SANDPIPER EB1-M User Manual

SERVICE AND OPERATING MANUAL

Model EB1-M

Type 3

PRINCIPLE OF PUMP OPERATION

This ball type 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 pressurizing 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 suction and discharge check valves
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 10-15 feet (9.14 meters)
or less. For suction lifts exceeding 15 feet of liquid, fill the chambers with liquid prior
to priming.

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.

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.

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 at all
times in the vicinity of the pump. Failure
to follow these recommendations may
result in serious injury or death.

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.

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
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.

WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • [phone] • Fax [phone] • www.warrenrupp.com

520-031-000 8/00 Model EB1-M Page 1

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 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 or additional copies, contact your
local Warren Rupp Distributor, or the Warren Rupp factory Literature Department at
the number shown on page one. To receive the correct manual, you must specify the
MODEL and TYPE information found on the name plate of the pump.

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.

MODELS WITH 1" SUCTION/DISCHARGE OR LARGER,
AND NON-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 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 o­ring 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). Re­install one end cap, and retaining ring on the valve body. Using the arbor press or
bench vise that was used in disassembly,
body, without shearing the o-rings. Re-install the spool, opposite end cap and
retaining ring 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, at 150 in./lbs. (16.94 Newton meters).

carefully press the sleeve back into the valve

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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 of the air exhaust can occur under certain temperature and
humidity conditions. Use of an air dryer unit should eliminate most icing problems.
Check exhaust regularly for build-up of ice or contaminants.

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 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 held into inner chambers with retaining
rings. An o-ring is behind each bushing. If the plunger has any sideways motion check
o-rings and bushing for deterioration or wear. 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.

CAUTION

If a diaphragm fails the pumped product
or fumes can enter the air side of the
pump. This side is exhausted through
the exhaust port (muffler).
When the product is a hazardous or
toxic material, the exhaust should be
piped to an appropriate area for safe
disposition. When the product source is
at a higher level than the pump (flooded
suction), the exhaust should be piped to
a higher level than the product to
prevent spills caused by siphoning.

CAUTION

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 disposal.

CAUTION

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.

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.

Remove the six bolts securing the manifold(s). Inspect the surfaces of both check
valve and seat for wear or damage that could prevent proper sealing. If pump is to prime
properly, valves must seat air tight.

DIAPHRAGM SERVICING

Remove the eight nuts securing the outer diaphragm chamber flange and remove
the chamber. Loosen the capscrew securing the diaphragm and plate to the rod by
leaving the diaphragm engaged with the capscrews around the outer flange, prevent­ing rotation of the rod. DO NOT USE A WRENCH ON THE DIAPHRAGM ROD. FLAWS
ON THE SURFACE MAY DAMAGE BEARINGS AND SEAL.

REASSEMBLY

During reassembly make certain that the rubber bumper is on the rod on each side.
Install the diaphragm with the natural bulge outward as indicated on the diaphragm.
Install the heavier plate on the outside of the diaphragm and make certain that the large
radius side of both plates are toward the diaphragm. Place the sealing washer
between the inner diaphragm plate and the end of the rod. Tighten the capscrew to
approximately 25 ft. lbs. (33.90 Newton meters). Torque while allowing diaphragm to
turn freely with plates. Except for EPDM Rubber, use a lightweight oil between plates
and diaphragm when doing this procedure. Use a wrench on the capscrew of the
opposite side to keep the rod from rotating. If the opposite chamber is assembled, the
rod need not be held.

When reassembling the outer chambers and the manifold, the bolts securing the
manifold flange to the chamber should be snugged prior to tightening the chamber
bolts, to insure that the chamber port flange is square with the manifold flange. Finish
tightening the manifold flange bolts after chamber bolting is secured.

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