Sandpiper HDB2-A Service And Operation Manual

7/05 Model HDB2-A Page 1 Rev B

WARNING

HAZARD WARNING — POSSIBLE
EXPLOSION HAZARD can result if 1,1,1­Trichloroethane, 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. (See page 6)

BEFORE OPERATION

Before pump operation, inspect all
gasketed fasteners fo r looseness
caused by gasket creep. Retorque loose
fasteners to prevent leakage. Follow
recommended torques stated in the card
attached to the new pump.

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, disasembling or servicing your pump.

PRINCIPLE OF PUMP OPERATION

This ball check valve pump is powered by compressed air and is a 1:1 pressure
ratio design. The pump is alternately pressurize through the inner side of one
diaphragm chamber, while simultaneously exhausting the other inner chamber. Air
pressure 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, and the unit can be operated at discharge
heads over 200 feet (61 meters) of water head.

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 air. 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 the pilot valve into position
for shifting of the air distribution valve.

The chambers are manifolded together with a suction and discharge check valve
for each chamber which maintains flow in one direction through the pump.

INSTALLATION & START-UP

Locate the pump as close to the product being pumped as possible. Keep 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 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.

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.

SERVICE AND OPERASERVICE AND OPERA

SERVICE AND OPERASERVICE AND OPERA

SERVICE AND OPERA

TING MANUTING MANU

TING MANUTING MANU

TING MANU

ALAL

ALAL

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Model HDB2-AModel HDB2-A

Model HDB2-AModel HDB2-A

Model HDB2-A

Type 3

I M2 c/b T5
II 2GD b T5

CE

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

7/05 Model HDB2-A Page 2 Rev B

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.

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.

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

For best priming and most efficient pumping performance, it is important to maintain
check valves and valve seats in good condition for proper sealing. Need for inspection
or service of ball valves is usually indicated by poor priming, unstable cycling, reduced
performance, or pump cycles but will not pump.

Inspection and service of check valves requires the removal of five hex nuts and
one capscrew for each set of check valves (i.e., suction & discharge), providing access
to the two ball valves and their valve seats. New ball valves are 3

5

/8" (9.21 cm)
in diameter and will require replacement when worn to approximately 33/8" (8.57 cm)
diameter.

DIAPHRAGM SERVICING

Need for inspection or service of diaphragm is usually indicated when unit pumps
from one chamber only and air is discharged out pump discharge port or when liquid
being pumped is discharged through air exhaust port.

To service diaphragms remove two capscrews which secure the chamber to the
manifold assembly, and twelve hex nuts that secure the chamber to the main pump
assembly. To remove diaphragms, loosen diaphragm assembly by turning it out of the
diaphragm rod using a 1

1

/8" (2.857 cm) socket or wrench. Removal of opposite outer
chamber will permit removal of second diaphragm assembly and diaphragm rod as
a unit.

To remove the diaphragm from the diaphragm assembly, hold the diaphragm rod
in a clamping device, making sure to protect the rod surface of shaft so as not to scratch
or mar it in any way. With a wrench turn the diaphragm assembly out of the diaphragm
rod. To disassemble the components, turn a 5/16-18 UNC capscrew by hand into the
tapped hole in the inner diaphragm plate. This will keep the plate from turning while
the capscrew is removed. To remove the capscrew, place the assembly in a vise so
the two protruding ends of screws are loose in the vise jaws (approximately 7/8" apart).
Turn the center screw loose from the back plate and the assembly will come apart.

REASSEMBLY

All procedures for reassembling the pump are the reverse of the disassembly
instructions with further instructions as shown:

Check valves.

Torquing the diaphragm.

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 prio r to
disassembly.

7/05 Model HDB2-A Page 3 Rev B

The diaphragm assemblies are to be installed with the natural bulge outward or
toward the head of the center screw. Make sure both plates are installed with outer
radii against the diaphragm. After all components are in position in a vise and hand
tight, set a torque wrench for 40 ft. pounds (54.23 Newton meters) using a 1

1

/8" (2.857
cm) socket. After each diaphragm sub assembly has been completed, thread one
assembly into the diaphragm rod. Make sure the 5/16-18 UNC capscrew has been
removed from the inner plate and the diaphragm rod bumper is in place on the
diaphragm rod.

Install this sub assembly into the pump and secure by installing the outer chamber
in place and tightening the capscrews. This will hold the assembly in place while the
opposite side is installed. Install the second diaphragm assembly into the diaphragm
rod checking to see that the diaphragm rod bumper is in place. Tighten to 30 ft. lbs.
(40.67 Newton meters) torque before installing the outer chamber in place. If the holes
in the diaphragm flange do not align with the holes in the inner chamber flange, turn
the diaphragm assembly in the direction of tightening to align the holes so that the
capscrews can be inserted. This final torquing of the last diaphragm assembly will lock
the two diaphragm assemblies together. Secure the last
outer chamber by tightening down the securing nuts
gradually and evenly. This tightening procedure should
be done on both sides.

When reinstalling check valves, take care that the
seat gaskets are aligned properly before securing
porting flange in place.

A Note about Air Valve Lubrication

The SANDPIPER pump’s pilot valve and main air valve
asse mblies are d esign ed to op erate W ITHOUT
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 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 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.

DANGER

Before doing any maintenance on
the pump, be certain all pressure
is co mple tel y vente d from th e
pump, suction, d ischarge, piping,
an d al l ot her open ing s an d
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.
Fa ilur e to fol l ow t hes e
recommendations may result in serious
in jur y or dea th.

Pilot valve.

Air valve body.