SANDPIPER RHDB2 User Manual
SERVICE & OPERATING MANUAL
II 2GD T5
RHDB2
Hazardous Duty
Heavy Duty Ball Valve
AirVantage Design Level 1
Table of Contents
SAFETY PRECAUTIONS
Engineering, Performance and Construciton Data ............................................................................ 1
Explanation of Pump Nomenclature .................................................................................................. 2
Performance Curve ........................................................................................................................... 3
Dimensions ........................................................................................................................................ 4
Important Installation Information ...................................................................................................... 5
Principle of Pump Operation .............................................................................................................. 7
Principle of AirVantage ...................................................................................................................... 7
Installation and Start-Up .................................................................................................................... 7
Air Supply .......................................................................................................................................... 7
Air Line Moisture ................................................................................................................................ 7
Air Valve Lubrication .......................................................................................................................... 7
Air Inlet and Priming .......................................................................................................................... 7
Between Uses ................................................................................................................................... 7
Pump Troubleshooting ....................................................................................................................... 9
AirVantage Troubleshooting ...................................................................................................... 10-11
Composite Repair Parts List ........................................................................................................... 12
Composite Repair Parts Kits ........................................................................................................... 13
Composite Repair Parts Drawing: Wetted Side ............................................................................... 14
Diaphragm and Check Valve Servicing ........................................................................................... 15
Composite Repair Parts Drawing: Air Side ...................................................................................... 16
BOTTOM PORTED
Intermediate and AirVantage Sensor Servicing ............................................................................... 17
Air Valve Servicing, Assembly Drawings and Parts List .................................................................. 18
Air Valve Servicing with Stroke Indicators, Assembly Drawings and Parts List .............................. 19
Pilot Valve and Actuator Plunger Servicing .................................................................................... 20
Pulse Output Kits and Drawing ....................................................................................................... 21
Composite Repair Parts Drawing - AirVantage Unit ........................................................................ 23
AirVantage Servicing - Pilot Valve and Pressure Regulator ............................................................ 24
AirVantage Servicing - Power Generation Module .......................................................................... 25
AirVantage Servicing - Control Module ........................................................................................... 26
AirVantage Servicing - Sensor Assembly ....................................................................................... 27
AirVantage Servicing - Poppet Valve Drawing ................................................................................. 28
AirVantage Servicing - Poppet Valve .............................................................................................. 29
AirVantage Servicing - Check Valve ............................................................................................... 30
Grounding the Pump ...................................................................................................................... 31
Pumping Hazardous Liquids - Shutdown Procedure ...................................................................... 32
Converting the Pump for Piping Exhaust Air ................................................................................... 32
Material Codes for the Last 3 Digits of the Part Number ................................................................ 33
CE Declaration of Conformity - Machinery ...................................................................................... 34
CE Declaration of Conformity - ATEX .............................................................................................. 35
Declaration of Conformity - IECEx ................................................................................................... 36
US Patent # 6,241,487
US Patent # 7,521,921 Pending
TOP PORTED
II 2GD T4
Ex d ib IIB T4 Gb
Ex tb IIIC 135°C Db IP66
-20°C to +40°C
Sira 10ATEX1151X
IECEx SIR 10.0110X
2350863
Class I Div 1 - Groups C,D T4
Class II Div 1 - Groups F,G
Class I Zone 1, Ex d ib IIB T4
Class I Zone 1, AEx d ib IIB T4
Enclosure Type 4X
12 Volt (2 - 8) mA
rhdb2dl1sm_haz duty-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 • warrenrupp.com
©Copyright 2014 Warren Rupp, Inc. All rights reserved.
Cautions - Read Operating and Safety Precautions First
IMPORTANT
Before installation and
start-up of the pump read
these safety warnings
and instructions in this
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.
manual completely. It is the
CAUTION
Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep. Re-
prevent leakage. Follow recommended torques
torque loose fasteners to
stated in this manual.
CAUTION
Pump not designed,
tested or certified to be
powered by compressed
natural gas. Powering the
pump with natural gas will
void the warranty.
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.
Recycling
Warren Rupp is committed to protecting the environment and preventing pollution
for the benet of our employees, as well as local and global communities, now
and in the future.
Many components of SANDPIPER® Metallic AODD pumps are made of recy-
clable materials (see chart on page 32 for material specications). We encourage
pump users to recycle worn out parts and pumps whenever possible. Follow all
applicable guidelines if hazardous material has been pumped.
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If
is hazardous or toxic, the air exhaust must be
piped to an appropriate area for safe disposition.
pumping a product which
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 30)
WARNING
This pump is pressurized
internally with air during
operation. Always make
certain that all bolts are in
good condition and that
all of the correct bolts are
reinstalled during assembly. Do not open when
an explosive atmosphere may be present.
Users of electrical and electronic equipment (EEE) with the WEEE marking
per Annex IV of the WEEE Directive must not dispose of end of life EEE as
unsorted municipal waste, but use the collection framework available to them
for the return, recycle, recovery of WEEE and minimize any potential effects of
EEE on the environment and human health due to the presence of hazardous
substances. The WEEE marking applies only to countries within the European
Union (EU) and Norway. Appliances are labeled in accordance with European
Directive 2002/96/EC. Contact your local waste recovery agency for a
designated collection facility in your area.
None of the equipment supplied within the AirVantage unit either use
of exceed the amounts stated above hazardous substances. A signed
declaration from our supplier of the electronic/electrical portion of the
AirVantage unit will be held on le stating their adherence to the RoHS,
2002/95/EC regulation.
The enclosure is non-conducting and may generate an ignition-capable level
of electrostatic charges under certain extreme conditions. The user should
ensure that the equipment is not installed in a location where it may be subjected to external conditions (such as high-pressure steam) which might cause
a build-up of electrostatic charges on non-conducting surfaces. Additionally,
cleaning of the equipment should be done only with a damp cloth.”
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 at 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.
WARNING
Substitution of
components may impair
intrinsic safety.
WARNING
Use safe practices
when lifting
kg
Quality System
II 2GD T5
ISO9001 Certied
Environmental
Management System
ISO14001 Certied
BOTTOM PORTED
US Patent # 6,241,487
US Patent # 7,521,921 Pending
TOP PORTED
II 2GD T4
Ex d ib IIB T4 Gb
Ex tb IIIC 135°C Db IP66
-20°C to +40°C
Sira 10ATEX1151X
IECEx SIR 10.0110X
2350863
Class I Div 1 - Groups C,D T4
Class II Div 1 - Groups F,G
Class I Zone 1, Ex d ib IIB T4
Class I Zone 1, AEx d ib IIB T4
Enclosure Type 4X
12 Volt (2 - 8) mA
RHDB2
Hazardous Duty
AirVantage
Design Level 1
Heavy Duty Ball
Air-Operated
Double Diaphragm Pump
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA
INTAKE/DISCHARGE PIPE SIZE
2" NPT (internal)
CAUTION! Operating temperature limitations are as follows:
CAPACITY
0 to 130 gallons per minute
(0 to 492 liters per minute)
AIR VALVE
No-lube, no-stall
design
SOLIDS-HANDLING
Up to 3/8 in. (9mm)
HEADS UP TO
125 psi or 289 ft. of water
(125 psi or 8.6 bar inlet) (8.6 bar or 88 meters)
Operating Temperatures
DISPLACEMENT/STROKE
.47 Gallon / 1.77 liter
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 hydrocarbons.
EPDM: Shows very good water and chemical resistance. Has poor resistance to oil and solvents, but is fair in ketones and alcohols.
Neoprene: All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally
attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons.
Santoprene®:: Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life.
Excellent abrasion resistance.
Virgin 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 triuoride or oxygen diuoride which readily liberate free uorine at elevated temperatures.
FKM (Fluorocarbon): Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons,
acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.
Polypropylene:
UHMW Polyethylene:
For specic applications, always consult The Warren Rupp Chemical Resistance Chart
SANDPIPER® pumps are designed to be powered only by compressed air.
