Sandpiper HDF50, HDF2 Service & Operating Manual

Download

SERVICE & OPERATING MANUAL

Original Instructions

Certied Quality

ISO 9001 Certied

ISO 14001 Certied

1: PUMP SPECS2: INSTAL & OP3: EXP VIEW4: AIR END5: WET END6: OPTIONAL7: WARRANTY

Model HDF2 & HDF50

Heavy Duty Flap Valve Design Level 6

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

SANDPIPERPUMP.COM

sa nd pi pe rp um p. co m

Safety Information

IMPORTANT

Read the safety warnings and instructions in this manual before pump installation and start-up. Failure to comply with the recommendations stated in this manual could damage the pump and void factory warranty.

When the pump is used for materials that tend to settle out

or solidify, the pump should be ushed after each use to

prevent damage. In freezing temperatures the pump should be completely drained between uses.

CAUTION

Before pump operation, inspect all fasteners for loosening

caused by gasket creep. Retighten loose fasteners to prevent leakage. Follow recommended torques stated in this manual.

Nonmetallic pumps and plastic components are not UV stabilized. Ultraviolet radiation can damage these parts and negatively affect material properties. Do not expose to UV light for extended periods of time.

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

WARNING

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

Before maintenance or repair, shut off the compressed air line, bleed the pressure, and disconnect the air line from the pump.

Be certain that approved eye protection and protective clothing are worn at all times. Failure to follow these recommendations may result in serious injury or death.

Airborne particles and loud noise hazards. Wear eye and ear protection.

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 that is hazardous or toxic, the air exhaust

must be piped to an appropriate area for safe containment.

Take action to prevent static sparking. Fire or explosion can

result, especially when handling ammable liquids. The pump, piping, valves, containers and other miscellaneous equipment

must be properly grounded.

This pump is pressurized internally with air pressure during operation. Make certain that all fasteners are in good condition and are reinstalled properly during reassembly.

WARNING The use of non-OEM replacement parts will void (or negate)

agency certications, including CE, ATEX, CSA, 3A and EC1935 compliance (Food Contact Materials). Warren Rupp, Inc. cannot

ensure nor warrant non-OEM parts to meet the stringent requirements of the certifying agencies.

Grounding ATEX Pumps

ATEX compliant pumps are suitable for use in explosive atmospheres when the equipment is properly grounded in accordance with local electrical codes. Pumps equipped with electrically conductive diaphragms are suitable for

the transfer of conductive or non-conductive uids of any explosion group. When operating pumps equipped with non-conductive diaphragms that exceed the maximum permissible projected area, as dened in EN 13463-1: 2009 section 6.7.5 table 9, the following protection methods must be applied:

• Equipment is always used to transfer electrically conductive uids or

• Explosive environment is prevented from entering the internal portions of the pump, i.e. dry running

For further guidance on ATEX applications, please consult the factory.

Use safe practices when lifting

Model HDF2/HDF50

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Table of Contents

SECTION 1: PUMP SPECIFICATIONS ................1

• Explanation of Nomenclature

• Performance

• Materials

• Dimensional Drawings

SECTION 2: INSTALLATION & OPERATION ......4

• Principle of Pump Operation

• Recommended Installation Guide

• Troubleshooting Guide

SECTION 3: EXPLODED VIEW ...........................7

• Composite Repair Parts Drawing

• Composite Repair Parts List

• Material Codes

1: PUMP SPECS2: INSTAL & OP3: EXP VIEW4: AIR END5: WET END6: OPTIONAL7: WARRANTY

SECTION 4: AIR END .......................................10

• Air Distribution Valve Assembly

• Air Valve with Stroke Indicator Assembly

• Pilot Valve Assembly

• Intermediate Assembly

SECTION 5: WET END .....................................13

• Diaphragm Drawings

• Diaphragm Servicing

SECTION 7: WARRANTY & CERTIFICATES ....15

• Warranty

• EC Declaration of Conformity - Machinery

• EC Declaration of Conformity - ATEX

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50

Explanation of Pump Nomenclature

HDF1

Your Model #:

__ __ _____ __ ___ __ __ __

(ll in from pump nameplate)

1: PUMP SPECS

Pump Pump Pump Series Design Size Porting

Model #:

XX X XXXX, X XX X XX X

Pump Series

HD Heavy Duty

Pump Design

F Flap

Pump Size

2 2" 50 2" SB Stainless-Brass sleeve and spool set

Discharge Porting Position

D (Top Suction- Bottom Discharge)

Diaphragm Check Valve Materials

A Neoprene - Urethane B Nitrile F FDA White Nitrile I EPDM N Neoprene R Hytrel P Santoprene V FKM

Design Level

Discharge Diaphragm/ Design

Options

Valve

Your Serial #: (ll in from pump nameplate) _____________________________________

Level

Construction

A Aluminum Wetted, Aluminum Air I Cast Iron Wetted, Aluminum Air II Cast Iron Wetted, Cast Iron Air SI Stainless Steel Wetted, Cast Iron Air S Stainless Steel Wetted, Aluminum Air

Options

P1 Intrinsically Safe ATEX Compliant Pulse Output

ATEX Detail

1 • Model HDF2/HDF50

ATEX Detail Construction Options

II 1G c T5 II 1D c T100°C I M1 c I M2 c

II 2G c T5 II 2D c T100°C

II 2G Ex ia c IIC T5 II 2D Ex c iaD 20 IP67 T100°C

II, SI, HI

A, HC, I, SI, SS

A, HC, HI, I, II, SI, SS P1

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Performance

HDF2/HDF50

SUCTION/DISCHARGE PORT SIZE

• HDF2: 2" (50mm) NPT(F)

• HDF50: 2" (50mm) BSP (T)

CAPACITY

• 0 to 208 gallons per minute (0 to 787 liters per minute)

AIR DISTRIBUTION VALVE

• No-lube, no-stall design

SOLIDS-HANDLING

• Up to 1.8in. (45mm)

HEADS UP TO

• 125 psi or 289 ft. of water (8.8 Kg/cm

MAXIMUM OPERATING PRESSURE

• 125 psi (8.6 bar)

DISPLACEMENT/STROKE

• .47 Gallon / 1.8 liter

SHIPPING WEIGHT

• Aluminum 88 lbs. (39.9kg)

• Cast Iron 130 lbs. (59kg)

• Stainless Steel 140 lbs. (63.5kg)

*for cast iron center add 35 lbs. (15.9 kg)

or 88 meters)

BAR

HEAD

AIR CONSUM PTION SCFM (M3/hr)

PSI

140

10(17)

20(34)

125 PSI

120

100

0 20 40 60 80 100 120 140 160 180 200 220

40(68)

(8.6 Bar)

100 PSI

(6.8 Bar)

80 PSI

(5.44 Bar)

60 PSI

(4.08 Bar)

40 PSI

(2.72 Bar)

20 PSI Air Inlet Pressure (1.36 Bar)

60(102)

80(136)

100(170)

Performance based on the following: elastomer fitted pump, flooded suction, water at ambient temperature.

The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.

120(204)

140(238)

MODEL HDF2 Performance Curve

U.S. Gallons per minute

0 200100 400300 500 600 700

Liters per minute

CAPACITY

1: PUMP SPECS

800

Materials

Material Prole:

CAUTION! Operating temperature limitations are as follows:

Conductive Acetal: Tough, impact resistant, ductile. Good abrasion resistance and low friction surface. Generally inert, with

Operating

Temperatures:

Max. Min.

190°F

88°C

-20°F

-29°C

good chemical resistance except for strong acids and oxidizing agents.

EPDM: Shows very good water and chemical resistance. Has poor resistance to oils and solvents, but is fair in ketones and

280°F 138°C

-40°F

-40°C

alcohols.

FKM: (Fluorocarbon) Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and

350°F 177°C

-40°F

-40°C

halogenated hydrocarbons, acids, animal and vegetable oils.

Hot water or hot aqueous solutions (over 70°F(21°C)) will attack FKM.

Hytrel®: Good on acids, bases, amines and glycols at room temperatures only.

Neoprene: All purpose. Resistance to vegetable oils. Generally not affected by moderate chemicals, fats, greases and many

220°F 104°C

200°F

93°C

-20°F

-29°C

-10°F

-23°C

oils and solvents. Generally attacked by strong oxidizing acids, ketones, esters and nitro hydrocarbons and chlorinated aromatic hydrocarbons.

Nitrile: General purpose, oil-resistant. Shows good solvent, oil,

water and hydraulic uid resistance. Should not be used with

190°F

88°C

-10°F

-23°C

highly polar solvents like acetone and MEK, ozone, chlorinated

hydrocarbons and nitro hydrocarbons.

Nylon: 6/6 High strength and toughness over a wide temperature range. Moderate to good resistance to fuels, oils

180°F

82°C

32°F

0°C

and chemicals.

Ambient temperature range: -20°C to +40°C Process temperature range: -20°C to +80°C for models rated as category 1 equipment

-20°C to +100°C for models rated as category 2 equipment

In addition, the ambient temperature range and the process temperature range do not exceed the operating temperature range of the applied non-metallic parts as listed in the manuals of the pumps.

Polypropylene: A thermoplastic polymer. Moderate tensile

and ex strength. Resists stong acids and alkali. Attacked by

chlorine, fuming nitric acid and other strong oxidizing agents.

PVDF: (Polyvinylidene Fluoride) A durable uoroplastic with

excellent chemical resistance. Excellent for UV applications. High tensile strength and impact resistance.

Santoprene®: Injection molded thermoplastic elastomer with

no fabric layer. Long mechanical ex life. Excellent abrasion

resistance.

UHMW PE: A thermoplastic that is highly resistant to a broad range of chemicals. Exhibits outstanding abrasion and impact resistance, along with environmental stress-cracking resistance.

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

Virgin PTFE: (PFA/TFE) Chemically inert, virtually impervious.

Very few chemicals are known to chemically react with PTFE;

molten alkali metals, turbulent liquid or gaseous uorine and a few uoro-chemicals such as chlorine triuoride or oxygen diuoride which readily liberate free uorine at elevated

temperatures.

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.

Metals:

Alloy C: Equal to ASTM494 CW-12M-1 specication for nickel and nickel alloy.

Stainless Steel: Equal to or exceeding ASTM specication A743 CF-8M for corrosion

resistant iron chromium, iron chromium nickel and nickel based alloy castings for

general applications. Commonly referred to as 316 Stainless Steel in the pump industry.

For specic applications, always consult the Chemical Resistance Chart.

180°F

82°C

250°F 121°C

275°F 135°C

180°F

82°C

150°F

66°C

220°F 104°C

32°F

0°C

0°F

-18°C

-40°F

-40°C

-35°F

-37°C

32°F

0°C

-35°F

-37°C

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50 • 2

DISCHARGE PORT

Dimensional Drawings

HDF2 & HDF50 Heavy Duty Flap Valve

Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm).

21.64 550

1: PUMP SPECS

OPTIONAL VERTICAL SUCTION PORT

2.61 66

13.56 344

7.06 179

2.59

2"NPT [2" BSPT] SUCTION PORT

3/4" NPT AIR INLET

20.30 516

19.87 505

11.00 279

9.81 249

8.88 226

2.61 66

OPTIONAL VERTICAL DISCHARGE PORT

16.00 406

.50 13

5.28 134

THRU

13.00 330

17.69 449

2.55 65

2.64 67

2"NPT [2" BSPT]

1" NPT EXHAUST PORT

3 • Model HDF2/HDF50

10.25 260

14.00 355

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Principle of Pump Operation

2: INSTAL & OP

Air-Operated Double Diaphragm (AODD) pumps are powered by compressed air or nitrogen.

The main directional (air) control valve an air chamber, exerting uniform pressure over the inner surface of the diaphragm opposite diaphragm is directed through the air valve assembly(s) to an exhaust port

As inner chamber pressure the rod side and suction on the opposite side. The discharged and primed liquid’s

directions are controlled by the check valves (ball or ap)

. At the same time, the exhausting air ③ from behind the

②

④

(P1) exceeds liquid chamber pressure (P2),

connected diaphragms shift together creating discharge on one

⑤

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

distributes compressed air to

①

orientation.

⑥

The pump primes as a result of the suction stroke. The suction stroke lowers the chamber pressure a pressure differential necessary for atmospheric pressure

uid through the suction piping and across the suction side check valve and into the outer uid chamber

Suction (side) stroking also initiates the reciprocating (shifting, stroking or cycling) action of the pump. The suction diaphragm’s movement is mechanically pulled through its stroke. The diaphragm’s inner plate makes contact with an actuator plunger aligned to shift the pilot signaling valve. Once actuated, the pilot valve sends a pressure signal to the opposite end of the main directional air valve, redirecting the compressed air to the opposite inner chamber.

(P3) increasing the chamber volume. This results in

(P4) to push the

⑦

Model HDF2/HDF50 • 4

Recommended Installation Guide

2: INSTALL & OP

Unregulated Air

Supply to Surge

Suppressor

Flexible Connector

Vacuum Gauge

Shut O Valve

Check Valve

Shut O Valve

2: INSTAL & OP

Air Inlet

Filter Regulator

Suction

Air Dryer

Drain

Valve

Flexible

Connector

Pipe Connection Style Optional

Pipe Connection

Style Optional

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.

Flexible

Connector

Drain

Valve

NOTE: Surge Suppressor and Piping must be Supported After the Flexible Connection

Surge Suppressor

Pressure Gauge

Shut O Valve

Discharge

Installation and Start-Up

Locate the pump as close to the product being pumped as possible. Keep the suction line length and number of ttings to a minimum. Do not reduce the suction line

diameter.

Air Supply

Connect the pump air inlet to an air supply with sufcient capacity and pressure to achieve desired performance. A pressure regulating valve should be installed to

insure air supply pressure does not exceed recommended limits.

Air Valve Lubrication The air distribution system is designed to operate WITHOUT lubrication. This is the standard mode of operation. If lubrication is desired, install an air line lubricator set to deliver one drop of SAE 10 non-detergent oil for every 20 SCFM (9.4 liters/sec.) of air the pump consumes. Consult the Performance Curve to determine air consumption.

Air Line Moisture Water in the compressed air supply may cause icing or freezing of the exhaust air, causing the pump to cycle erratically or stop operating. Water in the air supply can be reduced by using a point-of-use air dryer.

Air Inlet and Priming

To start the pump, slightly open the air shut-off valve. After the pump primes, the air valve can be opened to increase air ow as desired. If opening the valve increases cycling rate, but does not increase the rate of ow, cavitation has occurred. The valve should be closed slightly to obtain the most efcient air ow to pump ow ratio.

5 • Model HDF2/HDF50

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Symptom: Potential Cause(s): Recommendation(s):

Pump Cycles Once

Pump Will Not Operate / Cycle

Pump Cycles and Will Not Prime or No Flow

Pump Cycles Running Sluggish / Stalling, Flow Unsatisfactory

Product Leaking Through Exhaust

Premature Diaphragm Failure

Unbalanced Cycling

Deadhead (system pressure meets or exceeds air supply pressure).

Air valve or intermediate gaskets installed incorrectly. Install gaskets with holes properly aligned.

Bent or missing actuator plunger. Remove pilot valve and inspect actuator plungers.

Pump is over lubricated. Set lubricator on lowest possible setting or remove. Units are designed for lube free operation.

Lack of air (line size, PSI, CFM). Check the air line size and length, compressor capacity (HP vs. cfm required).

Check air distribution system. Disassemble and inspect main air distribution valve, pilot valve and pilot valve actuators.

Discharge line is blocked or clogged manifolds. Check for inadvertently closed discharge line valves. Clean discharge manifolds/piping.

Deadhead (system pressure meets or exceeds air supply pressure).

Blocked air exhaust mufer. Remove mufer screen, clean or de-ice, and re-install.

Pumped uid in air exhaust mufer. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.

Pump chamber is blocked. Disassemble and inspect wetted chambers. Remove or ush any obstructions.

Cavitation on suction side. Check suction condition (move pump closer to product).

Check valve obstructed. Valve ball(s) not seating

properly or sticking.

Valve ball(s) missing (pushed into chamber or manifold).

Valve ball(s) / seat(s) damaged or attacked by product. Check Chemical Resistance Guide for compatibility.

