Service Manual - Amalgamated Pumping Supplies
Contents
1. Warren Rupp SandPIPER is a registered tradename of Warren Rupp Inc A Available as Kit 475 102 000 Printed in U S A B Available as Kit 475 101 000 520 010 000 5 03 Model SA2 A Page 9 FOR DUAL PORTED UNITS To convert a standard unit to a dual ported unit the following parts are changed ITEM NO PART NUMBER DESCRIPTION Parts DELETED from standard unit for dual ported design 40 44 35 36 49 48 51 46 Parts 35 35 36 36 These Repair Parts changes apply only to the model and type specified 518 001 xxx 675 013 xxx 312 012 xxx 312 013 xxx 170 026 xxx 170 052 xxx 900 005 xxx 110 005 xxx 334 014 010 334 014 156 334 015 010 334 015 156 Model SA2 A Page 10 Manifold Sealing Ring Elbow Suction Elbow Discharge Capscrew Capscrew Lock Washer Spacer REQUIRED for dual ported units Flange Suction Dual Ported Flange Suction Dual Ported Flange Discharge Dual Ported Flange Discharge Dual Ported 21 TOTAL RQD MPO HRMONMPNDNDN FS PD NM Mh PD P 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 repair downtime to a minimum IMPORTANT When ordering repair parts always furnish pump model number serial number and typ2. Plated Steel 331 Chrome Plated Steel 332 Electroless Nickel Plated 335 Galvanized Steel 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 356 Hytrel 357 Rupplon Urethane Rubber 360 Buna N Rubber Color coded RED 363 Viton Fluorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile Color coded WHITE 375 Fluorinated Nitrile 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 440 Vegetable Fibre 500 Delrin 500 501 Delrin570 520 Injection Molded PVDF Natural Color Food Grade USDA Acceptable 540 Nylon 550 Polyethylene 551 Polypropylene 555 PVC Polyvinyl Chloride 580 Ryton 600 PTFE virgin material Tetrafluoroethylene TFE 608 Blue Gylon 604 PTFE Diaphragm 610 Encapsulated Silicon 611 PTFE Encapsulated Viton Delrin PTFE Hytrel and Viton are registered tradenames of E I DuPont Gylonis aregistered tradename of Garlock Inc Warren Rupp Rupplon and SandPIPER are registered tradenames of Warren Rupp Inc Ryton is aregistered tradename of Phillips Chemical Company Loctite is aregistered tradename of Loctite Corporation 520 010 000 5 03 SS units AL units Steel Only 55 For units with aluminum wetted end components only 2003 Warren Rupp Inc All rights reserved
3. Seat Flap Valve Seat Flap Valve Seat Flap Valve Spacer Stud Capscrew Hex Head Capscrew Hex Head Nut Hex Washer Lock Nut Stop Stat O Seal Muffler Exhaust O Ring O Ring Plate Base Plate Base Capscrew Hex Head Main Air Valve Assembly Inc Items 9 10 11 13 14 15 16 Bumper Capscrew Hex Head AL Units only 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 repair 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 0 Q 0 Assembly sub assembly and some purchased items 010 Castlron 015 Ductile Iron 025 Music Wire 080 Carbon Steel AISI B 1112 110 Alloy Type 316 Stainless Steel 112 Alloy C 114 303 Stainless Steel 115 301 302 304 Stainless Steel 120 416 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 150 6061 T6 Aluminum 151 6063 T6 Aluminum 154 Almag 35 Aluminum 1550r 156 356 T6 Aluminum 157 Die Cast Aluminum Alloy 380 159 Anodized Aluminum 162 Brass Yellow Screw Machine Stock 170 Bronze Bearing Type Oil lmpregnated 180 Copper Alloy 330
4. Almag 35 Aluminum aake jp ody 155 or 156 356 T6 Aluminum 13 360 010 425 Gasket End Cap 2 157 Die Cast Aluminum Alloy 380 z Ri 159 Anodized Aluminum is 960 020 360 O Ring 6 162 Brass Yellow Screw Machine Stock 15 031 012 000 Sleeve amp Spool Set 1 170 Bronze Bearing Type Oil Impregnated 2 2 180 Copper Alloy hi rs a nina nie ise 8 330 Plated Steel apscrew Hex Hea 4 331 Chrome Plated Steel 18 115 062 080 M p ti Foot Left Hand 9 332 Electroless Nickel Plated ounting Foot Le an 335 Galvanized Steel 19 132 002 360 Bumper Diaphragm 2 354 ee ee 20 196 001 157 Chamber Inner 2 aa 20 e 357 Rupplon Urethane Rubber 196 001 010 Chamber Inner 2 360 Buna N Rubber Color coded RED 21 196 002 157 Chamber Outer 2 363 Viton Fluorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 196 002 110 Chamber Outer 2 365 Neoprene Rubber Color coded GREEN 196 002 010 Chamber Outer 2 366 Food Grade Nitrile Color coded WHITE i 375 Fluorinated Nitril 22 286 007 365 Diaphragm 2 378 Conductive Nitrile 286 007 354 Di 384 Conductive Neoprene ee apnragm z 405 Cellulose Fibre 286 007 356 Diaphragm 2 408 Cork and Neoprene 007 l 425 C d Fib EOU al 440 Vegetable Fibre 286 007 360 Diaphragm 2 500 Delrin 500 f 501 Delrin 570 286 007 366 Diaphragm 2 520 Injection Molded PVDF Natural Color 286 007 364 Diaphragm 2 Food Grade USDA Acceptable 23 560 022 360 O Ring
5. 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 Model SA2 A Page 2 A WARNING A 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 6 A BEFORE OPERATION A Before pump operation inspect all gasketed fasteners for looseness caused by gasket creep Retorque loose fasteners to prevent leakage Follow recommended torques stated inthe card attached to the new pump A DANGER A Before doing any maintenance on the pump be certain all pressure is completely vented from the pum
6. 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 Check 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 diaphragm 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 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
7. pressuring and exhausting of the diaphragm chamber is performed by means of an externally mounted pilot operated four way spool type air distribution valve When the spool shifts to one end of the valve body inlet air pressure is applied to one diaphragm chamber and the other diaphragm chamber exhausts When the spool shifts to the opposite end of the valve body the porting of chambers is reversed The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool while exhausting the other side The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot 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 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
8. 2 B0 Polyethylene 24 612 008 330 Plate Diaphragm Outer 2 a B ei em 7 612 096 110 Plate Diaphragm Outer SS Units Only 2 an lie a 25 685 007 120 Rod Diaphragm 1 lt eee material Tetrafluoroethylene TFE 26 170 023 330 Capscrew Hex Head 8 604 PTFE Diaphragm __ 610 Encapsulated Silicon AL only 16 611 PTFE Encapsulated Viton 27 170 024 330 Capscrew Hex Head 8 eens elrin Hytrel and Viton are 28 618 003 330 Plug Pipe 4 registered tradenames of E I DuPont 618 003 110 Plug Pipe SS Pump Only 2 a Bl eral Ula ea i uppion an an are registere 29 1 1 5 063 080 Mounting Foot Right Hand 2 e a a Rupp Pa 30 171 002 330 Capscrew Socket Head 2 Ryton is a registered tradename of Phillips 1Available in kit form Order P N 031 055 000 which also includes items 5 7 12 amp 64 520 010 000 5 03 Chemical Company Loctite is a registered tradename of Loctite Corporation Model SA2 A Page 7 ITEM NO 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 51 52 53 54 55 57 99 62 64 PART NUMBER 171 002 110 545 007 330 807 008 330 900 006 330 612 047 330 312 012 156 312 012 110 312 012 010 334 014 156 334 014 010 312 013 156 312 013 110 312 013 010 334 015 010 334 015 156 338 010 357 338 005 365 338 005 360 338 005 366 338 005 363 338 005 364 338 010 356 338 010 354 360 011 425 360 011 366 360 012 379 360 012 384 360 012 366 722 070 3
9. 55 PVC Polyvinyl Chloride 580 Ryton 600 PTFE virgin material Tetrafluoroethylene TFE 608 Blue Gylon 604 PTFE Diaphragm 610 Encapsulated Silicon 611 PTFE Encapsulated Viton Delrin PTFE Hytrel and Viton are registered tradenames of E I DuPont Gylonis aregistered tradename of Garlock Inc Warren Rupp Rupplon and SandPIPER are registered tradenames of Warren Rupp Inc Ryton is a registered tradename of Phillips Chemical Company Loctite is a registered tradename of Loctite Corporation 520 010 000 5 03 WARREN RUPP IDEX CORPORATION Declaration of Conformity ATEX 100a In accordance with Directive 94 9 EC Annex VIII Equipment intended for use in potentially explosive environments Technical File is stored at KEMA Notified Body 0344 under document number 203040000 Manufacturer Applicable Standard Warren Rupp Inc 94 9 EC 800 North Main Street For potentially explosive environments P O Box 1568 Group Category M2 Mansfield OH 44902 USA Group II Category 2 GD Models Air Operated Double Diaphragm Metallic Pumps Series G SA SB S ST and U under Sandpiper and Marathon Brands SANDPIPER A WARREN RUPP PUMP BRAND ARATHO A WARREN RUPP PUMP BRAND DATE APPROVAL TITLE 8 May 2003 Rev B 23 October 2003 Jason Awad V P Engineering DCATEX1 003
10. 63 722 070 364 518 001 157 518 001 010 518 001 110 570 001 365 570 001 366 570 001 360 570 001 363 570 001 364 670 005 110 675 013 365 675 013 360 675 013 363 675 013 366 675 013 364 722 004 110 722 070 364 722 070 360 722 070 363 770 005 330 807 018 110 170 052 330 170 026 330 545 005 330 900 005 330 547 002 110 902 003 000 530 036 000 560 046 360 560 070 610 612 007 150 612 007 080 170 018 330 031 019 156 031 019 010 132 022 360 170 035 330 Model SA2 A Page 8 TOTAL DESCRIPTION RQD Capscrew Socket Head 2 Nut Hex 16 AL Units use 8 Stud 16 Washer Lock 8 AL Units use 12 Plate Diaphragm Elbow Suction Elbow Suction Elbow Suction Flange Suction Dual Ported Only Flange Suction Dual Ported Only 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 Seat Gasket Seat Gasket Flange Gasket Flange Gasket Flange Seat Flap Valve Viton only Seat Flap Valve EPDM amp Santoprene only Manifold Discharge Suction Manifold Discharge Suction Manifold Discharge Suction Pad Hinge Flap Valve Pad Hinge Flap Valve Pad Hinge Flap Valve Pad Hinge Flap Valve Pad Hinge Flap Valve Retainer Flap Valve Ring Sealing Ring Sealing Ring Sealing Ring Sealing Ring Sealing Seat Flap Valve
11. S RUPP PUMP ERANG l M2 c b T5 Ex eE CE ITEM TOTAL Repair Parts shown in bold face darker NO PART NUMBER DESCRIPTION RQD type are more likely to need replacement after extended periods of normal use l E Beauly S GEVE They are readily available from most Warren 2 114 002 156 Bracket Intermediate 1 auo de auoe hes DUG GE a ee Steels R oe to maintain i a ma of ee patched tiga RUP parts in his own stock to reduce repair 4 135 008 000 Bushing Threaded w O Ring ET E 5 620 004 114 Plunger Actuator 2 l 6 095 073 000 Pilot Valve Body Assembly 1 IMPORTANT When ordering repair parts 095 115 000 Pilot Valve Body Assembly CI Only 1 always furnish pump model number serial 6 A 095 070 551 Pilot Valve Body 1 number and type number 6 B 755 025 000 Sleeve w O Ring 1 6 C 560 033 360 O Ring Sleeve 4 a aiia ee 6 D 775 026 000 Spool w O Ring 1 eee eer 6 E 560 023 360 O Ring Spool 2 000 Assembly sub assembly and some 6 F 675 037 080 Retaining Ring 1 a 7 360 041 379 Gasket Valve Body 1 ee VT 7 inc USIC Ire 8 560 001 360 O Ring 2 080 Carbon Steel AISIB 1112 9 095 043 156 Body Valve i co AE 095 043 010 Body Valve 1 114 303 Stainless Steel 115 301 302 304 Stainless Steel 10 132 014 358 Bumper Valve Spool 2 120 416Stainless Steel Wrought Martensitic 11 165 011 157 Cap End 2 148 Hardcoat Anodized Aluminum 150 6061 T6 Alumi 165 011 010 Cap End 2 151 6063 T Aluminum 12 360 048 37 ket Val B 1 154
12. SERVICE AND OPERATING MANUAL sian ANDPIPERs A WARREN RUPP PUMP BRAND M2 c o T5 II 2GD b T5 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
13. 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 520 010 000 5 03 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 aproduct which is hazardous or toxic the air exhaust must be piped to anappropriate area for safe disposition Diaphragm Model SA2 A Page 3 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 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 the 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 ho
14. air inlet to the lowest cycling rate that does not reduce flow 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 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 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 pro
15. blem 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 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
16. e number MATERIAL CODES The Last 3 Digits of Part Number 0 Q 0 Assembly sub assembly and some purchased items 010 Castlron 015 Ductile lron 025 Music Wire 080 Carbon Steel AISIB 1112 110 Alloy Type 316 Stainless Steel 112 Alloy C 114 303 Stainless Steel 115 301 302 304 Stainless Steel 120 416 Stainless Steel Wrought Martensitic 148 Hardcoat Anodized Aluminum 150 6061 T6 Aluminum 151 6063 T6 Aluminum 154 Almag 35 Aluminum 155 or 156 356 T6 Aluminum 157 Die Cast Aluminum Alloy 380 159 Anodized Aluminum 162 Brass Yellow Screw Machine Stock 170 Bronze Bearing Type Oil lmpregnated 180 Copper Alloy 330 Plated Steel 331 Chrome Plated Steel 332 Electroless Nickel Plated 335 Galvanized Steel 354 Injection Molded 203 40 Santoprene Duro 40D 5 Color RED 356 Hytrel 357 Rupplon Urethane Rubber 360 Buna N Rubber Color coded RED 363 Viton Fluorel Color coded YELLOW 364 E P D M Rubber Color coded BLUE 365 Neoprene Rubber Color coded GREEN 366 Food Grade Nitrile Color coded WHITE 375 Fluorinated Nitrile 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 440 Vegetable Fibre 500 Delrin 500 501 Delrin 570 520 Injection Molded PVDF Natural Color Food Grade USDA Acceptable 540 Nylon 550 Polyethylene 551 Polypropylene 5
17. 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 re start In freezing temperatures the pump must be drained between uses in all cases CHECK VALVE SERVICING Valve inspection requires removal of 4 s hex nuts On the suction side the flange when removed carries the valve and seat as an assembly On the discharge side the valve and seat will stay with the diaphragm housing Visual inspection and cleaning is possible If parts
18. izer Surge Suppressor For nearly pulse free flow Warren Rupp Filter Regulator For modular installation and service convenience Warren Rupp Speed Control For manual or programmable process control Manual adjustment or 4 20mA reception For more detailed information on these accessories contact your local Warren Rupp Factory Authorized Distributor or Warren Rupp corporate headquarters 2003 Warren Rupp Inc All rights reserved Warren Rupp SandPIPER and Tranquilizer are registered tradenames of Warren Rupp Inc Printed in U S A 520 010 000 5 03 Model SA2 A Page 5 Grounding The Pump 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 THE EYELET END IS FASTENED TO THE PUMP HARDWARE THE CLAMP END IS INSTALLED TO A TRUE EARTH GROUND THIS 8 FOOT LONG 244 CENTIMETERS GROUND STRAP PART NUMBER 920 025 000 CAN BE ORDERED AS A SERVICE ITEM To reduce the risk of static electrical sparking this pump must be grounded Check the local electrical code for detailed grounding instruction and the type of equipment required or in the absence of local codes an industry or nationally recognized code having juristiction over specific installations Model SA2 A Page 6 520 010 000 5 03 SERVICE AND OPERATING MANUAL Model SA2 A Type 5 ANDPIPER
19. o 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 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 TROUBLESHOOTING 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 Check valve not seating properly Leakage at joint of suction manifold or elbow flange Suction line or strainer plugged Diaphragm ruptured NMOOW gt Model SA2 A Page 4 A IMPORTANT A Before pump operation all external gasketed fasteners must be inspected for looseness caused by gasket creep after leaving the factory Retorq
20. ocked 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 at all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death A CAUTION A In the event of diaphragm rupture pumped material may enter the airend of the pump and be discharged into the atmosphere If pumping aproduct which is hazardous or toxic the air exhaust must be piped to anappropriate area for safe disposition A CAUTION A 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 520 010 000 5 03 Model SA2 A_ Page 1 AIR INLET amp PRIMING For start up open an air valve approximately 1 2 to 3 4 turn After the unit primes an air valve can be opened to increase flow as desired If opening the valve increases cycling rate but does not increase flow rate cavitation has occurred and the valve should be closed slightly For the most efficient use of compressed air and the longest diaphragm life throttle the
21. operation lt 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 short length of flexible hose not less than 3 4 19mm in diameter between pump and piping to eliminate strain to pipes Model SA2 A Type 5 A IMPORTANT A Read these instructions completely before installation and start up Itis 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 HAZARD WARNING A 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 A DANGER A 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 l
22. p 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 at all times in the vicinity of the pump Failure to follow these recommendations may result in serious injury or death Air inlet 520 010 000 5 03 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 that the bumper stays in place allowing 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
23. ue loose fasteners to insure against leakage Follow recommended torques where called out A card is attached to each new pump stating this fact 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 520 010 000 5 03 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 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 unit is guaranteed for a period of five years against defective material and workmanship RECOMMENDED WARREN RUPP ACCESSORIES TO MAXIMIZE PUMP PERFORMANCE Tranquil
24. using 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 assembly is torqued to 30 ft lbs 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 tightening 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 check valves The valves are designed for some preload over the retainer hinge pad This is done to insure proper face contact with the seat After all parts are in place tighten the lock nuts down on the assembly to the point where visual inspection shows that seat and 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 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 t
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