SANDPIPER PULSE OUTPUT KIT User Manual
SERVICE AND OPERATING MANUAL
PULSE OUTPUT KIT
Design Level 5
WARNING!
Pulse Output Interface Kits cannot be
used if pump is to be submerged.
Pulse Output Interface
The Pulse Output Interface Kits are designed for easy eld installation. The Kits are also available factory-installed on new
pumps. The Pulse Output Interface Kit mounts on the pump and provides electrical pulses to operate the Warren Rupp Batch
Control/Stroke Counter, or a customer-supplied control. The unit creates an electrical interface between the control and the
air-powered pump. Pulse Output Kits can be purchased separately, for use in applications where a process controller is already
present in a system. This provides a direct interface with the pump and the customer’s system.
Operation
Each pump stroke generates a signal through a proximity sensor (PNP) on either end of the air valve. As the air valve reciprocates
back and forth during pump operation, targets on either end of the spool activate their respective proximity sensors. Each sensor
signals the control to register one count on the stroke counter / batch control unit. This method provides a positive signal for
every pump stroke, but with very few wearing parts.
Connecting a Factory-Installed Kit
Pulse Interface Kits are available factory-installed on new SANDPIPER and MARATHON diaphragm pumps. When installing,
always refer to the service manual for pump installation and operation recommendations. After installing the pump, connect
the interface to the control source. To connect the interface to the control source:
• Install input cable according to the wiring diagram for your specic interface kit.
• Connect to Warren Rupp Batch Controller or existing system control.
Field Installation of Kit
Before adding an interface kit to an existing SANDPIPER or MARATHON pump, verify the compatibility
of the pump model, kit number and voltage being used. A complete listing appears on page 3
Field Installation
•
Remove the main air valve body assembly and gasket.
• Install the Pulse Output Kit,and pulse output pump adapter kit tighten and torque the screws according to the pump
service manual instructions.
• Refer to the applicable wiring diagram when connecting to control source.
pokdl5sm-rev0614
Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA
Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com
©Copyright 2014 Warren Rupp, Inc. All rights reserved.
Replacing Proximity Sensors
• Shift the main air valve spool toward the sensor being replaced.
• Lock the spool in place by inserting the safety clip
(included in the kit) through the small hole of the opposite end cap.
• Disconnect the sensors from terminal junction.
• Loosen the hex nut holding the proximity sensor in place.
• Remove the sensor from the end cap. Install the replacement sensor.
• Set the clearance between the sensor and the actuator pin to .015" (.38mm), using a feeler gauge or shim stock. The gauge
or shim stock should slide freely, while making contact.
• Tighten the hex nut provided with the replacement proximity sensor to lock in place.
• Reattach terminal juction to proximity sensor
• Remove the safety clip from the end cap. The pump is now ready for use.
Safety clip locks pump for
security or service. Pump
will NOT operate with safety
clip in place.
CAUTION!
Pump Selection & Installation
Air-operated, double diaphragm pumps (AODD) are semi-positive displacement pumps designed with exible diaphragms.
AODD have successfully been applied in metering and batching applications where system design allows for minimal variation of:
• Air Inlet Pressure
• Suction Head/Lift
• Discharge Head
• Pump Speed (Stroke Rate)
• Product Viscosity
• NPSH(a)
Variations of any of the above can result in variable, volumetric displacement per pumping stroke which normally holds to
+/- 1% to 3% repeatability. To verify actual displacement in your application, it is essential to follow a calibration procedure. This
allows the batch control to be set for the actual average displacement per pump stroke. The larger the calibration volume, the
more precise the average.
Sizing
Follow the normal pump sizing procedures using published data. DO NOT OVERSIZE THE PUMP. Select the smallest pump
suitable for your use to ensure greater accuracy. The batch size from a SANDPIPER pump will be within +/- one stroke.
Installation
To ensure consistent repeating of the batch size, keep the suction piping short, straight, simple, and as large a diameter as
is practical.
Differential pressure across the check valves of the pump will insure that the check valves seat properly and consistently.
Discharge pressure must always be greater than the suction pressure in the application.
For consistent uid displacement and system accuracy it is mandatory to keep the discharge line full of product from the pump
to the point of discharge. A one-way check valve installed in the end of the discharge line will accomplish this.
In suction lift applications the pump must be kept primed at all times. Suction lift must be kept to a minimum and a foot valve
may be required in the suction line to keep the pump primed.
In ooded suction applications a back pressure device located in the discharge line may be required to insure sufcient differential
pressure across the pump check valves. The one-way check valve mentioned above may provide sufcient back pressure to
properly seat the pump check valves although additional means may be necessary in some applications.
Install an air line pressure regulator. This ensures a constant air pressure feed to the pump eliminating low to peak usage
pressure spikes which will increase and or decrease the stroke rate of the pump resulting in variable (non-controlled) ow.
pokdl5sm-rev0614 Pulse Output Kit Page 2
IMPORTANT
Pulse Output Interface Kit Selection Instructions
Step 1 475-244-001 Refer to Page 4
Step 2
Step 3 475-245-003 Refer to Page 10
Note: 1" 475-245-003 Refer to Page 10
Assembly Notes
Note 1
Determine the required sy stem voltage and
then chose one of the three
Kits from Table 1. Each kit will include
Proximit y Se
Terminal Junction
Determine the pump model being used and
then choose the requi red Pulse Output
Adapter Kit from Table 2. Each Kit include
all parts required for field installation of kit ,
which may include Air V alve Assembly,
Gaskets, Spac er Plate, and/ or Hardware
Order the combination of the Pulse Output
Kit and the Pulse Output Adapter Kit
together to successfully field install a Pulse
Output Interface.
When ordering a pump with a factory
installed Pulse Output interface refer to
Pump and Ass ecories Price Sheet for
proper pump model number
Pulse Output Adapter Kits do not not
require an Adapter Kit to install Pulse
Output kits to that partic ular pump. Order
only the appropriate Puls e Output Kit (S ee
Table 1)
nsor, Fiel d Connector, and
Pulse Output
Table 1
Pulse Output Kits
System Voltage
Standard 10-30VDC
Standard 110V AC
Standard 220V AC
Intrinsic ally Safe 10-30VDC, 110VAC, & 220VAC
Table 2
Kit Number Comment
475-244-002 Refer to Page 5
475-244-002 Refer to Page 6
475-244-003 Refer to Page 7
Pulse Output Adapter Kits
Pump Class Size Kit Number Comment
Standard Duty
Non-Metallic
Standard Duty
Metallic
Pump Class Size
Heavy Duty Ball
Heav
y Duty Flap
Containment Duty
Special Dut
y
PB1/4-A / MP01P
1/4" 475-245-001 Refer to Page 8
S05 / M0
1/2" 475-245-002 Refer to Page 9
S07 / M07
3/4" 475-245-002 Refer to Page 9
S10 / M10
1"
S1F / M1F
S15 / M15
1 1/2" 475-245-003 Refer to Page 10
S20 / M20
2" 475-245-003 Refer to Page 10
S30 / M30
3" 475-245-003 Refer to Page 10
S05 / M05
1/2" 475-245-002 Refer to Page 9
S1F / M1F
S15 / M15
1 1/2" 475-245-003 Refer to Page 10
S20 / M20
2" 475-245-003 Refer to Page 10
S30 / M30
3" 475-245-003 Refer to Page 10
SB1
1"
HDB1 1/2
1 1/2"
HDB2
2"
HDB3
3"
HDB4
4"
1" 475-245-004 Refer to Page 11
HDF1 / HDF25
HDF2
2"
HDF3-M
3"
HDF3-A
HDF4-M
4"
HDF4-A
ST1
1"
ET1-M / MP04D
ET1 1/2-SM / MP05D
ET1 1/2-M / MP07D
1 1/2"
ST1 1/2
ET2-M / MP08D
2"
ET3-M / MP12D
3"
MSB2
MSA2
2"
W09-2
W09-3
3"
W15-3
W15-4
4"
Pump Model
5
Pump Model Mid-Section
/ SB25
Aluminum
Cast Iron
Aluminum
Cast Iron
Aluminum
Cast Iron
/ ST
/ HDB40
2
5
/ ST40
475-245-002 Refer to Page 9
Kit Number Comment
475-245-004 Refer to Page 11
475-245-005 Refer to Page 12
475-245-006 Refer to Page 13
475-245-005 Refer to Page 12
475-245-006 Refer to Page 13
475-245-007 Refer to Page 14
475-245-007 Refer to Page 14
475-245-005 Refer to Page 12
475-245-006 Refer to Page 13
475-245-007 Refer to Page 14
475-245-008 Refer to Page 15
475-245-007 Refer to Page 14
475-245-008 Refer to Page 15
Refer to Note 1
Refer to Note 1
Refer to Note 1
Refer to Note 1
475-245-009 Refer to Page 15
Refer to Note 1
Refer
475-245-005 Refer to Page 12
475-245-005 Refer to Page 12
Refer to Note 1
Refer to Note 1
Refer to Note 1
Refer to Note 1
to Note 1
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