SERVICE & OPERATING MANUAL
Model S05 Non-Metallic Design Level 1
CE
Table of Contents
U.S. Patent # 400,210 5,996,627
Engineering Data and Temperature Limitations ......................................................... |
1 |
Explanation of Pump Nomenclature ......................................................................... |
2 |
Performance Curve .................................................................................................. |
3 |
Dimensions .............................................................................................................. |
4 |
Metric Dimensions ................................................................................................... |
5 |
Principle of Pump Operation .................................................................................... |
6 |
Installation and Start-up ........................................................................................... |
6 |
Air Supply ................................................................................................................ |
6 |
Air Valve Lubrication ................................................................................................ |
6 |
Air Line Moisture ...................................................................................................... |
6 |
Air Inlet and Priming ................................................................................................. |
6 |
Between Uses ......................................................................................................... |
6 |
Installation Guide ..................................................................................................... |
7 |
Troubleshooting ........................................................................................................ |
8 |
Warranty .................................................................................................................. |
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 ................................................................ |
10 |
Composite Repair Parts List ................................................................................ |
11 |
Air Distribution Valve Assembly Drawing ............................................................. |
12 |
Air Distribution Valve Assembly Parts List ............................................................ |
12 |
Air Distribution Valve Servicing ............................................................................ |
13 |
Air Distribution Valve Assembly Drawing w/Stroke Indicator Option ................... |
14 |
Air Distribution Valve w/Stroke Indicator Option Parts List ................................... |
14 |
Air Distribution Valve w/Stroke Indicator Option Servicing ................................... |
15 |
Solenoid Shifted Air Valve Drawing ..................................................................... |
16 |
Solenoid Shifted Air Valve Parts List .................................................................... |
16 |
Solenoid Shifted Air Distribution Valve Option ..................................................... |
17 |
Pilot Valve Assembly Drawing .............................................................................. |
18 |
Pilot Valve Assembly Parts List ............................................................................. |
18 |
Pilot Valve Servicing ............................................................................................. |
19 |
Intermediate Assembly Drawing and Parts List ................................................... |
20 |
Intermediate Assembly Servicing ......................................................................... |
20 |
Modular Check Valve Drawing ............................................................................. |
21 |
Modular Check Valve Servicing ........................................................................... |
21 |
Diaphragm Service Drawing, Non-Overlay ......................................................... |
22 |
Diaphragm Service Drawing, with Overlay .......................................................... |
22 |
Diaphragm Servicing ............................................................................................ |
23 |
Overlay Diaphragm Servicing .............................................................................. |
23 |
Dual Port Option Drawing ..................................................................................... |
24 |
Dual Porting Options ............................................................................................ |
25 |
Dual porting of both suction and discharge ends of the pump ............................ |
25 |
Single porting of the suction and dual porting of the pump discharge ................ |
25 |
Dual porting of the suction and single porting of the pump discharge ................ |
25 |
Single Port Suction Repair Parts List ................................................................... |
26 |
Single Port Discharge Repair Parts List ............................................................... |
26 |
Dual Port Suction and Discharge Repair Parts List ............................................. |
26 |
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 ..................................................................................... |
28 |
Pulse Output Kit Option ........................................................................................ |
28 |
Exhaust Port or Auxiliary Muffler Setup ................................................................ |
28 |
Integral Muffler Setup ........................................................................................... |
28 |
Grounding the Pump ............................................................................................ |
29 |
WARREN RUPP®, INC. • A Unit of IDEX Corporation • P.O. Box 1568, Mansfield, Ohio 44901-1568 USA • Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com
520-211-000 2/01 |
©Copyright 2001 Warren Rupp, Inc. All rights reserved. |
Quality System |
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CE |
S05 Non-Metallic |
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ISO9001 Certified |
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Design Level 1 |
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Environmental |
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Ball Valve |
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Management System |
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ISO14001 Certified |
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U.S. Patent # |
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Air-Powered |
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5,996,627 |
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Other U.S. Patents |
Double-Diaphragm Pump |
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Applied for |
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Air Exhaust Side View |
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Air Inlet Side View |
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ENGINEERING, PERFORMANCE |
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& CONSTRUCTION DATA |
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INTAKE/DISCHARGE PIPE SIZE |
CAPACITY |
AIR VALVE |
SOLIDS-HANDLING |
HEADS UP TO |
DISPLACEMENT/STROKE |
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½" NPT(Internal) or ½" BSPT |
0 to 14 gallons per minute |
No-lube, no-stall |
Up to .125 in. (3mm) |
100 psi or 231 ft. of water |
.026 Gallon / .098 liter |
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1" NPT(External) or 1" BSPT |
(0 to 52 liters per minute) |
design |
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(7 Kg/cm2 or 70 meters) |
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CAUTION! Operating temperature limitations are as follows: |
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Materials |
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Operating Temperatures |
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Maximum* |
Minimum* |
Optimum** |
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Santoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex |
212°F |
-10°F |
50° to 212°F |
