SANDPIPER HDF4-A User Manual

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SERVICE AND OPERATING MANUAL

II 2GD T5

Models HDF3-A Type 7

See pages 16 & 17 for ATEX ratings

HDF4-A Type 3

Table of Contents

Engineering Data and Performance Curve............................................................ 1

Explanation of Pump Nomenclature ...................................................................... 2

Dimensions ............................................................................................................ 3

Principle of Operation ............................................................................................ 4

Installation and Start-Up ........................................................................................ 4

Air Supply .............................................................................................................. 4

Air Inlet & Priming .................................................................................................. 4

Installation Guide ................................................................................................... 5

ESADS+Plus®:

Pilot Valve .............................................................................................................. 7

Pilot Valve Actuator ................................................................................................ 7

Externally Serviceable Air Distribution System ................................6

Air Exhaust ............................................................................................................ 7

Between Uses ....................................................................................................... 7

Flap Valve Servicing .............................................................................................. 7

Diaphragm Servicing ............................................................................................. 7

Reassembly ........................................................................................................... 7

Service Instructions: Troubleshooting ................................................................... 8

Warranty ................................................................................................................ 8

Grounding The Pump ............................................................................................ 9

Important Safety Information ............................................................................... 10

Recycling ............................................................................................................. 10

Material Codes .................................................................................................... 11

Composite Repair Parts List ........................................................................... 12-13

Composite Repair Drawing.................................................................................. 14

CE Declaration of Conformity - Machinery .......................................................... 15

CE Declaration fo Conformity - ATEX .................................................................. 16

Explanation of ATEX Certication ........................................................................ 17

Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA

Telephone (419) 524-8388 • Fax (419) 522-7867 • warrenrupp.com

hdf3adl7sm-rev0614

Quality System

II 2GD T5

ISO 9001 Certied

Environmental

Management System

ISO 14001 Certied

See pages 16 & 17 for ATEX ratings

Heavy Duty Flap Valve

HDF3-A Type 7 HDF4-A Type 3

Air-Operated Double Diaphragm Pump

ENGINEERING, PERFORMANCE & CONSTRUCTION DATA

INTAKE/DISCHARGE PIPE SIZE

3" 150# ANSI Flange

PSI

BAR

100

20(34)

100 PSI

80 PSI

60 PSI

HEAD

40 PSI

20 PSI Air Inlet Pressure

CAPACITY

0 to 260 gallons per minute

(0 to 988 liters per minute)

AIR CONSUMPTION

SCFM (M

40(68)

60(101.9)

/hr)

80(135.9)

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to nearly 3" (75mm)

125 psi or 289 ft. of water (8.8 Kg/cm2 or 88 meters)

MODEL HDF3-A Performance Curve

Performance based on the following: elastomer fitted pump, flooded suction,

water at ambient conditions. The use of other materials and varying hydraulic

100(169.9)

conditions may result in deviations in excess of 5%.

120(203.9)

HEADS UP TO

200

60 80

100

120

140 160

180

200

220

240

U.S. Gallons per minute

0 100 200 300 400 500 600 700 800 900 1000

Liters per minute

CAPACITY

SANDPIPER® pumps are designed to be powered only by compressed air.

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 1

260

Explanation of Pump Nomenclature, HDF3-A & HDF4-A

II 2GD T5

MATERIALS OF CONSTRUCTION

To order a pump or replacement parts, rst enter the Model Number HDF3-A, or HDF4-A, followed by the Type Designation listed below in the far left column.

Type Manifold

DA7. 356-T6AL 356-T6AL 356-T6AL Alm35AL Alm35AL 356-T6AL 416SS SS PS N R A B 245

DN7. 356-T6AL 356-T6AL 356-T6AL Alm35AL Alm35AL 356-T6AL 416SS SS PS N N A B 245

DB7. 356-T6AL 356-T6AL 356-T6AL Alm35AL Alm35AL 356-T6AL 416SS SS PS B B A B 245

DK7. 356-T6AL 356-T6AL 356-T6AL Alm35AL Alm35AL 356-T6AL 416SS SS PS N H A B 245

DS7. 356-T6AL 356-T6AL 356-T6AL Alm35AL Alm35AL 356-T6AL 416SS SS PS S S A B 245

Elbow

Outer

Chamber

Inner

Chamber

Outer

Diaphragm

Plates

Inner

Diaphragm

Plate

Intermedi-

ate Housing

Diaphragm

Rod

Valve

Hardware Diaphragm Flap

Seat

Valve

Material

Seat

Gasket

Sealing

Rings

Shippping

Wt. (lbs)

