SANDPIPER S05 User Manual

SERVICE & OPERATING MANUAL

Model S05 Non-Metallic Design Level 1

Table of Contents

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

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

Perf ormance Curve.................................................................................................. 3

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

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

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

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

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

Air V alve Lubrication ................................................................................................ 6

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

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

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

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

T roub leshooting........................................................................................................ 8

Warr anty.................................................................................................................. 8

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

Material Codes......................................................................................................... 9

Composite Repair Parts Drawing............................................................................10

Overlay Option Drawing, Muffler Option Drawing....................................................10

Available Service and Conversion Kits ................................................................ 1 0

Composite Repair Parts List ................................................................................ 11

Air Distribution Valve Assembly Drawing ............................................................. 1 2

Air Distribution Valve Assembly Parts List............................................................ 12

Air Distribution Valve Servicing ............................................................................ 13

Air Distribution Valve Assembly Drawing w/Stroke Indicator Option ................... 1 4

Air Distribution Valve w/Stroke Indicator Option Parts List................................... 14

Air Distribution Valve w/Stroke Indicator Option Servicing................................... 1 5

Solenoid Shifted Air Valve Drawing ..................................................................... 1 6

Solenoid Shifted Air Valve Parts List .................................................................... 1 6

Solenoid Shifted Air Distribution Valve Option ..................................................... 1 7

Pilot Valve Assembly Drawing.............................................................................. 18

Pilot Valve Assembly Parts List............................................................................. 18

Pilot Valve Servicing ............................................................................................. 1 9

Intermediate Assembly Drawing and Parts List ................................................... 20

Intermediate Assembly Servicing ......................................................................... 2 0

Modular Check Valve Drawing ............................................................................. 2 1

Modular Check Valve Servicing ........................................................................... 21

Diaphragm Service Drawing, Non-Overlay ......................................................... 22

Diaphragm Service Drawing, with Overlay .......................................................... 2 2

Diaphragm Servicing ............................................................................................ 23

Overlay Diaphragm Servicing .............................................................................. 23

Dual Port Option Drawing ..................................................................................... 2 4

Dual Porting Options ............................................................................................ 25

Dual porting of both suction and discharge ends of the pump ............................ 2 5

Single porting of the suction and dual porting of the pump discharge ................ 2 5

Dual porting of the suction and single porting of the pump discharge ................ 2 5

Single Port Suction Repair Parts List ................................................................... 2 6

Single Port Discharge Repair Parts List............................................................... 2 6

Dual Port Suction and Discharge Repair Parts List ............................................. 2 6

Pumping Hazardous Liquids ................................................................................ 27

Converting the pump for piping the exhaust air................................................... 27

Exhaust Conversion Drawing .............................................................................. 27

Converted Exhaust Illustration ............................................................................. 27

Pulse Output Kit Drawing ..................................................................................... 2 8

Pulse Output Kit Option ........................................................................................ 28

Exhaust Port or Auxiliary Muffler Setup ................................................................ 28

Integral Muffler Setup ........................................................................................... 2 8

Grounding the Pump ............................................................................................ 29

CE

U.S. Patent #
400,210

5,996,627

WARREN RUPP®, INC. • A Unit of IDEX Corporation • P.O. Box 1568, Mansfield, Ohio 44901-1568 USA • Telephone [phone] • Fax [phone] • www.warrenrupp.com

520-211-000 2/01

©Copyright 2001 Warren Rupp, Inc. All rights reserved.

Quality System

ISO9001 Certified

Environmental

Management System

ISO14001 Certified

Air Exhaust Side View

Air Inlet Side View

CE

U.S. Patent #
5,996,627
Other U.S. Patents
Applied for

S05 Non-Metallic

Design Level 1
Ball Valve

Air-PoweredAir-Powered

Air-Powered

Air-PoweredAir-Powered
Double-Diaphragm PumpDouble-Diaphragm Pump

Double-Diaphragm Pump

Double-Diaphragm PumpDouble-Diaphragm Pump

ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA

INTAKE/DISCHARGE PIPE SIZE

½" NPT(Internal) or ½" BSPT

1" NPT(External) or 1" BSPT

CAUTION!

MaterialsMaterials

Materials

MaterialsMaterials

SantopreneSantoprene

Santoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex 212°F -10°F 50° to 212°F

SantopreneSantoprene
life. Excellent abrasion resistance. 100°C -23°C 10°C to 100°C

VV

irginirgin

PTFEPTFE

V

irgin

PTFE Chemically inert, virtually imper vious. Very few chemicals are known to react chemically with

VV

irginirgin

PTFEPTFE
Virgin PTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 212°F -35°F 50°F to 212°F
chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 100°C -37°C 10°C to 100°C

PolyurethanePolyurethane

Polyurethane High tensile material with excellent abrasion resistance. A general purpose material 210°F -40F -40°F to 210°F

PolyurethanePolyurethane
with excellent resistance to most oils. 99°C -40°C -40°C to 99°C

PVDFPVDF

PVDF 200°F 10°F

PVDFPVDF

PolypropylenePolypropylene

Polypropylene 150°F 40°F

PolypropylenePolypropylene

NylonNylon

Nylon 120°F 32°F

NylonNylon

Conductive AcetalConductive Acetal

Conductive Acetal

Conductive AcetalConductive Acetal

BunaBuna

Buna

BunaBuna

For specific applications, always consult “Chemical Resistance Chart” Technical Bulletin

SandPIPER II

®

Operating temperature limitations are as follows:

pumps are designed to be powered only by compressed air .

CAPACITY

0 to 14 gallons per minute

(0 to 52 liters per minute)

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to .125 in. (3mm)

Maximum*Maximum*

Maximum*

Maximum*Maximum*

93°C -13°C

65°C 5°C

48°C 0°C

180°F180°F

180°F

180°F180°F

82°C82°C

82°C

82°C82°C
190°F

88°C

*Definite reduction in service life.
**Minimal reduction in service life at ends of range.

HEADS UP TO

100 psi or 231 ft. of water

(7 Kg/cm2 or 70 meters)

Operating TOperating T

Operating T

Operating TOperating T

emperaturesemperatures

emperatures

emperaturesemperatures

Minimum*Minimum*

Minimum*

Minimum*Minimum*

-20°F-20°F

-20°F

-20°F-20°F

-28°C-28°C

-28°C

-28°C-28°C

-10°F

-23°C

DISPLACEMENT/STROKE

.026 Gallon / .098 liter

Optimum**Optimum**

Optimum**

Optimum**Optimum**

50° to 140°F

10° to 60°C

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 1

Explanation of Pump Nomenclature

S05 Non-Metallic · Design Level 1· Ball Valve

Check Diaphragm/ Check Non-Wetted Shipping

MODEL Pump Pump V alve Design Wetted Check V alve Valve Material P orting Pump Pump Kit Weight

Brand Size T yp e Level Material Materials Seat Options Options Style Options Options lbs. (kg)

S05B1P1PPNS000. S 0 5 B 1 P 1 P P N S 0 00. 16 (8)
S05B1P2PPNS000. S 0 5 B 1 P 2 P P N S 0 00. 16 (8)
S05B1PUPPNS000. S 0 5 B 1 P U P P N S 0 00. 16 (8)
S05B1K1KPNS000. S 0 5 B 1 K 1 K P N S 0 00. 18 (9)
S05B1K2KPNS000. S 0 5 B 1 K 2 K P N S 0 00. 18 (9)
S05B1KUKPNS000. S 0 5 B 1 K U K P N S 0 00. 18 (9)
S05B1N1NPNS000. S 05 B 1 N 1 N P N S 0 00. 16 (8)
S05B1N2NPNS000. S 05 B 1 N 2 N P N S 0 00. 16 (8)
S05B1NUNPNS000. S 0 5 B 1 N U N P N S 0 00. 16 (8)
S05B1G1DXNS000. S 05 B 1 G 1 D X N S 0 00. 17 (8)
S05B1G2DXNS000. S 05 B 1 G 2 D X N S 0 00. 17 (8)
S05B1GUDXNS000. S 0 5 B 1 G U D X N S 0 00. 17 (8)
S05B1P1PPBS000. S 0 5 B 1 P 1 P P B S 0 00. 16 (8 )
S05B1P2PPBS000. S 0 5 B 1 P 2 P P B S 0 00. 16 (8 )
S05B1PUPPBS000. S 05 B 1 P U P P B S 0 00. 16 (8 )
S05B1K1KPBS000. S 0 5 B 1 K 1 K P B S 0 00. 18 (9 )
S05B1K2KPBS000. S 0 5 B 1 K 2 K P B S 0 00. 18 (9 )
S05B1KUKPBS000. S 05 B 1 K U K P B S 0 00. 18 (9 )
S05B1N1NPBS000. S 05 B 1 N 1 N P B S 0 00. 16 (8)
S05B1N2NPBS000. S 05 B 1 N 2 N P B S 0 00. 16 (8)
S05B1NUNPBS000. S 0 5 B 1 N U N P B S 0 00. 16 (8)
S05B1G1AXBS000. S 05 B 1 G 1 D X B S 0 00. 17 ( 8)
S05B1G2DXBS000. S 05 B 1 G 2 D X B S 0 00. 17 (8)
S05B1GUDXBS000. S 0 5 B 1 G U D X B S 0 00. 17 (8)

Pump Brand

S= SandPIPER II

Pump Size

05=½"

Check Valve Type

B= Ball

Design Level

1=Design Level

Wetted Material

K= PVDF
G= Conductive Acetal
N= Nylon
P= Polypropylene

®

Diaphragm/Check V alve Materials

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

Check V alve Seat

D= Delrin
K= PVDF
N= Nylon
P= Polypropylene

Non-Wetted Material Options

P= Polypropylene
1= Polypropylene with PTFE Coated Hardware
C= Conductive Acetal

Porting Options

N = NPT Threads
B= BSPT Threads
1= Dual Porting (NPT)
2= T op Dual P orting (NPT)
3= Bottom Dual Porting (NPT)
4= Dual Porting (BSPT)

5= T op Dual P orting (BSPT)
6= Bottom Dual Porting (BSPT)

Pump Style

S= Standard

Pump Options

0= None
1= 3M Muffler

Kit Options

00.=None
P0.=0-30VDC Pulse Output Kit
P1.=Intrinsically-Safe 10-30VDC Pulse Output Kit
P2.=110/120 or 220/240VA C Pulse Output Kit
P3.=Intrinsically-Safe 110/120VAC Pulse Output Kit
P4.=Intrinsically-Safe 220/240VAC Pulse Output Kit
E0.=Solenoid Kit with 24VDC Coil
E1.=Solenoid Kit with 24VDC Explosion-Proof Coil
E2.=Solenoid Kit with 24VAC/12VDC Coil
E3.=Solenoid Kit with 24VAC12VDC Explosion-Proof Coil
E4.=Solenoid Kit with 110VAC Coil
E5.=Solenoid Kit with 110VAC Explosion-Proof Coil
E6.=Solenoid Kit with 220VAC Coil
E7.=Solenoid Kit with 220V AC Explosion-Proof Coil
SP.=Stroke Indicator Pins

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 2

Performance Curve, S05 Non-Metallic, Design Level 1

BAR

PSI

100

7

6

5

4

Head

3

2

1

0

2 (3.5)

100 PSI (6.8 Bar)

90

80

80 PSI (5.44 Bar)

70
60

60 PSI (4.08 Bar)

50
40

40 PSI (2.72 Bar)

30

20

20 PSI (1.36 Bar)

10

0

0

1

4 (7)

6 (10)

8 (13.5)

Air Inlet Pressure

2

345678910111213141516

10 (17)

12 (20)

14 (24)

16 (27)

U.S. Gallons per minute

.

FEET

METERS

30
25
20
15
10

9.1

7.6
6

4.5
3

5

1.5

NPSHR

0

10 20 30 40 50 60

Liters per minute

Capacity

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 3

Dimensions: S05 Non-Metallic

Dimensions in Inches
Dimensional tolerance: ±1/8"

DIMENSION A B
Standard Pump 4 1/16" 7 1/16"
Pulse Output Kit 5 13/16" 8 13/16"
Mesh Muffler 5 3/4" 8 3/4"
Sound Dampening Muffler 7" 9 15/16"

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 4

Metric Dimensions: S05 Non-Metallic

Dimensions in millimeters
Dimensional tolerance: ±3mm

*DISCHARGE PORT
½" NPT (INTERANL)
1" NPT (EXTERNAL)

MANIFOLD CAN ROTATE
FROM VERTICAL CENTERLINE.

BOLT PATTERN
IS SYMETERICAL
ABOUT CENTERLINES

STANDARD
ENCAPSULATED MUFFLER:
3/8" NPT EXHUAST PORT
FOR OPTIONAL MUFFLER ­STYLES OR PIPING EXHAUST
AIR IN SUBMERGED
APPLICATIONS.

*SUCTION PORT
½" NPT (INTERNAL)
1" NPT (EXTERANL)

*BOTH SUCTION AND
DISCHARGE PORTS
ARE AVAILABLE IN
½" BSPT TAPERED (INTERNAL)
1" BSPT TAPERED (EXTERNAL)

AIR INLET
¼" NPT

DIMENSION A B
Standard Pump 103mm 179mm
Pulse Output Kit 148mm 224mm
Mesh Muffler 146mm 222mm
Sound Dampening Muffler 178mm 252mm

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 5

PRINCIPLE OF PUMP OPERATION

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

For maximum diaphragm life, keep
the pump as close to the liquid being
pumped as possible. Positive suction
head in excess of 10 feet of liquid (3.048
meters) may require a back pressure
regulating device to maximize
diaphragm life.

Alternate pressurizing and
exhausting of the diaphragm chamber
is performed by an externally mounted,
pilot operated, four way spool type air
distribution valve. When the spool shifts
to one end of the valve body, inlet
pressure is applied to one diaphragm
chamber and the other diaphragm
chamber exhausts. When the spool

shifts to the opposite end of the valve
body, the pressure to the chambers is
reversed. The air distribution valve spool
is moved by a internal pilot valve which
alternately pressurizes one end of the
air distribution valve spool while
exhausting the other end. The pilot valve
is shifted at each end of the diaphragm
stroke when a actuator plunger is
contacted by the diaphragm plate. This
actuator plunger then pushes the end of
the pilot valve spool into position to
activate the air distribution valve.

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

INST ALLA TION AND ST AR T -UP

Locate the pump as close to the
product being pumped as possible. Keep
the suction line length and number of
fittings to a minimum. Do not reduce the
suction line diameter.

For installations of rigid piping, short
sections of flexible hose should be
installed between the pump and the
piping. The flexible hose reduces
vibration and strain to the pumping
system. A Warren Rupp DA05 Surge
Dampener is recommended to further
reduce pulsation in flow.

AIR SUPPLY

Air supply pressure cannot exceed
100 psi (7 bar). Connect the pump air
inlet to an air supply of sufficient capacity
and pressure required for desired
performance. When the air supply line

is solid piping, use a short length of
flexible hose not less than ½" (13mm)
in diameter between the pump and the
piping to reduce strain to the piping. The
weight of the air supply line, regulators
and filters must be supported by some
means other than the air inlet cap. Failure
to provide support for the piping may
result in damage to the pump. A pressure
regulating valve should be installed to
insure air supply pressure does not
exceed recommended limits.

AIR VALVE LUBRICA TION

The air distribution valve and the pilot
valve are designed to operate WITHOUT
lubrication. This is the preferred mode of
operation. There may be instances of
personal preference or poor quality air
supplies when lubrication of the
compressed air supply is required. The
pump air system will operate with
properly lubricated compressed air
supply. Proper lubrication requires the
use of an air line lubricator (available from
Warren Rupp) set to deliver one drop of
SAE 10 non-detergent oil for every 20
SCFM (9.4 liters/sec.) of air the pump
consumes at the point of operation.
Consult the pump’s published
Performance Curve to determine this.

AIR LINE MOISTURE

Water in the compressed air supply
can create problems such as icing or
freezing of the exhaust air, causing the
pump to cycle erratically or stop
operating. Water in the air supply can
be reduced by using a point-of-use air
dryer to supplement the user’s air drying

equipment. This device removes water
from the compressed air supply and
alleviates the icing or freezing problems.

AIR INLET AND PRIMING

T o start the pump, open the air valve
approximately ½ to ¾ turn. After the
pump primes, the air valve can be opened
to increase air flow as desired. If opening
the valve increases cycling rate, but does
not increase the rate of flow, cavitation
has occurred. The valve should be closed
slightly to obtain the most efficient air
flow to pump flow ratio.

BETWEEN USES

When the pump is used for materials
that tend to settle out or solidify when
not in motion, the pump should be flushed
after each use to prevent damage.
(Product remaining in the pump between
uses could dry out or settle out. This
could cause problems with the
diaphragms and check valves at restart.)
In freezing temperatures the pump must
be completely drained between uses in
all cases.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 6

INSTALLATION GUIDE

Top Discharge Ball Valve Unit

Available from
Warren Rupp

1

DA05 Surge Suppressor
020-049-000 Filter/Regulator

2
3

020-049-001 Lubricator

4

020-046-008 Air Dryer

CAUTION

The air exhaust should be
piped to an area for safe
disposition of the product
being pumped, in the event
of a diaphragm failure.

1

4

2

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 7

3

TROUBLESHOOTING
Possible Symptoms:

• Pump will not cycle.

• Pump cycles, but produces no flow.

• Pump cycles, but flow rate is

unsatisfactory.

• Pump cycle seems unbalanced.

• Pump cycle seems to produce

excessive vibration.

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

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

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

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

What to Check: Undersized suction
line.

Corrective Action: Meet or exceed
pump connection recommendations
shown on the DIMENSIONAL
DRAWING.

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

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

What to Check: Rigid pipe connections
to pump.
Corrective Action: Install flexible
connectors and a Warren Rupp surge
dampener.

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

What to Check: Pumped fluid in air
exhaust muffler .
Corrective Action: Disassemble pump
chambers. Inspect for diaphragm rupture
or loose diaphragm plate assembly . Refer

to the Diaphragm Replacement section
of your pump SERVICE MANUAL.

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

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

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

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

obstruction. Check and clear all suction
screens and strainers.

What to Check: Blocked discharge line.
Corrective Action: Check for

obstruction or closed discharge line
valves.

What to Check: Blocked pumping
chamber.
Corrective Action: Disassemble and
inspect the wetted chambers of the
pump. Remove or flush any obstructions.

Refer to the pump SERVICE MANUAL
for disassembly instructions.

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

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

W ARRANTY

Refer to the enclosed Warren Rupp
Warranty Card.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 8

IMPORTANT SAFETY

INFORMA TION

IMPORTANT

Read these safety warnings
and instructions in this
manual completely, before
installation and start-up

of the pump. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual will
damage the pump, and void factory warranty.

CAUTION

Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep.

Re-torque loose fasteners
to prevent leakage. Follow recommended
torques stated in this manual.

WARNING

Before maintenance or

repair, shut off the com-

pressed air line, bleed the

pressure, and disconnect

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

WARNING

In the event of diaphragm

rupture, pumped material

may enter the air end of the

pump, and be discharged

into the atmosphere. If
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.

WARNING

Take action to prevent
static sparking. Fire or
explosion can result,
especially when handling

flammable liquids. The
pump, piping, valves, containers or other
miscellaneous equipment must be grounded.

WARNING

This pump is pressurized

internally with air pressure

during operation. Always

make certain that all bolting

is in good condition and that

all of the correct bolting is reinstalled during
assembly.

WARNING

When used for toxic or

aggressive fluids, the pump

should always be flushed

clean prior to disassembly.

WARNING

Before doing any main­tenance on the pump, be
certain all pressure is
completely vented from the

pump, suction, discharge,
piping, and all other openings and connections.
Be certain the air supply is locked out or made
non-operational, so that it cannot be started while
work is being done on the pump. Be certain that
approved eye protection and protective clothing
are worn all times in the vicinity of the pump.
Failure to follow these recommendations may
result in serious injury or death.

WARNING

Airborne particles and loud

noise hazards.

Wear ear and eye protection.

MATERIAL CODES

00 0 ........ Assembly, sub-assembly;

01 0 ........ Cast Iron

01 2 ........ Powered Metal

01 5 ........ Ductile Iron

02 0 ........Ferritic Malleable Iron

025 ........ Music Wire

080 ........ Carbon Steel, AISI B-1112

10 0 ........ Alloy 20

11 0 ........ Alloy Type 316 Stainless Steel

11 1 ........ Alloy Type 316 Stainless Steel (Electro Polished)

11 2 ........Alloy “C” (Hastelloy equivalent)

11 3 ........ Alloy Type 316 Stainless Steel (Hand Polished)

11 4 ........ 303 Stainless Steel

11 5 ........ 302/304 Stainless Steel

11 7 ........ 440-C Stainless Steel (Martensitic)

12 0 ........ 416 Stainless Steel (Wrought Martensitic)

12 3 ........ 410 Stainless Steel (Wrought Martensitic)

14 8 ........ Hardcoat Anodized Aluminum

14 9 ........ 2024-T4 Aluminum

15 0 ........ 6061-T6 Aluminum

15 1 ........ 6063-T6 Aluminum

15 2 ........ 2024-T4 Aluminum (2023-T351)

15 4 ........ Almag 35 Aluminum

15 5 ........ 356-T6 Aluminum

15 6 ........ 356-T6 Aluminum

15 7 ........ Die Cast Aluminum Alloy #380

15 8 ........ Aluminum Alloy SR-319

15 9 ........ Anodized Aluminum

16 2 ......... Brass, Yellow, Screw Machine Stoc k

16 5 ........ Cast Bronze, 85-5-5-5

16 6 ........ Bronze, SAE 660

17 0 ........ Bronze, Bearing Type, Oil Impregnated

17 5 ........ Die Cast Zinc

18 0 ........ Copper Alloy

30 5 ........ Carbon Steel, Black Epoxy Coated

30 6 ........ Carbon Steel, Black Virgin PTFE Coated

30 7 ........ Aluminum, Black Epoxy Coated

30 8 ........ Stainless Steel, Black Virgin PTFE Coated

30 9 ........ Aluminum, Black Virgin PTFE Coated

31 0 ........ Kynar Coated

33 0 ........ Zinc Plated Steel

33 1 ........ Chrome Plated Steel

33 2 ........ Aluminum, Electroless Nickel Plated

33 3 ........ Carbon Steel, Electroless Nickel Plated

33 5 ........ Galvanized Steel

33 6 ........ Zinc Plated Yellow Brass

33 7 ........ Silver Plated Steel

34 0 ........ Nickel Plated

34 2 ........ Filled Nylon

35 3 ........ Geolast; Color: Black

35 4 ........ Injection Molded #203-40 Santoprene -

35 5 ........ Thermal Plastic

35 6 ........ Hytrel

35 7 ........ Injection Molded Polyurethane

35 8 ........ Urethane Rubber

35 9 ........ Urethane Rubber

36 0 ........ Buna-N Rubber. Color coded: RED

36 1 ........ Buna-N

36 3 ........ Viton (Flurorel). Color coded: YELLOW

36 4 ........ E.P.D.M. Rubber. Color coded: BLUE

36 5 ........ Neoprene Rubber. Color coded: GREEN

36 6 ........ Food Grade Nitrile

36 8 ........ Food Grade EPDM

The Last 3 Digits of Part Number

and some purchased items

Duro 40D +/-5; Color: RED

(Some Applications) (Compression Mold)

37 0 ........ Butyl Rubber. Color coded: BROWN

37 1 ........Philthane (Tuftane)

37 4 ........ Carboxylated Nytrile

37 5 ........ Fluorinated Nitrile

37 8 ........ High Density Polypropylene

40 5 ........ Cellulose Fibre

40 8 ........ Cork and Neoprene

42 5 ........ Compressed Fibre

42 6 ........ Blue Gard

44 0 ........ Vegetable Fibre

46 5 ........ F ibre

50 0 ........ Delrin 500

50 1 ........ Delrin 570

50 2 ........ Conductive Acetal, ESD-800

50 3 ........ Conductive Acetal, Glass-Filled

50 5 ........ Acrylic Resin Plastic

50 6 ........ Delrin 150

52 0 ........ Injection Molded PVDF Natural color

54 0 ........ Nylon

54 1 ........ Nylon

54 2 ........ Nylon

54 4 ........ Nylon Injection Molded

55 0 ........ Polyethylene

55 1 ........ Glass Filled Polypropylene

55 2 ........ Unfilled Polypropylene

553 ......... Unfilled Polypropylene

55 5 ......... Polyvinyl Chloride

55 6 ......... Black Vinyl

57 0 ......... Rulon II

58 0 ......... Ryton

59 0 ......... Va lo x

59 1 ........ Nylatron G-S

59 2 ........ Nylatron NSB

60 0 ........ Virgin PTFE Tetrafluorocarbon (TFE)

60 1 ........Virgin PTFE (Bronze and moly filled)

60 2 ........ Filled Virgin PTFE

60 3 ........ Blue Gylon

60 4 ........ Virgin PTFE

60 7 ........ Envelon

60 6 ........ Virgin PTFE

61 0 ........ Virgin PTFE Encapsulated Silicon

61 1 ........ Virgin PTFE Encapsulated Viton

63 2 ........ Neoprene/Hytrel

63 3 ........ Viton/Virgin PTFE

63 4 ........ EPDM/Virgin PTFE

63 7 ........ Virgin PTFE, Viton/Virgin PTFE

63 8 ........ Virgin PTFE, Hytrel/Virgin PTFE

63 9 ........Buna-N/TFE

643 ......... Santoprene®/EPDM

644 ........ Santoprene®/Virgin PTFE

Delrin, Viton 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 Monsanto Corp.
Rulon II is a registered tradename of Dixion Industries Corp.
Hastelloy-C is a registered tradename of Cabot Corp.
Ryton is a registered tradename of Phillips Chemical Co.
Valo x is a registered tradename of General Electric Co.
Warren Rupp, Rupplon, SandPIPER, SandPIPER II, PortaPump,

T ranquilizer and SludgeMaster are registered tradenames of
Warren Rupp, Inc.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 9

21

1

13

1

36

9

4

9

32

20

31

28

25

7

30

33

10

10

3

19

8

12

22

9

10

17

24

34

29

2

35

34

14

11

24

24

26

15

11

34

29

2

35

10

10

17

5

24

10

9

33

22

34

33

18

27

6

25

14

13

Model S05 Non-Metallic Composite
Repair Parts Drawing

Availab le Service and Conversion Kits

PART NO. DESCRIPTION

476-219-000 AIR END KIT

476-220-000 AIR END KIT for pumps

476-221-000 AIR END KIT for standard

476-222-000 AIR END KIT for Conductive

476-202-360 WETTED END KIT

476-202-354 WETTED END KIT

476-202-357 WETTED END KIT

476-202-654 WETTED END KIT

PULSE OUTPUT KITS

(For use with 530-031-550 encapsulated muffler)

475-153-021 DC Kit
475-153-022 DC Intrinsically Safe Kit
475-153-023 110/120VAC or 220/240VAC Kit
475-153-024 110/120VAC Intrinsically Safe Kit
475-153-025 220/240VAC Intrinsically Safe Kit

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

equipped with Stroke Indicator
(same components as above,
except Spool Assembly with
pins replaces Air Valve Spool)

Conductive Acetal pumps
(same components as
475-160-000 above)

Acetal pumps equipped with
Stroke Indicator
(same components as
475-161-000 above)

Buna Diaphragm, Buna Check
Balls, PTFE Seats and PTFE
Seals.

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

Polyurethane Diaphragms,
Buna Spacer Gaskets,
Polyurethane Check Balls,
PTFE Seats and PTFE Seals.

Santoprene Diaphragms, PTFE
Overlay Diaphragm, PTFE
Check Balls, PTFE Seats and
PTFE Seals.

(For use with 530-023-000 and 530-024-000 mufflers or
piped exhaust)

475-153-026 DC Kit
475-153-027 DC Intrinsically Safe Kit
475-153-028 110/120VAC or 220/240VAC Kit
475-153-029 110/120VAC Intrinsically Safe Kit
475-153-030 220/240VAC Intrinsically Safe Kit

520-211-000 1/03 Rev. B Model S05 Non-Metallic Design Level 2 Page

Composite Repair Parts List

ITEM PART NUMBER DESCRIPTION QTY

1 031-166-000 Air Valve Assembly 1

031-166-001 Air Valve Assembly
031-166-002 Air V alve Assembly
031-167-000 Air Valve Assembly (with stroke Indicator Pins) 1
031-167-001 Air V alv e Assembly

Indicator Pins)

031-167-002 Air Valve Assembly (with Stroke Indicator Pins and 1

PTFE Coated Hardware)

031-168-000 Air Valve Assembly 1
031-169-000 Air Valve Assembly

2 050-027-354 Ball, Check 4

050-027-357 Ball, Check 4
050-027-360 Ball, Check 4
050-022-600 Ball, Check 4

3 095-091-000 Pilot Valve Assembly 1

095-091-001 Pilot Valve Assembly (Conductive Acetal) 1

4 114-023-551 Bracket, Intermediate 1

114-023-503 Bracket, Intermediate 1

5 115-140-080 Bracket, Mounting 2

115-140-305 Bracket, Mounting 2
115-140-306 Bracket, Mounting 2

115-140-333 Bracket, Mounting 2
6 132-034-360 Bumper, Diaphragm 2
7 135-036-506 Bushing, Plunger 2
8 165-110-551 Cap, Air Inlet 1

165-110-503 Cap, Air Inlet 1
9 171-062-115 Capscrew, Flanged 5/16-18 X 1.00 12

171-062-308 Capscrew, Flanged 5/16-18 X 1.00 12
10 171-063-115 Capscrew, Flanged 5/16-18 X 1.25 24

171-063-308 Capscrew, Flanged 5/16-18 X 1.25 24
11 171-064-115 Capscrew, Flanged 5/16-18 X 1.50 12

171-064-308 Capscrew, Flanged 5/16-18 X 1.50 12
12 171-066-115 Capscrew, Flanged 1/4-20 X 1.25 8

171-066-308 Capscrew, Flanged 1/4-20 X 1.25 8
14 196-161-502 Chamber, Outer 2

196-161-542 Chamber, Outer 2

196-161-552 Chamber, Outer 2
15 286-095-354 Diaphragm 2

286-095-357 Diaphragm 2

286-095-360 Diaphragm 2
16 286-096-600 Diaphragm, Overlay 2
17 312-106-502 Elbow 4

(Conductive Acetal) 1

(with PTFE Coated Hardware) 1

(Conductive Acetal with Stroke 1

ITEM PART NUMBER DESCRIPTION QTY

312-106-520 Elbow, Suction 4
312-106-542 Elbow, Suction 4

312-106-552 Elbow, Suction 4
18 360-099-360 Gasket, Spacer 2
19 360-100-360 Gasket, Air Inlet 1
20 360-101-360 Gasket, Pilot Valve 1
21 360-102-360 Gasket, Air Valve 1
22 518-138-502 Manifold, NPT 2

518-138-502E Manifold, BSPT (Tapered) 2

1

23 530-023-000 Muffler 1

24 544-005-115 Nut, Flanged 5/16-18 36
25 560-001-360 O-ring 2

26 612-091-502 Plate, Outer Diaphragm 2

27 612-177-150 Plate, Inner Diaphragm 2
28 620-019-115 Plunger, Actuator 2
29 670-049-520 Retainer, Ball 4

30 675-042-115 Ring, Retaining 2
31 685-056-120 Rod, Diaphragm 1
32 720-012-375 Seal, Diaphragm Rod 2
33 720-045-600 Seal, Manifold 4
34 720-048-600 Seal, Check Valve 8
35 722-080-506 Seat, Check Valve 4

36 901-037-115 Washer, Flat 1/4" 4
51 920-025-000 Ground Strap

518-138-520 Manifold, NPT 2

518-138-520E Manifold, BSPT (Tapered) 2

518-138-542 Manifold, NPT 2

518-138-542E Manifold, BSPT (Tapered) 2

518-138-552 Manifold, NPT 2

518-138-552E Manifold, BSPT (Tapered) 2

(not available for Conductive Acetal)

530-024-000 Muffler (not shown) 1

544-005-308 Nut, Flanged 5/16-18 36

612-091-520 Plate, Outer Diaphragm 2

612-091-542 Plate, Outer Diaphragm 2

612-091-552 Plate, Outer Diaphragm 2

670-049-542 Retainer, Ball 4

670-049-552 Retainer, Ball 4

722-080-520 Seat, Check Valve 4

722-080-542 Seat, Check Valve 4

722-080-552 Seat, Check Valve 4

722-093-552 Seat, Check Valve (for Buna & Polyurethane) 4

901-037-308 Washer, Flat 1/4" 4

(Conductive Acetal Only) 1

520-211-000 1/03 Rev. B Model S05 Non-Metallic Design Level 2 Page

Air Distribution Valve Assembly Drawing

MAIN AIR VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty

1 031-166-000 Air Valve Assembly 1
1-A 095-106-551 Body, Air Valve 1
1-B 031-132-000 Sleeve and Spool Set 1
1-C 560-101-360 O-Ring 8
1-D 132-036-357 Bumper 2
1-E 165-122-551 End Cap 2
1-F 560-026-360 O-Ring 2
1- G 675-062-115 End Cap Retainer 2
1-H 530-031-550 Muffler 1
1-I 165-109-551 Muffler Cap 1
1- J 710-011-115 Self-Tapping Screw 4

For Conductive Acetal pumps:

1 031-166-001 Air Valve Assembly 1
1-A 095-106-503 Body, Air Valve 1
1-E 165-122-503 Cap, End 2
1-I 165-109-503 Cap, Muffler 1
(Includes all other items used on 031-166-000 above)

For Pumps with Virgin PTFE coated hardware:

1 031-166-002 Air Valve Assembly 1
1- G 675-062-308 End Cap Retainer 2
1- J 710-011-308 Screws, Self-Tapping 4
(Includes all other items used on 031-166-000 above)

For pumps with alternate Mesh or Sound Dampening mufflers or P iped
Exhaust:

1 031-168-000 Air Valve Assembly 1
(Includes all items used on 031-166-000 above minus items 1-H, 1-I
and 1-J)

520-211-000 3/03 Rev C Model S05 Non-Metallic Design Level 2 Page 14

AIR DISTRIBUTION VAL VE
SERVICING

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

Step #1: See COMPOSITE REP AIR
P AR TS DRAWING.

Using a 3/8" wrench or socket,
remove the four hex flanged capscrews
(item 12). Remove the air valve
assembly from the pump.

Step #2: Disassembly of the air
distribution valve.

To access the internal air valve
components first remove the two end cap
retainers (ite m 1 -G) b y inserting a small
flat screwdriver into the two slotted
grooves on the valve body and gently
lifting the retainers out.

Next remove the two end caps (item
1-E) by grasping the pull tab with finger
and thumb or pliers and tugging. Inspect
the two o-rings (items 1-C and 1-F) on
each end cap for wear or cuts. Replace
the o-rings if necessary.

Remove the two bumpers (items
1-D) and inspect for wear or damage.
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 .

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

Inspect the inner diameter of the
sleeve (part of item 1-B) for dirt,
scratches, or other contaminants.
Remove the sleeve if needed and
replace with a new sleeve and spool set
(item 1-B). Note: The slee ve and spool
set is match-ground to a specified
clearance. Sleeves and spools cannot
be interchanged.

Step #3: Reassembly of the air
distribution valve.

Install one bumper (item 1-D) and one
end cap with o-rings (items 1-E, 1-C,
and 1-F) into one end of the air valve
body (item 1-A). Insert one end cap
retainer (item 1-G) into the two smaller
holes, align with groove in the end cap,
and push until the closed end of the
retainer is below the flat surface of the
valve body.

Remove the new sleeve and spool
set (item 1-B) from the plastic bag.
Carefully remove the spool from the
sleeve. Install the six o-rings (item 1-C)
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. Push the spool in until
touches the bumper on the opposite end.

Install the remaining bumper, end
cap with o-rings, and retainer.

Fasten the air v alv e assemb ly (item

1) and gasket (item 23) to the pump,
using the four hex flanged capscrews
(item 12).

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

IMPORTANT

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

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

520-211-000 3/03 Rev C Model S05 Non-Metallic Design Level 2 Page 15

Air Valve with Stroke Indicator Assembly Drawing, Parts List

MAIN AIR VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty

1 031-167-000 Air Valve Assembly 1
1-A 095-106-551 Body, Air Valve 1
1-B 031-134-000 Sleeve and Spool Set 1
1-C 560-101-360 O-Ring 8
1-D 132-036-357 Bumper 2
1-E 165-123-147 End Cap 2
1-F 560-029-360 O-Ring 2
1- G 675-062-115 End Cap Retainer 2
1-H 210-008-330 Safety Clip 1
1-I 530-031-550 Muffler 1
1- J 165-109-551 Muffler Cap 1
1-K 710-011-115 Self-Tapping Screw 4

For Conductive Acetal pumps:

1 031-167-001 Air Valve Assembly 1
1-A 095-106-503 Body, Air Valve 1
1- J 165-109-503 Cap, Muffler 1
(Includes all other items used on 031-166-000 above)

For Pumps with Virgin PTFE coated hardware:

1 031-167-002 Air Valve Assembly 1
1- G 675-062-308 End Cap Retainer 2
1- J 710-011-308 Screws, Self-Tapping 4
(Includes all other items used on 031-166-000 above)

For pumps with alternate Mesh or Sound Dampening mufflers or P iped
Exhaust:

1 031-169-000 Air Valve Assembly 1
(Includes all items used on 031-167-000 above minus items 1-I , 1-J
and 1-K)

520-211-000 3/03 Rev C Model S05 Non-Metallic Design Level 2 Page 16

AIR DISTRIBUTION VAL VE
SERVCING

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

Step #1: See COMPOSITE REP AIR
P AR TS DRAWING.

Using a 3/8" wrench or socket,
remove the four hex flanged capscrews
(item 12). Remove the air valve
assembly from the pump.

Step #2: Disassembly of the air
distribution valve.

Remove safety clip (item 1-H) to
access the internal air valve components
first remove the two end cap retainers
(item 1-G) by inserting a small flat
screwdriver into the two slotted grooves
on the valve body and gently lifting the
retainers out.

Next remove the two end caps (item
1-E) by grasping with finger and thumb
or pliers and tugging. Inspect the two
o-rings (items 1-C and 1-F) on each end
cap for wear or cuts. Replace the o-rings
if necessary .

Remove the two bumpers (items
1-D) and inspect for wear or damage.
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 .

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

Inspect the inner diameter of the
sleeve (part of item 1-B) for dirt,
scratches, or other contaminants.
Remove the sleeve if needed and
replace with a new sleeve and spool set
(item 1-B). Note: The slee ve and spool
set is match-ground to a specified
clearance. Sleeves and spools cannot
be interchanged.

Step #3: Reassembly of the air
distribution valve.

Install one bumper (item 1-D) and one
end cap with o-rings (items 1-E, 1-C,
and 1-F) into one end of the air valve
body (item 1-A). Insert one end cap
retainer (item 1-G) into the two smaller
holes, align with groove in the end cap,
and push until the closed end of the
retainer is below the flat surface of the
valve body. Install safety clip (item
1-H).

Remove the new sleeve and spool
set (item 1-B) from the plastic bag.
Carefully remove the spool from the
sleeve. Install the six o-rings (item 1-C)
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. Push the spool in until
touches the bumper on the opposite end,
aligning the actuator pin through the end
cap.

Install the remaining bumper, end cap
with o-rings, and retainer. Be careful to
align the end cap onto the actuator pin.

Fasten the air v alv e assemb ly (item

1) and gasket (item 23) to the pump,
using the four hex flanged capscrews
(item 12).

Connect the compressed air line to

the pump.

IMPORTANT: Remove the safety
clip. The pump will not function properly
until it is removed. The pump is now
ready for operation.

IMPORTANT

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

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

520-211-000 3/03 Rev C Model S05 Non-Metallic Design Level 2 Page 17

Solenoid Shifted Air Valve Drawing

SOLENOID SHIFTED AIR VALVE PARTS LIST

(Includes all items used on Composite Repair Parts List except as shown)

ITEM PART NUMBER DESCRIPTION QTY

4 114-023-551 Bracket, Intermediate 1
47 893-093-000 Solenoid V alv e, NEMA4 1
48 219-001-000 Solenoid Coil, 24VDC 1

49 241-001-000 Connector , conduit 1
50 171-065-115 Capscrew, Flanged ¼-20 x 1.00 4
52 618-050-150 Plug (Replaces Item 7) 2

For Explosion Proof Solenoid Valve

(Connector not required for explosion proof coil; coil is integral with valve)
47 893-094-001 Solenoid Valve, NEMA 7/9, 24VDC 1

219-004-000 Solenoid Coil, 24VAC/12VDC 1
219-002-000 Solenoid Coil, 120VAC 1
219-003-000 Solenoid Coil, 240VAC 1

893-094-002 Solenoid Valve, NEMA 7/9, 24VAC/12VDC 1
893-094-003 Solenoid Valve, NEMA 7/9, 120VAC 1
893-094-004 Solenoid Valve, NEMA 7/9, 240VAC 1

36

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 16

SOLENOID SHIFTED AIR
DISTRIBUTION VAL VE OPTION

Warren Rupp’s solenoid shifted, air
distribution valve option utilizes electrical
signals to precisely control your
SandPIPER’s speed. The solenoid coil
is connected to the Warren Rupp
Solenoid Rate Controller/Batch Control,
or a customer - supplied control.
Compressed air provides the pumping
power, while electrical signals control
pump speed (pumping rate).

OPERA TION

The Solenoid Shifted SandPIPER has a
solenoid operated, air distribution valve
in place of the standard SandPIPER’s
pilot operated, air distribution valve.
Where a pilot valve is normally utilized
to cycle the pump’s air distribution valve,
an electric solenoid is utilized. As the
solenoid is powered, one of the pump’s
air chambers is pressurized while the
other chamber is exhausted. When
electric power is turned off, the solenoid
shifts and the pressurized chamber is
exhausted while the other chamber is
pressurized. By alternately applying and
removing power to the solenoid, the
pump cycles much like a standard
SandPIPER pump, with one exception.
This option provides a way to precisely
control and monitor pump speed.

Solenoid Connector

Before wiring, remove
terminal block from
conduit connector.

Wiring
Diagram

#2 T erminal
Neutral
(Negative)

3rd T erminal
for ground.

#1 T erminal
Power
(Positive)

To Control

BEFORE INST ALLA TION

Before wiring the solenoid, make certain
it is compatible with your system voltage.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 17

Pilot Valve Assembly Drawing

PILOT VALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY

3 095-091-000 Pilot V alve Assembly
3-A 095-087-551 Body, Pilot Valve 1
3-B 135-035-506 Bushing, Pilot Valve 2
3-C 675-057-115 Ring, Spiral Retaining 2
3-D 770-065-175 Spacer 5
3-E 775-041-506 Spool, Pilot Valve 1
3-F 917-003-374 Wiper 6

For Conductive Acetal pumps:

3 095-091-001 Pilot V alve Assembly 1
3-A 095-087-503 Body, Pilot Valve 1
(includes all other items used on 095-091-000 Pilot Valve above)

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 18

PILOT VALVE SERVICING

T o service the pilot valve first shut off
the compressed air supply, bleed the
pressure from the pump, and disconnect
the air supply line from the pump. Insert
the safety clip (item 1-G from Air
Distribution Valve assembly drawing)
into the smaller unthreaded holes in the
end cap (item 1-F from air distribution
valve assembly drawing).

Step #1: See PUMP ASSEMBLY
DRAWING.

Using a 7/16" wrench or socket,
remove the four capscrews (items 12).
Remove the air inlet cap (item 8) and
air inlet gasket (item 19). The pilot valve
assembly (item 3) can now be removed
for inspection or service.

Step #2: Disassembly of the pilot
valve.

Remove the pilot valve spool (item
3-E). Wipe clean, and inspect for dirt,
scratches or wear. Replace the spool if
necessary .

Remove the two spiral retaining rings
(items 3-C) from each end of the pilot
valve body by inserting the tip of a small
flat screw driver under the notch in the
retaining ring. Lift and push the ring
clockwise in a circular motion.

Remove the two pilot valve bushings
(items 3-B), five spacers (items 3-D),
and six spool wipers (items 3-F) by
pushing gently from other end of the
pilot valve body . Inspect the wipers and
spacers for cuts and/or wear. Replace
wipers and/or spacers as necessary .

Step #3: Re-assembly of the pilot

valve.

First install a spiral retaining ring to
one end of the pilot valve body . Spread
the spiral and insert one end into the
groove in the pilot valve body . T wist the
ring in a clockwise motion until the full
ring is snapped into the groove. Install
one bushing making sure the step side
faces toward the wiper. Apply a light
coating of grease to the outside diameter
of each wiper. Next, gently push in the
wipers and spacers until they are against
the installed retaining ring in the opposite
end of the pilot valve body. Install the
remaining bushing making sure the step
side faces the wiper. Install the remaining
spiral retaining ring using the same
method described.

Apply a light coating of grease to the
inner diameter of each wiper. Also apply
a light coating of grease to the outer
diameter of the pilot valve spool and gently
push the spool through each wiper.

Step #4: Inspect the actuator
plungers.

See PUMP ASSEMBL Y DRAWING.

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

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

Step #5: Re-install the pilot valve
assembly into the intermediate
assembly.

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

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

12).

Connect the air supply to the pump.
Remove the safety clip (item 1-G) from
the end cap (item 1-F). The pump is now
ready for operation.

IMPORTANT

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

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

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 19

Intermediate Assembly Drawing

Intermediate Assembly Servicing

INTERMEDIA TE REPAIR PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY

4 114-023-551 Bracket, Intermediate 1
7 135-036-506 Bushing, Plunger 2
25 560-001-360 O-Ring 2
30 675-042-115 Ring, Retaining* 2
*NOTE: It is recommended that when plunger components are
serviced, new retaining rings be installed.

PLUNGER BUSHING, O-RING, AND
RET AINING RING SER VICING

To service the plunger bushing

components first remove the two

4

retaining rings (items 30) using a
small flat screwdriver. *Note: It is
recommended that new retaining rings
be installed.

Next remove the two plunger

bushings (items 7). Inspect the

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 in-

stallation and start-up. It

is the responsibility of

the purchaser to retain

bushings for wear or scratches. Replace
the bushings as necessary .

Inspect the two o-rings (25) for cuts

and/or wear.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 20

Modular Check Ball Valve Drawing

MODULAR CHECK BALL VAL VE
SERVICING

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

T o access the modular check valve,
remove the elbows (items 17 from pump
composite repair parts drawing). Use a
½" wrench or socket to remove the
fasteners. Once the elbows are removed,
the modular check valves can be seen
in the cavities of the outer chamber
(items 14).

Next remove the check valve seal
(item 34). Inspect the seal for cuts or
pinched areas. Replace seal as needed.

Disassemble the component parts of
each modular check valve. Inspect the
check valve retainer (item 29) for cuts,
abrasive wear, or embedded materials.
Replace as needed.

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

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

Remove the check valve seal (item

34). Inspect the seal for cuts or pinched
areas. Replace seal as needed.

RE-ASSEMBLE THE MODULAR
CHECK V ALVE

Place a check valve seal (item 34)

into the cavity of the outer chamber (item

14). Make sure the chamfer side of the
seal faces out. Insert the modular check
valve into the outer chamber with the
retainer facing up. Install a check valve
seal (item 34). Make sure the chamfer
side of the seals face the chamfer on
the check valve seat or retainer.

The pump can now be reassembled,

reconnected and returned to operation.

IMPORTANT

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

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

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 21

Diaphragm Service Drawing,

Diaphragm Service Drawing,

Non-Overlay

with Overlay

Cross Section of Diaphragm

THE DIAPHRAGMS FOR BOTH CONFIGURATIONS
SHOWN ABOVE ARE TO BE INSTALLED WITH
CONVOLUTIONS FACING TOWARDS CENTER OF
PUMP

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 22

DIAPHRAGM SERVICING

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

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

Using a ½" wrench or socket, remove
the 16 capscrews (item 10), and flanged
nuts that fasten the elbows (items 17)
to the outer chambers (items 14).
Remove the elbows with the manifolds
and spacers attached.

Step #2: Removing the outer
chambers.

Using a ½" wrench or socket, remove
the 16 capscrews (items 9 and 1 1), and
flanged nuts that fasten the outer
chambers, diaphragms, and intermediate
(item 4) together.

Step #3: Removing the diaphragm
assemblies.

Use a ¾" (19mm) wrench or six
pointed socket to remove the diaphragm
assemblies (outer plate, diaphragm, and
inner plate) from the diaphragm rod (item

31) by turning counterclockwise.

Insert a 6-32 set screw into the
smaller tapped hole in the inner
diaphragm plate (item 27). Insert the
protruding stud and the 6-32 fastener
loosely into a vise. Use a ¾" wrench or
socket to remove the outer diaphragm

plate (item 26) by turning
counterclockwise. Inspect the
diaphragm (item 15) for cuts, punctures,
abrasive wear or chemical attack.
Replace the diaphragms if necessary .

Step #4: Installing the diaphragms.

Push the threaded stud of the outer
diaphragm plate through the center hole
of the diaphragm. Thread the inner plate
clockwise onto the stud. Insert the loose
assembly with the above 6-32 fastener
back into the vise. Use a torque wrench
to tighten the diaphragm assembly
together to 7.5 ft. Lbs. (10.17 Newton
meters). Allow a minimum of 15 minutes
to elapse after torquing, then re-torque
the assembly to compensate for stress
relaxation in the clamped assembly .

Step #5: Installing the diaphragm
assemblies to the pump.

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

Thread the stud of the one diaphragm
assembly clockwise into the tapped hole
at the end of the diaphragm rod (item

31) until the inner diaphragm plate is flush
to the end of the rod. Insert rod into pump.

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

Fasten the outer chamber (item 14)
to the pump, using the capscrews (items
9 and 1 1) and flanged nuts.

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

6) is installed over the diaphragm rod.

Thread the stud of the remaining

diaphragm assembly clockwise into the
tapped hole at the end of the diaphragm
rod (item 31) as far as possible and still
allow for alignment of the bolt holes in
the diaphragm with the bolt pattern in
the inner chamber. Install diaphragms
with convolutions facing towards center
of pump. See sectional view on previous
page.

Fasten the remaining outer chamber
(item 14) to the pump, using the
capscrews (items 9 and 1 1) and flanged
nuts.

Step #6: Re-install the elbow/spacer/
manifold assemblies to the pump, using
the capscrews (item 10) and flanged
nuts.

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

OVERLAY DIAPHRA GM SERVICING

The overlay diaphragm (item 16)
is designed to fit snugly over the exterior
of the standard TPE diaphragm (item 15).

Follow the same procedures
described for the standard diaphragm for
removal and installation.

IMPORTANT

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

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

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 23

Dual P ort Option Drawing

½" NPT or ½" BSPT
Connection

1" NPT or 1" BSPT External

½" NPT or ½" BSPT Internal

Connection

½" NPT or ½" BSPT
Connection

1" NPT or 1" BSPT External
½" NPT or ½" BSPT Internal
Connection

37

38

½" NPT or ½" BSPT

Connection

Illustration for Single P ort Suction
with Dual Port Discharge

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 24

Illustration for Dual P ort Suction and
Single or Dual Port Dischar ge

DUAL PORTING OPTIONS

Several dual porting options are
possible. The pump can be converted
to a dual port arrangement on both the
suction and the discharge ends. The
porting can be configured to a single
suction and a dual discharge. The porting
can be changed to a dual suction and a
single discharge.

The above changes are possible
because the porting flange of the elbows
(items 17) are designed to mate with
½" NPT or ½" BSPT (tapered)
connection.

Dual porting of both suction and
discharge ends of the pump

Converting the pump from the
standard single suction and discharge
porting configuration to dual porting at
each end is easy. Simply remove the
manifold seals and manifolds (items 33
and 22 from pump assembly drawing)
from the pump.

The discharge elbows and suction
elbows can be rotated 90° increments
(see arrows and optional positioning in
the Dual Porting Drawing.

Single porting of the suction and
dual porting of the pump discharge

To convert the pump from the
standard single suction and single
discharge porting configuration to a dual
discharge porting arrangement remove
the only the discharge manifolds and
manifold seals. Position the discharge
elbows in the desired direction at 90°
increments. (See arrows and optional
positioning in the Dual Porting Drawing.)

Dual porting of the suction and
single porting of the pump
discharge

To convert the pump from the
standard single suction and single
discharge porting configuration to a dual
suction porting arrangement remove the
only the suction (bottom) manifolds and
manifold seals.

Position the suction elbows in the
desired direction at 90° increments. (See
arrows and optional positioning in the
Dual Porting Drawing.)

IMPORTANT

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

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

NOTE: See Repair Parts List on next page.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 25

SINGLE PORT SUCTION REPAIR PARTS LIST
ITEM PART NO. DESCRIPTION QTY

17* 312-106-502E Elbow, ½BSPT (replaces 312-106-502) 2

312-106-502N Elbow, ½NPT (replaces 312-106-502) 2
312-106-520E Elbow, ½BSPT (replaces 312-106-520) 2
312-106-520N Elbow, ½NPT (replaces 312-106-520) 2
312-106-542E Elbow, ½BSPT (replaces 312-106-542) 2
312-106-542N Elbow, ½NPT (replaces 312-106-542) 2
312-106-552E Elbow, ½BSPT (replaces 312-106-552) 2
312-106-552N Elbow, ½NPT (replaces 312-106-552) 2

22* 518-138-502 Manifold (installed in bottom position) NPT 1

518-138-502E Manifold (installed in bottom position) BSPT 1
518-138-520 Manifold (installed in bottom position) NPT 1
518-138-520E Manifold (installed in bottom position) BSPT 1
518-138-542 Manifold (installed in bottom position) NPT 1
518-138-542E Manifold (installed in bottom position) BSPT 1
518-138-552 Manifold (installed in bottom position) NPT 1
518-138-552E Manifold (installed in bottom position) BSPT 1

24* 544-005-115 Nut, Flanged 5/16-18 2 8

544-064-308 Nut, Flanged 5/16-18 2 8

SINGLE PORT DISCHARGE REPAIR PARTS LIST

11* 171-064-115 Capscrew, Flanged HD 5/16-18 X 1.50 4

171-064-308 Capscrew, Flanged HD 5/16-18 X 1.50 4

17* 312-106-502E Elbow, ½BSPT (replaces 312-106-502) 2

312-106-502N Elbow, ½NPT (replaces 312-106-502) 2
312-106-520E Elbow, ½BSPT (replaces 312-106-520) 2
312-106-520N Elbow, ½NPT (replaces 312-106-520) 2
312-106-542E Elbow, ½BSPT (replaces 312-106-542) 2
312-106-542N Elbow, ½NPT (replaces 312-106-542) 2
312-106-552E Elbow, ½BSPT (replaces 312-106-552) 2
312-106-552N Elbow, ½NPT (replaces 312-106-552) 2

22* 518-138-502 Manifold (installed in top position) NPT 1

518-138-502E Manifold (installed in top position) BSPT 1
518-138-520 Manifold (installed in top position) NPT 1
518-138-520E Manifold (installed in top position) BSPT 1
518-138-542 Manifold (installed in top position) NPT 1
518-138-542E Manifold (installed in top position) BSPT 1
518-138-552 Manifold (installed in top position) NPT 1
518-138-552E Manifold (installed in top position) BSPT 1

ITEM PART NO. DESCRIPTION Q T Y

37 115-144-080 Bracket, Free Standing 2

(replaces 115-140-080)

115-144-305 Bracket, Free Standing 2

(replaces 115-140-305)

115-144-306 Bracket, Free Standing 2

(replaces 115-140-306)

115-144-333 Bracket, Free Standing 2

(replaces 115-140-333)

38 171-068-115 Capscrew, Flanged 5/16-18 X 1.63 8

171-068-308 Capscrew, Flanged 5/16-18 X 1.63 8

DUAL PORT SUCTION AND DISCHARGE REPAIR PARTS LIST

11* 171-064-115 Capscrew, Flanged HD 5/16-18 X 1.50 4

171-064-308 Capscrew, Flanged HD 5/16-18 X 1.50 4

17* 312-106-502E Elbow, ½BSPT (replaces 312-106-502) 4

312-106-502N Elbow, ½NPT (replaces 312-106-502) 4
312-106-520E Elbow, ½BSPT (replaces 312-106-520) 4
312-106-520N Elbow, ½NPT (replaces 312-106-520) 4
312-106-542E Elbow, ½BSPT (replaces 312-106-542) 4
312-106-542N Elbow, ½NPT (replaces 312-106-542) 4
312-106-552E Elbow, ½BSPT (replaces 312-106-552) 4
312-106-552N Elbow, ½NPT (replaces 312-106-552) 4

22* 518-138-502 Manifold (none required)

518-138-502E Manifold (none required)
518-138-520 Manifold (none required)
518-138-502E Manifold (none required)
518-138-542 Manifold (none required)
518-138-502E Manifold (none required)
518-138-552 Manifold (none required)
518-138-502E Manifold (none required)

24* 544-005-115 Nut, Flanged 5/16-18 1 6

544-005-308 Nut, Flanged 5/16-18 1 6

37 115-144-080 Bracket, Free Standing 2

(replaces 115-140-080)

115-144-305 Bracket, Free Standing 2

(replaces 115-140-305)

115-144-306 Bracket, Free Standing 2

(replaces 115-140-306)

115-144-333 Bracket, Free Standing 2

(replaces 115-140-333)

38 171-068-115 Capscrew, Flanged 5/16-18 X 1.63 8

171-068-308 Capscrew, Flanged 5/16-18 X 1.63 8

*

Quantities change from Composite Repair Parts List.

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 26

PUMPING HAZARDOUS LIQUIDS

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

This pump can be submerged if the
pump materials of construction are
compatible with the liquid being pumped.
The air exhaust must be piped above the
liquid level. See illustration #2 at right.
Piping used for the air exhaust must not
be smaller than ½" (1.27 cm) diameter.
Reducing the pipe size will restrict air
flow and reduce pump performance.
When the pumped product source is at
a higher level than the pump (flooded
suction condition), pipe the exhaust
higher than the product source to
prevent siphoning spills. See illustration
#3 at right.

IMPORTANT INSTALLATION NOTE:

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

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

Exhaust Conversion Drawing

CONVERTED EXHAUST ILLUSTRATION

PUMP INSTALLATION AREA

1" DIAMETER AIR

½"

EXHAUST PIPING

Illustration #1

LIQUID
LEVEL

SUCTION

LINE

SAFE AIR
EXHAUST
DISPOSAL
AREA

MUFFLER

MUFFLER

1" DIAMETER AIR

½"

EXHAUST PIPING

CONVERTING THE PUMP FOR

Illustration #2

PIPING THE EXHAUST AIR

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

Use a Phillips screwdriver to remove

MUFFLER

the six self-tapping screws (item 1-H).

Remove the muffler cap and muffler

1" DIAMETER AIR

(items 1-G and 1-F). The 3/8" NPT molded
threads in the air distribution valve body

LIQUID
LEVEL

½"

EXHAUST PIPING

(item 1-A).

Piping or hose may now be installed.

Illustration #3

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 27

SUCTION

LINE

Pulse Output Kit Drawing

PULSE OUTPUT KIT OPTION

This pump can be fitted with a Pulse Output Kit. This converts the mechanical
strokes of the pump to an electrical signal which interfaces with the RuppTech™
Stroke Counter/ Batch Controller or user control devices such as a PLC.

The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution
Valve Assembly or onto the Air Distribution Valve Assembly when the threaded
exhaust port or an auxiliary muffler is being used.

See the individual kits listed on the Pump Repair Parts List for further information.

Exhaust Port or Auxiliary
Muffler Setup

Pulse Output Kit

Integral Muffler Setup

Muffler Cap

Adapter Plate

Pulse Output Kit

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 28

Grounding The Pump

(for Conductiv e Acetal Pumps only)

The eyelet end is fastened to the pump hardware.

This 8 foot long (244 centimeters) Ground Strap (Item 51) is shipped with
the eyelet end fastened to the pump hardware.

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

NOTE: Conductive Acetal Pumps
are available with encapsulated
muffler only.

The clamp end is installed
to a true earth ground.

WARNING

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

520-211-000 2/01 Model S05 Non-Metallic Design Level 1 Page 29