Model G1F Metallic Design Level 1
Contents
1. Then carefully insert sleeve into valve body Take CAUTION when inserting sleeve not to shear any o rings Install retaining ring to sleeve Generously lubricate outside diameter of spool and o rings Then carefully insert spool into sleeve Take CAUTION when inserting spool not to shear any o rings Use BP LS EP 2 multipurpose grease or equivalent STEP 4 Re install the pilot valve assembly into the intermediate Be careful to align the ends of the pilot valve stem between the plunger pins when inserting the pilot valve into the cavity of the intermediate Re install the gasket air inlet cap and capscrews Connect the air supply to the pump The pump is now ready for operation Model G1F Metallic Page 16 Diaphragm Service Drawing Non Overlay Diaphragm Service Drawing with Overlay Model G1F Metallic Page 17 g1fmdl1sm REV0908 DIAPHRAGM SERVICING To service the diaphragms first shut off the suction then shut off the discharge lines to the pump Shut off the natural gas supply bleed the pressure from the pump and disconnect the natural gas supply line from the pump Drain any remaining liquid from the pump Step 1 See the pump assembly drawing and the diaphragm servicing illustration Using a 1 2 wrench or socket remove the 16 capscrews item 9 that fasten the manifolds items 19 amp 20 to the outer chambers item 13 Step 2 Removing outer chambers Using a 1 2 wrench or soc2. 3 Model G1F Metallic Page 21 Grounding The Pump To be fully groundable the pumps must be ATEX Compliant Refer to pump data sheet for ordering One eyelet is installed to a true earth ground Requires a maximum 5 16 or 8mm maximum diameter blot One eyelet is fastened to the pump hardware g1fmdl1sm REV0908 This 8 foot long 244 centimeters Ground Strap Item 32 is shipped with the eyelet end 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 jurisdiction over specific installations and or CAN CGA B149 installation codes 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 Model G1F Metallic Page 22 AULIOJUOTD JO U0 eJe 230 WARREN RUPP FLUID amp METERING Declaration of Conformity Warren Rupp Inc 800 North Main Street Mansfield Ohio certifies that Air Operated Double Diaphragm Pumps Series HDB HDF M Non Metallic S Non Metallic M Metallic S Metallic Containment Duty Gas UL High Pressure W Submersible and Tranquilizers comply with the European Community Dir
3. Gaskets Retaining Rings Valve Assembly and Pilot Valve Assembly Gas End Kit FKM Seals O Rings Gaskets Retaining Rings Valve Assembly and Pilot Valve Assembly Wetted End Kit Nitrile Diaphagms Nitrle Check Balls and PTFE Check Valve Seats Wetted End Kit Nitrile Diaphragms PTFE Overlay Diaphragms PTFE Check Balls and PTFE Check Valve Seats Wetted End Kit Nitrile Diaphragms PTFE Check Balls and PTFE Check Valve Seats ATTACH EYELET TO ONE OF THE FOUR CAPSCREWS ITEM 11 CS N d OPTIONAL OVERLAY OPTIONAL METALLIC SEAT g1fmdl1sm REV0908 Model G1F Metallic Page 12 Composite Repair Parts List ITEM 1 10 11 12 13 14 15 16 17 18 PART NUMBER 031 183 000 031 183 363 050 028 360 050 028 600 070 012 170 095 110 000 095 110 363 114 025 157 132 019 360 132 019 363 135 036 506 165 120 000 170 044 330 170 045 330 170 069 330 170 006 330 196 173 157 196 173 110 286 008 360 286 015 604 360 093 360 360 103 360 360 104 379 g1fmdl1sm REV0908 DESCRIPTION Gas Valve Assembly Gas Valve Assembly Ball Check Ball Check Bushing Pilot Valve Assembly Pilot Valve Assembly Intermediate Bracket Bumper Diaphragm Bumper Diaphragm Bushing Plunger Cap Gas Inlet Assembly Capscrew Hex Hd 5 16 18 X 1 00 Capscrew Hex Hd 5 16 18 X 1 25 Capscrew Hex Hd 5 16 18 X 1 75 Capscrew Hex 3 8 16 X 1 00 Chamber Outer Chamber Outer Diaphragm Diaphragm Overlay Gasket Nat
4. D 4 XX Z We x QI OD OD OI ODIO QO O Q OQ OQ viviu uv wun wn wn www ONISIDN SIN ON S PION O YS DID Di wD Aiwa woal wmo SIEIEIEIEIEIES IEN EE O O O X x x x x x DOZZA ies lien ZIzz DI DIDI NI NDINI DNDN WM W XK OK DK OK DK OK KX OK OK lt Xx Note Models listed in the table are for reference only See nomenclature below for other models Pump Brand Design Level Diaphragm Check Ball Materials Non Wetted Material Options Porting Options G Sweet Gas Operated 1 Design Level B Nitrile Nitrile A Painted Aluminum N NPT Threads Pump Size Wetted Material T PTFE Nitrile PTFE X Unpainted Aluminum B BSP Tapered Threads 1F 1 S Stainless Steel 5 Nitrile PTFE 0 Unpainted Aluminum FKM Elastomer Pump Style Check Valve Type A Aluminum Check Valve Seat V Painted Aluminum FKM Elastomers S Standard B Ball T Virgin PTFE Pump Options A Aluminum 7 P X No Muffler Permitted S Stainless Steel Li These pump models are designed to pump the following fluids Crude Oil Salt Water Drilling Mud Condensate Lubrication Oils Glycol Caustic liquids and Acids The exhausted natural gas must be vented to a low pressure safe location in accordance with local fire safety and environmental codes an industry or nationally recognized code having jurisdiction over the specific installations and or CAN CGA B149 Installation Codes g1
5. suction stroke in the opposite chamber Gas pressure is applied over the entire inner surface of the diaphragm while liquid is discharged from the opposite side of the diaphragm The diaphragm operates in a balanced condition during the discharge stroke which allows the pump to be operated at discharge heads over 200 feet 61 meters of water 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 to maximize diaphragm life Alternate pressurizing and exhausting of the diaphragm chamber is performed by an externally mounted pilot operated four way spool type gas distribution valve When the spool shifts to one end of the valve body inlet g1fmdl1sm REV0908 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 pressure to the chambers is reversed The gas distribution valve spool is moved by a internal pilot valve which alternately pressurizes one end of the valve while exhausting the other end The pilot valve is shifted at each end of the diaphragm stroke when a actuator plunger is contacted by the diaphragm plate This actuator plunger then pushes the end of the pilot valve spool into position to activate the gas distribution valve The chambers are connected with manifolds with
6. 095 110 000 Pilot Valve Assembly 4 A 095 095 157 Valve Body 4 B 755 052 000 Sleeve With O rings 4 C 560 033 360 O ring Sleeve 4 D 775 055 000 Spool With O rings 4 E 560 023 360 O ring Spool 4 F 675 037 080 ITEM PART NUMBER 4 095 110 363 4 B 755 052 363 4 C 560 033 363 4 E 560 023 363 PILOT VALVE SERVICING To service the pilot valve first shut off the compressed air supply bleed the pressure from the pump and disconnect the air supply line from the pump STEP 1 See pump assembly drawing Using a 1 2 wrench or socket remove the four capscrews item 11 Remove the air inlet cap item 8 and air inlet gasket item 18 The pilot valve assembly item 4 can now be removed for inspection and service g1fmdl1sm REV0908 Retaining Ring DESCRIPTION Pilot Valve Assembly Sleeve With O rings O ring Sleeve O ring Spool includes all other items used on 095 110 000 STEP 2 Disassembly of the pilot valve Remove the pilot valve spool item 4 D Wipe clean and inspect spool and o rings for dirt cuts or wear Replace the o rings and spool if necessary Remove the retaining ring item 4 F from the end of the sleeve item 4 B and remove the sleeve from the valve body item 4 A Wipe clean and inspect sleeve and o rings for dirt cuts or wear Replace the o rings and sleeve if necessary STEP 3 Re assembly of the pilot valve Generously lubricate outside diameter of the sleeve and o rings
7. CURVE Pump is cavitating the fluid by fast cycling g1fmdl1sm REV0908 What to Check Undersized suction line Corrective Action Meet or exceed pump connection recommendations shown on the DIMENSIONAL DRAWING What to Check Restricted or undersized gas line Corrective Action Install a larger gas line and connection Refer to gas inlet recommendations shown in your pump s SERVICE MANUAL What to Check Check the externally serviceable gas distribution system of the pump Corrective Action Disassemble and inspect the natural gas distribution valve pilot valve and pilot valve actuators Refer to the parts drawing and valve section of the SERVICE MANUAL Check for clogged discharge or closed valve before reassembly What to Check Pumped fluid in gas exhaust line Corrective Action Disassemble pump chambers Inspect for diaphragm rupture or loose diaphragm plate assembly Refer to the Diaphragm Replacement section of your pump SERVICE MANUAL What to Check Fluid suction side air leakage or air in product Corrective Action Visually inspect all suction side gaskets and pipe connections What to Check Obstructed check valve Corrective Action Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket Refer to the Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Worn or misaligned check valve or check valve seat Co
8. Exhausted Natural Gas Both Suction and Discharge Ports Are With Available With 1 BSPT Tapered Threads BOTTOM VIEW Dimension a e fe oE 12 27 82 Stainless Steel 11 1 32 1 7 32 7 16 6 11 32 12 27 32 Note The pump is to be mounted in the horizontal position Natural Gas Inlet Port 1 2 NPT g1fmdl1sm REV0908 Model G1F Metallic Page 4 Metric Dimensions G1F Model Metallic Dimensions in Millimeters Dimensional Tolerance 3mm lu 119 Discharge Port 1 NPT A Suction Port D 1 NPT S Jm SIDE VIEW 105 eg FRONT VIEW 210 as b4 1 NPT For Piping Exhausted Natural Gas Both Suction and Discharge Ports are Available with 1 BSP Tapered Threads BOTTOM VIEW Dimension A B c D E Note The pump is to be mounted in the horizontal position Natural Gas Inlet Port 1 2 NPT g1fmdl1sm REV0908 Model G1F Metallic Page 5 PRINCIPLE OF PUMP OPERATION This ball type check valve pump is powered by sweet natural gas and is a 1 1 ratio design The inner side of one diaphragm chamber is alternately pressurized while simultaneously exhausting the other inner chamber This causes the diaphragms which are connected by a common rod secured by plates to the centers of the diaphragms to move in a reciprocating action As one diaphragm performs the discharge stroke the other diaphragm is pulled to perform the
9. MPORTANT INSTALLATION NOTE The manufacturer recommends installing a flexible conductive hose or connection between the pump and any rigid plumbing This reduces stresses on the molded threads of the natural g1fmdl1sm REV0908 gas exhaust port Failure to do so may result in damage to the natural gas distribution valve body Any piping or hose connected to the pump s natural gas exhaust port must be conductive and physically supported Failure to support these connections could also result in damage to the valve body If a high pressure gas spike is possible through the exhaust line a pressure regulator is required in the exhaust piping WARNING Natural gas exhaust is to be vented to low pressure safe location using conductive Nitrile rubber hose or metal piping in accordance with local fire and environmental codes or an industry or nationally recognized code having jurisdiction over specific installations and or CAN CGA B149 Installation Codes NATURAL GAS EXHAUST ILLUSTRATION PUMP INSTALLATION AREA 1 DIAMETER AIR EXHAUST PIPING SAFE AIR EXHAUST DISPOSAL AREA i MUFFLER Illustration 1 LIQUID LEVEL SUCTION LINE MUFFLER LA DO 1 DIAMETER AIR EXHAUST PIPING Illustration 2 T MUFFLER LA LIQUID cf LEVEL SUCTION LINE 1 DIAMETER AIR EXHAUST PIPING Illustration
10. Nylon Nylon Injection Molded Polyethylene Glass Filled Polypropylene Unfilled Polypropylene Unfilled Polypropylene Polyvinyl Chloride Black Vinyl Conductive HDPE Rulon Il Ryton Valox Nylatron G S Nylatron NSB PTFE virgin material Tetrafluorocarbon TFE PTFE Bronze and moly filled Filled PTFE Blue Gylon PTFE 606 607 608 610 611 632 633 634 635 637 638 639 643 644 649 656 PTFE Envelon Conductive PTFE PTFE Encapsulated Silicon PTFE Encapsulated FKM Neoprene Hytrel FKM PTFE EPDM PTFE Neoprene PTFE PTFE FKM PTFE PTFE Hytrel PTFE Nitrile TFE Santoprene EPDM Santoprene PTFE PTFE Nitrile PTFE Santoprene Diaphragm and Check Balls EPDM Seats Delrin and Hytrel are registered tradenames of EL DuPont Gylon is a registered tradename of Garlock Inc Nylatron is a registered tradename of Polymer Corp Santoprene is a registered tradename of Monsanto 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 Warren Rupp SANDPIPER PortaPump Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp Inc Model G1F Metallic Page 10 g1fmdl1sm REV0908 Model G1F Metallic Page 11 Composite Repair Parts Drawing Available Service Kits 476 228 000 476 228 363 476 204 360 476 204 649 476 204 672 Gas End Kit Seals O Rings
11. SERVICE amp OPERATING MANUAL SANDPIPER A WARREN RUPP PUMP BRAND Model G1F Metallic Design Level 1 Natural Gas Operated Diaphragm Pumps Table of Contents Engineering Data and Temperature Limitations i Explanation of Pump Nomenclature Performance CUIVEe ii DIMENSIONS i iii a Metric DIMENSIONS iii Principle of Pump Operation Installation and Start Up ii Natural Gas Supply i Natural Gas Valve Lubrication eee eeaeeeeeeeaeeeeeeeeeeseaeeeeetes Natural Gas Line Moisture eseesseeseeeeeeseeeeeettstttttsttsttnstnstrttnstnsttnrenntnseeneenneen Natural Gas Inlet and Priming i Between Us 6s iu iii iii a Installation Guide MPOUDIOSHOOTING EE Warranty PE ER dl ne A eld eh el RT ARE Recycling WEE Important Safety Information i Material Codes cock cites ee ala A lille lieta Composite Repair Parts Drawing i x Il 2GD T5 CE U S Patent 5 996 627 6 241 487 Other U S Patents Applied for Available Service and Conversion Kits AA 12 Composite Repair Parts Let 13 Natural Gas Distribution Valve Assembly Drawing and Parts List 14 Natural Gas Distribution Valve Servicing i 15 Pilot Valve Servicing Assembly Drawing amp Parts List i 16 Diaphragm Service Drawing with Overlay 17 Diaphragm Service Drawing Non CO
12. a suction and discharge check valve for each chamber maintaining flow in one direction through the pump INSTALLATION AND START UP Locate the pump as close to the product being pumped as possible Keep the suction line length and number of fittings to a minimum Do not reduce the suction line diameter For installations of rigid piping short sections of flexible conductive hose should be installed between the pump and the piping The flexible conductive hose reduces vibration and strain to the pumping system A surge suppressor is recommended to further reduce pulsation in flow NATURAL GAS SUPPLY Natural gas inlet pressure must be regulatedto 100 7 bar psi with a pressure regulator Connect the pump gas inlet to an gas supply of sufficient capacity and pressure required for desired performance When the gas supply line is solid piping use a short length of flexible conductive hose not less than 3 4 19mm in diameter between the pump and the piping to reduce strain to the piping The weight of the gas supply line regulators and filters must be supported by some means other than the gas inlet cap Failure to provide support for the piping may result in damage to the pump A pressure regulating valve should be installed to insure gas supply pressure does not exceed recommended limits VALVE LUBRICATION The natural gas distribution valve and the pilot valve are designed to operate WITHOUT lubrication This is the prefer
13. chart on page 10 for material specifications We encourage pump users to recycle worn out parts and pumps whenever possible after any hazardous pumped fluids are thoroughly flushed d PN R 14 CERTIFIED US x II 2GD T5 CE g1fmdl1sm REV0908 Certified to CSA Technical Letter No Certified to CSA Requirement 2 01 pump or use the pump near an open flame Fire or explosion could result A WARNING This pump must not be used for fluid transfer into aircraft Pump complies with EN809 Pumping Directive Directive 98 37 EC Safety of Machinery and Directive 94 9 EC EN13463 1 Equipment for use in Potentially Explosive Environments For reference to the directive certificates visit www warrenrupp com The Technical File No AX1 is stored at KEMA Notified Body 0344 under Document 203040000 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 pump operation inspect all gasketed fasteners for looseness caused by gasket creep Re torque loose fasteners to prevent leakage Follow recommended torques Stated in this manual A WARNING Before maintenance or repair shut off
14. d on 03 g1fmdl1sm REV0908 NATURAL GAS Assembly Parts List Description Gas Valve Assembly Valve Body Sleeve and Spool Set Bumper O ring Cap End Capscrew Description Gas Valve Assembly O ring 1 183 000 Qty OM AM zz CH Qty Model G1F Metallic Page 14 NATURAL GAS DISTRIBUTION VALVE SERVICING To service the natural gas valve first shut off the compressed air bleed pressure from the pump and disconnect the gas supply line from the pump Step 1 See COMPOSITE REPAIR PARTS DRAWING Using a 9 16 wrench or socket remove the four hex capscrews items 12 Remove the air valve assembly from the pump Remove and inspect gasket item 16 for cracks or damage Replace gasket if needed Step 2 Disassembly of the natural gas valve Using a 7 16 wrench or socket remove the eight hex capscrews items 1 F that fasten the end caps to the valve body Next remove the two end caps items 1 E Inspect the two o rings items 1 D on each end cap for damage or wear Replace the o rings as needed Remove the bumpers items 1 C Inspect the bumpers for damage or wear Replace the bumpers as needed Remove the spool part of item 1 B from the sleeve Be careful not to scratch or damage the outer diameter of the spool Wipe spool with a soft cloth and inspect for scratches or wear g1fmdl1sm REV0908 Inspect the inner diameter of the sleeve part of item 1 B for dirt scratches or other contaminan
15. d stud of the other outer diaphragm plate assembly through the center of the other diaphragm and through the other inner diaphragm plate Make sure the radius on the inner diaphragm plate is towards the diaphragm Thread the assembly onto the diaphragm rod Use a 7 8 wrench or socket to hold one outer diaphragm plate Then use a torque wrench to tighten the other outer diaphragm plate to the diaphragm rod to 500 in Ibs 56 5 Newton meters Align one diaphragm with the intermediate and install the outer chamber to the pump using the 8 capscrews Tighten the opposite diaphragm plate until the holes in the diaphragm align with the holes in the intermediate Then install the other outer chamber using the 8 capscrews Step 6 Reinstall the manifolds to the pump using the 16 capscrews The pump is now ready to be reinstalled connected and returned to operation OVERLAY DIAPHRAGM SERVICING The overlay diaphragm item 15 is designed to fit over the exterior of the standard diaphragm item 14 Follow the same procedures described for the standard diaphragm for removal and installation except tighten the outer diaphragm plate assembly diaphragms and inner diaphragm plate to the diaphragm rod to 500 in lbs 56 5 Newton meters A IMPORTANT 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
16. ective 98 37 EC Safety of Machinery This product has used EN 809 Pumps and Pump Units for Liquids Common Safety Requirements harmonized standard to verify conformance BAR desto October 20 2005 Signature of authorized person Date of issue David Roseberry Engineering Manager Printed name of authorized person Title CE Declaration of Conformity WARREN RUPP FLUID amp METERING Declaration of Conformity ATEX 100a In accordance with Directive 94 9 EC Annex VIII Equipment intended for use in potentially explosive environments Technical File No AX1 is stored at KEMA Notified Body 0344 under document number 203040000 Manufacturer Applicable Standard Warren Rupp Inc 94 9 EC 800 North Main Street EN13463 1 P O Box 1568 For potentially explosive environments Mansfield OH 44902 USA Group l Category M2 Group II Category 2 GD Models Air Operated Double Diaphragm Metallic Pumps Series EH ET G HDB HDF M MHP MS MP SH S SA SB ST T and U under SANDPIPER and MARATHON Brands Metal Surge Suppressors Series T and MSS under Tranquilizer and MARATHON Brands Air Operated Double Diaphragm Nonmetallic Conductive Acetal Pump Models PB and S05 Air Operated Double Diaphragm Nonmetallic Conductive Polypropylene Pump Models S05 S1F S15 S20 SANDPIPER MARATHON A WARREN RUPP PUMP BRAND DATE APPROVAL TITLE 8 May 2003 Rev F 12 January 2007 David Roseberry Engineering Mafrage
17. fmdl1sm REV0908 Model G1F Metallic Page 2 Performance Curve G1F Model Metallic Design Level 1 N BAR O HEAD g1fmdl1sm REV0908 60 40 20 The use of other materials and varying hydraulic con 5 00 SCFM M hr MODEL G1F Metallic Performance Curve Performance based on the following elastomer fitted pump flooded suction water at ambient conditions ditions may result in deviations in excess of 5 10 17 100 1 WEE i Z N 20 34 l d N 25 00 t t i 80 Pg elt 4 30 51 44 Ba N N Wei S 35 00 A N x N lt N t A x x 60 Pe 4 li x 3 N N N 40 68 08 Bar N N N N be H H N N N N N S H 3 N N X D S N n etc 72 Bar N N N 2 0 PSI 1 36 Bar Gas Inlet Pressule x J She hs S Eeee Gou io ce I _ mid bee 5 10 15 20 25 30 35 40 45 50 U S Gallons per minute a aie dARI Oa ao da 20 40 60 80 100 120 140 160 180 Liters per minute CAPACITY oc TLT He QA Z Wu fr mae ES 30 9 1 25 7 6 20 6 15 4 5 10 3 5 1 5 Model G1F Metallic Page 3 Dimensions G1F Model Metallic Dimensions in Inches Dimensional Tolerance s 9 10 1 4 4 3 4 Discharge Port 1 NPT 5 1 8 1 5 8 H SS AF D Suction Port 1 NPT i de B 7 L cd 1 7 8 i SIDE VIEW 4 1 8 1 5 8 FRONT VIEW 2 1 2 5 1 NPT For Piping
18. ket remove the 16 capscrews item 10 that fasten the outer chambers item 13 diaphragms item 14 and intermediate item 5 together Step 3 Removing the dia phragms and diaphragm plates Use a 7 8 wrench or six point socket to remove the outer diaphragm plate assemblies item 24 diaphragms item 14 and inner diaphragm plates item 23 from the diaphragm rod item 27 by turning counterclockwise In spect the diaphragm for cuts punctures abrasive wear or chemical attack Replace the diaphragms if necessary DO NOT USE A WRENCH ON THE DIAPHRAGM ROD FLAWS ON THE SURFACE MAY DAMAGE BEARINGS AND SEALS g1fmdl1sm REV0908 Step 4 Assembling the diaphragm and diaphragm plates to the diaphragm rod Push the threaded stud of one outer diaphragm plate assembly through the center of one diaphragm and through one inner diaphragm plate Install the diaphragm with the natural bulge facing away from the diaphragm rod and make sure the radius on the inner diaphragm plate is towards the diaphragm as indicated on the diaphragm servicing illustration Thread the assembly onto the diaphragm rod leaving loose Step 5 Installing the diaphragm and rod assembly to the pump Make sure the bumper item 6 is installed over the diaphragm rod Insert rod into pump On the opposite side of the pump pull the diaphragm rod out as far as possible Make sure the second bumper is installed over the diaphragm rod Push the threade
19. natural gas to a safe area for gas reclamation Make sure to ground the regulator hose and or pipe Gas Shut Off Valv SR Natural gas supply conductive piping must be supported Regulator w Gauge Filter ER g1fmdl1sm REV0908 Natural Gas Inlet CD The pump must be rigidly mounted in the horizontal position with fasteners to a conductive base or natural ground Model G1F Metallic Page 7 TROUBLESHOOTING Possible Symptoms e Pump will not cycle e Pump cycles but produces no flow e Pump cycles but flow rate is unsatisfactory e Pump cycle seems unbalanced e Pump cycle seems to produce excessive vibration What to Check Excessive suction lift in system Corrective Action For lifts exceeding 20 feet 6 meters filling the pumping chambers with liquid will prime the pump in most cases What to Check Excessive flooded suction in system Corrective Action For flooded conditions exceeding 10 feet 3 meters of liquid install a back pressure device What to Check System head exceeds natural gas supply pressure Corrective Action Increase the inlet gas pressure to the pump Most diaphragm pumps are designed for 1 1 pressure ratio at zero flow What to Check Natural gas supply pressure or volume exceeds system head Corrective Action Decrease inlet gas pressure and volume to the pump as calculated on the published PERFORMANCE
20. nd environmental codes or an industry or nationally recognized code having juristiction over specific installations and or CAN CGA B149 Installation Codes Model G1F Metallic Page 6 WARREN INSTALLATION GUIDE RUPP Top Discharge Ball Valve Pump Available from Warren Rupp A CAUTION The natural gas exhaust must be piped to an area for safe disposition of the product being pumped in the event of a diaphragm failure See page 23 Pipe Connection Style Optional Natural Gas Exhaust CRE See page 23 Gauge DIAPHRAGM Shut Off PUMP Valve a I Flexible SUCTION bh X Connection Di DN Drain Port Flexible Conductive Connection 020 063 000 Filter VENTING WARNING This filter is equipped with a stainless steel manual drain The port is 1 8 NPT When draining moisture from the filter first shut off the natural gas supply 020 058 000 REGULATOR WITH GAGE PRESSURE WARNING This regulator is to be installed at point of use with the pump The maximum gas supply is 400psi Full line pressure needs to be regulated below 400psi prior to the regulator installation position VENTING WARNING This regulator is equipped with a 1 4 NPT vent port In the event of a diaphragm rupture natural gas can be exhausted into the surrounding environment Connect a conductive hose or pipe to the vent port to send the escaping
21. of the intermediate Re install the gasket item 18 natural gas inlet cap item 8 and capscrews item 11 Connect the natural gas supply to the pump The pump is now ready for operation ACTUATOR PLUNGER SERVICING AA IMPORTANT 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 Model G1F Metallic Page 19 CHECK VALVE SERVICING Before servicing the check valve components first shut off the suction line and then the discharge line to the pump Next shut off the compressed natural gas supply bleed natural gas pressure from the pump and disconnect the natural gas supply line from the pump Drain any remaining fluid from the pump The pump can now be removed for service To access the check valve components remove the manifolds item 19 not shown Use a 9 16 wrench or socket to remove the fasteners Once the manifold is removed the check valve components can be seen Inspect the check balls items 2 for wear abrasion or cuts on the spherical surface The check valve seats item 29 should be inspected for cuts abrasive wear or embedded material on the surfaces of both the external and internal chambers The spherical surface of the check balls must seat flush to the surface of the check val
22. red mode of operation There may be instances of personal preference or poor quality gas supplies when lubrication of the supply is required The pump system will operate with properly lubricated supply Proper lubrication requires the use of an gas line lubricator available from Warren Rupp set to deliver one drop of SAE 10 non detergent oil for every 20 SCFM 9 4 liters sec of gas the pump consumes at the point of operation Consult the pump s published Performance Curve to determine this GAS INLET AND PRIMING To start the pump open the gas valve approximately 1 2 to 3 4 turn After the pump primes the valve can be opened to increase gas flow as desired If opening the valve increases cycling rate but does not increase the rate of flow cavitation has occurred The valve should be closed slightly to obtain the most efficient gas flow to pump flow ratio BETWEEN USES When the pump is used for materials that tend to settle out or solidify when not in motion the pump should be 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 the diaphragms and check valves at restart In freezing temperatures the pump must be completely drained between uses in all cases WARNING Natural gas exhaust is to be vented to low pressure safe location using conductive Buna rubber hose or metal piping in accordance with local fire a
23. rrective Action Inspect check valves and seats for wear and proper seating Replace if necessary Refer to Check Valve section of the pump SERVICE MANUAL for disassembly instructions What to Check Blocked suction line Corrective Action Remove or flush obstruction Check and clear all suction screens and strainers What to Check Blocked discharge line Corrective Action Check for obstruction or closed discharge line valves What to Check Blocked pumping chamber Corrective Action Disassemble and inspect the wetted chambers of the pump Remove or flush any obstructions Refer to the pump SERVICE MANUAL for disassembly instructions What to Check Entrained air or vapor lock in one or both fluid pumping chambers Corrective Action Purge chambers through tapped chamber vent plugs PURGING THE CHAMBERS OF AIR CAN BE DANGEROUS Contact the Warren Rupp Technical Services Group before performing this procedure Any model with top ported discharge will reduce or eliminate problems with entrained air If your pump continues to perform below your expectations contact your local Warren Rupp Distributor or factory Technical Services Group for a service evaluation WARRANTY Refer to the enclosed Warren Rupp Warranty Certificate Model G1F Metallic Page 8 RECYCLING Many components of Natural Gas AWARNING Do not smoke near the Operated SANDPIPER Metallic pumps are made of recyclable materials see
24. the compressed natural gas line bleed the pressure and disconnect the gas line from the pump The discharge line may be pressurized and must be bled of its pressure WARNING In the event of diaphragm rupture pumped material may enter the natural gas end of the pump and be discharged into the atmosphere The gas exhaust must be piped to an appropriate area for safe disposition 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 WARNING This pump is pressurized internally with natural gas pressure during operation Always make certain that all bolting is in good condition and that all of the correct bolting is reinstalled during assembly WARNING When used for toxic or aggressive fluids the pump should always be flushed clean prior to disassembly WARNING 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 natural gas 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 res
25. the recommendations stated in this manual will damage the pump and void factory warranty Model G1F Metallic Page 18 ACTUATOR PLUNGER SERVICING To service the actuator plunger first shut off the compressed natural gas supply bleed the pressure from the pump and disconnect the natural gas supply line from the pump Step 1 See PUMP ASSEMBLY DRAWING Using a 1 2 wrench or socket remove the four capscrews items 11 Remove the gas inlet cap item 8 and gas inlet gasket item 18 The pilot valve assembly item 4 can now be removed Step 2 Inspect the actuator plungers See ILLUSTRATION AT RIGHT The actuator plungers items 25 can be reached through the pilot valve cavity in the intermediate assembly item 5 Remove the plungers item 25 from the bushings item 7 in each end of the cavity Inspect the installed o ring items 21 for cuts and or wear Replace the o rings if necessary Apply a light coating of grease to each o ring and re install the plungers in to the bushings Push the plungers in as far as they will go To remove the bushings item 7 first remove the retaining rings item 26 by using a flat screwdriver g1fmdl1sm REV0908 NOTE It is recommended that new retaining rings be installed Step 3 Re install the pilot valve assembly into the intermediate assembly Be careful to align the ends of the stem between the plungers when inserting the stem of the pilot valve into the cavity
26. ts Remove the sleeve if needed and replace with a new sleeve and spool set item 1 A Step 3 Reassembly of the natural gas valve Install one bumper item 1 C and one end cap item 1 E with two o rings items 1 D and fasten with four hex capscrews items 1 F to the valve body item 1 A Remove the new sleeve an spool set item 1 B from the plastic bag Carefully remove the spool from the sleeve Install the six o rings item 1 D into the six grooves on the sleeve Apply a light coating of grease to the o rings before installing the sleeve into the valve body item 1 A align the slots in the sleeve with the slots in the valve body Insert the spool into the sleeve Be careful not to scratch or damage the spool during installation Install the remaining bumper and end cap with o rings and fasten with the remaining hex capscrews Fasten the natural gas valve assembly item 1 and gasket to the pump Connect the compressed gas line to the pump The pump is now ready for operation A IMPORTANT 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 Model G1F Metallic Page 15 Pilot Valve Servicing Assembly Drawing amp Parts List PILOT VALVE ASSEMBLY PARTS LIST ITEM PART NUMBER DESCRIPTION 4
27. ult in serious injury or death AA WARNING Airborne particles and loud noise hazards Wear ear and eye protection Model G1F Metallic Page 9 000 010 012 015 020 025 080 100 110 111 112 113 114 115 117 120 123 148 149 150 151 152 154 155 156 157 158 159 162 165 166 170 175 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 Hastelloy equivalent Alloy Type 316 Stainless Steel Hand Polished 303 Stainless Steel 302 304 Stainless Steel 440 C Stainless Steel Martensitic 416 Stainless Steel Wrought Martensitic 410 Stainless Steel Wrought Martensitic Hardcoat Anodized Aluminum 2024 T4 Aluminum 6061 T6 Aluminum 6063 T6 Aluminum 2024 T4 Aluminum 2023 T351 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 g1fmdl1sm REV0908 180 305 306 307 308 309 310 330 331 332 333 334 335 336 337 340 342 353 354 355 356 357 358 359 360 361 363 364 365 366 368 370 371 374 MATERIAL CODES The Last 3 Digits of Part Number Copper Allo
28. ural Gas Valve Gasket Pilot Valve Gasket Gas Inlet QTY A h A A NA BAA meh O O NNNNA A ITEM PART NUMBER DESCRIPTION 19 20 21 22 23 24 25 26 27 28 29 30 31 32 518 175 156 518 175 156E 518 175 110 518 175 110E 518 176 156 518 176 156E 518 176 110 518 176 110E 560 001 363 560 001 379 560 091 360 560 091 611 612 022 330 612 108 157 612 101 110 620 022 115 675 042 115 685 060 110 720 010 363 720 010 375 722 098 600 722 098 150 722 098 150 900 004 330 901 038 330 920 025 000 Manifold Suction Manifold Suction 1 BSP Tapered Manifold Suction Manifold Suction 1 BSP Tapered Manifold Discharge Manifold Discharge 1 BSP Tapered Manifold Discharge Manifold Discharge 1 BSP Tapered O ring O ring O ring metallic seats only O ring metallic seats only Plate Inner Diaphragm Plate Outer Diaphragm Assembly Plate Outer Diaphragm Assembly Pin Actuator Ring Retaining Rod Diaphragm Seal U Cup Seal U Cup Seat Check Valve Seat Check Valve Seat Check Valve Washer Lock 5 16 Flat Washer Ground Strap QTY bb bh AM OO OM MA ch A ch A a a Model G1F Metallic Page 13 Natural Gas Valve Assembly Drawing Parts List Item Part Number 1 031 183 000 1 A 095 109 157 1 B 031 139 000 1 C 132 029 357 1 D 560 020 360 1 E 165 127 157 1 F 170 032 330 Item Part Number 1 031 183 363 1 D 560 020 363 Included all other items use
29. ures Materials Maximum Minimum Nitrile General purpose oil resistant Shows good solvent oil water and hydraulic fluid resistance Should not be used with highly polar solvents like acetone and MEK ozone chlorinated hydrocarbons and nitro hydrocarbons Virgin PTFE Chemically inert virtually impervious Very few chemicals are known to react chemically with PTFE molten alkali metals turbulent liquid or gaseous fluorine and a few fluoro chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures FKM Fluorocarbon Excellent resistance to sour natural gas high temperatures acids hydrogen sulfide and oils 400 F 204 F 26 F For specific applications always consult Chemical Resistance Chart Technical Bulletin These G1F SANDPIPER models are designed to be powered only by natural gas The minimum pump operating temperature is 10 F and the maximum operating temperature is 180 F g1fmdl1sm REV0908 Model G1F Metallic Page 1 Explanation of Pump Nomenclature G1F Metallic Design Level 1 Ball Valve Diaphragm Non Wetted Design Wetted Check Valve Material Porting Pump Kit Level Material Materials Options Options Options Options G1FB1ABTXNSXO00 G1FB1ATTXNSX00 G1FB1SBTXNSX00 G1FB1STTXNSX00 G1FB1ABTXBSXO00 G1FB1ATTXBSXO0O G1FB1SBTXBSX00 G1FB1STTXBSX00 G1FB1ABTONSXOO G1FB1SBTONSXO0O G1FB1ABTOBSX00 G1FB1SBTOBSX00 vo gt
30. ve seats for the pump to operate to peak efficiency Replace any worn or damaged parts as necessary Re assemble the check valve components The seat should fit into the counter bore of the outer chamber The pump can now be reassembled reconnected and returned to operation g1fmdl1sm REV0908 Check Valve Drawing Model G1F Metallic Page 20 PUMPING HAZARDOUS LIQUIDS When a diaphragm fails the pumped liquid or fumes enter the natural gas end of the pump Fumes are exhausted into the surrounding environment When pumping hazardous or toxic materials the exhaust gas must be piped to an appropriate area for safe disposal See illustration 1 at right This pump can be submerged if the pump materials of construction are compatible with the liquid being pumped The natural gas exhaust must be piped above the liquid level See illustration 2 at right Piping used for the gas exhaust must not be smaller than 1 2 54 cm diameter Reducing the pipe size will restrict natural gas flow and reduce pump performance When the pumped product source is at a higher level than the pump flooded suction condition pipe the exhaust gas higher than the product source to prevent siphoning spills See illustration 3 at right PIPING THE NATURAL GAS EXHAUST The following steps are necessary to pipe the exhaust gas away from the pump The gas distribution valve assembly item 1 has 1 NPT threads for piped exhaust I
31. werlay i 17 Diaphragm Servicingi c acari 18 Overlay Diaphragm Servicing ii 18 Actuator Plunger Gerviclng 19 Check Ee EE 20 Check Valve Drawing aaa 20 Provision for Piping Gas ExhaUSt 21 Pumping Hazardous Laudes 21 Piping Exhaust Natural Gas A 21 Exhaust Illustrationi uccrazio vee al 21 Grounding The PUMP cerisier erica ia acc 22 CE Declaration of Conformity i 23 ATEX Declaration of Conformity ii 24 WARREN RUPP INC e A Unit of IDEX Corporation e P O Box 1568 Mansfield Ohio 44901 1568 USA e Telephone 419 524 8388 e Fax 419 522 7867 e www warrenrupp com g1fmdl1sm REV0908 Copyright 2008 Warren Rupp Inc All rights reserved HOPE SANDPIPER A WARREN RUPP PUMP BRAND amp Geen G1F metallic Quality System ISO9001 Certified Environmental Management System U S Patent Natural Gas Operated IS014001 Certified 5 996 627 6 241 487 Diaphragm Pumps Other U S Patents Applied for ENGINEERING PERFORMANCE amp CONSTRUCTION DATA FLUID amp METERING INTAKE DISCHARGE PIPE SIZE CAPACITY GAS VALVE SOLIDS HANDLING HEADS UP TO DISPLACEMENT STROKE 1 NPT internal 0 to 45 gallons per minute No lube no stall Up to 25 in 6mm 100 psi or 230 7 ft of water 11 Gallon 42 liter 1 BSP Tapered internal O to 170 liters per minute design 7Kg cm or 70 meters A CAUTION Operating temperature limitations are as follows Operating Temperat
32. y 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 Zinc Plated Steel Chrome Plated Steel Aluminum Electroless Nickel Plated Carbon Steel Electroless Nickel Plated Cast Iron Electroless Nickel Plated Galvanized Steel Zinc Plated Yellow Brass Silver Plated Steel Nickel Plated Filled Nylon Geolast Color Black Injection Molded 203 40 Santoprene Duro 40D 5 Color RED Thermal Plastic Hytrel Injection Molded Polyurethane Urethane Rubber Some Applications Compression Mold Urethane Rubber 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 Food Grade EPDM Butyl Rubber Color coded BROWN Philthane Tuftane Carboxylated Nitrile 375 377 378 379 405 408 425 426 440 465 500 501 502 503 505 506 520 540 541 542 544 550 551 552 553 555 556 558 570 580 590 591 592 600 601 602 603 604 Fluorinated Nitrile Conductive HNBR High Density Polypropylene Conductive Nitrile Cellulose Fibre Cork and Neoprene Compressed Fibre Blue Gard Vegetable Fibre Fibre Delrin 500 Delrin 570 Conductive Acetal ESD 800 Conductive Acetal Glass Filled Acrylic Resin Plastic Delrin 150 Injection Molded PVDF Natural color Nylon Nylon
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