This ball 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 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
pulsation in flow.
This pump was tested at the factory prior to shipment and is ready for operation. It
is completely self-priming from a dry start for suction lifts of 20 feet (6.096 meters) or
less. For suction lifts exceeding 20 feet of liquid, fill the chambers with liquid prior to
priming.
®
surge suppressor is recommended to further reduce
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.
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.
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. Use of a
Warren Rupp Filter/Regulator in the air line is recommended.
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.
WARREN RUPP®, INC., A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • (419) 524-8388 Fax (419) 522-7867 • www.warrenrupp.com
520-079-000 9/00Model EB1-SM Type 3 Page 1
Air inlet
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 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 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.
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.
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.
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 assembling 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.
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.
Before doing any maintenance on
DANGER
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 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.
Ball retainer
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.
Model EB1-SM Type 3 Page 2520-079-000 9/00
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 below. To receive the correct manual, you must specify the MODEL and
TYPE information found on the name plate of the pump.
MODELS WITH 1" SUCTION/DISCHARGE OR LARGER, AND
METAL CENTER SECTIONS
The main air valve sleeve and spool set is located in the valve body mounted on the
pump with four hex head capscrews. The valve body assembly is removed from the
pump by removing these four hex head capscrews.
With the valve body assembly off the pump, access to the sleeve and spool set is
made by removing four hex head capscrews (each end) on the end caps of the valve
body assembly. With the end caps removed, slide the spool back and forth in the sleeve.
The spool is closely sized to the sleeve and must move freely to allow for proper pump
operation. An accumulation of oil, dirt or other contaminants from the pump’s air supply,
or from a failed diaphragm, may prevent the spool from moving freely. This can cause
the spool to stick in a position that prevents the pump from operating. If this is the case,
the sleeve and spool set should be removed from the valve body for cleaning and further
inspection.
Remove the spool from the sleeve. Using an arbor press or bench vise (with an
improvised mandrel), press the sleeve from the valve body. Take care not to damage
the sleeve. At this point, inspect the o-rings on the sleeve for nicks, tears or abrasions.
Damage of this sort could happen during assembly or servicing. A sheared or cut o-ring
can allow the pump’s compressed air supply to leak or bypass within the air valve
assembly, causing the pump to leak compressed air from the pump air exhaust or not
cycle properly. This is most noticeable at pump dead head or high discharge pressure
conditions. Replace any of these o-rings as required or set up a routine, preventive
maintenance schedule to do so on a regular basis. This practice should include cleaning
the spool and sleeve components with a safety solvent or equivalent, inspecting for signs
of wear or damage, and replacing worn components.
To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve with
an o-ring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant). Re-install
one end cap, gasket and bumper on the valve body. Using the arbor press or bench vise
that was used in disassembly,
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. Re-install 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, re-install the valve body on the
pump using new gaskets. Tighten the four hex head capscrews evenly and in an
alternating cross pattern.
carefully press the sleeve back into the valve body,
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
520-079-000 9/00Model EB1-SM Type 3 Page 3
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 oring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant). Re-install one end
cap, and retaining ring 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 orings. 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, 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 150 in./lbs. (16.94 Newton meters).
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.
When removing capscrews on
CAUTION
suction or discharge valve retainer/
cap, make sure all pressure on
suction and discharge side of pump
has been relieved. Re-lock safety
wire on the capscrews before
continuing use.
Torquing the air inlet capscrews
Pilot valve removal
PILOT VALVE ACTUATOR
Bushings for the pilot valve actuators are held in the inner chambers wth retaining
rings. An o-ring is behind each bushing. If the plunger has any sideways motion check
o-rings and bushings for deterioration/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.
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 further service instructions.
E. Blockage in the liquid chamber can impede movement of diaphragm.
2. Pump cycles but will not pump
A. Suction side of pump pulling in air. Check the suction line for air leaks and be sure
that the end of the suction line is submerged. Check flange bolting. Check valve flanges
and manifold to chamber flange joints.
Pilot valve spool and o-rings
Bushings and o-rings
Model EB1-SM Type 3 Page 4520-079-000 9/00
B. Make certain the suction line or strainer is not plugged. Restriction at the suction is
indicated by a high vacuum reading when a vacuum gauge is installed in the suction line.
C. Check valves may not be seating properly. To check, remove the suction line and
cover the suction port with your hand. If the unit does not pull a good suction (vacuum),
the check valves should be inspected for proper seating.
D. Static suction lift may be too high. Priming can be improved by elevating the suction
and discharge lines higher than the check valves and pouring liquid into the unit through
the suction inlet. When priming at high suction lifts or with long suction lines operate the
pump at maximum cycle rate.
3. Low performance
A. Capacity is reduced as the discharge pressure increases, as indicated on the
performance curve. Performance capability varies with available inlet air supply. Check
air pressure at the pump inlet when the pump is operating to make certain that adequate
air supply is maintained.
B. Check vacuum at the pump suction. Capacity is reduced as vacuum increases.
Reduced flow rate due to starved suction will be evident when cycle rate can be varied
without change in capacity. This condition will be more prevalent when pumping viscous
liquids. When pumping thick, heavy materials the suction line must be kept as large in
diameter and as short as possible, to keep suction loss minimal.
C. Low flow rate and slow cycling rate indicate restricted flow through the discharge line.
Low flow rate and fast cycling rate indicate restriction in the suction line or air leakage
into suction.
D. Unstable cycling indicates improper check valve seating on one chamber. This
condition is confirmed when unstable cycling repeats consistently on alternate exhausts. Cycling that is not consistently unstable may indicate partial exhaust restriction
due to freezing and thawing of exhaust air. Use of an anti-freeze lubricant in an air line
lubricator should solve this problem.
For additional information, see the Warren Rupp Troubleshooting Guide.
BEFORE PUMP OPERATION all
WARNING
external gasketed fasteners must
be inspected for looseness caused
by gasket creep after leaving the
factory. Retorque loose fasteners
to insure against leakage. Follow
recommended torques where called
out. (A card is attached to each new
pump stating this fact.)
IMPORTANT
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.
WARRANTY
This pump is warranted for a period of five years against defective material and
workmanship. Failure to comply with the recommendations stated in this manual voids
all factory warranty.
RECOMMENDED WARREN RUPP ACCESSORIES TO
MAXIMIZE PUMP PERFORMANCE:
• Tranquilizer® Surge Suppressor: For nearly pulse-free flow.
• Warren Rupp Filter/Regulator: For modular installation and service
convenience.
• Warren Rupp Speed Control: For manual or programmable process
control. (Manual adjustment or 4-20mA reception.)
For more detailed information on these accessories, contact your local Warren
Rupp Factory-Authorized Distributor, or Warren Rupp corporate headquarters.
37170-045-330Capscrew, Hex Head8
38171-037-330Capscrew, Hex Head (Spec.)
3
4
39670-035-157Ball Retainer/Cap4
40560-083-360O-Ring4
Repair Parts shown in bold face (darker) type
are more likely to need replacement after
extended periods of normal use. 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
000...Assembly, sub-assembly;
and some purchased items
Reduce quantity by 4 when used with dual ported manifold.
2
Available in kit form. Order P/N 031-060-000 which also includes items 7, 8, 9, 24 & 25.
3
Increase quantity by 4 on model with free-standing base.
Repair Parts shown in bold face (darker) type
are more likely to need replacement after
extended periods of normal use. 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
000...Assembly, sub-assembly;
and some purchased items
010...Cast Iron
015...Ductile Iron
025…Music Wire
080...Carbon Steel, AISI B-1112
100...Alloy 20
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 Impregnated
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