190° F
88° C
280° F
138° C
200° F
93° C
275° F
135° C
220° F
104° C
350° F
177° C
180° F
82° C
180° F
82° C
-10° F
-23° C
-40° F
-40° C
-10° F
-23° C
-40° F
-40° C
-35° F
-37° C
-40° F
-40° C
32° F
0° C
32° F
0° C
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 1
Explanation of Pump Nomenclature, RHDB2 Hazardous Duty Ball Valve
Outer Inner Ball Manifold Manifold Shipping Shipping
Top Bottom Manifold Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard- Diaphragm Valve Seat Sealing Wt. (lbs.) Wt. (lbs.) AirVantage
Porting Porting Chamber Chamber Plate Plate Housing Rod Seat ware Material Gasket Rings Top P Bottom P Options
TB-3-A DB-3-A AL AL AL CI PS AL SS SS PS B B CB B 105 112 Y
TC-3-A DC-3-A AL AL AL CI PS AL SS SS PS V T CT V 105 112 Y
TI-3-A DI-3-A AL AL AL CI PS AL SS SS PS I I CT I 105 112 Y
TN-3-A DN-3-A AL AL AL CI PS AL SS SS PS N N CN N 105 112 Y
TGI-3-A DGI-3-A AL AL AL CI PS AL SS SS PS I/T T CT V 105 112 Y
TGN-3-A DGN-3-A AL AL AL CI PS AL SS SS PS N/T T CT V 105 112 Y
TGR-3-A DGR-3-A AL AL AL CI PS AL SS SS PS H/T T CT V 105 112 Y
TS-3-A DS-3-A AL AL AL CI PS AL SS SS PS S S CT I 105 112 Y
TB-3-I DB-3-I CI CI AL CI PS AL SS SS PS B B CB B 151 161 Y
TC-3-I DC-3-I CI CI AL CI PS AL SS SS PS V T CT V 151 161 Y
TI-3-I DI-3-I CI CI AL CI PS AL SS SS PS I I CT I 151 161 Y
TN-3-I DN-3-I CI CI AL CI PS AL SS SS PS N N CN N 151 161 Y
TGI-3-I DGI-3-I CI CI AL CI PS AL SS SS PS I/T T CT V 151 161 Y
TGN-3-I DGN-3-I CI CI AL CI PS AL SS SS PS N/T T CT V 151 161 Y
TGR-3-I DGR-3-I CI CI AL CI PS AL SS SS PS H/T T CT V 151 161 Y
TS-3-I DS-3-I CI CI AL CI PS AL SS SS PS S S CT I 151 161 Y
TB-3-S DB-3-S
TC-3-S DC-3-S
TI-3-S DI-3-S
TN-3-S DN-3-S
TGN-3-S DGN-3-S
TGR-3-S DGR-3-S
TS-3-S DS-3-S
Meanings of
Abbreviations:
‡SS ‡SS AL SS PS AL SS SS PS B B CB B 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS V T CT V 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS I I CT I 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS N N CN N 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS N/T T CT V 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS H/T T CT V 166 173 Y
‡SS ‡SS AL SS PS AL SS SS PS S S CT I 166 173 Y
A = Compressed Fibre
AL = Aluminum
B = Nitrile
CB
= Conductive Nitrile
CI = Cast Iron
CN = Conductive Neoprene
CT = Conductive PTFE
DC = Die Cast
H/T
= Hytrel® Backup/PTFE
Overlay
I = EPDM
I/T = EPDM Backup/PTFE Overlay
N = Neoprene
N/T
= Neoprene Backup/
PTFE Overlay
PS = Plated Steel
S = Santoprene
SS = Stainless Steel
T = PTFE
V = FKM
®
X = AirVantage
ATEXCertied
Y = US Hazardous Duty
‡ CF-8M Stainless SteelequaltoorexceedingASTMspecicationA743forcorrosionresistantironchromium,ironchromiumnickel,andnickelbasedalloycastingsfor
generalapplications.Commonlyreferredtoas316StainlessSteelinthepumpindustry.
Santoprene is a registered tradename of Exxon Mobil Corp.
Hytrel is a registered tradename of E.I. du Pont.
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 2
Performance Curve,
Model RHDB2 Performance Curve
Performace based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.
BAR
100
7
6
5
4
HEAD
3
2
1
RHDB2 Hazardous Duty Ball Valve
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
15
10
PSI
(17)
100 PSI (6.9 Bar)
90
80
80 PSI (5.5 Bar)
70
60
60 PSI (4.1 Bar)
50
40
40 PSI (2.8 Bar)
30
20
20 PSI (1.4 Bar)
10
(25)
20
(34)
30 (51)
40 (68)
50 (85)
60 (102)
70 (119)
80
(136)
0
0
0 20 40 60 80 100 120 140
U.S. Gallons per minute
500400300200100
Liters per minute
CAPACITY
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 3
Dimensions: RHDB2 Hazardous Duty
15.50
Dimensions: RHDB2 Hazardous Duty
Bottom Ported
Dimensions are ± 1/8"
Figuresinparenthesis=millimeters
394
AIR INLET
1" FNPT
22.63
575
14.93
379
16.07
408
.18
5
16.43
417
SUCTION AND DISCHARGE PORTS ARE
AVAILABLE WITH 2" BSP CONNECTIONS
SUCTION AND DISCHARGE PORTS CAN
BE ROTATED 90
26.40
671
FOR VERTICAL PORTING
9.59
Top Ported
Dimensions are ± 1/8"
Figuresinparenthesis=millimeters
15.50
394
3/4" NPT EXHAUST
DISCHARGE PORT
2" FNPT
22.45
570
15.27
388
3.43
87
SUCTION PORT
243
2" FNPT
7.06
179
4X
1.00
25
AIR INLET
1" NPT
8X
.44
[11] MTG.HOLE
16.07
408
.18
5
16.43
417
SUCTION AND DISCHARGE PORTS ARE
AVAILABLE WITH 2" BSP CONNECTIONS
SUCTION AND DISCHARGE PORTS CAN
BE ROTATED 90
26.40
670
FOR VERTICAL PORTING
9.59
243
DISCHARGE PORT
2" NPT
SUCTION PORT
2" NPT
9.05
230
3/4" NPT EXHAUST
20.89
531
8X
.44
[11] MTG. HOLE
12.50
318
12.50
318
10.50
267
8.63
219
8.63
219
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 4
Important Installation Information
Use of the standard AODD Installation Guide is recommended for pumps
tted with AirVantage technology. Install shut-off valves on both the suction and
discharge of the pump. (This will help limit the amount of product that enters the center section
of the pump in the event of a diaphragm failure.) Using shut-off valves in conjunction with a drain
port also provides a means of allowing the lines to be drained when maintenance needs to
be conducted.
When the supply liquid level is above the air inlet of the pump, and a
diaphragm fails, the pumped liquid or fumes can enter the air end through
the point of failure. When a diaphragm failure is detected, it is best to close
the shut-off valves and bleed the lines of product. This will limit the ability
of the material being pumped to enter the AirVantage. Failure to do so may
result in damage to the AirVantage and air distribution components.
If a diaphragm failure has been detected in pumps
tted with AirVantage, the following procedure for
shut-down must be used:
1. Close the suction shut-off valve
(this will limit any new product from
entering the pump)
2. Close the discharge shut-off valve
(this will stop any product from
reentering the pump)
3. Close the air supply shut-off valve
4. Drain the discharge line
5. Drain the suction line
6. Perform maintenance
Shut O
Valve
Shut-O Valve
Suction Port
Dessicant Dryer
(Optional)
Unregulated Air
Supply to Tranquilizer
Filter Regulator
PN: 020.107.000
Vacuum
Gauge
Drain Port
Flexible
Connection
Suggested Installation Guide
Pipe Connection
(Style Optional
Flexible Connector
(Optional Piped Exhaust)
Muer
Warren Rupp Tranquilizer
Limited to 125 psi
(Optional)
Pressure Gauge
Shut-O Valve
Discharge Port
Caution: When performing a direct spray washdown, a
plug must be installed in place of the AirVantage mufer.
Failure to do so may damage internal components.
(See page 23)
Flexible Connector
Pipe Connection
(Style Optional)
Drain Port
Note: Pipe weight should not be supported
by pump connections.
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 5
into the atmosphere. If
This Page Intentionally Blank
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 6
PRINCIPLE OF PUMP OPERATION
This ball valve tted pump has been equipped with IDEX’s patented AirVantage equipment. To fully understand the
operation of the AirVantage, one must rst understand the basics of Air Operated Double Diaphragm (AODD) pumps.
AODD’s are powered by compressed air. The compressed air is directed behind each of the exible diaphragms by a
Main Air Valve. Once the diaphragm has reached the end of its stroke, a Pilot Valve is mechanically actuated, sending
an air signal back to the Main Air Valve which redirects air to the opposite diaphragm. This causes the diaphragm
assemblies, which are connected by a common Diaphragm Rod, to move in a reciprocating action.
Air is directed to the inboard side of the diaphragm, which is closest to the center of the pump. This is referred to
as the air side of the diaphragm. The opposite side is commonly called the uid side. Most AODD pumps have a 1:1
ratio design. This means, when the discharge of the pump is closed completely (dead headed), the maximum pressure
the pump will create will be equal to the air pressure being applied to the pump. At this point, and only at this point, the
diaphragm will be completely balanced. The air pressure is equivalent to the uid pressure and there will be no movement
of the diaphragm. If the pump is stroking, then the system is not balanced. There will be more pressure applied to the air
side than uid pressure on the uid side.
During each stroke of the pump there are two distinct operations that occur. One diaphragm is moving away from
the center of the pump, moving uid out of the Discharge Manifold, while the other diaphragm is moving toward the
center, bringing uid into the Suction Manifold. Considering that the pump has a common suction and discharge port,
these two operations are separated from each other through a series of Check Valves.
PRINCIPLE OF AIRVANTAGE
AirVantage is a special air side device which uses equipment that can accurately monitor the operation of the pump.
Based on the monitored information, air is metered to the correct amount to perform the work required, and
NOTHING MORE.
Once the pump starts up, and the AirVantage is turned on, the LED indicator light will go through a series of patterns.
Initially the light will be solid green. This indicates the AirVantage is allowing the pump to reach a steady state. Next,
the light will pulse at a very rapid rate. This is called the learn phase. Learn is where the AirVantage monitors the pump
in non-AirVantage mode. This will set the parameters for operation in AirVantage mode. In less than one minute, the
pump will change tones. The LED indicator light will start an uneven blink when optimization has started. Optimization
will be completed once the LED light is blinking in unison with the stroke rate of the pump. All this is completed without
sacricing a signicant amount of ow.
AIR LINE MOISTURE
Water in the compressed air supply can create problems such as icing and freezing of the exhaust air. The
formation of ice in the exhaust can cause the pump to cycle erratically, degrade efciency, or even stop the pump. Fitting
the pump with the AirVantage technology reduces the exhaust temperature. This is due to more energy being extracted
from every pulse of air. When more energy is extracted, the temperature of the air is reduced. Some method of air drying
will be necessary. Most refrigerant dryers installed on compressors can reduce the dewpoint to about 40° F. This is
normally adequate for most pumping applications. If further drying needs to occur due to internal ice build-up, a desiccant
dryer can be installed. These air line dryers can lower the dewpoint to around -40° F.
AIR VALVE LUBRICATION
The air valve and pilot valve are designed to operate without lubrication. There may be instances of personal
preference or when extremely dry air is being used (instrument quality or nitrogen) that a small amount of lubrication will
improve the life of the rubber components being used on the air side of the pump. The lubrication may be added using an
air line lubricator (¾” PN: 020.051.001 – 1” PN: 020.052.001). At the point of operation use SAE 10 weight, non detergent
oil at a maximum rate of 1 drop per hour for every 20 scfm (9.4 liters/sec) of air consumption. Consult the pump curve to
determine this value. The smallest amount needed is preferred.
AIR INLET AND PRIMING
To start the pump, make sure the AirVantage switch is in the off position. Increase the pressure until the pump starts
to cycle. The pump stroke rate should slow slightly when the pump is primed. Once the pump is fully primed, increase
the pressure at the regulator until the desired ow rate is achieved. Again, the pump curve can be used to derive this
value. If increasing the pressure to the pump does not generate a higher ow rate, then cavitation has occurred. Back the
regulator off slightly. To gain the most efciency from the pump, try to run the pump fully primed at all times.
BETWEEN USES
When the pump is being used to move materials that tend to settle out or solidify, the pump should be ushed to
prevent damage. The product that remains in the pump could dry and settle out. This could potentially cause damage
to the diaphragms and/or check valves during restart. In freezing temperatures the pump must be completely drained
between uses. Due to the addition of the new technology, it is recommended the air supply to the pump be shut off if the
pump is going to be shut down for an extended length of time.
INSTALLATION AND START-UP
The pump should be located near the product being pumped, in order to keep the suction line as short as possible.
Minimize the number of ttings between the product and the pump and maintain the line size, if possible. Better results
will always be realized if the line size of the suction line is increased by one size. It's not recommended to hook up
rigid pipe directly to the pump. Some method of expansion joint or vibration isolator should be used. A Warren Rupp
Tranquilizer
the level of the pump, a pressure regulating device may need to be added to the exhaust of the pump (Consult the factory
for recommendations).
AIR SUPPLY
The air supply pressure cannot exceed 125 psi (8.6 bar). The air line and associated components (lters,
regulators, solenoid valves, etc.) should not be less than ½” (13 mm). However, 3/4" (19mm) or greater is preferred. An
air line lter-regulator is necessary for the AirVantage installation. The required component (PN: 020.107.000) is available
through the distributor. Rigid pipe should not be hooked directly to the air inlet of the AirVantage. A exible hose should be
installed to reduce the strain. Do not let the weight of the air line components be supported by the air inlet of the pump.
Failure to provide a means of supporting the weight may result in damage to the pump. If the pump will be shut down for
any extended length of time, it is recommended that the air supply to the pump should be shut off.
SPECIAL CONDITIONS FOR SAFE USE
For the safe operation of the equipment, it is necessary for the air supply to come from a safe area, therefore,
the supplied air shall be clean.
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 7
®
is recommended to reduce the pulsation in the ow. If the uid level is more than 10 feet (3 meters) above
WARNING
Hazardous Duty Rating
This pump is certied to be
operated in the hazardous areas
listed on the front cover. To
maintain this certification, only genuine, approved
parts must be used and assembled in accordance to
the instructions detailed in this manual by a competent
person. Any deviation or modication to this will invalidate
certication and may result in serious injury or death.
This Page Intentionally Blank
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 8
PUMP TROUBLESHOOTING
CAUTION! WHENEVER TROUBLESHOOTING OR PERFORMING ANY
REPAIRS ON ANY WARREN RUPP, INC. EQUIPMENT, ALWAYS REMOVE
THE AIR SUPPLY LINE TO THE PUMP AND WEAR PROPER PERSONAL
PROTECTIVE EQUIPMENT.
PUMP WILL NOT CYCLE
What to Check: • The system head exceeds the air supply pressure to the pump.
Corrective Action: • Increase the air inlet pressure to the pump. Most diaphragm pumps are
designed for 1:1 pressure at zero ow.
What to Check:• Check ESADS+, including pilot valve assembly and main air valve assembly.
Corrective Action: • Disassemble and inspect the main air distribution valve, pilot valve, and
pilot valve actuator pins. Check for scores, wear, or damaged o-rings. Replace parts as necessary.
Refer to the exploded view drawing and air valve section (P.18 & 20).
What to Check: • Blocked discharge line.
Corrective Action: • Check for obstruction or closed discharge line.
What to Check: • Blocked pumping chamber.
Corrective Action: • Disassemble and inspect wetted chambers of the pump. Remove or ush
any obstructions. Refer to page 14 for disassembly.
PUMP CYCLES, BUT WILL NOT FLOW OR FLOW RATE IS UNSATISFACTORY
What to Check: • Restricted or undersized air line.
Corrective Action: • Make sure there are no obstructions or restrictions in the air inlet to the
pump. Install proper size air line and/or air line equipment. Refer to air supply section (p.7) air inlet
plumbing recommendations.
What to Check: • Restricted or undersized suction piping.
Corrective Action: • Make sure there are no obstructions or restrictions in the suction line or
related suction components such as screens or strainers. Install the proper size suction line and/
or equipment. It is recommended that any suction line components and pipe size be at least the
same size as the suction line thread size to the pump. Though best results will always be realized
if the line size of the suction line is increased by one size. Refer to the installation section (p.5) for
recommended suction plumbing recommendations.
What to Check: • Excessive Suction Lift.
Corrective Action: • For lifts exceeding 20 feet (6 meters), lling the pump chambers with liquid
will prime the pump in most cases. If not, place pump closer to uid level.
What to Check: • Suction line cavitation.
Corrective Action: • If no obstructions are in the suction line of the pump, decrease the inlet
air pressure and/or volume to the pump. This will slow down the diaphragm speed and reduce the
cavitation.
What to Check: • Partially blocked exhaust mufer.
Corrective Action: • Remove mufer and make sure that some of the material being pumped has
not migrated into the mufer element. If it has, replace the element or clean it and reinstall. If product
has made it to the mufer, then the diaphragm assembly will need to be inspected. Refer to the
Diaphragm Replacement section (p.15).
What to Check: • Suction side air leakage or air in the product.
Corrective Action: • Visually inspect all suction side gaskets, seals, as well as pipe and pipe
connections.
PUMP CYCLE SEEMS UNBALANCED OR PRODUCES EXCESSIVE VIBRATION
What to Check: • Excessive ooded suction in system.
Corrective Action: • Check height of uid above pump. For ooded conditions, exceeding 10 feet
(3 meters) of liquid, install a back pressure device in the exhaust side of the pump.
What to Check: • Worn or misaligned check valve or check valve seat.
Corrective Action: • Disassemble the wet end of the pump and inspect check valves and seats
for wear and proper seating. Replace them if necessary. Refer to the Check Valve section (p.15) for
disassembly instructions.
What to Check: • Obstructed check valves.
Corrective Action: • Disassemble the wet end of the pump and look for obstructions that may
prevent the check valve from seating on the seat. Look for damage on the valve and the seat. Replace
them as necessary. Refer to the Check Valve section for disassembly (p.15).
What to Check: • Rigid pipe connections.
Corrective Action: • Install exible pipe isolators or expansion joints between the plumbing and
the pump.
What to Check: • Blocked air exhaust mufer.
Corrective Action: • Remove mufer, clean or de-ice and reinstall.
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 9
What to Check: • Pulsation in the discharge line.
Corrective Action: • Excessive pulsation in the discharge line may be corrected by installing a
Warren Rupp Tranquilizer Surge Suppressor.
AirVantage Troubleshooting
Caution! Whenever troubleshooting or performing any repairs on any
Warren Rupp, Inc. equipment, always remove air supply line to the pump
and wear proper personal protective equipment.
LED OUTPUT FOR AirVantage UNIT
STAT E LED OUTPUT
Startup/Settle/Deadhead Solid
Standby/Low Flow 1 Second ON / 1 Second OFF
Learn Mode 0.1 Seconds ON / 0.1 Seconds OFF
Seek/Optimize 1 Second ON / 0.1 Seconds OFF
Steady State/Air Savings OFF / ON in rhythm with Cycle Rate of Pump
AirVantage LED DOES NOT LIGHT UP AT ALL
What to Check:
• Make sure power switch on the control module is turned on, (depressed to the left)
• Make sure air is being supplied to pump or make sure 110 VAC unit has power
being supplied to it
Corrective Action:
• Cycle power switch off/on
• Unplug patch cable and cycle power switch off/on
• Consult Factory After Sales Support team
AirVantage LED LIGHTS UP AND STAYS ON SOLID
What to Check:
• Make sure patch cable is plugged in and locked
Corrective Action:
• Consult Factory After Sales Support team
VALVE FIRES ONCE AND IMMEDIATELY RESETS
Corrective Action:
• Consult Factory After Sales Support team
VALVE LED NEVER LEAVES SEEK MODE - AirVantage LED PULSING IN TIME TO
PUMP, BUT VALVE NOT ACTUATING AND THE PUMP IS NOT SAVING AIR
Corrective Action:
• Consult Factory After Sales Support team
UNEXPECTED OPERATING CONDITION (AIR SAVINGS OR FLOW RATE)
What to Check:
• Check for varying environmental pumping conditions (changing head or suction)
• Check ice buildup in exhaust area
• Inspect sleeve and spool set for damage
Corrective Action:
• Consult Factory After Sales Support team
PUMP CYCLING IS UNSTABLE OR ERRATIC
What to Check:
• Run pump without AirVantage and check pump operation
• Make sure pump has correct sleeve and spool set installed
• Make sure patch cable plug is connected and locked
• Make sure power wire connectors are tight
Corrective Action:
• Consult Factory After Sales Support team
PUMP RUNNING SLOWLY
What to Check:
• Run pump without AirVantage and check operation
• Cycle the power off/on to the control module to reset controller
• Check ice buildup in exhaust area
• Inspect sleeve and spool set for damage
Corrective Action:
• Consult Factory After Sales Support team
• Cycle the power switch on the control module off/on
rhdb2dl1sm_haz duty-rev0614 Model RHDB2 Hazardous Duty Page 10
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