SANDPIPER EB80M User Manual

SERVICE AND OPERATING MANUAL

®

Models EB3-M/EB4-M/EB80M

Type 2

PRINCIPLE OF PUMP OPERATION

The SandPIPER pump is powered by compressed air which alternately pressur­izes the inner sides of the two diaphragm chambers while simultaneously exhausting
the opposite inner chambers causing the diaphragms, which are connected by a shaft,
to move endwise. Since air pressure is applied over the entire surface of the
diaphragm which is forcing liquid to be discharged by its other side, the diaphragm is
operating under a balanced condition during the discharge stroke. This allows the unit
to be operated at discharge heads over 200 feet (61 meters) of water head.

Alternate pressurizing and exhausting of the diaphragm chamber is performed by
an externally mounted, pilot-operated, four way, spool type air distribution valve.
When the spool is at one end of the valve body, inlet air pressure is connected to one
diaphragm chamber and the other diaphragm chamber is connected to the exhaust.
When the spool is removed to the opposite end of the valve body, the porting of
chambers is reversed. The air distribution valve spool is moved from one end position
to the other in the valve body by means of an internal pilot valve which alternately
pressurizes the ends of the air distribution valve spool while simultaneously exhaust­ing the other ends. The pilot valve is positively shifted at each end of the diaphragm
stroke by the diaphragm plate’s coming in contact with the end of the pilot valve spool
and pushing 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 to
maintain flow in one direction through the pump.

INSTALLATION PROCEDURES

Position the pump as close as possible to the source of the liquid to be pumped.
Avoid long or undersize suction lines and use the minimum number of fittings.

For permanent installation involving rigid piping, install short flexible sections of
hose between the pump and piping. This reduces strains and permits easier removal
of the pump for service when required. At time of installation, inspect all external

gasketed fasteners for looseness caused by gasket creep. Tighten loose
fittings securely to prevent leakage.

AIR SUPPLY

Do not connect the unit to an air supply in excess of 125 PSI (8.61 bars). Install
a shutoff valve in the air supply line to permit removal of the unit for servicing. When
connecting an air supply of rigid piping, mount a section of flexible line to the pump
to eliminate piping strain. In permanent installations, an air line filter is recommended.

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.

AIR INLET & PRIMING

Your SandPIPER pump has been tested prior to shipment and is ready for use as
received. It is completely self-priming and no initial filling with fluid is required.

If the unit is to be totally submerged, the air exhaust must be piped above liquid
level to prevent the liquid and foreign material from entering the air distribution valve
mechanism.

Open the inlet air valve at least one turn to allow sufficient cycling rate for the pump
to prime (30 to 60 cycles per minute). After pumping starts, adjust the inlet air valve
for the desired pumping capacity. When further opening of the inlet air valve increases
cycling rate without increasing the flow rate, the pump is being starved of liquid due
to suction limitations. Further opening of the air inlet valve will waste compressed air.

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.

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 disposition.

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.

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

520-143-000 8/00 Models EB3-M/EB4-M/EB80M Page 1

Set the inlet air valve for lowest cycling rate that does not decrease flow rate for most
efficient operation.

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 set to deliver one drop of 10 wt., non­detergent 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 below. 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.

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.

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 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). 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 arbor press or bench vise that was
used in disassembly, press the sleeve back into the valve body. You may have to clean

Page 2 Models EB3-M/EB4-M/EB80M 520-143-000 8/00

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.

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 through 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 o­ring seal.

When reinserting an externally serviceable pilot valve, push both plungers out of
the path of the pilot valve. This will prevent damage to the plungers and pilot valve.

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.

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-up of the air exhaust can occur under certain temperature and
humidity conditions. Use of an air dryer unit should eliminate most icing problems.

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.

BETWEEN USES

When the pump is used for materials that tend to settle out or transform from liquid
to solid form, care must be taken after each use or during idle time to remove them
and flush the pump as required to prevent damage.

In freezing temperatures the pump must be completely drained when idle. This
model must be tilted to allow the liquid from the chambers to run out of the discharge
port.

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 twelve bolts (six 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
plate lugs. To disassemble the diaphragm assemblies, screw into the inner plates two
threaded pins, place the pins in a vise and turn the outer plate counterclockwise using

1

/8" wrench. The interior components consisting of shaft seals, sleeve bearings

the 1
and bearing retainers are now accessible for service.

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

1

/8" (3.17 cm) wrench on the outer

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