Meanings of Abbreviations:

A = Compressed Fibre B = Nitrile N = Neoprene SS = Stainless Steel AL = Aluminun CI = Cast Iron PS = Plated Steel S = Santoprene ALM = Almag 35 Aluminum H = Hytrel® R = Urethane

Hytrel is a registered tradename of E.I. du Pont. Santoprene is a registered tradename of Exxon Mobil Corp.

Maximum and Minimum Temperatures are the limits for which these materials can be operated. Temperatures coupled with pressure affect the longevity of diaphragm pump components. Maximum life should not be expected at the extreme limits of the temperature ranges.

Materials

Nitrile General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic uid resistance. Should

not be used with highly polar solvents like acetone and MEK, ozone, chlorinated hydrocarbons and nitro hydrocarbons.

NEOPRENE All purpose. Resistant to vegetable oils. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons.

HYTREL

Urethane

Santoprene

lent abrasion resistance.

‡

For specic applications, always consult “Chemical Resistance Chart" Technical Bulletin

Good on acids, bases, amines and glycols at room temperature.

Shows good resistance to abrasives. Has poor resistance to most solvents and oils.

Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life. Excel-

CF-8M Stainless Steel equal to or exceeding ASTM specication A743 for corrosion resistant iron chro- mium, iron chromium nickel, and nickel based alloy castings for general applications. Commonly referred to as 316 Stainless Steel in the pump industry.

Maximum Minimum

Operating Temperatures

190°F -10°F 88°C -23°C

200°F -10°F 93°C -23°C

220°F -20°F 104°C -29°C

150°F +32°F 66°C 0°C

275°F -40°F 135°C -40°C

hdf3adl7sm-rev0614

II 2 G c T5 II 3/2 G c T5 II 2 D c T100oC All models, including pumps equipped with Aluminum wetted and midsection parts. See page 6 for ATEX Explanation of Type

Examination Certicate.

Dimensions:

Dimensions are ± 1/8" Figures in parenthesis = millimeters

HDF3-A & HDF4-A

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 3

SERVICE AND OPERATING MANUAL

II 2GD T5

Models HDF3-A Type 7

See pages 16 & 17 for ATEX ratings

PRINCIPLE OF PUMP OPERATION

This ap swing 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 ow in one direction through the pump.

HDF4-A Type 3

INSTALLATION & START-UP

Locate the pump as close to the product being pumped as possible, keeping suction

line length and number of ttings to a minimum. Do not reduce line size.

For installations of rigid piping, short exible 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 ow.

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, ll the chambers with liquid prior to priming.

Surge Suppressor is recommended to further reduce

AIR SUPPLY

Air supply pressures cannot exceed 125 psi (8.61 bar). Connect the pump air inlet

to an air supply of sufcient capacity and pressure required for desired performance. When the air line is solid piping, use a short length of exible 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 ow as desired. If opening the valve increases cycling rate, but does not increase ow rate, cavitation has occurred, and the valve

should be closed slightly.

For the most efcient use of compressed air and the longest diaphragm life, throttle the air inlet to the lowest cycling rate that does not reduce ow.

hdf3adl7sm-rev0614

Available from Distributor

Available from Warren Rupp

INSTALLATION GUIDE

Bottom Discharge Flap Valve Unit

CAUTION

The air exhaust should be piped to an area for safe disposition of the product being pumped, in the event of a diaphragm failure.

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 5

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 weight, 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 (available from Warren Rupp) 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.

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). 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 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.

hdf3adl7sm-rev0614

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 threaded into the intermediate bracket from the outside. 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 ne 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.

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 ow and reduce pump performance. When the product source is at a higher level than the pump (ooded

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 a Warren Rupp Extractor/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 ushed 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 ap valve inspection or replacement, remove the ange bolts securing the suction and discharge elbows and loosen Dresser-type couplings. The ap valves are exposed

for inspection or servicing upon removal of elbows.

DIAPHRAGM SERVICING

Diaphragms are serviced by removing the outer diaphragm chambers which are secured with 12 bolts. After removing the outer chamber, unbolt the diaphragm plate by removing 6 socket head capscrews (Allen wrench required). To remove the diaphragm rod, remove the inner diaphragm plate secured by a nut on the end of the diaphragm rod. The opposite diaphragm and rod can then be removed as a unit. The interior components consisting of sleeve bearings, rod seals, and pilot valve actuator bushings are now accessible for service if required.

REASSEMBLY

All procedures for reassembling the pump are the reverse of the above with these further instructions:

1. Install the diaphragms with their natural bulge outward. Make certain that the rubber diaphragm rod bumper is installed on the rod behind each inner diaphragm plate. Retorque the 6 socket head capscrews that secure the diaphragm between the plates to 30 foot Ibs. (40.67 Newton meters) torque reading.

2. Caution should be used while reassembling the check valves. The valves are designed for some preload over the retainer and the hinge pad. This is done to insure proper face contact with the seat. After all parts are in place, tighten the lock nuts down on the assembly to the point where visual inspection shows that seat and valve face mate without gap. This is important for dry primes. However, after priming action has started, valves will function due to differential pressure without concern or trouble.

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 7

TROUBLE SHOOTING

PROBLEM: Pump cycles but will not pump. (Note: higher suction lifts require faster

cycling speed for priming.)

POSSIBLE CAUSES:

A. Air leak in suction line. B. Excessive suction lift. C. Check valve not closing.

D. Leakage at joint of suction manifold or elbow ange.

E. Suction line plugged. F. Diaphragm ruptured.

PROBLEM: Pump will not cycle. (Note: Always disconnect air supply to relieve air pressure before disassembling any portion of pump.)

POSSIBLE CAUSES:

A. Discharge hose or line plugged, or discharge head requirement greater than air

pressure. (Disconnect discharge line to check.)

B. Spool in air distribution valve not shifting. (Remove end cap and check spool - must

slide freely.) C. Diaphragm ruptured. (Air will escape out discharge line in this case.) D. Blockage in diaphragm chamber preventing movement. (Shut off air supply and

reopen after pressure is relieved.)

E. Plugged or dirty exhaust mufer.

PROBLEM: Uneven discharge ow. (Indicates one chamber not operating properly.) POSSIBLE CAUSES:

A. Check valve not sealing properly in one chamber. B. Diaphragm failure in one chamber.

C. Air leak at suction manifold joint or elbow ange one side.

For additional information, see the Warren Rupp Troubleshooting Guide.

WARRANTY

This pump is warranted for a period of ve 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:

• Tranquiilizer® Surge Suppressor. For nearly pulse-free ow.

• Warren Rupp Air Dryer. For clean, dry compressed air.

• 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.

hdf3adl7sm-rev0614

Grounding The Pump

One eyelet is fastened to the pump hardware.

One eyelet is installed to a true earth ground.

WARNING

Take action to prevent static sparking. Fire or explosion can result, especially when handling ammable liquids. The pump, piping, valves, containers or other miscellaneous equipment must be grounded.

This 8 foot long (244 centimeters) Ground Strap, part number 920.025.000 can be ordered as a service item.

To reduce the risk of static electrical sparking, this pump must be grounded. Check the local electrical code for detailed grounding instruction and the type of equipment required, or in the absence of local codes, an industry or nationally recognized code having jurisdiction over

specic installations.

