SANDPIPER M05 User Manual

II 2GD T5

SERVICE & OPERATING MANUAL

Original Instructions

Model M05 Conductive Acetal
Design Level 2

Table of Contents

Engineering Data and Temperature Limitations .......................................................1

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

Performance Curve ..................................................................................................3

Dimensions ...............................................................................................................4

Metric Dimensions ....................................................................................................5

Principle of Pump Operation.....................................................................................6

Installation and Start-up............................................................................................6

Air Supply .................................................................................................................6

Air Valve Lubrication .................................................................................................6

Air Line Moisture.......................................................................................................6

Air Inlet and Priming .................................................................................................6

Between Uses ..........................................................................................................6

Installation Guide ......................................................................................................7

Troubleshooting .......................................................................................................8

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

Important Safety Information ....................................................................................9

Material Codes .......................................................................................................10

Composite Repair Parts Drawing ...........................................................................12

Overlay Option Drawing, Mufer Option Drawing...................................................12

Available Service and Conversion Kits ...................................................................12

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

Composite Repair Parts List ...................................................................................13

Air Valve Assembly Drawing ...................................................................................14

Air Valve Assembly Parts List .................................................................................14

Air Valve Servicing ..................................................................................................15

Intermediate Assembly Drawing and Servicing ......................................................16

Check Valve Drawing .............................................................................................17

Check Valve Servicing ............................................................................................17

Diaphragm Service Drawing, Non-Overlay.............................................................18

Diaphragm Service Drawing, with Overlay .............................................................18

Diaphragm Servicing ..............................................................................................19

Overlay Diaphragm Servicing ................................................................................19

Pumping Hazardous Liquids...................................................................................20

Converting the Pump for Piping the Exhaust Air ....................................................20

Exhaust Conversion Drawing .................................................................................20

Converted Exhaust Illustration................................................................................20

Grounding the Pump ..............................................................................................21

EC Declaration of Conformity - Machinery .............................................................22

EC Declaration of Conformity - ATEX .....................................................................23

Explanation of ATEX Certicate ..............................................................................24

WARREN RUPP, INC. • A Unit of IDEX Corporation • 800 N. Main St., Ohio 44902 USA • Telephone [phone] • Fax [phone] • www.warrenrupp.com

m05conductiveacetal-rev0812

©Copyright 2012 Warren Rupp, Inc. All rights reserved.

Quality System

II 2GD T5

ISO9001 Certied

Environmental

Management System

ISO14001 Certied

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

M05 Conductive Acetal
Design Level 2

Ball Valve

Air Operated
Double-Diaphragm Pump

ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA

INTAKE/DISCHARGE PIPE SIZE

1/2" NPT(Internal) or 1/2" BSPT (Tapered)

1" NPT(External) or 1" BSPT (Tapered)

MATERIALS Maximum* Minimum*

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 hyrdrocarbons.

PTFE - Chemically inert, virtually impervious. Very few chemicals are known to react chemically 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.

CONDUCTIVE ACETAL - Tough, impact resistant, ductile. Good abrasion resistance and low friction surface. Generally inert, with good chemical resistance
except for strong acids and oxidizing agents.

SANTOPRENE - Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life. Excellent abrasion resistance.

For specic applications, always consult the Warren Rupp “Chemical Resistance Chart”

CAUTION: 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.

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

CAPACITY

0 to 14 gallons per minute

(0 to 52 liters per minute)

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to .125 in. (3mm)

CAUTION! Operating temperature limitations are as follows:

HEADS UP TO

100 psi or 231 ft. of water

(7 Kg/cm2 or 70 meters)

Operating Temperatures

190° F

88° C

220° F

104° C

190° F

88° C

275° F
135° C

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.

DISPLACEMENT/STROKE

.026 Gallon / .098 liter

-10° F

-23° C

-35° F

-37° C

-20° F

-29° C

-40° F

-40° C

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 1

Explanation of Pump Nomenclature

M05 Conductive Acetal · Design Level 2· Ball Valve

Check Diaphragm/ Check Non-Wetted Shipping
Model Pump Pump Valve Design Wetted Check Valve Valve Material Porting Pump Pump Kit Weight
Brand Size Type Level Material Materials Seat Options Options Style Options Options lbs. (kg)

M05B2G1TXNS000. S 05 B 2 G 1 T X N S 0 00. 17 (8)
M05B2G2TXNS000. S 05 B 2 G 2 T X N S 0 00. 17 (8)
M05B2GUTXNS000. S 05 B 2 G U T X N S 0 00. 17 (8)
M05B2G1TXBS000. S 05 B 2 G 1 T X B S 0 00. 17 (8)
M05B2G2TXBS000. S 05 B 2 G 2 T X B S 0 00. 17 (8)
M05B2GUTXBS000. S 05 B 2 G U T X B S 0 00. 17 (8)

Pump Brand

M= Marathon

Pump Size

05=1/2"

Check Valve Type

B= Soild Ball

Design Level

2=Design Level

Wetted Material

G=Conductive Acetal

Diaphragm/Check Valve Materials

1= Santoprene/Santoprene
2= Virgin PTFE-Santoprene
Backup/Virgin PTFE
B= Nitrile/Nitrile
U= Polyurethane/Polyurethane

Check Valve Seat

T= Virgin PTFE

Non-Wetted Material Options

X= Non-painted Aluminum

Porting Options

N= NPT Threads
B= BSPT (Tapered) Threads

Pump Style

S= Standard

Pump Options

0= None
6= Metal Mufer

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 2

Performance Curve, M05 Conductive Acetal Design Level 2

MODEL S05 Conductive Acetal Performance Curve

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

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

3 4 5 6 7 8 9 10 11 12 13 14 15 16

2

1

0

U.S. Gallons per minute

Liters per minute

100

90

2 (3.5)

4 (7)

80

70

60

50

40

30

20

10

10 20 30 40 50 60

0

0

BAR

PSI

HEAD

1

2

3

4

5

6

7

0

30

20

25

10

15

5

9.1

6

7.6

3

4.5

1.5

NPSHR

FEET

METERS

6 (10)

8 (13.5)

10 (17)

12 (20)

14 (24)

16 (27)

100 PSI (6.8 Bar)

80 PSI (5.44 Bar)

60 PSI (4.08 Bar)

20 PSI (1.36 Bar)

Air Inlet Pressure

40 PSI (2.72 Bar)

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 3

Bolt Pattern is
Symmetrical About
Centerlines

*Both Suction And Discharge
Ports Are available In: ½" BSP tapered
(Internal) BSP tapered (external)

Suction Port
½" NPT (Internal)
1" NPT (External)

Integral Muffler:

3/8" NPT Exhaust Port For Metal

Muffler or Piping Exhaust Air

In Submerged Applications.

Discharge Port

1/2" NPT (Internal)

1" NPT (External)

Manifold Can Rotate ±90°
From Vertical Centerline

Air Inlet 1/4" NPT

Dimensions: M05 Conductive Acetal

Dimensions in Inches
Dimensional tolerance: ±1/8"

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 4

DIMENSION A B
Integral Mufer 4 1/16" 7 1/16"

Metal Mufer 5 1/8" 8 1/8"

Bolt Pattern Is
Symmetrical About
Centerlines

*Both Suction And Discharge
Ports Are Available In 1/2" BSP
Tapered (Internal) 1" Tapered (External)

* Suction Port

1/2" NPT (Internal)

1" NPT (External)

Integral Muffler:

3/8" NPT Exhaust Port
For Metal Muffler or Piping
Exhaust Air In Submerged

Applications.

* Discharge Port

1/2" NPT (Internal)

1" NPT (External)

44mm

Manifold Can Rotate ± 90°
From Vertical Centerline.

Air Inlet 1/4" NPT

Metric Dimensions: M05 Conductive Acetal

Dimensions in millimeters
Dimensional tolerance: ±3mm

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 5

DIMENSION A B
Integral Mufer 103mm 179mm

Metal Mufer 130mm 206mm

PRINCIPLE OF PUMP OPERATION

This ball type check valve pump
is powered by compressed air and is
a 1:1 ratio design. The inner side of
one diaphragm chamber is alternately
pressurized while simultaneously
exhausting the other inner chamber.
This causes the diaphragms, which
are connected by a common rod
secured by plates to the centers of the
diaphragms, to move in a reciprocating
action. (As one diaphragm performs the
discharge stroke the other diaphragm is
pulled to perform the suction stroke in
the opposite chamber.) Air pressure is
applied over the entire inner surface of
the diaphragm while liquid is discharged
from the opposite side of the diaphragm.
The diaphragm operates in a balanced
condition during the discharge stroke
which allows the pump to be operated
at discharge heads over 200 feet (61
meters) of water.

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 to maximize
diaphragm life.

Alternate pressurizing and
exhausting of the diaphragm chamber
is performed by an externally mounted,
pilot operated, four way spool type
air distribution valve. When the spool
shifts to one end of the valve body, inlet
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 pressure to the chambers
is reversed. The air distribution valve
spool is moved by a internal pilot valve
which alternately pressurizes one end
of the air distribution valve spool while
exhausting the other end. The pilot valve
is shifted at each end of the diaphragm
stroke when a actuator plunger is
contacted by the diaphragm plate. This
actuator plunger then pushes the end
of the pilot valve spool into position to
activate the air distribution valve.

The chambers are connected with
manifolds with a suction and discharge
check valve for each chamber,
maintaining flow in one direction
through the pump.

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.

For installations of rigid piping,
short sections of exible hose should
be installed between the pump and
the piping. The exible hose reduces
vibration and strain to the pumping
system. A Warren Rupp Tranquilizer®
surge suppressor is recommended to
further reduce pulsation in ow.

AIR SUPPLY

Air supply pressure cannot exceed
125 psi (8.6 bar). Connect the pump
air inlet to an air supply of sufcient
capacity and pressure required for
desired performance. When the air
supply line is solid piping, use a short
length of exible hose not less than

1/2" (13mm) in diameter between
the pump and the piping to reduce
strain to the piping. The weight of the
air supply line, regulators and lters
must be supported by some means
other than the air inlet cap. Failure to
provide support for the piping may result
in damage to the pump. A pressure
regulating valve should be installed
to insure air supply pressure does not
exceed recommended limits.

AIR VALVE LUBRICATION

The air distribution valve and the
pilot valve 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 supply. Proper
lubrication requires the use of an air line
lubricator (available from Warren Rupp)
set to deliver one drop of SAE 10 non­detergent oil for every 20 SCFM (9.4
liters/sec.) of air the pump consumes
at the point of operation. Consult the
pump’s published Performance Curve
to determine this.

AIR LINE MOISTURE

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. Water in the air supply can
be reduced by using a point-of-use
air dryer to supplement the user’s air
drying equipment. This device removes

water from the compressed air supply
and alleviates the icing or freezing
problems.

AIR INLET AND PRIMING

To start the pump, open the air valve
approximately 1/2" to 3/4" turn. 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.

BETWEEN USES

When the pump is used for materials
that tend to settle out or solidify when
not in motion, the pump should be
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 the diaphragms and check valves
at restart.) In freezing temperatures
the pump must be completely drained
between uses in all cases.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 6

1

3�

Available from
Warren Rupp

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.

INSTALLATION GUIDE

Top Discharge Ball Valve Unit

2

DA05 Surge Suppressor

1

020-049-000 Filter/Regulator

020-049-001 Lubricator

3

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 7

TROUBLESHOOTING
Possible Symptoms:

• Pump will not cycle.

• Pump cycles, but produces no ow.

• Pump cycles, but ow rate is

unsatisfactory.

• Pump cycle seems unbalanced.

• Pump cycle seems to produce

excessive vibration.

What to Check: Excessive suction lift
in system.
Corrective Action: For lifts exceeding
20 feet (6 meters), lling the pumping
chambers with liquid will prime the
pump in most cases.

What to Check: Excessive flooded
suction in system.
Corrective Action: For flooded
conditions exceeding 10 feet (3 meters)
of liquid, install a back pressure device.

What to Check: System head exceeds
air supply pressure.
Corrective Action: Increase the
inlet air pressure to the pump. Most
diaphragm pumps are designed for 1:1
pressure ratio at zero ow.

What to Check: Air supply pressure or
volume exceeds system head.
Corrective Action: Decrease inlet
air pressure and volume to the pump
as calculated on the published
PERFORMANCE CURVE. Pump is
cavitating the uid by fast cycling.

What to Check: Undersized suction
line.
Corrective Action: Meet or exceed
pump connection recommendations
shown on the DIMENSIONAL
DRAWING.

What to Check: Restricted or
undersized air line.
Corrective Action: Install a larger
air line and connection. Refer to air
inlet recommendations shown in your
pump’s SERVICE MANUAL.

What to Check: Check ESADS, the
Externally Serviceable Air Distribution
System of the pump.
Corrective Action: Disassemble and
inspect the main air distribution valve,
pilot valve and pilot valve actuators.
Refer to the parts drawing and air valve
section of the SERVICE MANUAL.
Check for clogged discharge or closed
valve before reassembly.

What to Check: Rigid pipe connections
to pump.
Corrective Action: Install flexible
connectors and a Warren Rupp
Tranquilizer® Surge Suppressor.

What to Check: Blocked air exhaust
mufer.
Corrective Action: Remove mufer
screen, clean or de-ice and reinstall.
Refer to the Air Exhaust section of your
pump SERVICE MANUAL.

What to Check: Pumped uid in air
exhaust mufer.
Corrective Action: Disassemble pump
chambers. Inspect for diaphragm rupture
or loose diaphragm plate assembly. Refer
to the Diaphragm Replacement section
of your pump SERVICE MANUAL.

What to Check: Suction side air leakage
or air in product.
Corrective Action: Visually inspect
all suction side gaskets and pipe
connections.

What to Check: Obstructed check
valve.
Corrective Action: Disassemble the wet
end of the pump and manually dislodge
obstruction in the check valve pocket.
Refer to the Check Valve section of
the pump SERVICE MANUAL for
disassembly instructions.

What to Check: Worn or misaligned
check valve or check valve seat.
Corrective Action: Inspect check
valves and seats for wear and proper
seating. Replace if necessary. Refer
to Check Valve section of the pump
SERVICE MANUAL for disassembly
instructions.

What to Check: Blocked suction line.
Corrective Action: Remove or ush

obstruction. Check and clear all suction
screens and strainers.

What to Check: Blocked discharge
line.
Corrective Action: Check for
obstruction or closed discharge line
valves.

What to Check: Blocked pumping
chamber.
Corrective Action: Disassemble
and inspect the wetted chambers
of the pump. Remove or flush any
obstructions. Refer to the pump
SERVICE MANUAL for disassembly
instructions.

What to Check: Entrained air or vapor
lock in one or both pumping chambers.
Corrective Action: Purge chambers
through tapped chamber vent plugs.
PURGING THE CHAMBERS OF
AIR CAN BE DANGEROUS! Contact
the Warren Rupp Technical Services
Department before performing this
procedure. Any model with top-ported
discharge will reduce or eliminate
problems with entrained air.

If your pump continues to perform
below your expectations, contact your
local Warren Rupp Distributor or factory
Technical Services Group for a service
evaluation.

WARRANTY

Refer to the enclosed Warren Rupp
Warranty Certicate.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 8

Recycling

Many components of MARATHON®
Conductive Acetal AODD pumps are
made of recyclable materials (see chart
on page 10 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.

Important Safety

Information

IMPORTANT

Read these safety warnings
and instructions in this

manual completely, before

installation and start-up
of the pump. 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.

CAUTION

Before pump operation,

inspect all gasketed

fasteners for looseness

caused by gasket creep. Re-

torque loose fasteners to

prevent leakage. Follow recommended torques
stated in this manual.

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

pressurized and must be bled of its pressure.

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

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. (See Page 19)

WARNING

This pump is pressurized

internally with air pressure

during operation. Always

make certain that all bolting

is in good condition and

that all of the correct

bolting is reinstalled during assembly.

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,
piping, and all other 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.

WARNING

Airborne particles and loud

noise hazards.

Wear ear and eye protection.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 9

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

Santoprene- Duro 40D +/-5;

Color: RED
355 Thermal Plastic
356 Hytrel
357 Injection Molded Polyurethane
358 Urethane Rubber

(Some Applications)

(Compression Mold)
359 Urethane Rubber
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
368 Food Grade EPDM
370 Butyl Rubber

Color coded: BROWN
371 Philthane (Tuftane)

374 Carboxylated Nitrile
375 Fluorinated Nitrile
378 High Density Polypropylene
379 Conductive Nitrile
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
503 Conductive Acetal, Glass-Filled
505 Acrylic Resin Plastic
506 Delrin 150
520 Injection Molded PVDF

Natural color
540 Nylon
541 Nylon
542 Nylon
544 Nylon Injection Molded
550 Polyethylene
551 Glass Filled Polypropylene
552 Unlled Polypropylene
553 Unlled Polypropylene
555 Polyvinyl Chloride
556 Black Vinyl
558 Conductive HDPE
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
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®/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 and Hytrel are registered
tradenames 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.

®

/EPDM

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 10

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 11

Composite Repair Parts Drawing

23

12

1

14

15

26

4

9

31

21

1

9

20

6

27

18

14

32

22

32

10

10

24

5

10

9

16

33

24

2

24

10

33

13

26

2

24

17

10

9

32

22

32

10

10

30

29

7

25

28

11

8

19

3

Available Service And Conversion Kits

476-221-000 AIR END KIT

Seals, O-ring, Gaskets, Retaining Rings,
Air Valve Assembly, Pilot Valve Assembly

476-202-360 WET END KIT

Nitrile Diaphragms, Nitrile Check Balls, PTFE
Seats and PTFE Seals

476-202-354 WET END KIT

Santoprene Diaphragms, Nitrile Spacer Gaskets,
Santoprene Check Balls, PTFE Seats and
PTFE Seals

476-202-357 WET END KIT

Polyurethane Diaphragms, Nitrile Spacer Gaskets,
Santoprene Check Balls, PTFE Seats and PTFE
Seals

476-202-654 WET END KIT
Santoprene Diaphragms, PTFE Overlay

Diaphragm, PTFE Check Balls, PTFE Seats
and PTFE Seals

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 12

Composite Repair Parts List

Item Part Number Description Qty

1 031.186.003 Air Valve Assembly 1

031.191.001 Air Valve Assembly (with integral mufer) 1
2 050.027.354 Ball, Check 4

050.027.357 Ball, Check 4

050.027.360 Ball, Check 4

050.022.600 Ball, Check 4
3 095.116.000 Pilot Valve Assembly 1
4 114.023.157 Bracket, Intermediate 1
5 115.140.115 Bracket, Mounting 2
6 132.034.360 Bumper, Diaphragm 2
7 135.036.506 Bushing, Plunger 2
8 165.110.157 Cap, Air Inlet 1
9 171.062.115 Capscrew, Flanged 5/16-18 X 1.00 12
10 171.063.115 Capscrew, Flanged 5/16-18 X 1.25 36
11 171.076.115 Capscrew, Flanged 1/4-20 X 1.50 4
12 171.077.115 Capscrew, Flanged 1/4-20 X .75 4
13 196.178.502 Chamber, Outer 2
14 286.095.354 Diaphragm 2

286.095.357 Diaphragm 2

286.095.360 Diaphragm 2

286.116.000 Diaphragm, One.Piece Bonded 2
15 286.096.600 Diaphragm, Overlay 2
16 312.106.502 Elbow, Suction 2

Item Part Number Description Qty

17 312.112.502 Elbow, Discharge 2
18 360.099.360 Gasket, Spacer
19 360.100.379 Gasket, Air Inlet 1
20 360.108.360 Gasket, Pilot Valve 1
21 360.102.360 Gasket, Air Valve 1
22 518.138.502 Manifold, NPT 2

518.138.502E Manifold, BSPT
23 530.035.000 Mufer, Metal (not used with 031.191.001) 1
24 544.005.115 Nut, Flanged 5/16-18 24
25 560.001.360 O.ring 2
26 612.091.502 Plate, Outer Diaphragm 2
27 612.177.330 Plate, Inner Diaphragm 2

612.221.330 Plate, Inner Diaphragm (
28 620.019.115 Plunger, Actuator 2
29 675.042.115 Ring, Retaining 2
30 685.056.120 Rod, Diaphragm 1
31 720.012.360 Seal, Diaphragm Rod 2
32 720.045.600 Seal, Manifold 4
33 722.099.600 Seat, Check Valve 4
34 920.025.000 Grounding Cable 1

(Use w/TPE Diaphragms Only) 2

(Tapered) 2

use with 286.116.000

) 2

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 13

Air DistributionValve Assembly Drawing

1-I

1-H

1-G

1-A

1-C

1-E

1-F

1-F

1-C

1-D

MAIN AIR VALVE ASSEMBLY PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY

1 031-191-001 Valve Assembly 1

1-A 031-132-000 Sleeve and Spool Set 1
1-B 095-106-157 Valve Body 1
1-C 132-038-357 Bumper 2
1-D 165-128-157 End Cap 2
1-E 171-076-115 Hex Flange Capscrew 1/4-20 x .75 8
1-F 560-101-360 O-ring 4
1-G 530-030-550 Mufer 1
1-H 165-109-503 Mufer Cap 1
1-I 706-027-115 Machine Screw 6-32 x 1.25 4

MAIN AIR VALVE ASSEMBLY PARTS LIST

(For pumps equipped with metal mufer or piped exhaust)

1 031-186-003 Valve Assembly 1

(Same as above 031-191-001 minus items
1-G, 1-H, and 1-I)

1-D

1-B

1-F

1-F

1-E

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 14

AIR DISTRIBUTION VALVE
SERVICING

To service the air valve rst shut
off the compressed air, bleed pressure
from the pump, and disconnect the air
supply line from the pump.

Step #1: See COMPOSITE REPAIR
PARTS DRAWING.

Using a 3/8" wrench or socket,
remove the four hex capscrews (items

11). Remove the air valve assembly
from the pump.

Remove and inspect gasket (item

22) for cracks or damage. Replace
gasket if needed.

Step #2: Disassembly of the air valve.

Using a 3/8" wrench or socket,
remove the eight hex capscrews
(items 1-E) that fasten the end caps to
the valve body. Next remove the two
end caps (items 1-D). Inspect the two
o-rings (items 1-F) on each end cap for
damage or wear. Replace the o-rings
as needed.

Remove the bumpers (items 1-C).
Inspect the bumpers for damage or
wear. Replace the bumpers as needed.

Remove the spool (part of item
1-A) from the sleeve. Be careful not to
scratch or damage the outer diameter
of the spool. Wipe spool with a soft cloth
and inspect for scratches or wear.

Inspect the inner diameter of the
sleeve (part of item 1-A) for dirt,

scratches, or other contaminants. Remove
the sleeve if needed and replace with
a new sleeve and spool set (item 1-A).

Step #3: Reassembly of the air valve.

Install one bumper (item 1-C) and
one end cap (item 1-D), with two o-rings
(items 1-F), and fasten with four hex
capscrews (items 1-E) to the valve body
(item 1-B). Align hole in end cap with roll
pin on valve body.

Remove the new sleeve an spool
set (item 1-A) from the plastic bag.
Carefully remove the spool from the
sleeve. Install the six o-rings (item 1-F)
into the six grooves on the sleeve. Apply
a light coating of grease to the o-rings
before installing the sleeve into the
valve body (item 1-B), align the slots
in the sleeve with the slots in the valve
body. Insert the spool into the sleeve.
Be careful not to scratch or damage
the spool during installation. Install the
remaining bumper and end cap (with
o-rings), and fasten with the remaining
hex capscrews. Align hole in end cap
with roll pin on valve body.

Fasten the air valve assembly (item

1) and gasket to the pump.Connect the
air line to the pump. The pump is now
ready for operation.

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.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 15

Intermediate Assembly Drawing

29

25

7

28

28

25

29

INTERMEDIATE REPAIR PARTS LIST
Item Part Number Description Qty

4 114-023-157 Bracket, Intermediate 1
7 135-036-506 Bushing, Plunger 2
25 560-001-360 O-Ring 2
28 620-019-115 Plunger, Actuator 2
29 675-042-115 Ring, Retaining* 2

*Note: It is recommended that when plunger components are serviced,
new retaining rings be installed.

ACTUATOR PLUNGER SERVICING

To service the actuator plunger rst
shut off the compressed air supply,
bleed the pressure from the pump, and
disconnect the air supply line from the
pump.

Step #1: See PUMP ASSEMBLY
DRAWING.

Using a

3/8" wrench or socket,

remove the four capscrews (items 11).
Remove the air inlet cap (item 8) and
air inlet gasket (item 19). The pilot valve
assembly (item 3) can now be removed.

Step #2: Servicing the actuator
plungers.

See PUMP ASSEMBLY DRAWING.

The actuator plungers (items 28)
can be reached through the stem cavity
of the pilot valve in the intermediate
bracket (item 4). To service bushings,
o-rings and retaining rings, see
Intermediate Drawing.

Remove the plungers (items 28) from
the bushings (item 7) in each end of the
intermediate cavity. Inspect for wear or
damage. Replace plunger as needed.
Apply a light coating of grease to each
o-ring and re-install the plungers in to
the bushings. Push the plungers in as
far as they will go.

Step #3: Re-install the pilot valve
assembly into the intermediate
assembly.

Be careful to align the ends of
the stem between the plungers when
inserting the stem of the pilot valve into
the cavity of the intermediate.

Re-install the gasket (item 19),
air inlet cap (item 8) and capscrews
(items 11).

Connect the air supply to the pump.
The pump is now ready for operation.

PLUNGER BUSHING, O-RING, AND
RETAINING RING SERVICING

To service the plunger bushing
components first remove the two
retaining rings (items 29) using a
small flat screwdriver. *Note: It is
recommended that new retaining rings
be installed.

Next remove the two plunger
bushings (items 7). Inspect the bushings
for wear or scratches. Replace the
bushings as necessary.

Inspect the two o-rings (25) for cuts
and/or wear.

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.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 16

Check Ball Valve Drawing

33

2

24

13

17

10

9

MODULAR CHECK BALL VALVE
SERVICING

Before servicing the check valves,
rst shut off the suction line and then
the discharge line to the pump. Next,
shut off the compressed air supply,
bleed air pressure from the pump, and
disconnect the air supply line from
the pump. Drain any remaining uid
from the pump. The pump can now be
removed for service.

To access the modular check valve,
remove the elbows (items 16 and 17
from pump composite repair parts
drawing). Use a 1/2" wrench or socket
to remove the fasteners. Once the
elbows are removed, the modular check
valves can be seen in the cavities of the
outer chamber (items 13).

Inspect the check balls (items 2) for
wear, abrasion, or cuts on the spherical
surface. The check valve seats (items

33) should be inspected for cuts,
abrasive wear, or embedded material
on the surfaces of both the external
and internal chamfers. The spherical
surface of the check balls must seat
ush to the surface of the inner chamfer
on the check valve seats for the pump to
operate to peak efciency. Replace any
worn or damaged parts as necessary.

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.

RE-ASSEMBLE THE CHECK VALVE

Place a check ball (item 2) in the
ball cage of either the discharge elbow
or the outer chamber. Install a check
valve seat in the counter on each end
of the chamber. Refasten the elbows to
the chamber.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 17

Diaphragm Service Drawing

30

6

27

18

14

26

13

10

24

10

9

18

14

26

13

9

30

6

27

14

15

26

13

10

24

10

14

15

26

13

9

30

6

27

14

13

10

24

10

9

14

13

*

*

(Use With TPE Diaphragms Only)

9

9

286.116.000

Diaphragm Service Drawing,
with Overlay

Diaphragm Service Drawing
with One-Piece Bonded

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 18

DIAPHRAGM SERVICING

To service the diaphragms first
shut off the suction, then shut off the
discharge lines to the pump. Shut
off the compressed air supply, bleed
the pressure from the pump, and
disconnect the air supply line from the
pump. Drain any remaining liquid from
the pump.

Step #1: See the pump composite
repair parts drawing, and the diaphragm
servicing illustration.

Using a 1/2" wrench or socket,
remove the 16 capscrews (items 9 &

10), and anged nuts that fasten the
elbows (items 16 and 17) to the outer
chambers (items 13). Remove the
elbows with the manifolds and spacers
attached.

Step #2: Removing the outer
chambers.

Using a 1/2" wrench or socket,
remove the 16 capscrews (items 9
and 10), and anged nuts that fasten
the outer chambers, diaphragms, and
intermediate (item 4) together.

Step #3: Removing the diaphragm
assemblies.

Use a 3/4" (19mm) wrench or
six pointed socket to remove the
diaphragm assemblies (outer plate,
diaphragm, and inner plate) from the
diaphragm rod (item 30) by turning
counterclockwise.

Insert a 6-32 set screw into the
smaller tapped hole in the inner
diaphragm plate (item 27). Insert
the protruding stud and the 6-32
fastener loosely into a vise. Use a
3/4" wrench or socket to remove the
outer diaphragm plate (item 26) by
turning counterclockwise. Inspect the
diaphragm (item 14) for cuts, punctures,
abrasive wear or chemical attack.
Replace the diaphragms if necessary.

Step #4: Installing the diaphragms.

Push the threaded stud of the outer
diaphragm plate through the center hole
of the diaphragm. Thread the inner plate
clockwise onto the stud. Insert the loose
assembly with the above 6-32 fastener
back into the vise. Use a torque wrench
to tighten the diaphragm assembly
together to 90 in lbs. (10.17 Newton
meters) 120 in lbs. Santoprene (13.56
Newton meters). 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 #5: Installing the diaphragm
assemblies to the pump.

Make sure the bumper (item 6) is
installed over the diaphragm rod.

Thread the stud of the one diaphragm
assembly clockwise into the tapped
hole at the end of the diaphragm rod
(item 30) until the inner diaphragm plate
is ush to the end of the rod. Insert rod
into pump.

Align the bolt holes in the diaphragm
with the bolt pattern in the intermediate
(item 4).

Fasten the outer chamber (item

13) to the pump, using the capscrews
(items 9 and 10) and anged nuts.

On the opposite side of the pump,
pull the diaphragm rod out as far as
possible. Make sure the bumper (item

6) is installed over the diaphragm rod.

Thread the stud of the remaining
diaphragm assembly clockwise into the
tapped hole at the end of the diaphragm
rod (item 30) as far as possible and
still allow for alignment of the bolt
holes in the diaphragm with the bolt
pattern in the inner chamber. Install
diaphragms with convolutions facing
towards center of pump. See sectional
view on previous page.

Fasten the remaining outer chamber
(item 13) to the pump, using the
capscrews (items 9 and 10) and anged
nuts.

Step #6: Re-install the elbow/
spacer/manifold assemblies to the
pump, using the capscrews (items 9 &

10) and anged nuts.

The pump is now ready to be
re-installed, connected and returned to
operation.

OVERLAY DIAPHRAGM SERVICING

The overlay diaphragm (item 15) is
designed to t snugly over the exterior of
the standard TPE diaphragm (item14).

ONE PIECE DIAPHRAGM SERVICING

(Bonded PTFE with intergral plate)

The One Piece diaphragm has a
treaded stud installed in the intergral
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
diapragm 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 daiphragm / inner
plate onto the diaphragm rod. Turn the
diapragm 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.

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.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 19

SAFE AIR
EXHAUST
DISPOSAL
AREA

PUMP INSTALLATION AREA

1" DIAMETER AIR

EXHAUST PIPING

1" DIAMETER AIR
EXHAUST PIPING

1" DIAMETER AIR
EXHAUST PIPING

MUFFLER

LIQUID
LEVEL

SUCTION

LINE

LIQUID
LEVEL

SUCTION

LINE

MUFFLER

MUFFLER

PUMPING HAZARDOUS LIQUIDS

When a diaphragm fails, the pumped
liquid or fumes enter the air end of the
pump. Fumes are exhausted into
the surrounding environment. When
pumping hazardous or toxic materials,
the exhaust air must be piped to an
appropriate area for safe disposal. See
illustration #1 at right.

This pump can be submerged if
the pump materials of construction
are compatible with the liquid being
pumped. The air exhaust must be
piped above the liquid level. See
illustration #2 at right. Piping used for
the air exhaust must not be smaller
than 1/2" (2.54 cm) diameter. Reducing
the pipe size will restrict air ow and
reduce pump performance. When the
pumped product source is at a higher
level than the pump (ooded suction
condition), pipe the exhaust higher than
the product source to prevent siphoning
spills. See illustration #3 at right.

IMPORTANT INSTALLATION NOTE:

The manufacturer recommends
installing a conductive exible hose or
connection between the pump and any
rigid plumbing. This reduces stresses
on the molded plastic threads of the
air exhaust port. Failure to do so may
result in damage to the air distribution
valve body.

Any piping or hose connected to
the pump’s air exhaust port must be
groundable and physically supported.
Failure to support these connections
could also result in damage to the air
distribution valve body.

1

CONVERTED EXHAUST ILLUSTRATION

Illustration #1

CONVERTING THE PUMP FOR
PIPING THE EXHAUST AIR

The following steps are necessary

Illustration #2

to convert the pump to pipe the exhaust
air away from the pump.

Use a Phillips screwdriver
to remove the four machine screws
(item 1-I).

Remove the mufer cap and mufer.
The air distribution valve body has 3/8"
NPT threads for installation of metal
mufer or piped exhaust.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 20

Illustration #3

Grounding The Pump

One eyelet end is fastened to the pump hardware.

The other end is installed to a true earth ground.

This 8 foot long (244 centimeters) Ground Strap (Item

34) is shipped with the eyelet end fastened to the pump
hardware.

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.

WARNING 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.

m05conductiveacetal-rev0812 Model M05 Conductive Acetal Design Level 2 Page 21

Declaration of Conformity

Manufacturer: Warren Rupp, Inc.®, 800 N. Main Street, P.O. Box 1568,

Mansfield, Ohio, 44901-1568 USA

certifies that Air-Operated Double Diaphragm Pump Series:
M Non-Metallic, M Metallic, and 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.

October 20, 2005

Signature of authorized person

Date of issue

David Roseberry
Printed name of authorized person

Revision Level: F

Engineering Manager
Title

August 23, 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.

800 North Main Street, P.O. Box 1568, Mansfield, OH 44901-1568 USA

EN 60079-25: 2004

For pumps equipped with Pulse Output ATEX Option
KEMA 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
KEMA Quality B.V.
Utrechtseweg 310
6812 AR Arnhem, The Netherlands

DATE/APPROVAL/TITLE:
27 MAY 2010

®

, A Unit of IDEX Corportion

Applicable Standard:

EN13463-1: 2001,
EN13463-5: 2003

David Roseberry, Engineering Manager

EC Declaration of Conformity

ATEX Summary of Markings

Type Marking Listed In

Pump types, M05, M1F, M15,
M20 and M30 provided with the
pulse output option

Pump types, M05, M1F, M15
M20 and M30 provided with the
integral solenoid option

Pump types, MPB1/4, M05,
M1F, M15, M20, M30, MSB1,
MHDF1, MHDF2 without the
above listed options, no
aluminum parts

Pump types,
MPB1/4, M05, M1F, M15,
M20, M30, MSB1, MHDF1,
MHDF2, MHDF3

MT Series Surge Suppressors 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

o

C

o

C

o

C

o

C

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 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
Yes

No
Yes
Yes

No
Yes

No
Yes
Yes

No
Yes
Yes