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