Check valve and/or seat is worn or needs adjusting. Inspect check valves and seats for wear and proper setting. Replace if necessary.

Suction line is blocked. Remove or ush obstruction. Check and clear all suction screens or strainers.

Excessive suction lift. For lifts exceeding 20’ of liquid, lling the chambers with liquid will prime the pump in most cases.

Suction side air leakage or air in product. Visually inspect all suction-side gaskets and pipe connections.

Pumped uid in air exhaust mufer. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.

Over lubrication. Set lubricator on lowest possible setting or remove. Units are designed for lube free operation.

Icing. Remove mufer screen, de-ice, and re-install. Install a point of use air drier.

Clogged manifolds. Clean manifolds to allow proper air ow.

Deadhead (system pressure meets or exceeds air supply pressure).

Cavitation on suction side. Check suction (move pump closer to product).

Lack of air (line size, PSI, CFM). Check the air line size, length, compressor capacity.

Excessive suction lift. For lifts exceeding 20’ of liquid, lling the chambers with liquid will prime the pump in most cases.

Air supply pressure or volume exceeds system hd. Decrease inlet air (press. and vol.) to the pump. Pump is cavitating the uid by fast cycling.

Undersized suction line. Meet or exceed pump connections.

Restrictive or undersized air line. Install a larger air line and connection.

Suction side air leakage or air in product. Visually inspect all suction-side gaskets and pipe connections.

Suction line is blocked. Remove or ush obstruction. Check and clear all suction screens or strainers.

Pumped uid in air exhaust mufer. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.

Check valve obstructed. Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket.

Check valve and/or seat is worn or needs adjusting. Inspect check valves and seats for wear and proper setting. Replace if necessary.

Entrained air or vapor lock in chamber(s). Purge chambers through tapped chamber vent plugs. Purging the chambers of air can be dangerous.

Diaphragm failure, or diaphragm plates loose. Replace diaphragms, check for damage and ensure diaphragm plates are tight.

Diaphragm stretched around center hole or bolt holes. Check for excessive inlet pressure or air pressure. Consult Chemical Resistance Chart for compatibility

Cavitation. Enlarge pipe diameter on suction side of pump.

Excessive ooded suction pressure. Move pump closer to product. Raise pump/place pump on top of tank to reduce inlet pressure.

Misapplication (chemical/physical incompatibility). Consult Chemical Resistance Chart for compatibility with products, cleaners, temperature limitations

Incorrect diaphragm plates or plates on backwards, installed incorrectly or worn.

Excessive suction lift. For lifts exceeding 20’ of liquid, lling the chambers with liquid will prime the pump in most cases.

Undersized suction line. Meet or exceed pump connections.

Pumped uid in air exhaust mufer. Disassemble pump chambers. Inspect for diaphragm rupture or loose diaphragm plate assembly.

Suction side air leakage or air in product. Visually inspect all suction-side gaskets and pipe connections.

Check valve obstructed. Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket.

Check valve and/or seat is worn or needs adjusting. Inspect check valves and seats for wear and proper setting. Replace if necessary.

Entrained air or vapor lock in chamber(s). Purge chambers through tapped chamber vent plugs.

Increase the inlet air pressure to the pump. Pump is designed for 1:1 pressure ratio at zero ow. (Does not apply to high pressure 2:1 units).

Disassemble the wet end of the pump and manually dislodge obstruction in the check valve pocket. Clean out around valve ball cage and valve seat area. Replace valve ball or valve seat if damaged. Use heavier valve ball material.

Worn valve ball or valve seat. Worn ngers in valve ball cage (replace part). Check Chemical Resistance Guide for compatibility.

Increase the inlet air pressure to the pump. Pump is designed for 1:1 pressure ratio at zero ow. (Does not apply to high pressure 2:1 units).

with products, cleaners, temperature limitations and lubrication.

Install Back pressure device (Tech bulletin 41r). Add accumulation tank or pulsation dampener.

and lubrication.

Check Operating Manual to check for correct part and installation. Ensure outer plates have not been worn to a sharp edge.

2: INSTAL & OP

For additional troubleshooting tips contact After Sales Support at service.warrenrupp@idexcorp.com or 419-524-8388

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50 • 6

Composite Repair Parts Drawing

ITEM

NO.

PART

NUMBER

031.212.156

ASSEMBLY, MAIN AIR VALVE

070.006.170

095.073.001

ASSEMBLY, PILOT VALVE

114.002.XXX

BRACKET, INTERMEDIATE

115.158.080

115.159.080

132.002.360

BUMPER, DIAPHRAGM

135.016.162

BUSHING, THREADED

170.023.330

CAPSCREW, HEX-HD 7/16-14 X 1.75

170.024.330

CAPSCREW, HEX HD, 7/16-14 X 1

170.026.330

CAPSCREW, HEX HEAD 3/8-16 X 3.50

170.035.330

CAPSCREW, HEX-HD 7/16-14 X 1.50

170.045.330

CAPSCREW, HEX-HD, 5/16-18 X 1.25

170.052.330

CAPSCREW, HEX HD 3/8-16 X 2.25

170.061.115

CAPSCREW, HX-HD 3/8-16 X 1.75

171.002.110

CAPSCREW, SOC HD, 5/8-11 X 1.50

196.001.XXX

196.002.XXX

286.007.XXX

312.012.XXX

312.013.XXX

ELBOW, DISCHARGE

338.XXX.XXX

VALVE, FLAP ASSEMBLY

360.041.379

GASKET, PILOT VALVE

360.048.425

GASKET, AIR VALVE

518.001.XXX

530.033.000

545.007.330

547.002.110

NUT, NYLON STOP, 1/4-20

560.001.360

560.022.360

570.001.XXX

570.009.XXX

612.047.330

PLATE, DIAPHRAGM

612.XXX.XXX

PLATE, OUTER DIAPHRAM

618.003.330

618.003.XXX

620.011.114

PLUNGER, ACTUATOR

670.005.110

RETAINER, FLAP VALVE

675.013.XXX

685.007.120

ROD, DIAPHRAGM

720.004.360

722.070.000

770.005.330

807.018.110

900.005.330

WASHER, LOCK, 3/8"

900.006.330

WASHER, LOCK, 7/16

902.003.000

WASHER, SEALING

560.046.360

O-RING (SST UNITS ONLY) 2

3: EXP VIEW

Service & Repair Kits

476.247.000 Air End Kit

Sleeve and Spool Set, Pilot Valve Body Assembly, Bumpers, Bushings, Gaskets, O-rings, Seals,

and Plungers

476.314.000 Air End Refurbishment Kit Bumpers, Bushings, Gaskets, O-rings, Seals, Plungers, and Retaining Rings

476.270.360 Wet End Kit Nitrile Diaphragms, Nitrile Flaps, Nitrile Hinge Pads,

Nitrile Wear Pads, sealing washers

476.270.363 Wet End Kit FKM Diaphragms, FKM Flaps, FKM Hinge Pads,

FKM Wear Pads, sealing washers

476.270.364 Wet End Kit EPDM Diaphragms, EPDM Flaps, EPDM Hinge

Pads, EPDM Wear Pads, sealing washers

476.270.365 Wet End Kit Neoprene Diaphragms, Neoprene Flaps, Neoprene

Hinge Pads, Neoprene Wear Pads, sealing washers

476.270.356 Wet End Kit Hytrel Diaphragms, Hytrel Flaps, Neoprene Hinge

Pads, Neoprene Wear Pads, sealing washers

7 • Model HDF2/HDF50

3539

TORQUE: 480 IN-LBS (54 N-m)

TORQUE: 360 IN-LBS (40 N-m)

476.270.632 Wet End Kit Neoprene Diaphragms, Urethane Flaps, Neoprene

Hinge Pads, Neoprene Wear Pads, sealing washers

476.270.643 Wet End Kit Santoprene Diaphragms, Santoprene Flaps, EPDM

Hinge Pads, EPDM Wear Pads, sealing washers

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Composite Repair Parts List

Item Part Number Description Qty

1* 031.019.156 Air Valve Assy (Aluminum Center - see pg #10 for details) 1

031.019.010 Air Valve Assy (Cast Iron Center) 1

031.019.001 Air Valve Assy (Alum Center SS/BRASS Sleeve Spool-High Clr) 1

031.019.004 Air Valve Assy (Alum Center SS/BRASS Sleeve-Spool) 1

031.089.156 Air Valve Assy (Alum Center - stroke Indicator) 1

031.089.010 Air Valve Assy (Cast Iron Center - stroke Indicator) 1 2 070.006.170 Bushing, Intermediate (included in item #4) 2 3 095.073.001 Pilot Valve Assy 1 4 114.002.156 Intermediate (w/ aluminum center) 1

114.002.010 Intermediate (w/ cast iron center) 1 5 115.158.080 Bracket, Leg 2 6 115.159.080 Bracket, Leg 2 7 132.002.360 Bumper, Diaphragm 2 8 135.016.162 Bushing, Plunger 2 9 170.023.330 Capscrew, Hx-Hd 7/16-14 x 1.75 (Aluminum wetted) 8

170.023.330 Capscrew, Hx-Hd 7/16-14 x 1.75 (CI and SS wetted) 16 10 170.024.330 Capscrew, Hx-Hd 7/16-14 x 1.00 8 11 170.026.330 Capscrew, Hx-Hd 3/8-16 x 3.50 2 12 170.035.330 Capscrew, Hx-Hd 7/16-14 x 1.50 (Aluminum wetted) 8 13 170.045.330 Capscrew, Hx-Hd 5/16-18 x 1.25 4 14 170.052.330 Capscrew, Hx-Hd 3/8-16 x 2.25 2 15 170.061.330 Capscrew, Hx-Hd 3/8-16 x 2.00 16 16 171.002.330 Capscrew, Socket, Fl-Hd 5/8 11 x 1.50 (Alum/CI Wetted) 2

171.002.110 Capscrew, Socket, Fl-Hd 5/8 11 x 1.50 (Stainless Wetted) 2 17 196.001.157 Chamber, Inner (w/ aluminum center) Includes #35 2

196.001.010 Chamber, Inner (w/ cast iron center) Includes #35 2 18 196.002.157NS Chamber, Outer (w/ aluminum wetted) Includes #36,44 4

196.002.010NS Chamber, Outer (w/ cast iron wetted) Includes #36,44 4

196.002.110NS Chamber, Outer (w/ stainless wetted) Includes #36,44 4 19 286.007.354 Diaphragm - Santoprene 2

286.007.356 Diaphragm - Hytrel 2

286.007.360 Diaphragm - Buna 2

286.007.363 Diaphragm - FKM 2

286.007.364 Diaphragm - EPDM 2

286.007.365 Diaphragm - Neoprene 2 20 312.012.156 Elbow, Suction (w/ aluminum wetted) includes item #44) 2

312.012.010 Elbow, Suction (w/ cast iron wetted) includes item #44) 2

312.012.110 Elbow, Suction (w/ stainless wetted) includes item #44) 2 21 312.013.156 Elbow, Discharge (w/ aluminum wetted) 2

312.013.010 Elbow, Discharge (w/ cast iron wetted) 2

312.013.110 Elbow, Discharge (w/ stainless wetted) 2 22 338.005.360 Valve, Flap Assembly - Buna 4

338.005.363 Valve, Flap Assembly - FKM 4

338.005.364 Valve, Flap Assembly - EPDM 4

338.005.365 Valve, Flap Assembly - Neoprene 4

Item Part Number Description Qty

23 360.041.379 Gasket, Pilot Valve 1 24 360.048.425 Gasket, Air Valve 1 25 518.001.157 Manifold (w/ aluminum wetted) 2

518.001.010 Manifold (w/ cast iron wetted) 2

518.001.110 Manifold (w/ stainless wetted) 2 26 530.033.000 Mufer, Metal 1 27 545.007.330 Nut, Hex 7/16-14 (aluminum wetted only) 12 28 547.002.110 Nut, Nylon Stop 1/4 x 20 8 29 560.001.360 O-ring 2 30 560.022.360 O-ring 2 31 570.001.360 Pad, Hinge - Buna 4

570.001.363 Pad, Hinge - FKM 4

570.001.364 Pad, Hinge - EPDM (also used w/ Santoprene) 4

570.001.365 "Pad, Hinge - Neoprene (also used with Hytrel & Urethane)" 4 32 570.009.360 Pad, Wear - Buna 2

570.009.363 Pad, Wear - FKM 2

570.009.364 Pad, Wear - EPDM (also used w/ Santoprene) 2

570.009.365 Pad, Wear - Neoprene (also used with Hytrel & Urethane) 2 33 612.047.330 Plate, Inner Diaphragm 2 34 612.008.330 Plate, Outer Diaphragm (w/ aluminum/cast iron wetted) 2

612.096.110 Plate, Outer Diaphragm (w/ stainless wetted) 2 35 618.003.330 Plug, Pipe 1/4" NPT 2 36 618.003.330 Plug, Pipe 1/4" NPT (w/ aluminum/ cast iron wetted) 4

618.003.110 Plug, Pipe 1/4" NPT (w/ stainless wetted) 4 37 620.011.114 Plunger, Actuator 2 38 670.005.110 Retainer, Flap Valve 4 39 675.013.360 Ring, Sealing - Buna 4

675.013.363 Ring, Sealing - FKM 4

675.013.364 Ring, Sealing - EPDM (used w/ Santoprene) 4

675.013.365 Ring, Sealing - Neoprene (used with Hytrel & Urethane) 4 40 685.007.120 Rod, Diaphragm 1 41 720.004.360 Seal, U-Cup 2 42 722.070.360 Seat, Check Valve - Buna 4

722.070.363 Seat, Check Valve - FKM 4

722.070.364 Seat, Check Valve - EPDM (used w/ Santoprene) 4

722.070.365 Seat, Check Valve - Neoprene (used with Hytrel & Urethane) 4 43 770.005.330 Spacer (w/ aluminum wetted) 2 44 807.018.110 Stud, 1/4-20 (inlcuded with item #18 & #20) 8 45 900.005.330 Washer, Lock 3/8" 20 46 900.006.330 Washer, Lock 7/16" (w/ aluminum wetted) 16

900.006.330 Washer, Lock 7/16" (w/ cast iron and stainless wetted) 8 47 902.003.000 Washer, Sealing 2 48 560.046.360 O-ring (w/ stainless steel wetted) 2

LEGEND:

= Items contained within Air End Kits = Items contianed within Wet End Kits

* Air end kit contains sleeve and spool set only, not complete air valve assembly

Note: Kits contain components specic to the material codes.

3: EXP VIEW

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

ATEX Compliant

Model HDF2/HDF50 • 8

Material Codes - The Last 3 Digits of Part Number

000.....Assembly, sub-assembly;

and some purchased items

010.....Cast Iron

015.....Ductile Iron

020.....Ferritic Malleable Iron

080.....Carbon Steel, AISI B-1112

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)

148.....Hardcoat Anodized Aluminum

150.....6061-T6 Aluminum

152.....2024-T4 Aluminum (2023-T351)

155.....356-T6 Aluminum

156.....356-T6 Aluminum

157.....Die Cast Aluminum Alloy #380

158.....Aluminum Alloy SR-319

3: EXP VIEW

162.....Brass, Yellow, Screw Machine Stock

165.....Cast Bronze, 85-5-5-5

166.....Bronze, SAE 660

170.....Bronze, Bearing Type,

Oil Impregnated

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

313.....Aluminum, White Epoxy Coated

330.....Zinc Plated Steel

332.....Aluminum, Electroless Nickel Plated

333.....Carbon Steel, Electroless

Nickel Plated

335.....Galvanized Steel

337.....Silver Plated Steel

351.....Food Grade Santoprene

353.....Geolast; Color: Black

354.....Injection Molded #203-40

Santoprene

Duro 40D +/-5;

Color: RED

356.....Hytrel

357.....Injection Molded Polyurethane

358.....Urethane Rubber

(Some Applications) (Compression Mold)

359.....Urethane Rubber

360.....Nitrile Rubber Color coded: RED

363.....FKM (Fluorocarbon)

Color coded: YELLOW

364.....EPDM Rubber

Color coded: BLUE

365.....Neoprene Rubber

Color coded: GREEN

366.....Food Grade Nitrile

368.....Food Grade EPDM

371.....Philthane (Tuftane)

374.....Carboxylated Nitrile

375.....Fluorinated Nitrile

378.....High Density Polypropylene

379.....Conductive Nitrile

408.....Cork and Neoprene

425.....Compressed Fibre

426.....Blue Gard

440.....Vegetable Fibre

500.....Delrin

500

502.....Conductive Acetal, ESD-800

503.....Conductive Acetal, Glass-Filled

506.....Delrin

150

520.....Injection Molded PVDF

Natural color

540.....Nylon

542.....Nylon

544.....Nylon Injection Molded

550.....Polyethylene

551.....Glass Filled Polypropylene

552.....Unlled Polypropylene

555.....Polyvinyl Chloride

556.....Black Vinyl

557.....Conductive Polypropylene

558.....Conductive HDPE

570.....Rulon II

580.....Ryton

600.....PTFE (virgin material)

Tetrauorocarbon (TFE)

603.....Blue Gylon

604.....PTFE

606.....PTFE

607.....Envelon

608.....Conductive PTFE

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

644.....Santoprene

656 .....Santoprene

/EPDM

/PTFE

Diaphragm and

Check Balls/EPDM Seats

661.....EPDM/Santoprene

666.....FDA Nitrile Diaphragm,

PTFE Overlay, Balls, and Seals

668.....PTFE, FDA Santoprene®/PTFE

• Delrin and Hytrel are registered tradenames of E.I. DuPont.

• Nylatron is a registered tradename of Polymer Corp.

• Gylon is a registered tradename of Garlock, Inc.

• 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.

RECYCLING

Many components of SANDPIPER® AODD

pumps are made of recyclable materials.

We encourage pump users to recycle worn

out parts and pumps whenever possible, after any hazardous pumped fluids are

thoroughly ushed.

9 • Model HDF2/HDF50

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Air Distribution Valve Assembly

1-G

1-F

1-E

Air Distribution Valve Servicing

See repair parts drawing, remove screws.

Step 1: Remove Hex Head Cap Screws (1-G).

Step 2: Remove end cap (1-F), gasket (1-E) and bumper (1-C).

Step 3: Remove spool part of (1-B) (caution: do not scratch).

Step 4: Press sleeve (1-B) from body (1-A).

Step 5: Inspect O-Ring (1-D) and replace if necessary.

Step 6: Lightly lubricate O-Rings (1-D) on sleeve (1-B).

Step 7: Press sleeve (1-B) into body (1-A).

Step 8: Reassemble in reverse order, starting with step 3.

Note:

sleeve and spools (1-B) cannot be interchanged.

1-C

1-A

1-D

1-B1-B

1-C

1-E

1-F

1-G

4: AIR END

MAIN AIR VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty

1 031.019.156 Air Valve Assembly 1 1-A 095.043.156 Body, Air Valve 1 1-B 031.012.000 Sleeve and Spool Set 1 1-C 132.014.358 Bumper 2 1-D 560.020.360 O-Ring 6 1-E 360.010.425 Gasket 2 1-F 165.011.157 End Cap 2 1-G 170.032.330 Hex Head Capscrew 8

FOR CAST IRON CENTERS ONLY

Item Part Number Description Qty

1 031.019.010 Air Valve Assembly 1 1-A 095.043.010 Body, Air Valve 1 1-B 031.012.000 Sleeve and Spool Set 1 1-C 132.014.358 Bumper 2 1-D 560.020.360 O-Ring 6 1-E 360.010.425 Gasket 2 1-F 165.011.010 End Cap 2 1-G 170.032.330 Hex Head Capscrew 8

LEGEND:

= Items contained within Air End Kits

Note:

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.

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50 • 10

Pilot Valve Assembly

3-F

3-A

3-D

3-B

Pilot Valve Servicing

With Pilot Valve removed from pump.

Step 1: Remove snap ring (3-F).

Step 2: Remove sleeve (3-B), inspect O-Rings (3-C),

replace if required.

Step 3: Remove spool (3-D) from sleeve (3-B),

inspect O-Rings (3-E), replace if required.

Step 4: Lightly lubricate O-Rings (3-C) and (3-E).

Reassemble in reverse order.

3-E

3-C

PILOT VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty

3 095.073.001 Pilot Valve Assembly 1 3-A 095.070.558 Valve Body 1 3-B 755.025.000 Sleeve (With O-Rings) 1 3-C 560.033.360 O-Ring (Sleeve) 4 3-D 775.026.000 Spool (With O-Rings) 1 3-E 560.023.360 O-Ring (Spool) 2 3-F 675.037.080 Retaining Ring 1

LEGEND:

= Items contained within Air End Kits

Note:

4: AIR END

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50 • 11

Diaphragm Servicing

Step 1: With manifolds and outer chambers

removed, remove diaphragm assemblies from diaphragm rod. DO NOT use a pipe wrench or similar tool to remove assembly from rod. Flaws in the rod surface may damage bearings and seal. Soft jaws in a vise are recommended to prevent diaphragm rod damage.

Step 1.A: NOTE: Not all inner diaphragm plates

are threaded. Some models utilize a through hole in the inner diaphragm plate. If required to separate diaphragm assembly, place assembly in a vise, gripping on the exterior cast diameter of the inner plate. Turn the outer plate clockwise to separate the assembly.

Always inspect diaphragms for wear cracks or chemical attack. Inspect inner and outer plates for deformities, rust scale and wear. Inspect intermediate bearings for elongation and wear. Inspect diaphragm rod for wear or marks. Clean or repair if appropriate. Replace as required.

Step 2: Reassembly: There are two different types

of diaphragm plate assemblies utilized throughout the

Sandpiper product line: Outer plate with a threaded

stud, diaphragm, and a threaded inner plate.

Outer plate with a threaded stud, diaphragm, and an inner plate with through hole. Secure threaded inner plate in a vise. Ensure that the plates are being installed with the outer radius against the diaphragm.

Step 8: On opposite side of pump, thread the remaining assembly onto the diaphragm rod. Using a torque wrench, tighten the assembly to the diaphragm rod. Align diaphragm through bolt holes, always going forward past the recommended torque. Torque values are called out on the exploded view. NEVER reverse to align holes, if alignment cannot be achieved without damage to diaphragm, loosen complete assemblies, rotate diaphragm and reassemble as described above.

Step 9: Complete assembly of entire unit.

One Piece Diaphragm Servicing (Bonded PTFE with integral plate) The One Piece diaphragm has

a threaded stud installed in the integral plate at the factory. The inner diaphragm plate has a through hole instead of a threaded hole. Place the inner

plate over the diaphragm stud and thread the rst diaphragm / inner plate onto the diaphragm rod only

until the inner plate contacts the rod. Do not tighten. A small amount of grease may be applied between the inner plate and the diaphragm to facilitate assembly.

Insert the diaphragm / rod assembly into the pump

and install the outer chamber. Turn the pump over

and thread the second diaphragm / inner plate onto

the diaphragm rod. Turn the diaphragm until the inner plate contacts the rod and hand tighten the assembly. Continue tightening until the bolt holes align with the inner chamber holes. DO NOT LEAVE

THE ASSEMBLY LOOSE.

Step 3: Lightly lubricate, with a compatible material, the inner faces of both outer and inner diaphragm plates

when using on non Overlay diaphragms (For EPDM water is recommended). No lubrication is required.

Step 4: Push the threaded outer diaphragm plate through the center hole of the diaphragm. Note: Most diaphragms are installed with the

natural bulge out towards the fluid side. S05, S07, and S10 non–metallic units are installed

with the natural bulge in towards the air side.

Step 5: Thread or place, outer plate stud into the inner plate. For threaded inner plates, use a torque wrench to tighten the assembly together. Torque values are called out on the exploded view.

Repeat procedure for second side assembly.

Allow a minimum of 15 minutes to elapse after

torquing, then re-torque the assembly to compensate for stress relaxation in the clamped assembly.

Step 6: Thread one assembly onto the diaphragm rod with sealing washer (when used) and bumper.

Step 7: Install diaphragm rod assembly into pump and secure by installing the outer chamber in place and tightening the capscrews.

5: WET END

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.

sa n d pip er pu mp .c om

hdf2dl6sm-rev0817

Model HDF2/HDF50 • 12

5 - YEAR Limited Product Warranty

Warren Rupp, Inc. (“Warren Rupp”) warrants to the original end-use purchaser that no product sold by Warren Rupp that

bears a Warren Rupp brand shall fail under normal use and service due to a defect in material or workmanship within five

years from the date of shipment from Warren Rupp’s factory. Warren Rupp brands include Warren Rupp

SANDPIPER Signature Series

, MARATHON®, Porta-Pump®, SludgeMaster™ and Tranquilizer®.

The use of non-OEM replacement parts will void (or negate) agency certifications, including CE, ATEX, CSA, 3A and

EC1935 compliance (Food Contact Materials). Warren Rupp, Inc. cannot ensure nor warrant non-OEM parts to meet the

stringent requirements of the certifying agencies.

~ See sandpiperpump.com/content/warranty-certifications for complete warranty,

including terms and conditions, limitations and exclusions. ~

,SANDPIPER®,

Declaration of Conformity

Manufacturer: Warren Rupp, Inc., 800 N. Main Street

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, U Series, EH and SH High Pressure,

RS Series, W Series, SMA and SPA Submersibles, and Tranquilizer

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

Authorised Representative: IDEX Pump Technologies R79 Shannon Industrial Estate Shannon, Co. Clare, Ireland

Attn: Barry McMahon

Revision Level: F

7: WARRANTY

Surge Suppressors comply with

October 20, 2005 Date of issue

Director of Engineering Title

February 27, 2017 Date of revision

EC / EU Declaration of Conformity

The objective of the declaration described is in conformity with the relevant Union harmonisation

legislation: Directive 94/9/EC (until April 19, 2016) and Directive 2014/34/EU (from April 20, 2016).

Manufacturer:

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

Applicable Standard:

EN13463-1: 2001 EN13463-5: 2003 EN60079-25: 2004

Harmonised Standard:

EN13463-1: 2009 EN13463-5: 2011 EN60079-25:2010

The harmonised standards have been compared to the applicable standards used for certification purposes and no changes in the state of the art technical knowledge apply to the listed equipment.

AODD Pumps and Surge Suppressors

Technical File No.: 203104000-1410/MER

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

Hazardous Locations Applied:

I M1 c II 2 G Ex ia c IIC T5 II 2 D Ex c iaD 20 IP67 T100°C II 2 G Eex m c II T5 II 2 D c IP65 T100°C

II 1 G c T5 II 1 D c T100°C II 2 G c T5 II 2 D c T100°C II 2 G c IIB T5

DATE/APPROVAL/TITLE: 18 March 2016

David Roseberry, Director of Engineering

Sandpiper HDF50, HDF2 Service & Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual