Forthe 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 hdf2dl6sm rev0515 Model HDF2 Page 4 WARREN RUPP Available from Distributor Available from Warren Rupp Air Inlet Line Surge Suppressor Gauge INSTALLATION GUIDE Bottom Discharge Flap Valve Unit 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 Pipe Connection Style Optional Gauge Shut Off Valve Flexible Connection AIR EXHAUST SUCTION Flexible Connection Air Shut Off Drain Port Valve BOTTOM Filter Regulator Air Dryer DISCHARGE DIAPHRAGM PUMP T e AIR INLET DISCHARGE lt Flexible Connection Shut Off Drain Port Valve Pipe Connection Style Optional hdf2dl6sm rev0515
28. uids Common Safety Requirements to verify conformance KAT Jarkon October 20 2005 Signature of authorized person Date of issue David Roseberry Engineering Manager Printed name of authorized person Title April 19 2012 Date of revision FLUID amp METERING C Revision Level WARREN RUPP INC EC Declaration of Conformity In accordance with ATEX Directive 94 9 EC Eguipment intended for use in potentially explosive environments Manufacturer Applicable Standard Warren Rupp Inc e EN13463 1 2009 A Unit of IDEX Corportion EN13463 5 2011 800 North Main Street P O Box 1568 Mansfield OH 44902 USA EN 60079 25 2011 For pumps eguipped with Pulse Output ATEX Option Ouality 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 O9ATEX0071 X DEKRA Certification B V 0344 Meander 1051 6825 MJ Arnhem The Netherlands SANDPIPER Tranquilizer A WARREN RUPP INC BRAND DATE APPROVAL TITLE 13 May 2015 WR_DofC_ATEX_V_rev0515 WARREN RUPP INC EC Declaration of Conformity ATEX Summary of Markings Pump types S1F 515 S20 and S30 provided with the pulse output option Pump types S1F 515 520 and S30 provided with the integral solenoid option Pump types HDB1 HDB40 HDB2 HDB50 HDB3 HDF1 HDF25 HDF2 HDF3M
29. ump 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 avoid damage PILOT VALVE ACTUATOR Bushings for the pilot valve actuators are threaded into the intermediate bracketfrom the outside The plunger may be removed for in spection 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 afine piece of wire to pullthem out The bushing can be turned outthrough the inner chamber by removing the outer chamber assembly Replace the bushings if pins have bent WARRANTY This unit is guaranteed for a period of five years against defective material and workmanship TROUBLESHOOTING For additional information see the Warren Rupp Troubleshooting Guide PROBLEM Pump cycles but will not pump Note higher suction lifts require faster cycling speed for priming POSSIBLE CAUSES Air leak in suction line Excessive suction lift Flap
30. valve not seating properly Leakage at joint of suction manifold or elbow flange Suction line or strainer plugged 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 supply pressure Disconnect 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 PROBLEM Uneven discharge flow Indicates one chamber not operating properly POSSIBLE CAUSES A Flap 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 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 Factor
31. 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 spool This pushes it into position for shifting of the air distribution valve The chambers are manifolded together with a suction and discharge flap type 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 suc tion 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 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 completely 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
32. y Authorized Distributor or Warren Rupp corporate headquarters hdf2dl6sm rev0515 Model HDF2 Page 9 Grounding The Pump Take action to prevent static This 8 foot long 244 centimeters Ground Strap part number 2 sparking Fire or explosion 920 025 000 can be ordered as a service item can result especially when handling flammable liquids The pump piping valves containers or other miscellaneous equipment must be grounded 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 THIS END IS INSTALLED TO A TRUE EARTH GROUND THE EYELET END IS FASTENED TO THE PUMP HARDWARE 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 hdf2dl6sm rev0515 Model HDF2 Page 10 IMPORTANT SAFETY INFORMATION A 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 A CAUTION Before pum
33. ying hydraulic conditions may result in deviations in excess of 5 N 3 pore ST SIS ASSO 75 ROSE KN OMS NN 0 13 0 60 80 100 120 140 160 U S Gallons per minute 100 200 300 400 500 600 Liters per minute CAPACITY SANDPIPER PUMPS ARE DESIGNED TO BE POWERED ONLY BY COMPRESSED AIR hdf2dl6sm rev0515 Model HDF2 Page 1 Explanation of Pump Nomenclature HDF2 MATERIALS OF CONSTRUCTION To order a pump or replacement parts first enter the Model Number HDF2 followed by the Type Designation listed below in the far left column Flap Manifold Outer Inner ermediate Diaphragm Valve Hard Diaphragm Valve Sealing Shipping Chamber Chamber Housing Rod Seat ware Material Rings i E PS N AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC AL380DC AL380DC 356 T6AL 316SS l AL380DC AL380DC AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 316557 31655 31655 31655 31655 31655 316557 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 31655 AL380DC 356 T6AL 316SS l AL380DC 356 T6AL 31655

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