SANDPIPER EB2-SM User Manual

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SERVICE AND OPERATING MANUAL
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Model EB2-SM
Type 3
PLEASE NOTE!
The photos 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
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.
The chambers are manifolded together with a suction and discharge check valve for each chamber, maintaining flow in one direction through the pump.
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.
WARNING
The weight of the air supply line and of the filter must be supported by some means other than the air valve cap. Failure to provide support may result in damage to 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 sation in flow.
AIR SUPPLY
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surge suppressor is recommended to further reduce pul-
Figure 1: Air Inlet
AIR INLET & PRIMING
For start-up, open an air valve approximately ½ to ¾ turn. After the unit primes, an air valve can be opened to increase flow as desired. If opening the valve in-
WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • www.warrenrupp.com (419) 524-8388 Fax (419) 522-7867
520-097-000 8/00 MODEL EB2-SM PAGE 1
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creases 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.
A NOTE ABOUT AIR VALVE LUBRICATION
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.
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.
Freezing or icing of the air exhaust can occur under certain temperature and humidity conditions. Use of an air dryer should eliminate most icing problems.
Figure 2: Ball check valve and seat.
Figure 3: Torquing the diaphragm plate.
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.
DIAPHRAGM SERVICING
Remove the eight bolts (four each side) securing the manifold assemblies to the outer chambers. Remove the eight bolts securing the outer chamber to the inner chamber. Remove the diaphragm assembly (outer plate, diaphragm, inner plate) by turning the assembly counterclockwise using a 1" (2.54 cm) wrench on the outer plate lugs. To disassemble the diaphragm assemblies, secure in a vise and turn the outer plate counterclockwise using the 1” wrench.
Procedures for reassembling the diaphragms are the reverse of the above. The diaphragms must be installed with their natural bulge to the outside, toward the outer diaphragm plate. Install the inner plate with the flat face against the diaphragm.
After all components are in position in a vise and hand tight, tighten with a wrench to approximately 40 ft. Ibs. (54.23 Newton meters) torque. After both diaphragm assemblies have been assembled, thread one assembly into the shaft (hold the shaft near the middle in a vise with soft jaws, to protect the finish). Install this sub assembly
Figure 4: Installed diaphragm.
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
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 the pump is used for toxic or aggressive fluids, it should be flushed clean prior to disassembly.
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into the pump and secure by placing the outer chamber on the end with the dia­phragm. This holds the assembly in place while the opposite side is installed. Torque the last diaphragm assembly to 30 ft. Ibs. (40.67 Newton meters). This final torquing will lock the diaphragm assemblies together. Place the remaining outer chamber on the open end and loosely tighten the bolts. Replace the manifold assemblies to square the flanges before final tightening of the remaining bolts.
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.
The main air valve sleeve and SpooI set Iist 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). Press the set into the valve body easily, without shearing the o-rings. Re-install one end cap, gasket and bumper on the valve body. Using the ardor press or bench vise that was used in disassembly, press the sleeve back into the valve body. You may have to clean the surfaces of the valve body where the end caps mount. Material may remain from the old gasket. Old material not cleaned from this area may cause air leakage after reassembly. Take care that the bumper stays in place allowing the sleeve to press in all the way. Reinstall the spool, the opposite end cap, gasket and bumper on the valve body. After inspecting and cleaning the gasket surfaces on the valve body and intermediate, reinstall the valve body on the pump using new gas­kets. Tighten the four hex head capscrews evenly and in an alternating cross pattern.
CAUTION
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 safety wire on the capscrews before continuing use.
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.
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.
CAUTION
At time of installation, inspect all external gasketed fasteners for looseness caused by gasket creep. Tighten loose fittings securely to prevent leakage.
PILOT VALVE
This assembly is reached by removing the air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing.
When reinserting an externally serviceable pilot valve, push both plungers out of the path of the pilot valve so that they and the pilot valve are not damaged.
Service Note: If a problem arises with the pilot valve, it is usually corrected by replacing only o-rings. Always grease the spool prior to inserting into the sleeve. If the sleeve is removed from the body, reinsertion must be from the same side it was removed from, the chamfered side. Again, grease the o-rings so that it slides into the body. Make sure the retaining ring has securely been inserted around the sleeve.
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PILOT VALVE ACTUATOR
The bushings for the pilot valve actuators are threaded into the intermediate bracket from the outside. The plunger may be removed for inspection or replacement from the inside by removing the air distribution valve body and the pilot valve body from the pump. The plungers should be visible as you look into the intermediate from the top. Depending on their position, you may find it necessary to use a fine piece of wire to pull them out.