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 9

IMPORTANT SAFETY

INFORMATION

IMPORTANT

Read these safety warnings

Read these safety warnings and instructions in this

and instructions in this manual completely, before

manual completely, before installation and start-up

of the pump. It is the responsibility of the

of the pump. It is the responsibility of the purchaser to retain this manual for reference.

purchaser to retain this manual for reference. Failure to comply with the recommendations

Failure to comply with the recommendations stated in this manual will damage the pump,

stated in this manual will damage the pump, and void factory warranty.

and void factory warranty.

prevent leakage. Follow recommended torques stated in this manual.

gas will void the warranty.

pressurized and must be bled of its pressure.

installation and start-up

CAUTION

Before pump operation, inspect all gasketed fasteners for looseness caused by gasket creep. Retorque loose fasteners to

CAUTION

Pump not designed, tested or certied to be powered by compressed natural gas. Powering the pump with natural

WARNING

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

WARNING

Take action to prevent static sparking. Fire or explosion can result, especially when handling ammable liquids.

containers or other miscellaneous equipment must be grounded. (See page 10)

The pump, piping, valves,

WARNING

This pump is pressurized internally with air pressure during operation. Always make certain that all bolting is in good condition and

bolting is reinstalled during assembly.

that all of the correct

WARNING

When used for toxic or aggressive uids, the pump should always be ushed clean prior to disassembly.

WARNING

Before doing any maintenance on the pump, be certain all pressure is completely vented from the pump, suction, discharge,

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

piping, and all other

WARNING

Airborne particles and loud noise hazards.

Wear ear and eye protection.

WARNING

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.

WARNING

Use safe practices when lifting

RECYCLING

Many components of SANDPIPER® AODD pumps are made

of recyclable materials (see chart on page 12 for material

specications). We encourage pump users to recycle worn out parts and pumps whenever possible, after any hazardous pumped uids are thoroughly ushed.

hdf3adl7sm-rev0614

MATERIAL CODES

THE LAST 3 DIGITS OF PART NUMBER

000 Assembly, sub-assembly;

and some purchased items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable 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 115 302/304 Stainless Steel 117 440-C Stainless Steel (Martensitic) 120 416 Stainless Steel

(Wrought Martensitic) 123 410 Stainless Steel

(Wrought Martensitic) 148 Hardcoat Anodized Aluminum 149 2024-T4 Aluminum 150 6061-T6 Aluminum 151 6063-T6 Aluminum 152 2024-T4 Aluminum (2023-T351) 154 Almag 35 Aluminum 155 356-T6 Aluminum 156 356-T6 Aluminum 157 Die Cast Aluminum Alloy #380 158 Aluminum Alloy SR-319 159 Anodized Aluminum 162 Brass, Yellow, Screw Machine Stock 165 Cast Bronze, 85-5-5-5 166 Bronze, SAE 660 170 Bronze, Bearing Type, Oil Impregnated 175 Die Cast Zinc 180 Copper Alloy 305 Carbon Steel, Black Epoxy Coated 306 Carbon Steel, Black PTFE Coated 307 Aluminum, Black Epoxy Coated 308 Stainless Steel, Black PTFE Coated 309 Aluminum, Black PTFE Coated 310 PVDF Coated 313 Aluminum, White Epoxy Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminum, Electroless Nickel Plated 333 Carbon Steel, Electroless

Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 351 Food Grade Santoprene; Color: NATURAL

353 Geolast; Color: BLACK 354 Injection Molded #203-40

Santoprene- Duro 40D +/-5; Color: RED 355 Thermal Plastic 356 Hytrel; Color: BLUE 357 Injection Molded Polyurethane;

Color: GREEN 358 Urethane Rubber; Color: NATURAL

(Some Applications)

(Compression Mold) 359 Urethane Rubber; Color: NATURAL 360 Nitrile Rubber; Color Coded: RED 361 Nitrile 363 FKM (Fluorocarbon).