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life. Excellent abrasion resistance. |
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100°C |
-23°C |
10°C to 100°C |
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Virgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically with |
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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 |
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chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. |
100°C |
-37°C |
10°C to 100°C |
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Polyurethane High tensile material with excellent abrasion resistance. A general purpose material |
210°F |
-40F |
-40°F to 210°F |
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with excellent resistance to most oils. |
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99°C |
-40°C |
-40°C to 99°C |
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PVDF |
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200°F |
10°F |
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93°C |
-13°C |
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Polypropylene |
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150°F |
40°F |
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65°C |
5°C |
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Nylon |
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120°F |
32°F |
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48°C |
0°C |
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Conductive Acetal |
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180°F |
-20°F |
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82°C |
-28°C |
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Buna |
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190°F |
-10°F |
50° to 140°F |
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88°C |
-23°C |
10° to 60°C |
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For specific applications, always consult “Chemical Resistance Chart” Technical Bulletin |
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*Definite reduction in service life. |
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SandPIPER II® pumps are designed to be powered only by compressed air. |
**Minimal reduction in service life at ends of range. |
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520-211-000 |
2/01 |
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Model S05 Non-Metallic Design Level 1 Page 1 |
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Explanation of Pump Nomenclature
S05 Non-Metallic · Design Level 1· Ball Valve
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Check |
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Diaphragm/ |
Check |
Non-Wetted |
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Shipping |
MODEL |
Pump |
Pump |
Valve |
Design |
Wetted |
Check Valve |
Valve |
Material |
Porting |
Pump |
Pump |
Kit |
Weight |
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Brand |
Size |
Type |
Level |
Material |
Materials |
Seat |
Options |
Options |
Style |
Options |
Options |
lbs. (kg) |
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S05B1P1PPNS000. |
S |
05 |
B |
1 |
P |
1 |
P |
P |
N |
S |
0 |
00. |
16 (8) |
S05B1P2PPNS000. |
S |
05 |
B |
1 |
P |
2 |
P |
P |
N |
S |
0 |
00. |
16 (8) |
S05B1PUPPNS000. |
S |
05 |
B |
1 |
P |
U |
P |
P |
N |
S |
0 |
00. |
16 (8) |
S05B1K1KPNS000. |
S |
05 |
B |
1 |
K |
1 |
K |
P |
N |
S |
0 |
00. |
18 (9) |
S05B1K2KPNS000. |
S |
05 |
B |
1 |
K |
2 |
K |
P |
N |
S |
0 |
00. |
18 (9) |
S05B1KUKPNS000. |
S |
05 |
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 |
05 |
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 |
05 |
B |
1 |
G |
U |
D |
X |
N |
S |
0 |
00. |
17 (8) |
S05B1P1PPBS000. |
S |
05 |
B |
1 |
P |
1 |
P |
P |
B |
S |
0 |
00. |
16 (8) |
S05B1P2PPBS000. |
S |
05 |
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 |
05 |
B |
1 |
K |
1 |
K |
P |
B |
S |
0 |
00. |
18 (9) |
S05B1K2KPBS000. |
S |
05 |
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 |
05 |
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 |
05 |
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 Valve Materials
1= Santoprene/Santoprene
2= Virgin PTFE-Santoprene Backup/Virgin PTFE
B= Buna N
U= Polyurethane/Polyurethane
Check Valve 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= Top Dual Porting (NPT)
3= Bottom Dual Porting (NPT)
4= Dual Porting (BSPT)
5= Top Dual Porting (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 220/240VAC 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 220VAC 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
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BAR |
PSI |
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2 (3.5) |
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100 |
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4 (7) |
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90 |
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(6 |
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6 (10) |
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6 |
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8 |
Bar) |
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8 (13.5) |
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80 |
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80 |
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10 (17) |
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PSI |
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5 |
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12 (20) |
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70 |
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(5 |
44 |
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Bar) |
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14 (24) |
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Head |
4 |
60 |
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60 |
PSI |
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(4. |
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08 |
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16 (27) |
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50 |
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Bar) |
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METERS |
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FEET |
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3 |
40 |
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40 |
PSI |
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(2. |
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2 |
30 |
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72 |
Bar) |
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30 |
9.1 |
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25 |
7.6 |
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20 |
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20 |
PSI (1. |
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Bar) |
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Pressure |
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U.S. Gallons per minute
0 |
10 |
20 |
30 |
40 |
50 |
60 |
Liters per minute
Capacity
NPSHR
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)
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)
BOLT PATTERN
IS SYMETERICAL
ABOUT CENTERLINES
*BOTH SUCTION AND
DISCHARGE PORTS
ARE AVAILABLE IN
½" BSPT TAPERED (INTERNAL) 1" BSPT TAPERED (EXTERNAL)
MANIFOLD CAN ROTATE 
FROM VERTICAL CENTERLINE.
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.
INSTALLATION AND START-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 LUBRICATION
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
To 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
1
Available from
Warren Rupp
1 DA05 Surge Suppressor
2 020-049-000 Filter/Regulator
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.
4
2 3
520-211-000 |
2/01 |
Model S05 Non-Metallic Design Level 1 Page 7 |
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 Valve 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.
WARRANTY
Refer to the enclosed Warren Rupp Warranty Card.
520-211-000 |
2/01 |
Model S05 Non-Metallic Design Level 1 Page 8 |
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