Under rare circumstances, it may become necessary to replace the o-ring seal. The bushing can be turned out through the inner chamber by removing the outer chamber assembly to reach the bushing.
TROUBLE SHOOTING
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.
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.
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.
CAUTION
BEFORE PUMP OPERATION all 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.
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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.
• WarrenRupp 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.
© 2000 Warren Rupp, Inc. All rights reserved. ®Warren Rupp, SandPIPER, and Tranquilizer are registered tradenames of Warren Rupp, Inc. ®Neverseize is a registered tradename of Loctite Printed in U.S.A.
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REPAIR PARTS LIST and DRAWING
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Model EB2-SM
Type 3
ITEM TOTAL
NO. PART NUMBER DESCRIPTION RQD.
1 070-006-170 Bearing, Sleeve 2 2 114-002-156 Bracket, Intermediate 1
114-002-010 Bracket, Intermediate 1
3 720-004-360 Seal, U-Cup 2
4 135-008-000 Bushing, Threaded,
with O-Ring 2 5 620-004-114 Plunger, Actuator 2 6 095-073-000 Assembly, Pilot Valve* 1 6-A 095-070-551 Valve Body 1 6-B 755-025-000 Sleeve (without O-Ring) 1 6-C 560-033-360 O-Ring (Sleeve) 4 6-D 775-026-000 Spool (without O-Ring) 1 6-E 560-023-360 O-Ring (Spool) 2 6-F 675-037-080 Retaining Ring 1 7 360-041-425 Gasket, Valve Body 1 8 560-001-360 O-Ring 2
9 095-043-156 Body, Valve 1
095-043-010 Body, Valve 1
10 132-014-358 Bumper, Valve Spool 2
11 165-011-157 Cap, End 2
165-011-010 Cap, End 2
12 360-048-425 Gasket, Valve Body 1 13 360-010-425 Gasket, End Cap 2 14 560-020-360 O-Ring 6 15 031-012-000 Sleeve & Spool Set 1
16 170-032-330 Capscrew, Hex Head 8 17 170-045-330 Capscrew, Hex Head 4
18 132-002-360 Bumper, Diaphragm 2
19 196-001-157 Chamber, Inner 2
196-001-010 Chamber, Inner 2
20 286-007-365 Diaphragm 2
286-007-363 Diaphragm 2 286-007-360 Diaphragm 2 286-007-356 Diaphragm 2 286-007-354 Diaphragm 2
21 560-022-360 O-Ring 2 22 685-007-120 Rod, Diaphragm 1
24 170-024-330 Capscrew, Hex Head 8 25 618-003-330 Plug, Pipe 2 26 900-006-330 Washer, Lock 28 27 612-047-330 Plate, Diaphragm 2 28 612-039-010 Plate, Outer 2 29 807-026-330 Stud 2 30 902-003-000 Stat-O-Seal 2 31 530-002-000 Muffler, Exhaust 1
* Available in Kit Form. Order P/N 031-055-000 which also includes Items 5, 7, 12, & 46.
Repair Parts shown in bold face (darker) type are more likely to need replacement after extended periods of normal use. They are readily available from most War­ren Rupp distributors. The pump owner may prefer to maintain a limited inventory of these parts in his own stock to reduce repair downtime to a minimum.
IMPORTANT: When ordering repair parts always furnish pump model number, serial number and type number.
MATERIAL CODES
The Last 3 Digits of Part Number
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 111…Alloy Type 316 Stainless Steel (Electro Polished) 112…Alloy “C” 113…Alloy Type 316 Stainless Steel (Hand Polished) 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 355…Thermoplastic Elastomer 356…Hytrel 357…Rupplon (Urethane Rubber)
358...Rupplon (UrethaneRubber) Colorcoded: PURPLE
(Some Applications, Compression Mold) 360…Buna-N Rubber Color coded: RED 363…Viton (Fluorel) Color coded: YELLOW 364…E.P.D.M Rubber Color coded: BLUE 365…Neoprene Rubber Color coded: GREEN 366…Food Grade Nitrile Color coded: WHITE 368…Food Grade EPDM 375…Fluorinated Nitrile 405…Cellulose Fibre 408…Cork and Neoprene 425…Compressed Fibre 426…Blue Gard 440…Vegetable Fibre 500…Delrin 500 501…Delrin 570 520…Injection Molded PVDF Natural Color 541…Nylon, glass filled 542…Nylon, unfilled 544…Nylon Injection Molded 550…Polypropylene 551…Polypropylene, glass filled 552…Polypropylene, unfilled 555…PVC (Polyvinyl Chloride) 580…Ryton 600…Teflon (virgin material) Tetrafluoroethylene (TFE) 603…Blue Gylon 604…Teflon – Diaphragm 606…Teflon 610…Teflon Encapsulated Silicon 611…Teflon Encapsulated Viton
WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • www.warrenrupp.com (419) 524-8388 Fax (419) 522-7867
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ITEM TOTAL
NO. PART NUMBER DESCRIPTION RQD.