Color Coded: YELLOW 364 E.P.D.M. Rubber. Color Coded: BLUE 365 Neoprene Rubber;

Color Coded: GREEN 366 Food Grade Nitrile; Color: WHITE 368 Food Grade EPDM; Color: GRAY 370 Butyl Rubber

Color Coded: BROWN 371 Philthane (Tuftane) 374 Carboxylated Nitrile 375 Fluorinated Nitrile 378 High Density Polypropylene 379 Conductive Nitrile;

Color Coded: RED & SILVER 384 Conductive Neoprene;

Color Coded: GREEN & SILVER 405 Cellulose Fibre 408 Cork and Neoprene 425 Compressed Fibre 426 Blue Gard 440 Vegetable Fibre 465 Fibre 500 Delrin 500 501 Delrin 570 502 Conductive Acetal, ESD-800; Color: BLACK 503 Conductive Acetal, Glass-Filled Color: BLACK; Color Coded: YELLOW 505 Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF; Color: NATURAL 521 Injection Molded Conductive PVDF;

Color: BLACK; Color Coded: LIGHT

GREEN 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene 551 Glass Filled Polypropylene; Color: BLACK 552 Unlled Polypropylene; Color: NATURAL 555 Polyvinyl Chloride 556 Black Vinyl

557 Conductive Polypropylene;

Color: BLACK; Color Coded: SILVER 558 Conductive HDPE; Color: BLACK Color Coded: SILVER 559 Conductive Polypropylene; Color: BLACK Color Coded: SILVER 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G-S 592 Nylatron NSB 600 PTFE (virgin material)

Tetrauorocarbon (TFE) 601 PTFE (Bronze and moly lled)

602 Filled PTFE 603 Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE; Color: BLACK 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated FKM 632 Neoprene/Hytrel 633 FKM/PTFE 634 EPDM/PTFE 635 Neoprene/PTFE 637 PTFE , FKM/PTFE 638 PTFE , Hytrel/PTFE 639 Nitrile/TFE 643 Santoprene®/EPDM 644 Santoprene®/PTFE 656 Santoprene Diaphragm and

Check Balls/EPDM Seats 661 EPDM/Santoprene 666 FDA Nitrile Diaphragm,

PTFE Overlay, Balls, and Seals 668 PTFE, FDA Santoprene/PTFE

Delrin is a registered tradename of E.I. DuPont.

Gylon is a registered tradename of Garlock, Inc.

Nylatron is a registered tradename of Polymer Corp.

Santoprene is a registered tradename of Exxon Mobil Corp.

Rulon II is a registered tradename of Dixion Industries Corp.

Ryton is a registered tradename of Phillips Chemical Co.

Valox is a registered tradename of General Electric Co.

PortaPump, Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp, Inc.

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 11

SERVICE AND OPERATING MANUAL

II 2GD T5

Models HDF3-A Type 7

See pages 16 & 17 for ATEX ratings

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 031.012.000 SLEEVE & SPOOL SET 1 2 070.006.170 BEARING 2 3 095.043.156 BODY, AIR VALVE 1 4 095.073.001 ASSEMBLY, PILOT VALVE 1 4-A 095.070.558 BODY, PILOT VALVE 1 4-B 560.023.360 O-RING (SPOOL) 2 4-C 560.033.360 O-RING 4 4-D 675.037.080 RETAINING RING 1 4-E 755.025.000 SLEEVE, PILOT VALVE 1 4-F 775.026.000 SPOOL, PILOT VALVE 1 5 114.002.156 INTERMEDIATE 1 6 115.020.080 BRACKET, FOOT 2 7 115.021.080 BRACKET, FOOT 2 8 132.002.360 BUMPER, DIAPHRAGM PLATE 2 9 132.014.358 BUMPER, AIR VALVE 2 10 135.016.162 BUSHING, THREADED, W/ O-RING 560.001.360 2 11 165.011.157 CAP, END 2 12 170.012.330 CAPSCREW, HEX HEAD 1/2-13 UNC X 2.00 8 13 170.023.330 CAPSCREW, HEX HEAD 4 14 170.024.330 CAPSCREW, HEX HEAD, 7/16-14 X 1 8 15 170.032.330 CAPSCREW, HEX HEAD 8 16 170.045.330 CAPSCREW HEX HEAD 4 17 170.066.330 CAPSCREW, HEX, 1/2-13 X 2.25 36 18 172.001.330 CAPSCREW, SOCKET 12 19 196.003.155 CHAMBER, INNER 2 20 196.004.155 CHAMBER, OUTER 2 21 286.018.354 DIAPHRAGM 2

286.018.357 DIAPHRAGM 2

286.018.360 DIAPHRAGM 2

286.018.365 DIAPHRAGM 2 22 312.015.155 ELBOW, SUCTION 2 23 312.016.155 ELBOW, DISCHARGE 2 24 334.020.000 FLANGE, FOLLOWER 4 25 338.008.360 FLAP VALVE 4

338.008.365 FLAP VALVE 4

338.011.354 FLAP VALVE 4

338.011.356 FLAP VALVE 4

338.011.357 FLAP VALVE 4 26 360.010.425 GASKET, END CAP 2 27 360.013.379 GASKET, FLANGE 4

360.013.384 GASKET, FLANGE 4 28 360.014.379 GASKET, FLANGE 4

360.014.384 GASKET, FLANGE 4 29 360.021.000 GASKET 4

HDF4-A Type 3

hdf3adl7sm-rev0614

ITEM NO. PART NUMBER DESCRIPTION QTY.

30 360.041.379 GASKET, VALVE BODY 1 31 360.048.425 GASKET, VALVE BODY 1 32 518.014.156 MANIFOLD 2 33 545.007.330 NUT, HEX - 7/16-14 20 34 545.008.330 NUT, HEX, 1/2-13 24 35 547.002.110 NUT, STOP 8 36 547.006.330 NUT, STOP 2 37 560.001.360 O-RING 2 38 560.020.360 O-RING 6 39 560.022.360 O-RING 2 40 570.002.360 PAD, HINGE 4

570.002.364 PAD, HINGE 4

570.002.365 PAD, HINGE 4 41 570.012.371 PAD, WEAR 2 42 612.014.000 PLATE, DIAPHRAGM 2 43 612.015.156 PLATE, OUTER DIAPHRAGM 2 44 618.003.330 PLUG, PIPE, 1/4 2 45 618.004.330 PIPE, PLUG 2 46 620.011.114 PLUNGER, ACTUATOR 2 47 670.006.115 RETAINER, FLAP VALVE 4 48 685.008.120 ROD, DIAPHRAGM 1 49 720.004.360 SEAL, U-CUP 2 50 722.007.115 SEAT, FLAP VALVE 4 51 807.016.330 7/16-14 X 3 STUD 12 52 807.017.330 7/16-14 X 3 STUD 8 53 807.018.110 STUD, 1/4-20 8 54 900.003.330 WASHER, LOCK, 1/2 8 55 900.006.330 WASHER, LOCK - 7/16 1 2 56 901.006.330 WASHER, FLAT, 1/2 12 57 901.011.180 WASHER 12 58 901.013.180 WASHER, SEALING 2 59 901.023.330 WASHER, FLAT 2

NOT SHOWN:

031.019.156. MAIN AIR VALVE ASSEMBLY 1 (includes items 10, 11, 13, 14, 15 &16)

901.035.115. WASHER FLAT 8 (used w/Santoprene Flaps)

HDF4-A Type 3 60 545.009.330. HEX NUT 8 61 900.007.330. LOCK WASHER 8 62 807.005.330. STUD 8 63 360.036.426. FLANGE GASKET 2 64 334.037.010. ADAPTOR FLANGE 2

NOT SHOWN:

770.020.080. SPACER, FOOT 4

901.006.330. WASHER, FLAT (used w/ foot spacer) 8

900.003.330. WASHER, LOCK 8

170.013.330. CAPSCREW, HEX HEAD 8

545.008.330 NUT, HEX 4

hdf3adl7sm-rev0614 Model HDF3-A & HDF4-A Page 13

The HDF4-A top is the same

as the standard HDF3-A with

the addition of the adaptor

ange hardware listed.

4-A

4-D

®SANDPIPER is a registered tradename of Warren Rupp, Inc.

4-B

4-F

4-E

4-C

1511

hdf3adl7sm-rev0614

Declaration of Conformity

Manufacturer:

Warren Rupp, Inc.

Mansfield, Ohio, 44902 USA

certifies that Air-Operated Double Diaphragm Pump Series: HDB, HDF,

M Non-Metallic, S Non-Metallic, M Metallic, S Metallic, T Series, G Series, RS Series

U Series, EH and SH High Pressure, W Series, SMA and SPA Submersibles,

and Tranquilizer Surge Suppressors comply with the European Community

Directive 2006/42/EC on Machinery, according to Annex VIII. This product

has used Harmonized Standard EN809:1998+A1:2009, Pumps and Pump Units

for Liquids - Common Safety Requirements, to verify conformance.

Signature of authorized person

, 800 N. Main Street

October 20, 2005 Date of issue

David Roseberry Printed name of authorized person

Revision Level: F

Engineering Manager Title

April 19, 2012 Date of revision

EC Declaration of Conformity

In accordance with ATEX Directive 94/9/EC,

Equipment intended for use in potentially explosive environments.

Manufacturer:

Warren Rupp, Inc. A Unit of IDEX Corportion 800 North Main Street P.O. Box 1568 Mansfield, OH 44902 USA

EN 60079-25: 2011

For pumps equipped with Pulse Output ATEX Option Quality B.V. (0344)

AODD Pumps and Surge Suppressors

For Type Examination Designations, see page 2 (back)

AODD (Air-Operated Double Diaphragm) Pumps

EC Type Examination Certificate No. Pumps: KEMA 09ATEX0071 X

DEKRA Certification B.V. (0344) Meander 1051 6825 MJ Arnhem The Netherlands

Applicable Standard:

EN13463-1: 2009 EN13463-5: 2011

DATE/APPROVAL/TITLE: 14 MAY 2014

David Roseberry, Engineering Manager

EC Declaration of Conformity

ATEX Summary of Markings

Type Marking Listed In

Pump types, S1F, S15, S20, and S30 provided with the pulse output option

Pump types, S1F, S15, S20, and S30 provided with the integral solenoid option

Pump types, HDB1½, HDB40, HDB2, HDB50, HDB3, HDF1, HDF25, HDF2, HDF3M, PB¼, S05, S1F, S15, S20, S30, SB1, SB25, ST1½, ST40, G15, G20, and G30, without the above listed options, no aluminum parts

Pump types, DMF2, DMF3, HDB1½, HDB40, HDB2, HDB50, HDB3, HDF1, HDF25, HDF2, HDF3M, PB¼, S05, S1F, S15, S20, S30, SB1, SB25, SE½, ST1, ST25, ST1½, ST40, U1F, G05, G1F, G15, G20, and G30

Surge Suppressors all types II 2 G T5

EC Type Certificate No. Pumps: KEMA 09ATEX0071 X Type Certificate No. Pumps: KEMA 09ATEX0072 X Type Certificate No. Suppressors: KEMA 09ATEX0073

II 2 G Ex ia c IIC T5 II 3/2 G Ex ia c IIC T5 II 2 D

Ex c iaD 20 IP67 T100oC

II 2 G EEx m c II T5 II 3/2 G EEx m c II T5 II 2 D c IP65 T100

II 1 G c T5 II 3/1 G c T5 II 1 D c T100 I M1 c I M2 c

II 2 G c T5 II 3/2 G c T5 II 2 D c T100

II 3/2 G T5 II 2 D T100

Non-Conductive

Fluids

KEMA 09ATEX0071 X CE 0344

KEMA 09ATEX0071 X

CE 0344

KEMA 09ATEX0071 X KEMA 09ATEX0072 X CE 0344

KEMA 09ATEX0072 X CE

KEMA 09ATEX0073 CE

KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X

KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0071 X KEMA 09ATEX0072 X

KEMA 09ATEX0072 X KEMA 09ATEX0072 X KEMA 09ATEX0072 X

KEMA 09ATEX0073 KEMA 09ATEX0073 KEMA 09ATEX0073

No Yes Yes

No Yes

No Yes Yes

Pumps marked with equipment Category II 3/1 G (internal 3 G / eternal 1 G), 1D, M1 and M2 when used for non-conductive fluids. The pumps are Category II 2 G when used for conductive fluids.

Pumps and surge suppressors marked with equipment Category II 3/2 (internal 3 G / external 2 G), 2D when used for non-conductive fluids. The pumps are Category II 2 G when used for conductive fluids.

SANDPIPER HDF4-A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual