SERVICE AND OPERATING MANUAL
® Model EB½-A
Type 2
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 ball 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 reversed. The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool, while exhausting the other side. The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot valve spool. This pushes it into position for shifting of the air distribution valve.
The chambers are manifolded together with a suction and discharge check valve for each chamber, maintaining flow in one direction through the pump.
INSTALLATION & START-UP
Locate the pump as close to the product being pumped as possible, keeping suction line length and number of fittings to a minimum. Do not reduce line size.
For installations of rigid piping, short flexible sections of hose should be installed between pump and piping. This reduces vibration and strain to the piping system. A Warren Rupp Tranquilizer® surge suppressor is recommended to further reduce pulsation in flow.
This pump was tested at the factory prior to shipment and is ready for operation. It is completely self-priming from a dry start for suction lifts of 10 feet (3.05 meters) or less. For suction lifts exceeding 10 feet of liquid, fill the chambers with liquid prior to priming.
AIR SUPPLY
Air supply pressures cannot exceed 100 psi (6.89 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. Use of a Warren Rupp Filter/Regulator in the air line is recommended.
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.
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.
BEFORE OPERATION 
Before pump operation, inspect all gasketed fasteners for looseness caused by gasket creep. Retorque loose fasteners to prevent leakage. Follow recommended torques stated in the card attached to the new pump.
HAZARD WARNING 
POSSIBLE EXPLOSION HAZARD can result if 1, 1, 1,-Trichloroethane, Methylene Chloride or other Halogenated Hydrocarbon solvents are used in pressurized fluid systems having Aluminum or Galvanized wetted parts. Death, serious bodily injury and/ or property damage could result. Consult with the factory if you have questions concerning Halogenated Hydrocarbon solvents.
Air Inlet Capscrews.
AIR INLET & 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
WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • (419) 524-8388 Fax (419) 522-78 67 • www.warrenrupp.com
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cycling rate, but does not increase flow rate, cavitation has occurred, and the valve should be closed slightly.
For the most efficient use of compressed air and the longest diaphragm life, throttle the air inlet to the lowest cycling rate that does not reduce flow.
AIR EXHAUST
If a diaphragm fails, the pumped liquid or fumes can enter the air end of the pump, and be exhausted into the atmosphere. When pumping hazardous or toxic materials, pipe the exhaust to an appropriate area for safe disposition.
This pump can be submerged if materials of construction are compatible with the liquid. The air exhaust must be piped above the liquid level. Piping used for the air exhaust must not be smaller than 3/8" (.9525 cm). Reducing the pipe size will restrict air flow and reduce pump performance. When the product source is at a higher level than the pump (flooded suction), pipe the exhaust higher than the product source to prevent siphoning spills. Use exhaust kit 475-107-000 to pipe out exhaust.
Freezing or icing-up of the air exhaust can occur under certain temperature and humidity conditions. Use of a Warren Rupp Air Dryer unit should eliminate most icing problems.
BETWEEN USES
When used for materials that tend to settle out or transform to solid form, the pump should be completely flushed after each use, to prevent damage. Product remaining in the pump between uses could dry out or settle out. This could cause problems with valves and diaphragms at re-start. In freezing temperatures, the pump must be drained between uses in all cases.
DIAPHRAGM SERVICING
Remove the two V-Band clamps securing the outer chambers to the intermediate housing. Remove the diaphragm assembly (outer plate, diaphragm, inner plate) by turning the assembly counterclockwise using a 3/4" wrench on the outer plate lugs. If a socket is used, it must be a six point socket. The interior components consisting of the shaft seal and pilot valve assembly are now accessible for service.
Procedures for reassembling the diaphragms are the reverse of the above. During reassembly make certain that the rubber bumper is on the rod on each side. Install the diaphragm with the natural bulge outward.
Install the outer diaphragm plate on the outside of the diaphragm and make certain that the large radius side of the inner plate is toward the diaphragm. Tighten the outer diaphragm plate to approximately 90 in. lbs. (10.16 Newton meters).
Torque while allowing the diaphragm to turn freely with plates. Use a wrench on the outer diaphragm plate of the opposite side to keep rod from rotating. If the opposite chamber is assembled, the rod need not be held.
CHECK VALVE SERVICING
Need for inspection or service is usually indicated by poor priming, unstable cycling, reduced performance or the pump's cycling but not pumping.
Inspect the surfaces of both check valve and seat for wear or damage that could prevent proper sealing. If pump is to prime properly, valves must seat air tight.
A Note about Air Valve Lubrication
The pump’s pilot 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
Accessing the check valves.
Exhaust cap assembly.(475-107-000)
Sleeve and spool.
CAUTION 
When removing capscrews on suction or discharge valve retainer/cap, make sure all pressure on suction and discharge side of pump has been relieved. Re-lock wire the capscrews before continuing use.
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addressed by using a point of use air dryer (available from Warren Rupp) 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: 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 of 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 suction/discharge less than 1"
The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head capscrews. The valve body assembly is removed from the pump by removing these four hex head capscrews.
With the valve body assembly off the pump, access to the sleeve and spool set is made by removing a retaining ring (each end) securing the end cap on the valve body assembly. With the end caps removed, slide the spool back and forth in the sleeve. The spool is closely sized to the sleeve and must move freely to allow for proper pump operation. An accumulation of oil, dirt or other contaminants from the pump’s air supply, or from a failed diaphragm, may prevent the spool from moving freely. This can cause the spool to stick in a position that prevents the pump from operating. If this is the case, the sleeve and spool set should be removed from the valve body for cleaning and further inspection.
Remove the spool from the sleeve. Using an arbor press or bench vise (with an improvised mandrel), press the sleeve from the valve body. Take care not to damage the sleeve. At this point, inspect the o-rings on the sleeve for nicks, tears or abrasions. Damage of this sort could happen during assembly or servicing. A sheared or cut o-ring can allow the pump’s compressed air supply to leak or bypass within the air valve assembly, causing the pump to leak compressed air from the pump air exhaust or not cycle properly. This is most noticeable at pump dead head or high discharge pressure conditions. Replace any of these o-rings as required or set up a routine, preventive maintenance schedule to do so on a regular basis. This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent, inspecting for signs of wear or damage, and replacing worn components.
To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve with an o-ring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant). Press the set into the valve body easily, without shearing the o-rings. Re-install one end cap, and retaining ring on the valve body. Using the arbor press or bench vise that was used in disassembly, press the sleeve back into the valve body. Re-install the spool, keeping the counter-bored end toward you, and install the spring, opposite end cap, and retaining ring on the valve body. After inspecting and cleaning the gasket surfaces in the valve body and intermediate, re-install the valve body on the pump using new gaskets. Tighten the four hex head capscrews evenly and in an alternating cross pattern, at 70 in./lbs. (7.9 Newton meters).
PILOT VALVE
The pilot valve spool (item 9C on main parts list) contains 6 o-rings (item 9D). This spool moves through the sleeve (item 9B). Check condition of o-rings for cuts or gouges before re-assembly. Apply a light coating of grease to the o-rings when inserting into the sleeve. Insert spool in to sleeve from chamfered side. The o-ring on the end should be installed after the spool is in place (install last). Make sure the sleeve is locked into the intermediate bracket (item 16) with retainer ring (item 9E).
TROUBLESHOOTING
1. Pump will not cycle
A.Check to make sure the unit has enough pressure to operate and that the air inlet valve is open.
B.Check the discharge line to insure that the discharge line is neither closed nor blocked.
C.If the spool in the air distribution valve is not shifting, check the main spool. It must slide freely.
D.Excessive air leakage in the pump can prevent cycling. This condition will be evident. Air leakage into the discharge line indicates a ruptured diaphragm. Air leakage from the exhaust port indicates leakage in the air distribution valve. See
Diaphragm and diaphragm plate.
Disassembling the pilot valve.
Pilot valve with o-rings.
DANGER 
Before doing any maintenance on the pump, be certain all pressure is completely vented from the pump, suction, discharge, piping, and all other openings and connections. Be certain the air supply is locked out or made nonoperational, 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.
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