32 545-007-330 Nut, Hex 8 33 196-088-010 Outer Chamber 2 34 722-055-012 Valve Seat 4
35 560-079-611 O-Ring 4
560-079-360 O-Ring 4
36 050-005-360 Check Valve, Ball 4
050-005-354 Check Valve, Ball 4 050-005-365 Check Valve, Ball 4 050-010-600 Check Valve, Ball 4
37 560-008-611 O-Ring 4
560-008-360 O-Ring 4 38 670-037-010 Ball Retainer 4 39 900-003-330 Lockwasher 8 40 171-040-330 Capscrew 8 41 326-031-080 Mounting Foot 2 42 286-020-604 Overlay Diaphragm 2 43 518-110-010 Suction Side Only For Filter Press 2
44 560-012-611 O-Ring 4
560-012-360 O-Ring 4 45 170-081-330 Capscrew, Hex Head 4 46 132-022-360 Bumper 2 47 170-060-330 Capscrew, Hex Head 8 48 170-035-330 Capscrew, Hex Head 8
ITEMS NOT SHOWN:
031-019-156 Valve Body Assembly 1
(consisting of Items 9, 10, 11, 13, 14, 15, 16)
031-019-010 Valve Body Assembly 1
(consisting of Items 9, 10, 11, 13, 14, 15, 16)
535-037-000 Caution Plate 4
NOTE: To make suction side in-line serviceable, order Free Standing Base Kit 475-129-000.
Repair Parts shown in bold face (darker) type are more likely to need replacement after extended periods of normal use. They are readily available from most War­ren Rupp distributors. The pump owner may prefer to maintain a limited inventory of these parts in his own stock to reduce repair downtime to a minimum.
IMPORTANT: When ordering repair parts always furnish pump model number, serial number and type number.
MATERIAL CODES
The Last 3 Digits of Part Number
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 111…Alloy Type 316 Stainless Steel (Electro Polished) 112…Alloy “C” 113…Alloy Type 316 Stainless Steel (Hand Polished) 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 355…Thermoplastic Elastomer 356…Hytrel 357…Rupplon (Urethane Rubber) 358…Rupplon (UrethaneRubber) Colorcoded: PURPLE
(Some Applications,CompressionMold) 360…Buna-N Rubber Color coded: RED 363…Viton (Fluorel) Color coded: YELLOW 364…E.P.D.M Rubber Color coded: BLUE 365…Neoprene Rubber Color coded: GREEN 366…Food Grade Nitrile Color coded: WHITE 368…Food Grade EPDM 375…Fluorinated Nitrile 405…Cellulose Fibre 408…Cork and Neoprene 425…Compressed Fibre 426…Blue Gard 440…Vegetable Fibre 500…Delrin 500 501…Delrin 570 520…Injection Molded PVDF Natural Color 541…Nylon, glass filled 542…Nylon, unfilled 544…Nylon Injection Molded 550…Polypropylene 551…Polypropylene, glass filled 552…Polypropylene, unfilled 555…PVC (Polyvinyl Chloride) 580…Ryton 600…Teflon (virgin material) Tetrafluoroethylene (TFE) 603…Blue Gylon 604…Teflon – Diaphragm 606…Teflon 610…Teflon Encapsulated Silicon 611…Teflon Encapsulated Viton
Delrin, Teflon, Hytrel and Viton are registered tradenames of E.I. DuPont.
Gylon is a registered tradename of Garlock Inc. Warren Rupp, Rupplon, and SandPIPER are registered
tradenames of Warren Rupp, Inc. Ryton is a registered tradename of Phillips Chemical
Company.
520-097-000 8/00 MODEL EB2-SM PAGE 7
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6-D
6-E
6-B
6-C
6-F
Use with Overlay Diaphragm
© 2000 Warren Rupp, Inc. All rights reserved. ®Warren Rupp and SandPIPER are registered tradenames of Warren Rupp, Inc. Printed in U.S.A.
MODEL EB2-SM PAGE 8 520-097-000 8/00
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