SANDPIPER RHDF2 User Manual

SERVICE & OPERATING MANUAL

RHDF2 Heavy Duty Flap 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

US Patent # 6,241,487 US Patent # 7,521,921 Pending

Composite Repair Parts Drawing: Air Side ...................................................................................... 16

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 - Solenoid 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 .......................................................................................................... 34

rhdf2dl1-rev0614

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

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

Cautions - Read Operating and Safety Precautions First

IMPORTANT

Before installation and

start-up of the pump read

these safety warnings and

instructions in this manual completely. 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.

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

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 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.

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.

Recycling

Warren Rupp is committed to protecting the environment and

preventing pollution for the benet 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 recyclable materials (see chart on page 32 for material specications). We encourage pump users to recycle worn out parts and pumps whenever possible. Follow all applicable guidelines if hazardous material has been pumped.

WARNING

Use safe practices

kg

when lifting

the pump. The discharge line may be pressurized and must be bled of its pressure.

Before maintenance

or repair, shut off the

compressed air line,

bleed the pressure, and

disconnect the air line from

WARNING

Quality System

ISO 9001 Certied

Environmental

Management System

ISO 14001 Certied

US Patent # 6,241,487 US Patent # 7,521,921 Pending

RHDF2

AirVantage Design Level 1

Heavy Duty Flap

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 165 gallons per minute

(0 to 624 liters per minute)

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to 2 in. (50mm)

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

.48 Gallon / 1.81 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 triuoride or oxygen diuoride 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:

®

HYTREL

For specic applications, always consult The Warren Rupp Chemical Resistance Chart

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

rhdf2dl1sm-rev0614 Model RHDF2 Page 1

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

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

190° F

88° 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.

-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

-10° F

-23° C

Explanation of Pump Nomenclature, RHDF2 · Flap Valve

To order a pump or replacement parts, rst enter the Model Number RHDF2, followed by Type Designation listed below in the far left columns.

Inner Flap Type AirVantage Manifold Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard- Diaphragm Valve Sealing Shipping

Designation

Options Elbow Chamber Chamber Plate Plate Housing Rod Seat ware Material Rings Wt. lbs. DA6A S. AL AL AL PS PS AL SS SS PS N U N 107 DB6A S. AL AL AL PS PS AL SS SS PS B B B 107 DV6A S. AL AL AL PS PS AL SS SS PS V V V 107 DN6A S. AL AL AL PS PS AL SS SS PS N N N 107 DI6A S. AL AL AL PS PS AL SS SS PS I I I 107 DP6A S. AL AL AL PS PS AL SS SS/I PS S S I 107 DR6A S. AL AL AL PS PS AL SS SS PS H H N 107 DA6I S. CI CI AL PS PS AL SS SS PS N U N 150 DB6I S. CI CI AL PS PS AL SS SS PS B B B 150 DV6I S. CI CI AL PS PS AL SS SS PS V V V 150 DN6I S. CI CI V PS PS AL SS SS PS N N N 150 DI6I S. CI CI AL PS PS AL SS SS PS I I I 150 DR6I S. CI CI AL PS PS AL SS SS PS H H N 150 DP6I S. CI CI AL PS PS AL SS SS/I PS S S I 150 DA6S S. DB6S S. DF6S S. DV6S S. DN6S S. DI6S S. DP6S S. DR6S S.

‡SS ‡SS AL ‡SS PS AL SS SS PS N U N 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS B B B 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS F F F 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS V V V 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS N N N 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS I I I 157 ‡SS ‡SS AL ‡SS PS AL SS SS/I PS S S I 157 ‡SS ‡SS AL ‡SS PS AL SS SS PS H H N 157

Meanings of Abbreviations:

S = Self Contained Electrical Generator P = 100 VAC Electrical Conneciton

A = Compressed Fibre DC = Die Cast PS = Plated Steel SS/I = Stainless Steel seat w/EPDM O-Ring AL = Aluminum H = Hytrel B = Nitrile I = EPDM SS = Stainless Steel U = Urethane CI = Cast Iron N = Neoprene V = FKM (Fluorocarbon) F = FDA Accepted White Nitrile

®

S = Santoprene® T = PTFE

‡ CF-8M Stainless Steel equal to or exceeding ASTM specication A743 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.

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

rhdf2dl1sm-rev0614 Model RHDF2 Page 2

Performance Curve, RHDF2 Design Level 1

Model RHDF2 Performance Curve

Performace 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%.

10

20

30

BAR

100

7

6

5

4

HEAD

3

2

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

(34)

(51)

40

(68)

SCFM (M3/hr)

50 (85)

60 (102)

(119)70

20

1

20 PSI (1.4 Bar)

10

0

0 20 40 60 80 100 120 140 160 180

U.S. Gallons per minute

500400300200100

600

Liters per minute

CAPACITY

rhdf2dl1sm-rev0614 Model RHDF2 Page 3

Dimensions: RHDF2

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

19.87 505

20.30 516

OPTIONAL VERTICAL

SUCTION

PORT

8.48 215

1" NPT AIR INLET

17.68 449

SUCTION PORT 2" NPT

2.62 67

3/4" NPT EXHAUST

DISCHARGE PORT 2" NPT

2.57 65

9.81 249

.25

6

11.00 279

8.88 226

21.64 550

10.25

260

14.00

355

8X

.50

[13] MTG. HOLE

15.37 390

15.62 397

BOTH SUCTION AND DISCHARGE PORTS ARE AVAILABLE WITH 2" BSP CONNECTIONS

24.29 617

2.62 67

rhdf2dl1sm-rev0614 Model RHDF2 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)

Shut O Valve

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

Caution: When performing a direct spray washdown, a

plug must be installed in place of the AirVantage mufer.

Failure to do so may damage internal components. (See page 23)

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.

into the atmosphere. If

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)

Flexible Connector

Pipe Connection (Style Optional)

Muer

Drain Port

Note: Pipe weight should not be supported by pump connections.

Warren Rupp Tranquilizer Limited to 125 psi (Optional)

Pressure Gauge

Shut-O Valve

Discharge Port

rhdf2dl1sm-rev0614 Model RHDF2 Page 5

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rhdf2dl1sm-rev0614 Model RHDF2 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

sacricing a signicant 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 efciency, 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 efciency 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).

®

is recommended to reduce the pulsation in the ow. If the uid level is more than 10 feet (3 meters) above

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.

rhdf2dl1sm-rev0614 Model RHDF2 Page 7

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rhdf2dl1sm-rev0614 Model RHDF2 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 mufer. Corrective Action: • Remove mufer and make sure that some of the material being pumped has

not migrated into the mufer element. If it has, replace the element or clean it and reinstall. If product has made it to the mufer, 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 mufer. Corrective Action: • Remove mufer, clean or de-ice and reinstall.

rhdf2dl1sm-rev0614 Model RHDF2 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

rhdf2dl1sm-rev0614 Model RHDF2 Page 10

AirVantage Troubleshooting Continued

Optional 1/4" NPT Pipe Plug (P/N 618.011.330)

AirVantage RESETS AND ENTERS LEARN MODE TOO FREQUENTLY

What to Check:

• Check for excessive varying environmental pumping conditions (changing head or suction)

• Check ice buildup in exhaust area

• Inspect sleeve and spool set for damage

• Make sure patch cable plug is connected and locked

Corrective Action:

• Consult Factory After Sales Support Team

PUMP STALLS, RESETS, LEARNS, SEEKS AND REPEATS

What to Check:

• Make sure patch cable plug is connected and locked

• Check ice buildup in exhaust area

Corrective Action:

• Consult Factory After Sales Support Team

REGULATOR

CAPSCREW, HEX SOC HD, 10-32 X .50

COVER

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

PUMP MOVES OUT OF STEADY STATE AND NEVER ATTEMPTS TO RELEARN (LED ON)

What to Check:

• Make sure patch cable plug is connected and locked

• Cycle the power off/on to the control module

CONTROL MODULE

Corrective Action:

• Consult Factory After Sales Support Team

• Cycle the power switch on the control module off/on

WHAT TO DO IN THE EVENT OF A DIAPHRAGM FAILURE

If a diaphragm failure has been detected in pumps tted with AirVantage,

see page 5 for shut-down procedure. What to Check:

• Has product migrated to the sensor?

Corrective Action:

• If the sensor has been submerged in product, the sensor will need to be replaced. Consult the AirVantage servicing section of the manual for detailed instructions.

What to Check:

• Has product contaminated the check valve cartridge?

Correct Action:

• If a signicant amount of product has made it into the check valve assembly, then the unit will need to

be disassembled for inspection. If the check valve assembly is damaged, then it will need to be replaced. Consult parts list for information.

O-RING

SEAL, O-RING

Must be installed if performing direct spray

wash-down of pump

MUFFLER

SEAL, O-RING

ASSEMBLY, POWER GENERATOR

CAPSCREW, HEX SOC HD, 10-32 X 1.00

CAPSCREW, HEX SOC HD, 10-32 X 2.25

SEAL, O-RING

CAPSCREW, HEX SOC HD, 10-32 X .50

(Purchased Separately)

rhdf2dl1sm-rev0614 Model RHDF2 Page 11

Composite Repair Parts List

Item Part Number Description Qty

1 031.019.004 Ass’y - Air Valve 1

031.098.001 Ass’y - Air Valve (Pulse Output Application) 1 2 032.058.000 Ass’y - AirVantage 1

3 070.006.170 Bearing 2 4 095.073.001 Pilot Valve Assembly 1 5 114.032.156 F Intermediate 1 6 115.158.080 Bracket, Leg 2 7 115.159.080 Bracket, Leg 2 8 115.172.159 Bracket, Mounting, R.H. 1 9 115.173.159 Bracket, Mounting, L.H. 1 10 132.002.360 Bumper, Diaphragm Plate 2 11 135.016.162 Bushing, Threaded, W/ O-Ring 560.001.360 2 12 165.138.150 Cap, End, Sensor 1 13 170.024.330 Capscrew, Hex Hd, 7/16-14 X 1 8 14 170.026.330 Capscrew, Hex Head 3/8-16 X 3 1/2 2 15 170.031.330 Capscrew, Soc Hd, 7/16-14 x 2 1/2 4 16 170.035.330 Capscrew, Hex Hd, 7/16-14 X 2 8 17 170.045.330 Capscrew, Hex Head 5/16-18 X 1 1/4 4 18 170.052.330 Capscrew, Hex Head 3/8-16 X 2 1/2 2 19 170.060.330 Capscrew, Hex Hd, 7/16-14 X 1 1/2 4 20 170.061.330 Capscrew, Hex Head 3/8-16 X 2 16 21 170.121.330 Capscrew, Hex Head 5/16-18 X 5 1/2 4 22 171.002.330 Capscrew, Socket Head 2

171.002.110 Capscrew, Socket Head (Stainless Steel Only) 2 23 171.100.115 Capscrew, Soc Hd, 5/16-18 x 2 1/2 4 24 196.001.157 Chamber, Inner 2 25 196.002.010 NS Chamber, Outer 2

196.002.110 NS Chamber, Outer 2

196.002.157 NS Chamber, Outer 2 26 258.023.147 Cover, Sensor 1 27 286.007.354 Diaphragm 2

286.007.356 Diaphragm 2

286.007.360 Diaphragm 2

286.007.363 Diaphragm 2

286.007.364 Diaphragm 2

286.007.365 Diaphragm 2

286.007.366 Diaphragm 2 28 312.012.010 Elbow Suction 2

312.012.110 Elbow Suction 2

312.012.156 Elbow Suction 2 29 312.013.010 Elbow, Discharge 2

312.013.110 Elbow, Discharge 2

312.013.156 Elbow, Discharge 2 30 338.005.360 Flap Valve 4

338.005.363 Flap Valve 4

338.005.364 Flap Valve 4

338.005.365 Flap Valve 4

338.005.366 Flap Valve 4

338.010.354 Flap Valve 4

338.010.356 Flap Valve 4

338.010.357 Flap Valve 4 31 360.041.379 Gasket, Pilot Valve 1 32 360.048.425 Gasket, Main Air Valve 1 33 518.001.010 Manifold 2

518.001.110 Manifold 2

518.001.157 Manifold 2

Item Part Number Description Qty

34 530.041.000 Mufer 1

35 538.108.110 Nipple, Pipe 1 36 545.007.330 Nut, Hex - 7/16-14 8 37 547.002.110 Nut, Stop 8 38 560.001.360 O-Ring 2 39 560.011.360 O-Ring 2 40 560.022.360 O-Ring 2 41 560.033.360 O-Ring 2 42 560.046.360 O-Ring (Stainless Steel Units Only) 2 43 560.200.360 O-Ring 1 44 560.201.360 O-Ring 2 45 560.203.360 O-Ring 2 46 570.001.360 Pad, Hinge-Flap Valve 4

570.001.363 Pad, Hinge-Flap Valve 4

570.001.364 Pad, Hinge-Flap Valve 4

570.001.365 Pad, Hinge-Flap Valve 4

570.001.366 Pad, Hinge-Flap Valve 4 47 570.009.360 Pad, Wear 2

570.009.363 Pad, Wear 2

570.009.364 Pad, Wear 2

570.009.365 Pad, Wear 2 48 612.047.330 Plate, Inner Diaphragm 2 49 612.008.330 Plate, Outer Diaphragm 2

612.096.110 Plate, Outer Diaphragm (SST Units Only) 2 50 612.241.147 Plate, Adapter 1 51 618.003.330 Plug, Pipe, 1/4 4 52 618.003.330 Plug, Pipe, 1/4 2

618.003.110 Plug, Pipe, 1/4 (Stainless Steel Only) 2 53 620.011.114 Plunger, Actuator 2 54 670.005.110 Retainer, Flap Valve 4 55 675.013.360 Ring, Sealing 4

675.013.363 Ring, Sealing 4

675.013.364 Ring, Sealing 4

675.013.365 Ring, Sealing 4

675.013.366 Ring, Sealing 4 56 685.007.120 Rod, Diaphragm 1 57 720.004.360 Seal, U-Cup 2 58 722.070.360 Seat, Flap Valve 4

722.070.363 Seat, Flap Valve 4

722.070.364 Seat, Flap Valve 4

722.070.365 Seat, Flap Valve 4 59 724.008.000 Sensor, Feed Back 1 60 770.005.330 Spacer (Aluminum Only) 2 61 770.074.159 Spacer 4 62 807.018.110 Stud, 1/4-20 8 63 846.001.167 Probe Tip 2 64 894.014.000 Valve, Check 1 64a 031.206.000 Cartridge, Check Valve 1 65 900.005.330 Washer, Lock, 3/8 20 66 900.006.330 Washer, Lock - 7/16 (Aluminum) 16 67 901.022.330 Washer, Flat 7/16 8 68 902.003.000 Washer, Sealing 2 69 920.028.000 Cable, Patch 1 70 P126-0011 Foam Bumper, Sensor 2 71 P126-0032 Capscrew, Socket Head, 8/32 x 7/16 8

rhdf2dl1sm-rev0614 Model RHDF2 Page 12

Composite Repair Parts Kits

Available Service And Conversion Kits

Air End Kit - 476.247.162

Seals, O-rings, Gaskets, Air Valve Sleeve and Spool Set, and Pilot Valve Assembly

Wet End Kit – 476.270.356 (RHDF2, HDF2)

Hytrel Diaphragms, Flap Valves and Neoprene Hinge Pads, Wear Pads, Sealing Rings

Wet End Kit – 476.270.360 (RHDF2, HDF2)

Nitrile Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings

Wet End Kit – 476.270.364 (RHDF2, HDF2)

EPDM Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings

Wet End Kit – 476.270.365 (RHDF2, HDF2)

Neoprene Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings

Wet End Kit – 476.270.632 (RHDF2, HDF2)

Neoprene Diaphragms, Hinge Pads, Wear Pads, and Sealing Rings, and Hytrel Flap Valves

Wet End Kit – 476.270.643 (RHDF2, HDF2)

Santoprene Diaphragms, Flap Valves and EPDM Hinge Pads, Wear Pads, Sealing Rings

Sensor Kit - 476.304.000

(Sensor, Probe Tips and O-rings)

Poppet Valve Kit – 476.271.000

(Poppet Valve Assembly, O-ring)

Poppet Valve Assembly Kit – 476.272.000

(Poppet Valve Assembly, O-ring, Regulator and Solenoid Valve)

Cover Kit – 476.273.000

(Enclosures, Hardware and O-rings)

Control Module Kit – 476.298.000 (Power Gen AirVantage Only)

(Control Module Assembly, Gaskets, Hardware and O-rings)

Control Module Kit – 476.299.000 (Power Supply AirVantage Only)

(Control Module Assembly, Gaskets, Hardware and O-rings)

Power Gen Kit – 476.278.000 (Power Gen AirVantage Only)

(Power Gen, Gasket, Hardware and O-ring)

Power Supply Kit – 476.279.000 (Power Supply AirVantage Only)

(Power Supply, Gasket, Hardware and O-ring

Seal Kit – 476.280.000

O-rings and Gaskets

Probe Tip Kit – 476.283.000

(Probe Tips and O-rings)

Midsection Upgrade Kit – 475.XXX.000 Consult Factory

(Replaces S20 Metallic Midsection with AirVantage Components)

Electronic Leak Detector Kits

032.037.000 100-120/220-240 VAC

032.045.000 12-32 VDC

GASKET, PILOT VAVLVE

PILOT VALVE

GASKET, MAIN AIR VALVE

BUMBER, AIR VALVE

GASKET, AIR VALVE

PAD, HINGE

FLAP VALVE

SEAL, U-CUP

O-RING

BUSHING

PLUNGER, ACTUATOR

O-RING

AIR END KIT

RING, SEALING

PAD, WEAR

DIAPHRAGM

WETTED END KIT

rhdf2dl1sm-rev0614 Model RHDF2 Page 13

Composite Repair Parts Drawing: Wetted Side

55

34

16

66

33

55

28

65

18

37

54

46

52

30

58

62

29

54

60

64

23

36

69

67

61

55

25

15

52

62

58

30

46

7

Note: Refer to Composite Repair Parts List on page 12 for part numbers

2

9

39

43

65

37

65

14

20

8

21

rhdf2dl1sm-rev0614 Model RHDF2 Page 14

FLAP VALVE SERVICING

Valve inspection requires removal of 3/8" hex nuts and elbows. When the top suction elbows are removed, the valve and seat are connected as an assembly. When the bottom discharge elbows are removed, the valve and seat stay with the outer chamber. Visual inspection and cleaning is possible. If parts are to be replaced, remove the self-locking nuts and all parts are accessible.

DIAPHRAGM SERVICING

Diaphragms can be inspected or the diaphragm assembly removed without removing the suction and

discharge anges. Remove (8) nuts around the chamber ange, and the housing assembly will pull

off. Flap valves can be inspected for proper seating at this point as well as the diaphragm. Use care to keep foreign matter from behind the diaphragm. The opposite diaphragm may be inspected by the same procedure. If either diaphragm has to be replaced, follow closely these steps: Pull the outer diameter of one diaphragm off the (8) capscrews. NOTE: One side only! On the free diaphragm assembly, use a 3/8" allen wrench to turn the assembly (diaphragm, plates and screw) loose from the shaft. Once the assembly has turned, it will turn out by hand by use of the diaphragm. Now the opposite diaphragm assembly and the drive shaft will pull free from the capscrews and pump intermediate assembly. The interior components consisting of sleeve bearings, rod seals, and pilot valve actuator bushings are now accessible for service if required. Hold the shaft in a clamping device making sure to protect surface of shaft so as not to scratch or mar it in any way. The diaphragm assembly will turn loose. To disassemble the components, turn a 1/4"-20 capscrew by hand into the tapped hole in the inner plate. This keeps the plate from turning while the socket head capscrew is removed. To do this, place assembly in a vise so the two protruding ends of screws are loose in the vise jaws (about 3/4" apart). Turn the center screw loose from the back plate and the assembly will come apart.

“AirVantage CAUTION” – If product is observed on the air side of the diaphragm, refer to the “AirVantage Servicing” section of the service manual.

the holes in the chamber ange, turn the diaphragm assembly in the direction of tightening to align the holes so that the capscrews can be inserted. This nal torquing of the last diaphragm assembly will lock

the two diaphragm assemblies together. Place remaining outer chamber on the open end and tighten down the securing nuts gradually and evenly on both sides. Caution should be used while reassembling Flap valves. The valves are designed for some preload over the retainer hinge pad. This is done to insure proper face contact with the seat. After all parts are in place, tighten the lock nuts down on the assembly to the point where visual inspection shows that seat and valve face mate without gap. This is important for dry prime. However, after priming action has started, valves will function due to differential pressure without concern or trouble.

PILOT VALVE

The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing. Most problems with the pilot valve can be corrected by replacing the o-rings. Always grease the spool prior to inserting it into the sleeve. If the sleeve is removed from the body, reinsertion must be at the chamfered side. Grease the o-rings to slide the sleeve into the valve body. Securely insert the retaining ring around the sleeve. When reinserting the pilot valve, push both plungers (located inside the intermediate bracket) out of the path of the pilot valve spool ends to avoid damage.

PILOT VALVE ACTUATOR

Bushings for the pilot valve actuators are threaded into the intermediate bracket from the outside. The plunger may be removed for inspection or replacement. First remove the air distribution valve body and the pilot valve body from the pump. The plungers can be located by looking into the intermediate. It may be necessary to use a ne piece of wire to pull them out. The bushing can be turned out through the inner chamber by removing the outer chamber assembly. Replace the bushings if pins have bent.

REASSEMBLY

All procedures for reassembling the pump are the reverse of the previous

instructions with further instructions as shown:

The diaphragm assemblies are to be installed with the natural bulge outward or toward the head of the center screw. Make sure both plates are installed with outer radii against the diaphragm. After all components are in position in a vise and hand tight, set a torque wrench for 480 inch pounds (40 ft. pounds) (54.23 Newton meters) or, 600 inch pounds (50 ft. pounds) (67.79 Newton meters) for Santoprene, using a (3/8") allen head socket. After each diaphragm sub assembly has been completed, thread one assembly into the shaft (held near the middle in a vise having soft jaws to protect

the nish) making sure the stainless steel washer is in place on the capscrew.

Make sure 1/4"-20 mounting screw has been removed and that the bumper (Item #19 on drawing) is in place in the shaft. Install this sub assembly into the pump and secure by placing the outer chamber housing and capscrews on the end with the diaphragm. This will hold the assembly in place while the opposite side is installed. Make sure the last diaphragm assembly is torqued to 30 ft. lbs. (40.67 Newton meters) before

placing the outer diaphragm over the capscrews. If the holes in the diaphragm ange do not line up with

rhdf2dl1sm-rev0614 Model RHDF2 Page 15

this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

IMPORTANT

Read these instructions completely, before installation and start-up. It is the responsibility of the purchaser to retain

Composite Repair Parts Drawing: Air Side

13

66

17

63

24

45

12

10

71

68

48

27

47

49

42

22

40

57

56

31

4

32

1

53

38

11

51

59

70

41

44

26

71

Note: Refer to Composite Parts List on page 12 for part numbers

rhdf2dl1sm-rev0614 Model RHDF2 Page 16

A

BRACKET, INTERMEDIATE, ASSEMBLY

SENSOR, FEEDBACK

NUT

SEAL

DIAPHRAGM

PLATE, OUTER DIAPHRAGM

PLATE, INNER DIAPHRAGM

PROBE TIP

O-RING

SENSOR, FEEDBACK

BUMPER

DETAIL A

FLAT EDGE

INTERMEDIATE AND AirVantage SENSOR SERVICING

• To service the intermediate and AirVantage sensor, rst shut off and bleed the air being supplied to the pump. For safety purposes, the air supply line should be disconnected from the pump. Shut off both the suction and discharge lines to the pump. Consult the “Composite Repair Parts Drawing”.

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom.

Step #3: Remove the Manifolds, Chambers, and Diaphragms (See Diaphragm Servicing Section)

Step#8: Reinstallation

• Slide the new sensor assembly in the intermediate.

• “AirVantage CAUTION” – Make sure the cable assembly ts into the groove machined in the intermediate. Failure to do so may damage the cable during assembly.

• Feed the connector through the hole in the intermediate, making sure the gasket is on the connector

before installation. The at edge on the connector should line up with the inside of the intermediate.

Install the nut and hand tighten it using a 13/16" socket.

• The inner chambers and gaskets can now be reinstalled. Use blue thread locker on the inner chamber bolts and torque them to 300 in-lbs.

• Refer to the “Diaphragm Servicing” section of the manual to nish the diaphragm installation procedure.

Step #4: Remove the Diaphragm Assemblies

• Refer to the “Diaphragm Servicing” section of the manual to remove diaphragm assembly from the pump.

• “AirVantage CAUTION” – When the diaphragm assembly is removed, watch for the brass probe tips located on the end of the sensor rod. There is one brass probe tip and one o-ring per side. Inspect the probe tips and o-rings for wear. For every diaphragm service, these parts should be

replaced and are available in kit form. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

• Note: For AirVantage sensor servicing, refer to page 27.

Step #5: Remove the End Caps

• Use an Allen wrench and remove the two screws from the End Caps on either side of the intermediate.

• Use two small at-head screw drivers to simultaneously pry the End Caps up at the ends.

• “AirVantage CAUTION” – Remove the End Caps from the intermediate with caution, taking care not to damage the sensor. Inspect the gaskets and u-cup seals under each End Cap and replace them as necessary.

Step #6: Accessing the Actuator Plunger Bushings and O-rings

• The actuator plunger pin bushings and o-rings can now be accessed. If it is determined that these parts need to be replaced, use a small screwdriver and remove the retaining rings.

• NOTE: It is recommended that new retaining rings be installed after disassembly. The bushing and o-ring can now be removed and inspected.

Step #7: Accessing the AirVantage Sensor

• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut securing the connector to the intermediate. Slide the connector out of the hole, taking care not to lose/misplace the gasket on the connector.

• The sensor can now be removed from the intermediate assembly.

JAM NUT

O-RING

FOAM BUMPER

BEARING

SENSOR COVER

CAPSCREW

INTERMEDIATE

SEAL

FEED BACK SENSOR

O-RING

Note: Refer to Composite Repair Parts List on page 12 for part numbers

END CAP

CAPSCREW

PLATE,

OUTER DIAPHRAGM

PAD, WEAR

DIAPHRAGM

PLATE, DIAPHRAGM

WASHER, SEALING

PROBE TIP

O-RING

SENSOR, FEED BACK

rhdf2dl1sm-rev0614 Model RHDF2 Page 17

Page 17

Air Valve Servicing, Assembly Drawing & Parts List

1.B

1.A1.A

1.C

1.F

1.D

1.E

1.F

1.C

1.F

1.D

Note to Trent: Do not paste this table in S/M. Only use to modify on on page 18

ITEM

NO.

PART NUMBER DESCRIPTION

QTY.

1.A

031.012.162

SLEEVE & SPOOL SET

1

1.B

095.043.156

DESCRIPTION

1

1.C

132.014.358

BUMBER, AIR VALVE

2

1.D

165.011.157

CAP, END

2

1.E

170.032.330

CAPSCREW, HEX HEAD 1/4-20 X 3/4

8

1.F

360.010.427

BODY, AIR VALVE

2

1.F

560.020.360

O-RING

6

AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty 1 031-183-003 Air Valve Assembly 1

1-A 031.012.162 Sleeve and Spool Set 1 1-B 095.043.156 Description 1 1-C 132-014.358 Bumper, Air Valve 2 1-D 165.011.157 Cap, End 2 1-E 170.032.330 Capscrew, Hex Head 1/4-20 x 3/4 8 1-F 360.010.427 Body, Air Valve 2 1-F 560.020.360 O-ring 6

AIR DISTRIBUTION VALVE SERVICING STEP #1: Remove Air Valve

The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head cap-screws. The valve body assembly is removed from the pump by removing these four hex head cap-screws.

STEP #2: Disassembly of the Air Valve

With the valve body assembly off the pump, access to the sleeve and spool set is made by removing four hex head cap-screws (each end) on the end caps of the valve body assembly. With the end caps removed, slide the spool back and forth in the sleeve. The spool is closely sized to the sleeve and must move freely to allow for proper pump operation. An accumulation of oil, dirt or other

contaminants from the pump’s air supply, or from a failed diaphragm, may prevent the spool from moving

freely. This can cause the spool to stick in a position that prevents the pump from operating. If this is the case, the sleeve and spool set should be removed from the valve body for cleaning and further inspection. Remove the spool from the sleeve. Using an arbor press or bench vise (with an improvised mandrel), press the sleeve from the valve body. Take care not to damage the sleeve. At this point, inspect the o-rings on the sleeve for nicks, tears or abrasions. Damage of this sort could

happen during assembly or servicing. A sheared or cut o-ring can allow the pump’s compressed air supply

to leak or bypass within the air valve assembly, causing the pump to leak compressed air from the pump

air exhaust or not cycle properly. This is most noticeable at pump dead head or high discharge pressure conditions. Replace any of these o-rings as required or set up a routine, preventive maintenance schedule to do so on a regular basis. This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent, inspecting for signs of wear or damage, and replacing worn components.

Reassembly of the Air Valve

To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve with an o-ring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant). Re-install one end cap, gasket and bumper on the valve body. Using the arbor press or bench vise that was used in disassembly, carefully press the sleeve back into the valve body, without shearing the o-rings. You may have to clean the surfaces of the valve body where the end caps mount. Material may remain from the old gasket. Old material not cleaned from this area may cause air leakage after reassembly. Take care that the bumper stays in place allowing the sleeve to press in all the way. Reinstall the spool, opposite end cap, gasket and bumper on the valve body. After inspecting and cleaning the gasket surfaces on the valve body and intermediate, reinstall the valve body on the pump using new gaskets. Tighten the four hex head cap-screws evenly and in an alternating cross pattern.

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.

rhdf2dl1sm-rev0614 Model RHDF2 Page 18

Air Valve with Stroke Indicator Assembly Drawing and Parts List

1.D

1.F

1.C

1.A1.A

1.F

1.B

1.G

1.D

1.E

1.H

Note to Trent: Do not paste this table in S/M. Only use to modify on on page 19

AIR VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty 1 031-147-003 Air Valve Assembly 1

1-A 031-012.162 Sleeve and Spool Set 1 1-B 095-043.156 Description 1 1-C 132-014.358 Bumper, Air Valve 2 1-D 165-065.010 Cap, End 2 1-E 170.032.330 Capscrew, Hex Head 1/4-20 x 3/4 8 1-F 360.010.427 Body, Air Valve 2 1-F 560.020.360 O-Ring 6 1-G 210-008-330 Clip, Safety 1 1-H 560-029-360 O-Ring 2

Air Distribution Valve With Stroke Indicator Option Servicing

To service the air valve 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 COMPOSITE REPAIR PARTS DRAWING.

• Using a 5/16" Allen wrench, remove the four hex socket capscrews and four at washers. Remove the air valve assembly from the pump.

• Remove and inspect gasket for cracks or damage. Replace gasket if needed.

Step #2: Disassembly of the air valve.

• To access the internal air valve components rst remove the two retaining rings from each end of the air valve assembly using clip ring pliers.

• Next remove the two end caps. Inspect the o-ring for cuts or wear. Replace the o-rings if necessary.

• Remove the two bumpers. Inspect the bumpers for cuts, wear or abrasion. Replace if necessary.

• Remove the spool 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 for dirt, scratches, or other contaminants. Remove the sleeve if needed and replace with a new sleeve and spool set.

rhdf2dl1sm-rev0614 Model RHDF2 Page 19

Step #3: Reassembly of the air valve.

• Install one bumper and one end cap with o-rings into one end of the air valve body. Install one retaining ring, into the groove on the same end. Insert the safety clip through the smaller unthreaded hole in the endcap.

• Remove the new sleeve and spool set from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings 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. 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

IMPORTANT

during installation. Push the spool in until the pin touches the safety clip on the opposite end.

• Install the remaining bumper, end cap with o-rings and retaining ring.

• Fasten the air valve assembly and gasket to the pump.

• Connect the compressed air line to the pump. Remove the safety clip. The pump is now ready for operation.

manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

Read these instructions completely, before

installation and

start-up. It is the responsibility of the purchaser to retain this

Pilot Valve and Actuator Plunger Servicing

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, carefully set the unit down on the plastic cover located on the bottom.

STEP #3: Remove the Pilot Valve

• Remove the main air distribution valve body from the pump.

• Lift the pilot valve body out of the intermediate housing. (Most problems with the pilot valve can be corrected by replacing the o-rings.)

STEP #4: Dissasemble the Pilot Valve

• Remove the pilot spool and wipe it clean. Inspect the spool and o-rings for dirt, cuts or wear. Replace parts if necessary.

• Use a set of outside snap ring pliers and remove the retaining ring holding the sleeve in the pilot valve body.

• Gently push the sleeve from the body and wipe it clean. Inspect the sleeve and o-rings.

• Replace parts if necessary

STEP #5: Inspect the Actuator Plungers

• Remove the plungers by sliding them out of the bushings. It may be necessary to use a ne piece of wire to pull them out.

STEP #6: Reassemble the Pilot Valve

• Generously lubricate the o-rings on the pilot sleeve with multipurpose grease (BP-LSEP-2 or equivalent).

• Carefully insert the sleeve in the pilot valve body on the chamfered side, taking care not to shear any of the o-rings.

• Securely insert the retaining ring around the sleeve.

• Generously lubricate the o-rings on the pilot spool. Carefully insert the spool in the sleeve.

• If the pilot valve does not t ush against the gasket, check to make sure the actuator plunger are pushed all the way. Failure to do so may cause damage to the pilot valve or the actuators.

• Insert the pilot valve body onto the intermediate housing.

• Reinstall the main air distribution valve body onto the pump.

Step #8: Reassemble AirVantage and Cable

• Reinstall the AirVantage using the four 5/16-18 x 5½ cap screws and torque to 90 in-lbs.

• Reattach the patch cable connector that connects the AirVantage module to the intermediate.

Item Part Number Description Qty

4.A 095.070.558 BODY, Pilot VALVE 1

4.B 755.025.162 SLEEVE, Pilot VALVE 1

4.C 560.033.360 O-RING 4

4.D 775.026.115 SPOOL, Pilot VALVE 1

4.E 560.023.360 O-RING 2

4.F 675.037.080 RING, RETAINING 1

5

28

4.A

4.F

15

49

35

4.B

4.D

10

STEP #7: Reinstall the Pilot Valve

• Push both plungers (located inside the intermediate bracket) out of the path of the pilot valve spool ends to avoid damage.

rhdf2dl1sm-rev0614 Model RHDF2 Page 20

29

1

4.C

4.E

Note: Refer to Composite Repair Parts List on page 12 for part numbers

Pulse Output Kit Drawing

PULSE OUTPUT KIT OPTION

This pump can be tted with a Pulse Output Kit. This converts the mechanical strokes of the

pump to an electrical signal which interfaces with the Stroke Counter/ Batch Controller or user control devices such as a PLC.

The Pulse Output Kits mount directly onto the Mufer Cap on the Air Distribution Valve Assembly

or onto the air valve and senses each stroke of the main spool.

Consult the factory for further information and availability.

Pulse Output Kits

475-244-001 10-30 VDC

475-244-002 110/220 VAC

475-244-003 10-30VDC, 110VAC and 220 VAC

rhdf2dl1sm-rev0614 Model RHDF2 Page 21

This Page Intentionally Blank

rhdf2dl1sm-rev0614 Model RHDF2 Page 22

Composite Repair Parts Drawing: AirVantage Unit

2.L

2.K

2.C

2.G

2.J

2.H

2.J

2.B

2.E

2.J

2.D

2.C

2.I

2.F

2.A

020.069.000 1

2.B

031.199.000 1

2.C

171.079.115 8

2.D

171.080.115 2

2.E

171.081.115 4

2.F

249.025.000 1

2.G

258.018.551 2

2.H

530.044.000 1

2.I 560.200.360 2

2.J

720.071.360 4

2.K

765.004.000 1

2.L 893.102.000 1

Optional 1/4" NPT Pipe Plug (P/N 618.011.330)

Must be installed if performing direct spray

wash-down of pump

(Purchased Separately)

ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

REGULATOR

POWER GENERATION MODULE

CAPSCREW, HEX SOC HD, 10-32 X .50

CAPSCREW, HEX SOC HD, 10-32 X 1.00

CAPSCREW, HEX SOC HD, 10-32 X 2.25

CONTROL MODULE

COVER

MUFFLER

O-RING

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

2.A

020.069.000

REGULATOR

1

2.B

031.199.000

POWER GENERATION MODULE

1

2.C

171.079.115

CAPSCREW, HEX SOC HD, 10-32 X .50

8

2.D

171.080.115

CAPSCREW, HEX SOC HD, 10-32 X 1.00

2

2.E

171.081.115

CAPSCREW, HEX SOC HD, 10-32 X 2.25

4

2.F

249.023.000

CONTROL MODULE

1

2.G

258.018.551

COVER

2

2.H

530.044.000

MUFFLER

1

2.I 560.200.360

O-RING

2

2.J

720.071.360

SEAL, O-RING

4

2.K

765.004.000

VALVE, SOLENOID

1

2.L 893.102.000

VALVE, POPPET

1

AirVantage Composite Parts List

rhdf2dl1sm-rev0614 Model RHDF2 Page 23

AirVantage Servicing Solenoid Valve and Pressure Regulator

Solenoid Valve and Pressure Regulator

To service the solenoid valve or the pressure regulator, rst shut off and bleed the air being supplied to

the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”. (page 14)

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

CAPSCREW, HEX SOC HD 10-32 X .50

TOP COVER

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on bottom cover. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Solenoid Valve and Pressure Regulator

• Use a 5/32 hex-key wrench and remove the four 10-32 x .50 socket head cap screws securing the top cover on. Lift the cover off, exposing the solenoid valve and pressure regulator. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• If the solenoid valve needs to be replaced, unplug the connector attached to it. Use a miniature 4-way Phillips screwdriver and remove the two screws holding the solenoid valve to the plate. The valve and gasket can now be removed and/replaced. When reinstalling the solenoid valve, tighten the screws to snug with a miniature 4-way Phillips screwdriver.

• “AirVantage CAUTION” – Be sure to reattach the connector to the solenoid valve.

• If the pressure regulator needs to be replaced, use slip-joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction.

• “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator.

Step #4: Reinstallation

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws.

• Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.

CONNECTOR

(To Solenoid)

PRESSURE REGULATOR

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

CONNECTER (To Intermediate)

CABLE, PATCH

BOTTOM COVER

Note: Refer to Composite Repair Parts List on page 12 for part numbers

rhdf2dl1sm-rev0614 Model RHDF2 Page 24

AirVantage Servicing Power Generation Module

To service the power generation module, rst shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”. (page 14)

CAPSCREW, HEX SOC HD, 10-32 X .50

BOTTOM COVER

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down, upside down, on the top cover. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Power Generation Module

• Use a 5/32 hex-key wrench and loosen the four 10-32 x .50 socket head cap screws securing the bottom cover. Lift the bottom cover off, exposing the power generation module. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• If the power generation module needs to be replaced, unplug the connector that connects the power generator to the control board. Use a 5/32 hex-key wrench to loosen the four 10-32 x 2 ¼ socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

• "AirVantage CAUTION" - Take caution not to lose the small o-ring that seals between the components.

Step #4: Reinstallation

• When reinstalling the new module make sure to feed the control module wire through the hole in the power generation case. Install the four 10-32 x 2 ¼ socket head cap screws and tighten to 60 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the control board.

• Reinstall the bottom cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 x .50 socket head cap screws to 30 in-lbs.

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws. Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.

CONNECTORS

(Control Module to

Power Generation

Module)

SEAL, O-RING

O-RING

SEAL, O-RING

CAPSCREW, HEX SOC HD, 10-32 X 2.25

Note: Unit shown upside down.

Note: Refer to Composite Repair Parts List on

page 12 for part numbers

POWER GENERATION MODULE

CABLE, PATCH

CONTROL MODULE

VALVE, POPPET

TOP COVER

rhdf2dl1sm-rev0614 Model RHDF2 Page 25

AirVantage Servicing - Control Module

To service the control module, rst shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”. (page 23)

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Solenoid Valve

• Use a 5/32 hex-key wrench and loosen the four 10-32 x .50 socket head cap screws securing the top cover on. Lift the cover off, exposing the solenoid valve. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove. The connector will need to be removed from the solenoid valve. Once the plug has been removed, feed the wire assembly into the hole in the valve body to the point where the connector just enters the valve body. Reinstall the top cover and loosely reinstall the bolts. The connector will eventually need to be reconnected.

Step #4: Access the Control Module

• Turn until upside down on top cover.

• Use a 5/32 hex-key wrench and loosen the four 10-32 x .50 socket head cap screws securing the bottom cover on. Lift the bottom cover off, exposing the power generation module. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector that connects the power generator to the control board. Use a 5/32 hex-key wrench to loosen the four 10-32 x 2 ¼ socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

• "AirVantage CAUTION" - Take caution not to lose the o-ring seals between the components.

• If the control module needs to be replaced, use a 5/32 hex-key wrench and loosen the two 10-32 x 1.00 socket head cap screws holding the control module to the poppet assembly. The control module should now be loose. Carefully lift the control module off the poppet assembly, making sure that the solenoid valve connector wire slips through the hole in the poppet valve assembly.

• "AirVantage CAUTION" - Take caution not to lose the small o-ring that seals between the components.

Step #5: Reinstalling

• When reinstalling the new control module, make sure to feed the solenoid valve connector wire through the hole in the poppet valve assembly. Install the two 10-32 x 1.00 socket head cap screws and tighten to 30 in-lbs.

• Reinstall the power generation module. Make sure to feed the control module wire through the hole in the power generation case. Install the four 10-32 x 2 ¼ socket head cap screws and tighten to 60 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the control board.

• Reinstall the bottom and top covers, making sure the o-ring seals are still in the groove. Tighten the four 10-32 screws.

• Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.

CAPSCREW, HEX SOC HD 10-32 X .50

BOTTOM COVER

SEAL, O-RING

CONNECTORS

(Control Module to

Power Generation Module)

POWER GENERATION

MODULE

O-RINGO-RING

CAPSCREW, HEX SOC HD, 10-32 X 2.25

MUFFLER

CONNECTOR (To Intermediate)

CABLE, PATCH

CONTROL MODULE

SEAL, O-RING

VALVE, POPPET

Note: Unit shown upside down

Note: Refer to AirVantage

Composite Repair Parts List on page 23 for part numbers

rhdf2dl1sm-rev0614 Model RHDF2 Page 26

AirVantage Servicing - Sensor Assembly

A

BRACKET, INTERMEDIATE, ASSEMBLY

SENSOR, FEEDBACK

NUT

SEAL

DIAPHRAGM

PLATE, OUTER DIAPHRAGM

PLATE, INNER DIAPHRAGM

PROBE TIP

O-RING

SENSOR, FEEDBACK

BUMPER

DETAIL A

FLAT EDGE

To service the control module, rst shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”. (page 23)

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Diaphragm Disassembly

• Refer to the “Diaphragm Servicing” section (p.15) of the manual to remove diaphragm assembly from the pump.

• “AirVantage CAUTION” – When the diaphragm assembly is removed, watch for the brass probe tips located on the end of the sensor rod. There is one brass probe tip and one o-ring per side. Inspect the probe tips and o-rings for wear. For every diaphragm service, these parts should be replaced and are available in kit form. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

Step #4: Accessing the Actuator Plunger Bushings and O-rings

• The actuator plunger pin bushings and o-rings can now be accessed. If it is determined that these parts need to be replaced, use a small screwdriver and remove the retaining rings.

• NOTE: It is recommended that new retaining rings be installed after disassembly. The bushing and o-ring can now be removed and inspected.

JAM NUT

O-RING

FOAM BUMPER

BEARING

SENSOR COVER

CAPSCREW

INTERMEDIATE

SEAL

FEED BACK SENSOR

O-RING

END CAP

CAPSCREW

PLATE,

OUTER DIAPHRAGM

PAD, WEAR

DIAPHRAGM

PLATE, DIAPHRAGM

WASHER, SEALING

PROBE TIP

O-RING

SENSOR, FEED BACK

Step #5: Accessing the AirVantage Sensor

• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut securing the connector to the intermediate. Slide the connector out of the hole, taking care not to lose/misplace the gasket on the connector.

• The sensor can now be removed from the intermediate assembly.

Step #6: Reinstallation

• Slide the new sensor assembly in the intermediate.

• “AirVantage CAUTION” – Make sure the cable assembly ts into the groove machined in the intermediate. Failure to do so may damage the cable during assembly.

• Feed the connector through the hole in the intermediate and install the plastic nut. Hand tighten the nut using a 13/16" socket. Make sure the gasket is to the inside of the intermediate.

• The inner chambers and gaskets can now be reinstalled. Use blue thread locker on the inner chamber

Note: Refer to Composite Repair Parts List on page 12 for part numbers

bolts and torque them to 300 in-lbs.

• Refer to the “Diaphragm Servicing” section of the manual to nish the diaphragm installation procedure.

rhdf2dl1sm-rev0614 Model RHDF2 Page 27

Optional 1/4" NPT Pipe Plug (P/N 618.011.330)

AirVantage Servicing Poppet Valve Drawing

CAPSCREW, HEX SOC HD, 10-32 X .50

COVER

REGULATOR

O-RING

CONTROL MODULE

O-RING

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

SEAL, O-RING

MUFFLER

SEAL, O-RING

ASSEMBLY, POWER GENERATOR

CAPSCREW, HEX SOC HD, 10-32 X 1.00

CAPSCREW, HEX SOC HD, 10-32 X 2.25

Must be installed if performing direct spray

wash-down of pump

(Purchased Separately)

SEAL, O-RING

CAPSCREW, HEX SOC HD, 10-32 X .50

Note: Refer to AirVantage Composite Repair Parts List on page 23 for part numbers

rhdf2dl1sm-rev0614 Model RHDF2 Page 28

AirVantage Servicing - Poppet Valve

Step #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the bottom cover. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Solenoid Valve and Pressure Regulator

• Use a 5/32 hex-key wrench and loosen the four 10-32 x .50 socket head cap screws securing the top cover on. Lift the cover off, exposing the solenoid valve and pressure regulator. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector attached to it. Use a miniature 4-way Phillips screwdriver and remove the two screws securing the solenoid valve to the plate. The valve and gasket can now be removed and/or replaced.

• Use slip-joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction.

• “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator. Reinstall the top cover and loosely reinstall the bolts.

Step #4: Access the Power Generation Module

• Turn the assembly over and let it now rest on the top cover.

• Use a 5/32 hex-key wrench and remove the four 10-32 x .50 socket head cap screws securing the bottom cover on. Lift the bottom cover off, exposing the power generation module. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector that connects the power generator to the control board. Use a 5/32 hex-key wrench to loosen the four 10-32 x 2 ¼ socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

Step #6: Reinstallation

• Install the control module on the poppet valve assembly. Make sure to feed the solenoid valve connector wire through the hole in the poppet valve assembly. Install the two 10-32 x 1.00 socket head cap screws and tighten to 30 in-lbs.

• Install the power generation module onto the control module. Make sure to feed the control module wire through the hole in the power generation case. Install the four 10-32 x 2 ¼ socket head cap screws and tighten to 60 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the control board.

• Install the bottom cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws. The unit can now be turned over and set on the bottom cover.

• Install the solenoid valve, tighten the screws snug with a miniature 4-way Phillips screwdriver.

• “AirVantage CAUTION” – Be sure to reattach the connector to the solenoid valve.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.

• If the pressure regulator needs to be replaced, use slip-joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction.

• “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator.

Step #4: Reinstallation

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws.

• Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.

• Refer to Page 28 for Illustration

Step #5: Access the Control Module

• Use a 5/32 hex-key wrench and loosen the two 10-32 x 1.00 socket head cap screws securing the control module to the poppet assembly. The control module should now be loose. Carefully lift the control module off the poppet assembly, making sure that the solenoid valve connector wire slips through the hole in the poppet valve assembly.

• The Poppet valve assembly can now be replaced.

rhdf2dl1sm-rev0614 Model RHDF2 Page 29

AirVantage Servicing - Check Valve

AirVantage - Check Valve Assembly

To service the check valve, rst shut off and bleed the air being supplied to the pump. For safety

purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing” (Page 11)

Step #1: Remove the Patch Cable

Twist the ribbed portion of the patch cable connector in the counterclockwise direction, until it un-threads from the connector. The cable can be either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump

Use a ½” socket and remove the four 5/16 x 5 ½ cap screws that hold the AirVantage to the pump. Remove the two chamber bolts/nuts that are holding the right side bracket to be able to remove the right bracket and the AirVantage unit from the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and adapter plate for damage.

Step 3: Remove the Check Valve from the Pump

Use a ½” socket and remove the four 5/16 x 2 ½ cap screw that holds the check valve to the pump.

Step 4: Inspect Check Valve

Using a 1 ¼” open socket wrench, remove the cartridge valve. Inspect o-rings and mechanism for any signs of wear, degradation, or damage. If any is present, replace with new cartridge valve

assembly. Remove any remaining uid contamination on inside of body and/or cartridge valve.

Be careful not to lose the large and small o-rings on either face of the check valve body.

Step 5: Re-assembly of Check Valve

Apply a thin layer of white lithium grease to the threads on the valve cartridge. Insert cartridge valve into body and hand-tighten being careful not to pinch o-ring. Using a 9” torque wrench with crow-foot, torque cartridge vale to 250 in-lbs. Re-apply o-rings, as necessary, to both faces of check valve. After applying Blue Loctite 248, 222 (or equivalent) secure check valve back to pump with four 5/16 x 2 ½ cap screws, re-torque to 90 in-lbs.

To secure the AirVantage, re-install the four 5/16 x 5 ½ cap screws, torquing to 90 in-lbs. Reinstall Patchcable.

rhdf2dl1sm-rev0614 Model RHDF2 Page 30

Grounding The Pump

One eyelet is fastened to the pump hardware.

One eyelet is installed to a true earth ground. (Requires a 5/16 or 8mm maximum diameter bolt)

This 8-foot long (244 centimeters) Ground Strap, part number 920-025-000, can be ordered as a service item.

To reduce the risk of static electrical sparking, this pump must be grounded. Check the local electrical code for detailed grounding instruction and the type of equipment required.

WARNING

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

rhdf2dl1sm-rev0614 Model RHDF2 Page 31

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.

• Piping used for the air exhaust must not be smaller than 1" (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 #2 at right.

CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR

• The following steps are necessary to convert the pump to pipe the exhaust air away from the pump.

• Remove the mufer. The air distribution valve has 1" NPT threads for piped exhaust.

CONVERTED EXHAUST ILLUSTRATION

PUMP INSTALLATION AREA

1" DIAMETER AIR

EXHAUST PIPING

SAFE AIR EXHAUST DISPOSAL AREA

MUFFLER

IMPORTANT INSTALLATION NOTE:

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

• Failure to support these connections could also result in damage to the air distribution valve body.

Illustration #1

Illustration #2

LIQUID LEVEL

SUCTION

LINE

MUFFLER

1" DIAMETER AIR EXHAUST PIPING

rhdf2dl1sm-rev0614 Model RHDF2 Page 32

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) 147 Clear Anodized Aluminum 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 660 167 Bronze, Alloy 954, ASTM B505 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 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 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 FDA Accepted 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 Fiber 408 Cork and Neoprene 425 Compressed Fiber 426 Blue Gard 440 Vegetable Fiber 465 Fiber 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 521 Conductive PVDF 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 557 Conductive Polypropylene 558 Conductive HDPE 559 Glass-Filled Conductive Polypropylene 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 Integral Silicon 611 PTFE Integral FKM 632 Neoprene/Hytrel 633 FKM (Fluorocarbon)/PTFE 634 EPDM/PTFE 635 Neoprene/PTFE 637 PTFE, FKM (Fluorocarbon)/PTFE 638 PTFE, Hytrel/PTFE 639 Nitrile/TFE 643 Santoprene/EPDM 644 Santoprene/PTFE 650 Bonded Santoprene and PTFE 654 Santoprene Diaphragm, PTFE Overlay Balls and

seals

656 Santoprene Diaphragm and

Check Balls/EPDM Seats

661 EPDM/Santoprene

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.

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

rhdf2dl1sm-rev0614 Model RHDF2 Page 33

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 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

SANDPIPER RHDF2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual