SANDPIPER RS20 User Manual

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SERVICE & OPERATING MANUAL

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

II 2GD T5

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

Hazardous Duty RS20 Metallic 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

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

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

rs20mdl1sm_haz duty-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

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 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 recy-

clable 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

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. 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

Use safe practices

when lifting

WARNING

Substitution of components may impair intrinsic safety.

Quality System

II 2GD T5

ISO 9001 Certied

Environmental

Management System

ISO 14001 Certied

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

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

Hazardous Duty RS20 Metallic

AirVantage Design Level 1

Ball Valve

Air-Operated Double Diaphragm Pump

ENGINEERING, PERFORMANCE & CONSTRUCTION DATA

INTAKE/DISCHARGE PIPE SIZE

2" NPT (internal)

2" BSP Tapered (internal)

CAPACITY

0 to 145 gallons per minute

(0 to 548 liters per minute)

CAUTION! Operating temperature limitations are as follows:

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to .25 in. (6mm)

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

.42 Gallon / 1.59 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:

For specic 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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 1

Explanation of Pump Nomenclature, Hazardous Duty RS20 Metallic · Design Level 1· Ball Valve

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

RS20B1ABBANASX0 RS 20 B 1 A B B A N A S X0 91 (41) RS20B1AEEANASX0 RS 20 B 1 A E E A N A S X0 91 (41) RS20B1AGTANASX0 RS 20 B 1 A G T A N A S X0 91 (41) RS20B1ANNANASX0 RS 20 B 1 A N N A N A S X0 91 (41) RS20B1A1EANASX0 RS 20 B 1 A 1 E A N A S X0 91 (41) RS20B1ACTANASX0 RS 20 B 1 A C T A N A S X0 91 (41) RS20B1IBBANASX0 RS 20 B 1 I B B A N A S X0 157 (71) RS20B1IEEANASX0 RS 20 B 1 I E E A N A S X0 157 (71) RS20B1IGTANASX0 RS 20 B 1 I G T A N A S X0 157 (71) RS20B1INNANASX0 RS 20 B 1 I N N A N A S X0 157 (71) RS20B1I1EANASX0 RS 20 B 1 I 1 E A N A S X0 157 (71) RS20B1ICTANASX0 RS 20 B 1 I C T A N A S X0 157 (71) RS20B1SBBANASX0 RS 20 B 1 S B B A N A S X0 142 (64) RS20B1SEEANASX0 RS 20 B 1 S E E A N A S X0 142 (64) RS20B1SGTANASX0 RS 20 B 1 S G T A N A S X0 142 (64) RS20B1SNNANASX0 RS 20 B 1 S N N A N A S X0 142 (64) RS20B1S1EANASX0 RS 20 B 1 S 1 E A N A S X0 142 (64) RS20B1SCTANASX0 RS 20 B 1 S C T A N A S X0 142 (64)

Note: Models listed in the table are for reference only. See nomenclature below for other models.

Pump Brand

RS= SANDPIPER® AirVantage

Pump Size

20 = 2"

Check Valve Type

B = Ball

Design Level 1 = Design Level

Wetted Material A = Aluminum I = Cast Iron S = Stainless Steel H = Alloy C

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 2

Diaphragm Check Valve Materials 1 = Santoprene/Santoprene 2 = PTFE-Santoprene/PTFE B = Nitrile/Nitrile C = FKM/PTFE E = EPDM/EPDM I = EPDM/Santoprene G = PTFE-Neoprene/PTFE N = Neoprene/Neoprene

Check Valve Seat A = Aluminum B = Nitrile C = Carbon Steel E = EPDM N = Neoprene S = Stainless Steel T = PTFE V = FKM

Non-Wetted Material Options A = Painted Aluminum J = Painted Aluminum w/PTFE Coated Hardware Y = Painted Aluminum with Stainless Steel Hardware

Porting Options N = NPT Threads B = BSP (Tapered) Threads R = Raised Face 150# Threaded ANSI Flange

Pump Style A = Anodized Aluminum Air Saving Valve

Pump Options S = Self-Contained Electrical Generation with High Flow

  MetalMufer

Kit Options

X0= EST ATEX Compliant

X1= ATEX, Intrinsically-Safe 5-30VDC, 110/120VAC, 220/240VAC Pulse Output Kit

Y0= EST US Hazardous Duty

Y1= US Hazardous Duty, Intrinsically Safe 5-30VDC, 110/120VAC, 220/240VAC Pulse Output Kit

Performance Curve, Hazardous Duty RS20 Metallic Design Level 1

Model RS20 Metallic 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%.

BAR

PSI

10 (17)

100

100 PSI

80 PSI

20 (34)

30 (51)

(6.8 Bar)

(5.44 Bar)

40 (68)

50 (85)

HEAD

60 PSI (4.08 Bar)

60 (102)

40 PSI (2.72 Bar)

0 20 40 60 80 100 120 140 160

U.S. Gallons per minute

Liters per minute

CAPACITY

NPSHR

FEET

30 25 20

15 10

600500400300200100

METERS

9.1

7.6 6

4.5 3

1.5

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 3

Dimensions: Hazardous Duty RS20 Metallic

AIR INLET 1" NPT

SUCTION PORT 2" NPT

DISCHARGE PORT 2" NPT

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

English

.125

Aluminum

Stainless

Cast Iron

Alloy "C"

1.88 2.00 48 51

13.81 13.94 351 354

24.75 24.88 629 632

26.25 26.38 667 681

12.50 26.62 317 321 F G H J K L M N P Q

2.25 57

12.46 316

13.50 343

26.31 668

16.94 430

9.00 229

10.06 256

10.00 254 .38 10 .50 13

Aluminum

Cast Iron

Metric

3mm

Stainless Alloy "C"

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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

Suggested Installation Guide

PN: 020.107.000

Caution: When performing a direct spray washdown, the AirVantage exhaust outlet should be covered with protective tape. 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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 5

into the atmosphere. If

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rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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 happen. 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, meter the correct amount of air needed 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, keeping the suction line as short as possible. Keep

the number of ttings between the product and the pump to a minimum 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, solenoids valves, etc.) should not be less than ½” (13 mm). Though, 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 is going to 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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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 certied 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 modication to this will invalidate certication and may result in serious injury or death.

This Page Intentionally Blank

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 8

PUMP TROUBLESHOOTING

CAUTION! WHENEVER TROUBLESHOOTING OR PERFORMING ANY REPAIRS ON ANY WARREN RUPP 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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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 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

Corrective Action:

• Cycle power switch off/on in a safe area

• Unplug patch cable and cycle power switch off/on in a safe area

• 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 (turn off AirVantage in a safe area)

• 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 (turn off AirVantage in a safe area)

• Cycle the power off/on to the control module to reset controller (turn off AirVantage in a safe area)

• 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 (turn off AirVantage in a safe area)

WARNING

Do not open when an explosive atmosphere may be present.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 10

ITEM NO.

PART NUMBER

DESCRIPTION

032.054.000

1 171.092.115

CAPSCREW, HEX SOC, M6 X 35mm

2 258.020.147

COVER, END, ATEX

3 720.071.360

SEAL, O-RING

4 765.004.000

VALVE, SOLENOID

5 893.104.000

VALVE, POPPET

6 171.091.115

CAPSCREW, HEX SOC, M6 X 25mm

7 031.202.000

POWER GENERATION MODULE, ATEX

8 258.022.147

COVER, END, ATEX

9 020.069.000

REGULATOR

10 560.200.360

O-RING

11 249.019.000

CONTROL MODULE, RS20 HAZ. DUTY

12 560.104.360

O-RING

13 165.135.330

CAP, SWITCH

B27.7M - 3BM1-25

RING, RETAINER

15 430.050.147

HOUSING, MUFFLER

16 720.073.365

SEAL, DUST VALVE

HX-SHCS 0.125-40x0.188x0.188-N

CAPSCREW, HEX SOC HD, 5-40 X .25

BSI 4518 0221-16

O-RING

19 530.045.115

MUFFLER, SPARK ARRESTOR

20 165.137.115

PLATE, PERFORATED

21 535.096.000

TAG, WARNING

22 710.010.115

SCREW, SELF TAPPING, 4-24 X .25 LG

23 901.051.115

WASHER, FLAT, M6

24 535.094.000

TAG, NAME

AirVantage Troubleshooting Continued

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

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

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.

REGULATOR

O-RING

CONTROL MODULE

O-RING

CAP, SWITCH

O-RING

WASHER, FLAT, M6

CAPSCREW, HEX SOC, M6 X 35mm

WASHER, FLAT, M6

COVER

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

SEAL, O-RING

CAPSCREW, HEX SOC, M6 X 25mm

POWER GENERATOR MODULE

CAPSCREW, HEX SOC, M6 X 25mm

SEAL, O-RING

COVER

CAPSCREW, HEX SOC, M6 X 35mm

Page 28

Do not open when an explosive atmosphere may be present.

WARNING

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 11

Composite Repair Parts List

Item Part Number Description Qty

1 031-183-003 Assy - Air Valve (See Exploded View for Details 1 2 032-054-000 Assy - AirVantage (See Exploded View for Details) 1 3 050-017-354 Check Ball, Santoprene 4 050-017-360 Check Ball, Nitrile 4 050-017-364 Check Ball, EPDM 4 050-017-365 Check Ball, Neoprene 4 050-018-600 Check Ball, PTFE 4 4 070-006-170 Bushing, Intermediate 2 5 095-110-000 Assy, Pilot Valve (See Exploded View for Details) 1 6 114-029-157 Assy, Intermediate (See Exploded View for Details) 1 7 132-035-360 Bumper, Diaphragm 2 8 135-034-506 Bushing, Plunger 2 9 170-006-115 Cap Screw, Hex Head (3/8-16 x 1 Stainless) 4 170-006-330 Cap Screw, Hex Head (3/8-16 x 1 Zinc Plated Steel) 4 171-059-115 Cap Screw, Socket Head (3/8-16 x 2 1/2 Stainless (Pulse Output Kit) 4 171-059-330 Cap Screw, Socket Head (3/8-16 x 2 1/2 Zinc Plates Steel (Pulse Output Kit) 4 10 170-052-115 Cap Screw, Hex Head (3/8-16 x 2-1/2 Stainless) 16 170-052-330 Cap Screw, Hex Head (3/8-16 x 2-1/2 Zinc Plated Steel) 16 11 170-060-115 Cap Screw, Hex Head (7/16-14 x 2 Stainless) 16 170-060-330 Cap Screw, Hex Head (7/16-14 x 2 Zinc Plated Steel) 16 12 170-121-115 Cap Screw, Hex Head (5/16-18 x 5 1/2 Stainless) 4 170-121-330 Cap Screw, Hex Head (5/16-18 x 5 1/2 Zinc Plated Steel) 4 13 171-059-330 Cap Screw, Socket Flat Head (7/16-14 x 1-1/4) 8 14 171-082-115 Cap Screw, Socket Head (5/16-18 x 1-1/4 Stainless) 4 171-082-330 Cap Screw, Socket Head (5/16-18 x 1-1/4 Zinc Plated Steel) 4 15 171-100-115 Cap Screw, Socket Head (5/16-18 x 2-1/2 Stainless) 4 16 196-167-010 Chamber, Outer (Cast Iron Units) 2 196-167-110 Chamber, Outer (Stainless Units) 2 196-167-112 Chamber, Outer (Alloy-C Units) 2 196-167-157(156) Chamber, Outer (Aluminum Units) 2 17 196-205-157 Chamber, Inner 1 18 196-206-157 Chamber, Inner 1 19 286-007-354 Diaphragm, Santoprene 2 286-007-356 Diaphragm, Hytrel 2 286-007-360 Diaphragm, Nitrile 2 286-007-363 Diaphragm, FKM 2 286-007-364 Diaphragm, EPDM 2 286-007-365 Diaphragm, Neoprene 2

20 286-020-604 Diaphragm, Teon Overlay 2

21 360-093-360 Gasket, Main Air Valve 1 22 360-104-379 Gasket, Air Inlet Cap 1 23 360-112-365 Gasket, Inner Chamber 2 24 360-114-360 Gasket, Pilot Valve 1 25 518-145-010 Manifold, Suction (Cast Iron Units) 1 518-145-010E Manifold, Suction (Cast Iron Units) 1 518-145-110 Manifold, Suction (Stainless Units) 1 518-145-110E Manifold, Suction (Stainless Units) 1 518-145-112 Manifold, Suction (Alloy-C Units) 1 518-145-112E Manifold, Suction (Alloy-C Units) 1 518-145-156 Manifold, Suction (Aluminum Units) 1 518-145-156E Manifold, Suction (Aluminum Units) 1

Item Part Number Description Qty

26 518-146-010 Manifold, Discharge (Cast Iron Units) 1 518-146-010E Manifold, Discharge (Cast Iron Units) 1 518-146-110 Manifold, Discharge (Stainless Units) 1 518-146-110E Manifold, Discharge (Stainless Units) 1 518-146-112 Manifold, Discharge (Alloy-C Units) 1 518-146-112E Manifold, Discharge (Alloy-C Units) 1 518-146-156 Manifold, Discharge (Aluminum Units) 1 518-146-156E Manifold, Discharge (Aluminum Units) 1

27 530-038-000 Mufer 1

28 545-005-115 Nut, Hex (3/8-16 Stainless) 16 545-005-330 Nut, Hex (3/8-16 Zinc Plated Steel) 16 29 545-007-115 Nut, Hex (7/16-14 Stainless) 16 545-007-330 Nut, Hex (7/16-14 Zinc Plated Steel) 16 30 560-001-360 O-ring, Plunger Pin 2 31 560-011-360 O-ring, Adapter Plate 2 32 560-033-360 O-ring, Sensor Bushing 2 33 560-200-360 O-ring 1 34 560-201-360 O-ring, Probe Tip 2 35 612-240-147 Plate, Air Inlet Adapter 1 36 612-194-010 Plate Assy, Outer Diaphragm (Cast Iron Units) 2 612-194-110 Plate Assy, Outer Diaphragm (Stainless Units) 2 612-194-157 Plate Assy, Outer Diaphragm (Aluminum Units) 2 612-039-010 Plate Assy, Outer Diaphragm (Cast Iron Units w/ Overlay) 2 612-097-110 Plate Assy, Outer Diaphragm (Stainless Units w/ Overlay) 2 612-039-157 Plate Assy, Outer Diaphragm (Aluminum Units w/ Overlay) 2 37 612-231-150 Plate, Inner Diaphragm 2 612-239-150 Plate, Inner Diaphragm (Overlay Diaphragm) 2 38 620-020-115 Plunger, Actuator 2 39 675-042-115 Ring, Retaining 2 40 685-058-120 Rod, Diaphragm 1 41 720-004-360 Seal, Diaphragm Rod 2 42 722-040-360 Seat, Buna 4 722-040-363 Seat, FKM 4 722-040-364 Seat, EPDM 4 722-040-365 Seat, Neoprene 4 722-040-550 Seat, UHMW Polyethylene 4 722-040-600 Seat, PTFE 4 722-040-080 Seat, Carbon Steel (must use with seals - item #41) 4 722-040-110 Seat, Stainless (must use with seals - item #41) 4 722-040-150 Seat, Aluminum (must use with seals - item #41) 4 43 560-106-360 Seal, Nitrile O-ring 8 560-106-363 Seal, FKM O-ring 8 560-106-364 Seal, EPDM O-ring 8 560-106-365 Seal, Neoprene O-ring 8 720-060-608 Seal, Conductive PTFE 8 44 724-006-000 Sensor Assembly, AirVantage 1 45 846-001-167 Tip, AirVantage Probe 2 46 894-014-000 Valve, Check 1 46a 031-206-000 Cartridge, Check Valve 1 47 900-005-115 Washer, 3/8 lock (Stainless) 16 900-005-330 Washer, 3/8 lock (Zinc Plated Steel) 16

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 12

Composite Repair Parts Kits

Available Service And Conversion Kits

Air End Kit - 476.281.000 (RS20 Only)

Seals, O-rings, Gaskets, Retaining Rings, Air Valve Assembly and Pilot Valve Assembly

Wet End Kit – 476.042.354 (RS20, S20 metal)

Santoprene Diaphragms, Balls and EPDM Seats

Wet End Kit – 476.042.360 (RS20, S20 metal)

Nitrile Diaphragms, Balls and Seats

Wet End Kit – 476.042.364 (RS20, S20 metal)

EPDM Diaphragms, Balls and Seats

Wet End Kit – 476.042.365 (RS20, S20 metal)

Neoprene Diaphragms, Balls and Seats

Wet End Kit – 476.042.633 (RS20, S20 metal)

FKM Diaphragms, PTFE Balls and FKM Seats

Wet End Kit – 476.042.635 (RS20, S20 metal)

Neoprene Diaphragms, PTFE overlays, PTFE Balls and Seats

Wet End Kit – 476.042.654 (RS20, S20 metal)

Santoprene Diaphragms, PTFE Overlays, PTFE Balls and Seats

Wet End Kit – 476.042.656 (RS20, S20 metal)

Santoprene Diaphragms, Balls and EPDM Seats

Sensor Kit - 476.284.000

(Sensor, Probe Tips and O-rings)

Poppet Valve Kit – 476.289.000

(Poppet Valve Assembly, O-ring)

Poppet Valve Assembly Kit – 476.290.000

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

Control Module Kit – 476.291.000 (Power Gen AirVantage Only)

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

Power Gen Kit – 476.293.000 (Power Gen AirVantage Only)

(Power Gen, 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)

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 13

Composite Repair Parts Drawing: Wetted Side

METALLIC SEAT OPTION

PROBE TIP DETAIL

PROBE TIP

O-RING

SENSOR ROD

OVERLAY DIAPHRAGM OPTION

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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 14

DIAPHRAGM AND CHECK VALVE SERVICING

• To service the diaphragms, 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.

• Drain any remaining liquid from the pump.

• During the servicing of the diaphragms, consult the “Composite Repair Parts Drawing” (p.7).

Step #1: Removing the Manifolds

• Using a 9/16" wrench or socket, remove the 16 cap-screws, hex-nuts, and lockwashers that fasten the manifolds to the outer chambers.

• Remove the manifolds.

Step #2: Inspect Check Valve Components

• Inspect the four check balls for wear, abrasion or cuts on the spherical surface. Also inspect the four check valve seats for cuts, abrasive wear or embedded material around the area where the ball contacts the seat.

• For maximum pump performance and efciency, the surface of the ball must seal against the seat without any gaps.

• Replace worn or damaged parts as necessary. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

Step #3: Removing the Outer Chambers

• Using an 11/16" and a 5/8" wrench or socket, remove the 16 cap-screws, and hexnuts that fasten the outer chambers, diaphragms, and inner chambers.

Step #4: Removing the Diaphragm Assemblies

• Once the outer chambers are removed, use a 1-1/16” (27mm) wrench or six-pointed socket to remove the diaphragm assemblies (outer plate, diaphragm, and inner plate) from the diaphragm rod by turning counterclockwise.

• “AirVantage CAUTION” – When diaphragm assemblies are 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.

• The diaphragm connecting rod will usually stay with one of the diaphragm assemblies. Install the rod in

a vise tted with soft jaws and loosen the diaphragm assembly from the rod. Take care not to scar the

surface of the rod.

• Insert a 1/4-20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate.

• Insert the protruding stud and the 1/4-20 fastener loosely into a vise. Use the 1-1/16" wrench or socket to remove the outer diaphragm plate by turning counter-clockwise.

Step #5: Inspect Diaphragms, Diaphragm Connecting Rod, U-cup Seals and Bumpers

• Inspect the diaphragms for cuts and/or punctures in the exing area. Even the smallest hole or crack can allow product to get to the air side of the pump. If there is product noticed on the air side of the diaphragm, there is a good possibility the diaphragm needs to be replaced.

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

• Abrasive wear of the diaphragm needs to be inspected at the point where the diaphragm contacts the outer chamber or where the diaphragm plates contacts the diaphragm. Chemical attack of a diaphragm will usually result in swelling or deformity. Replace the diaphragms if necessary. Inspect the diaphragm connecting rod for scars, nicks or any imperfection that could cause damage to the u-cup seal. Inspect the u-cup seal for imperfections on the sealing lip. Inspect the bumpers for damage on the face.

Replace components as necessary. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

Step #6: Assemble the Diaphragms

• Push the threaded stud of the outer diaphragm plate through the center hole of the diaphragm. Thread the inner plate clockwise onto the stud.

• Insert the loose assembly with the above 1/4-20 fastener back into the vise. Use a torque wrench and 1-1/16” socket (27 mm) to tighten the diaphragm assembly together to 480 in.-lbs. (54.23 Newton meters).

• Allow a torqued assembly to set for 15-minutes. This will allow the diaphragm to relax. Re-torque the assembly to compensate for stress relaxation in the clamped assembly.

Step #7: Installing the Diaphragm Assemblies to the Pump

• Make sure the bumper is installed over the diaphragm rod. Thread the stud of the one diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod until the inner diaphragm plate

is ush to the end of the rod.

• “AirVantage CAUTION” – With the pump lying on one inner chamber, pull the sensor rod UP the full length of its stroke. Insert the brass probe tip and o-ring into the sensor rod. Insert rod and diaphragm assembly into pump, taking care not to damage the u-cup seal. Make sure the diaphragm plate contacts the brass probe tip and stays in contact with it. This will help make sure the probe tip does not fall out during reassembly.

• Align the bolt holes in the diaphragm with the bolt pattern in the inner chamber. Fasten the outer chamber to the pump, using the cap screws, and hex nuts, but do not tighten. Flip the pump over so that it is now setting on the outer chamber. Pull the diaphragm rod out as far as possible. Make sure the bumper is installed over the diaphragm rod.

• “AirVantage CAUTION” – Install the second brass probe tip and o-ring on the sensor rod.

• Thread the stud of the remaining diaphragm assembly clockwise into the tapped hole at the end of the diaphragm rod (item 34) until the diaphragm plate contacts the end surface of the diaphragm rod. If the bolt holes in the diaphragm do not line up with the inner chamber, use a 1-1/16” (27 mm) socket or wrench to tighten the assembly until they line up.

• Fasten the remaining outer chamber to the pump, using the cap screws and hex nuts, and once again,

do not tighten at this point. Tip the pump 90° and set it on a at surface with the discharge side of the

chambers down. This will allow the outer chambers to be aligned with each other. Tighten the sixteen fasteners. Make sure to use a cross tightening pattern to ensure an even sealing on the diaphragm.

Step #8: Re-install the Check Valve Components and Manifolds

• While the pump is setting on the discharge side, insert the check balls and seats on the suction side of

the pump. Make sure the seats t within the counter bore of the chambers. The suction manifold can

now be installed, using the eight cap screws, hex nuts and lock washers.

• Flip the pump 180° and install the seats and check balls on the discharge side.

• Now the discharge manifold can be installed and fastened using the remaining cap screws, hex nuts, and lock washers.

OVERLAY DIAPHRAGM SERVICING

The overlay diaphragm is a PTFE diaphragm

that ts over the exterior of the diaphragm. The

PTFE diaphragm is used to protect the standard diaphragm from the chemicals being pumped. Repeat step #6 when diaphragms need to be serviced.

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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 15

Composite Repair Parts Drawing: Air Side

48a

PTFE OVERLAY OPTION

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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 16

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 be removed from only the intermediate .

Step #2: Remove the AirVantage from the Pump

• Use a ½” socket and remove the four 5/16-18 x 5 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 #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.

• 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.

SENSOR, FEEDBACK

BRACKET, INTERMEDIATE, ASSEMBLY

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

NUT

PLATE, OUTER DIAPHRAGM

DIAPHRAGM

Step #5: Remove the Inner Chambers

• Use a ¼” hex key wrench and remove the four at head socket cap screws on each inner chamber. These bolts have been assembled using blue thread locker, so they may be difcult to remove. The

inner chambers and gaskets can now be removed.

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

SEAL

FLAT EDGE

PLATE, INNER DIAPHRAGM

BUMPER

PROBE TIP

O-RING

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.

DETAIL A

SENSOR, FEEDBACK

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.

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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 17

WARNING

Do not open when an explosive atmosphere may be present.

Air Valve Servicing, Assembly Drawing & Parts List

1.D

1.F

1.E

1.D

1.C

1.B1.B

1.A

1.C

1.D

1.E

1.F

AIR DISTRIBUTION VALVE SERVICING

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

the air supply line from the pump.

Step #1:

• Using a 9/16" wrench or socket, remove the four hex capscrews. 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.

• Using a 7/16" wrench or socket, remove the eight hex capscrews that fasten the end caps to the valve body. Next, remove the two end caps. Inspect the two o-rings on each end cap for damage or wear. Replace the bumpers as needed.

• Remove the bumpers. Inspect the bumpers for damage or wear. Replace the bumpers as needed.

• 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.

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

1-A 095-109-157 Body, Air Valve 1 1-B 031-139-162 Sleeve and Spool Set 1 1-C 132-029-357 Bumper 2 1-D 560-020-360 O-Ring 10 1-E 165-127-157 Cap, End 2 1-F 170-032-330 Hex Head Capscrew 1/4-20 x .75 8

Step #3: Reassembly of the air valve.

• Install one bumper and one end cap, with two o-rings, and fasten with four hex capscrews to the valve body.

• 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 during installation. Carefully insert the sleeve into the bumper and end cap (with o-rings) and fasten with the remaining hex capscrews.

• Fasten the air valve assembly and gasket to the pump. Connect the compressed air line to the pump. 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.

IMPORTANT

Read these instructions completely, before

installation and

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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 18

Air Valve with Stroke Indicator Assembly Drawing and Parts List

1.G

1.H

1.E

Check gap after assembly to

.297

1.F

1.E

1.D

NOTE:

insure complete installation of Retaining Ring

1.B

1.H

1.F

1.E

1.D

1.C

1.A1.A

1.C

AIR VALVE ASSEMBLY PARTS LIST

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

1-A 031-143-162 Sleeve and Spool Set 1 1-B 095-094-559 Body, Air Valve 1 1-C 132-029-552 Bumper 2 1-D 165-098-147 Cap, End 2 1-E 560-020-360 O-Ring 8 1-F 675-044-115 Ring, Retaining 2 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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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

To service the pilot valve or the actuator plungers, 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.

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 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 Air Inlet Adapter Plate Adapter

• Use a ¼” hex key wrench and remove the four 5/16-18 x 1 ¼ socket head cap screws. This will allow access to the pilot valve, gaskets and actuator plungers.

Step #4: Disassemble 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: 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, taking care not to shear any of the o-rings. Install the retaining ring.

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

• sleeve.

Step #6: Inspect the Actuator Plungers

• With the pilot valve assembly off the pump, the actuator plungers can be accessed.

• Remove the plungers and inspect them for nicks or unusual wear. Replace them if necessary. If the bushings or o-rings need to be replaced, refer to the Intermediate Servicing section (p.17). Apply a generous amount of lubricant and install the plungers back in the intermediate. Push the as far in as they will go.

Step #7: Reassembly

• Reinstall the pilot valve and gaskets. Take caution during the installation to align the ends of the pilot valve

stem between the plunger pins. 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.

Step #8: Reassemble AirVantage and Cable

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

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

ITEM NO.

5.A

5.B

5.C

5.D

5.E

5.F

PART NUMBER

095.095.157

755.051.148

560.033.360

775.055.110

560.023.360

675.037.080

5.F

5.A

DESCRIPTION

BODY, PILOT VALVE

SLEEVE, PILOT VALVE

SPOOL, PILOT VALVE

RING, RETAINING

O-RING

5.B

QTY.

5.D

5.C

5.E

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 20

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

475-244-003 10-30VDC, 110VAC and 220 VAC Intrisincally Safe 5-30 VDC, 110-120VAC, 220-240VAC

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 21

This Page Intentionally Blank

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 22

Composite Repair Parts Drawing: AirVantage Unit

ITEM NO.

PART NUMBER

DESCRIPTION

032.054.000

1 171.092.115

CAPSCREW, HEX SOC, M6 X 35mm

2 258.020.147

COVER, END, ATEX

3 720.071.360

SEAL, O-RING

4 765.004.000

VALVE, SOLENOID

5 893.104.000

VALVE, POPPET

6 171.091.115

CAPSCREW, HEX SOC, M6 X 25mm

7 031.202.000

POWER GENERATION MODULE, ATEX

8 258.022.147

COVER, END, ATEX

9 020.069.000

REGULATOR

10 560.200.360

O-RING

11 249.019.000

CONTROL MODULE, RS20 HAZ. DUTY

12 560.104.360

O-RING

13 165.135.330

CAP, SWITCH

B27.7M - 3BM1-25

RING, RETAINER

15 430.050.147

HOUSING, MUFFLER

16 720.073.365

SEAL, DUST VALVE

HX-SHCS 0.125-40x0.188x0.188-N

CAPSCREW, HEX SOC HD, 5-40 X .25

BSI 4518 0221-16

O-RING

19 530.045.115

MUFFLER, SPARK ARRESTOR

20 165.137.115

PLATE, PERFORATED

21 901.051.115

WASHER, FLAT, M6

22 535.096.000

TAG, WARNING

23 710.010.115

SCREW, SELF TAPPING, 4-24 X .25 LG

24 535.094.000

TAG, NAME

AirVantage Composite Parts List

ITEM No. PART NUMBER DESCRIPTION QTY.

171.092.115

,WERCSPAC1 HEX SOC HD, M6-1.0 x 35 8

1REVOC000.020.8522

3 720. 004.360 SEAL, O-RING 4

4 765. 004.000 VALVE, SOLENOID 1

5 893. 104.000 VALVE, POPPET 1

171.091.115

031.202.000

,WERCSPAC6 HEX SOC HD, M6-1.0 x 25 8

REWOP7 GENERATION MODULE 1

8 258. 019.000 COVER, END 1

9 020. 069.000 REGULATOR 1

Page 23

10 560.20 0.360 SEAL, O-RING 2

249.019.000

560.104.360

13 165.13 5.33 0 CAP, SWITCH 1

21 901.051.115 WASHER, FLAT, M6 8

675.067.115

430.050.147

720.073.365

171.093.115

560.205.360

530.045.115

165.137.115

LORTNOC11 MODULE 1

,LAES21 O-RING 1

RING, RETAINING

,PAC51 DUST 1

,EVLAV61 DUST 1

,WERCSPAC71 HEX SOC HD, 5

,LAES81 O-RING 1

,ETALP02 PERFORATED 1

, RS20

-40 x .25 1

,ROTSERRA91 SPARK 1

Substitution of components may impair intrinsic safety.

WARNING

141

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 23

AirVantage Servicing Pilot Valve and Pressure Regulator

Pilot Valve and Pressure Regulator

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

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 be removed only from the intermediate.

CAPSCREW, HEX SOC HD M6 X 1.0 X 35

WASHER, FLAT, M6

COVER

SEAL, O-RING

Step #2: Remove the AirVantage from the Pump

Step #3: Access the Pilot Valve and Pressure Regulator

• Use a 5mm hex-key wrench and remove four M6 x 35mm socket head cap screws & washers securing the top cover on. Lift the cover off, exposing the pilot 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 pilot 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 pilot valve to the plate. The valve and gasket can now be removed and/replaced. When reinstalling the pilot valve, tighten the screws to snug with a miniature 4-way Phillips screwdriver.

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

Step #4: Reinstallation

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M6 screws.

• Reinstall the AirVantage using the four 5/16-18 x 5 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.

Note: Ensure all mating faces are free from scores or damage prior to re-assembly.

Check each metallic face joint with a 0.003” feeler gage to ensure all ange

faces are fully closed after assembly. Failure to do so may compromise the

ameproof design of the assembly.

REGULATOR

O-RING

CAP, SWITCH

WARNING

Substitution of components may impair intrinsic safety.

VALVE, SOLENOID

VALVE, POPPET

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

WARNING

Do not open when an explosive atmosphere may be present.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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”.

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 be removed only from the intermediate.

Step #2: Remove the AirVantage from the Pump

Step #3: Access the Power Generation Module

• Use a 5mm hex-key wrench and remove four M6 x 35mm socket head cap screws & washers 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 5mm hex-key wrench and remove four M6 x 25mm 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 loosen the 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 M6 x 25mm socket head cap screws and tighten to 6.8 N-M.

• “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 M6 x 35 socket head cap screws to 3.4 N-M.

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M6 screws. Reinstall the AirVantage using the four 5/16-18 x 5 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.

SEAL, O-RING

CONNECTOR (Power Generation Module to Control Module)

BREATHER ASSEMBLY

CAPSCREW, HEX SOC HD

M6 X 1.0 X 25

SEAL, O-RING

CAPSCREW, HEX SOC HD M6 X 1.0 X 35

WASHER, FLAT, M6

COVER

CAPSCREW, HEX SOC HD M6 X 1.0 X 25

CASE, POWER GENERATOR, ATEX

CONNECTOR (To Intermediate)

CONNECTOR (Control Module to Power Generation Module)

CONTROL MODULE

O-RING

VALVE, POPPET

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

Note: Ensure all mating faces are free from scores or damage prior to re-assembly.

Check each metallic face joint with a 0.003” feeler gage to ensure all ange

faces are fully closed after assembly. Failure to do so may compromise the

ameproof design of the assembly.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 25

WARNING

Substitution of components may impair intrinsic safety.

WARNING

Do not open when an explosive atmosphere may be present.

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”.

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 be removed only from the intermediate.

Step #2: Remove the AirVantage from the Pump

Step #3: Access the Pilot Valve

• Use a 5mm hex-key wrench and remove four M6 x 35mm socket head cap screws & washers securing the top cover on. Lift the cover off, exposing the pilot 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 pilot 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

• Use a 5mm hex-key wrench and remove four M6 x 35mm socket head cap screws & washers 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 5mm hex-key wrench to loosen the four M6 x 25mm 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 that seals between the components.

• If the control module needs to be replaced, use a 5mm hex-key wrench to loosen the four M6 x 25mm 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 pilot valve connector wire slips through the hole in the poppet valve assembly.

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

Step #5: Reinstalling

• When reinstalling the new control module, make sure to feed the pilot valve connector wire through the hole in the poppet valve assembly. Install the four M6 x 25mm socket head cap screws and tighten to 3.4 N-M.

• Reinstall the power generation module. Make sure to feed the control module wire through the hole in the power generation case. Install the four M6 x 25mm socket head cap screws and tighten to 6.8 N-M.

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

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M6 screws. Reinstall the AirVantage using the four 5/16-18 x 5 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 M6 X 1.0 X 35

WASHER, FLAT, M6

SEAL, O-RING

CONNECTOR (Power Generation Module to Control Module)

CAPSCREW, HEX SOC HD

M6 X 1.0 X 25

SEAL, O-RING

COVER

CAPSCREW, HEX SOC HD M6 X 1.0 X 25

POWER GENERATION MODULE

CONNECTOR (To Intermediate)

CONNECTOR (Control Module to Power Generation Module)

CONTROL MODULE

O-RING

VALVE, POPPET

O-RING

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

Note: Ensure all mating faces are free from scores or damage prior to re-assembly.

Check each metallic face joint with a 0.003” feeler gage to ensure all ange

faces are fully closed after assembly. Failure to do so may compromise the

ameproof design of the assembly.

WARNING

Substitution of components may impair intrinsic safety.

WARNING

Do not open when an explosive atmosphere may be present.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 26

AirVantage Servicing - Sensor Assembly

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 be removed only from the intermediate.

Step #2: Remove the AirVantage from the Pump

Step #3: Diaphragm Disassembly

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

Step #4: Accessing the Sensor Assembly

• Use a ¼” hex key wrench and remove the four, at head socket cap screws on each inner chamber. These bolts have been assembled using blue thread locker, so they may be difcult to remove. The

inner chambers and gaskets can now be removed.

• “AirVantage CAUTION” – Remove the inner chamber from the intermediate with caution, taking care not to damage the sensor.

• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut holding the connector to the intermediate. Slide the connector out of the hole.

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

SENSOR, FEEDBACK

SEAL

FLAT EDGE

DETAIL A

BRACKET, INTERMEDIATE, ASSEMBLY

NUT

PLATE, OUTER DIAPHRAGM

DIAPHRAGM

PLATE, INNER DIAPHRAGM

BUMPER

PROBE TIP

O-RING

SENSOR, FEEDBACK

Step #5: 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.

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

• 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 bolts and torque them to 300 in-lbs.

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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 27

WARNING

Do not open when an explosive atmosphere may be present.

AirVantage Servicing -

CAPSCREW, HEX SOC, M6 X 35mm

COVER

SEAL, O-RING

VALVE, SOLENOID

VALVE, POPPET

SEAL, O-RING

CONTROL MODULE

O-RING

CAP, SWITCH

POWER GENERATOR MODULE

CAPSCREW, HEX SOC, M6 X 25mm

SEAL, O-RING

CAPSCREW, HEX SOC, M6 X 25mm

SEAL, O-RING

COVER

CAPSCREW, HEX SOC, M6 X 35mm

O-RING

REGULATOR

WASHER, FLAT, M6

Page 28

ITEM NO.

PART NUMBER

DESCRIPTION

032.054.000

1 171.092.115

CAPSCREW, HEX SOC, M6 X 35mm

2 258.020.147

COVER, END, ATEX

3 720.071.360

SEAL, O-RING

4 765.004.000

VALVE, SOLENOID

5 893.104.000

VALVE, POPPET

6 171.091.115

CAPSCREW, HEX SOC, M6 X 25mm

7 031.202.000

POWER GENERATION MODULE, ATEX

8 258.022.147

COVER, END, ATEX

9 020.069.000

REGULATOR

10 560.200.360

O-RING

11 249.019.000

CONTROL MODULE, RS20 HAZ. DUTY

12 560.104.360

O-RING

13 165.135.330

CAP, SWITCH

B27.7M - 3BM1-25

RING, RETAINER

15 430.050.147

HOUSING, MUFFLER

16 720.073.365

SEAL, DUST VALVE

HX-SHCS 0.125-40x0.188x0.188-N

CAPSCREW, HEX SOC HD, 5-40 X .25

BSI 4518 0221-16

O-RING

19 530.045.115

MUFFLER, SPARK ARRESTOR

20 165.137.115

PLATE, PERFORATED

21 535.096.000

TAG, WARNING

22 710.010.115

SCREW, SELF TAPPING, 4-24 X .25 LG

23 901.051.115

WASHER, FLAT, M6

24 535.094.000

TAG, NAME

Poppet Valve Drawing

Caution: When performing a direct spray washdown, the AirVantage exhaust outlet should be covered with protective tape. Failure to do so may damage internal components. (See page 23)

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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 be removed from only the intermediate.

Step #2: Remove the AirVantage from the Pump

Step #3: Access the Pilot Valve and Pressure Regulator

• Unplug the connector attached to it. Use a miniature 4-way Phillips screwdriver and remove the two screws securing the pilot 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. Turn the assembly over and let it now rest on the top cover.

Step #4: Access the Power Generation Module

• Unplug the connector that connects the power generator to the control board. use a 5mm hex-key wrench to loosen the four M6 x 25mm 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 pilot valve connector wire through the hole in the poppet valve assembly. Install the four M6 x 25mm socket head cap screws and tighten to 3.4 N-M.

• 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 M6 x 25mm socket head cap screws and tighten to 6.8 N-M.

• “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 M6 screws. The unit can now be turned over and set on the bottom cover.

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

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

Step #7: Reinstallation

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M6 screws.

• Reinstall the AirVantage using the four 5/16-18 x 5 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

Note: Ensure all mating faces are free from scores or damage prior to re-assembly.

Check each metallic face joint with a 0.003” feeler gage to ensure all ange

faces are fully closed after assembly. Failure to do so may compromise the

ameproof design of the assembly.

Step #5: Access the Control Module

• Use a 5mm hex-key wrench and loosen the four M6 x 25mm 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 pilot valve connector wire slips through the hole in the poppet valve assembly.

• The Poppet valve assembly can now be replaced.

WARNING

Substitution of components may impair intrinsic safety.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic Page 29

WARNING

Do not open when an explosive atmosphere may be present.

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.

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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.

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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 Unlled 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

rs20mdl1sm_haz duty-rev0614 Model RS20 Hazardous Duty Metallic 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

EC Declaration of Conformity

In accordance with ATEX Directive 94/9/EC,

Equipment intended for use in potentially explosive environments.

Manufacturer: Warren Rupp, Inc.

800 North Main Street, P.O. Box 1568, Mansfield, OH 44902 USA

, A Unit of IDEX Corportion

Airvantage-equipped ATEX-Certified Air-Operated Double Diaphragm Pump Models RHDB2. RHDF2, RS20, and RS30.

Certificate Number: Sira 10ATEX1151X Issue: 2 Equiptment: AirVantage Air Flow Control Unit

Sira Certification Service

Rake Lane Eccleston Chester CH4 SJN United Kingdom

DATE/APPROVAL/TITLE: 27 MAY 2010

0518

Applicable Standard:

AirVantage Marking:

EN 60079-0:2009 II 2 G D EN 60079-1:2007 Ex d ib IIB T4 Gb IEC 60079-31:2006 Ex tb IIIC 135° C Db IP66

Position Sensor Rating (not marked):

EN 60079-0:2006 II 2 G D EN 60079-11:2007 Ex ib IIB T4 EN 61241-0:2006 Ex ibD 21 T132° C EN 61242-11:2006

David Roseberry, Engineering Manager

Declaration of Conformity

INTERNATIONAL ELECTROTECHNICAL COMMISSION

IEC Certification Scheme for Explosive Atmospheres

Manufacturer: Warren Rupp, Inc.

800 North Main Street, P.O. Box 1568, Mansfield, OH 44902 USA

, A Unit of IDEX Corportion

Airvantage-equipped Air-Operated Double Diaphragm Pump Models RHDB2, RHDF2, RS20 and RS30.

Certificate Number: IECEx SIR 10.0110X Issue: 2 Equiptment: AirVantage Air Flow Control Unit

Sira Certification Service

Rake Lane Eccleston Chester CH4 SJN United Kingdom

DATE/APPROVAL/TITLE: 27 MAY 2010

Applicable Standard:

AirVantage Marking:

IEC 60079-0:2004 Ex d ib IIB T4 Gb IEC 60079-1:2007-4 Ex tb IIIC 135° C Db IP66 IEC 60079-31:2008

Position Sensor Rating (not marked):

IEC 60079-0:2007-10 Ex ib IIB T4 IEC 60079-11:2006 Ex ibD 21 T132° C IEC 61241-0:2004 IEC 61242-11:2005

David Roseberry, Engineering Manager

SANDPIPER RS20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual