SANDPIPER S15 User Manual

SERVICE & OPERATING MANUAL

Model S15 Non-Metallic Design Level 2

U.S. Patent # 400,210; 5,996,627; 6,241,487

Table of Contents

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

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

Performance Curve, Model S15 Non-Metallic Design Level 2 ............................................... 3

Dimensions: S15 Non-Metallic ................................................................................................. 4

Metric Dimensions: S15 Non-Metallic...................................................................................... 5

Dimensions: S15 Non-Metallic with RuppGUARD™ Spill Prevention..................................... 6

Metric Dimensions: S15 Non-Metallic with RuppGUARD™ Spill Prevention......................... 7

Principle of Pump Operation .................................................................................................... 8

Installation and Start-up ........................................................................................................... 8

Air Supply ................................................................................................................................. 8

Air Valve Lubrication ................................................................................................................. 8

Air Line Moisture ...................................................................................................................... 8

Air Inlet and Priming ................................................................................................................. 8

Between Uses .......................................................................................................................... 8

Installation Guide...................................................................................................................... 9

Important Safety Information ................................................................................................. 10

Material Codes ....................................................................................................................... 10

Troubleshooting...................................................................................................................... 11

Warranty................................................................................................................................. 11

Composite Repair Parts Drawing .......................................................................................... 12

Overlay Option Drawing ........................................................................................................ 12

Composite Repair Parts List.................................................................................................. 13

RuppGUARD™ Spill Prevention Option for Virgin PTFE Equipped Pumps......................... 14

RuppGUARD™ Spill Prevention Repair Parts List ............................................................... 14

RuppGUARD™ Spill Prevention Concept ............................................................................. 15

RuppGUARD™ Spill Prevention Option Diaphragm Servicing ............................................ 15

Filling RuppGUARD™ Chambers with Liquid ....................................................................... 15

RuppGUARD™ Spill Prevention Option for TPE Equipped Pumps ..................................... 16

RuppGUARD™ Spill Prevention Repair Parts List ............................................................... 16

RuppGUARD™ Spill Prevention Concept with TPE Diaphragms ........................................ 17

RuppGUARD™ Spill Prevention Option with TPE Diaphragm ............................................. 17

Air Distribution Valve Assembly Drawing............................................................................... 18

Main Air Valve Assembly Parts List ....................................................................................... 18

Air Distribution Valve Servicing .............................................................................................. 19

Air Distribution Valve with Stroke Indicator Options.............................................................. 20

Air Distribution Valve with Stroke Indicator Parts List ........................................................... 20

Air Distribution Valve with Stroke Indicator Servicing ........................................................... 21

Solenoid Shifted Air Valve Drawing ........................................................................................ 22

Solenoid Shifted Air Valve Parts List ...................................................................................... 22

Solenoid Shifted Air Distribution Valve Option ....................................................................... 23

Pilot Valve Assembly Drawing ................................................................................................ 24

Pilot Valve Assembly Parts List.............................................................................................. 24

Pilot Valv e Servicing ............................................................................................................... 25

Diaphragm Service Drawing, Non-Overlay .......................................................................... 26

Diaphragm Service Drawing, with Overlay ........................................................................... 26

Diaphragm Servicing .............................................................................................................. 27

Overlay Diaphragm Service .................................................................................................. 27

Pumping Hazardous Liquids .................................................................................................. 28

Converting the pump for piping the exhaust air .................................................................... 28

Exhaust Conversion Drawing ................................................................................................ 28

Converted Exhaust Illustration .............................................................................................. 28

Modular Check Valve Servicing............................................................................................. 29

Modular Check Valve Drawing............................................................................................... 29

Dual Port Option Drawing ...................................................................................................... 30

Dual Porting Options .............................................................................................................. 31

Dual porting of both suction and discharge ends of the pump ............................................. 31

Single porting of the suction and dual porting of the pump discharge.................................. 31

Dual porting of the suction and single porting of the pump discharge ................................. 31

RuppTech® Leak Detection Options Drawing...................................................................... 32

RuppTech® Electronic Leak Detector Installation ................................................................ 32

RuppTech® Mechanical Leak Detector Installation .............................................................. 32

RuppTech® Pulse Output Kit Drawing .................................................................................. 33

RuppTech® Pulse Output Kit Option ..................................................................................... 33

Exhaust Port or Auxiliary Muffler Setup................................................................................. 3 3

Integral Muffler Setup ............................................................................................................. 33

Warren Rupp®, Inc.  A Unit of IDEX Corp.  Box 1568, Mansfield, OH 44901-1568 USA  Tel: (419) 524-8388  Fax (419) 522- 7867  www.warrenrupp.com

520-193-000 9/02

Quality System

ISO9001 Certified

Environmental

Management System

ISO14001 Certified

U.S. Patent # 5,851,109; 5,996,627; 400,210 & 6,241,487

Other U.S. Patents Applied for

S15 Non-Metallic

Design Level 2 Ball Valve

Air-Powered Double-Diaphragm Pump

INTAKE/DISCHARGE PIPE SIZE

1½" ANSI Flange or

PN10 40mm DIN Flange

CAUTION!

Operating temperature limitations are as follows:

Air Exhaust Side View

CAPACITY

0 to 90 US gallons per minute

(0 to 340 liters per minute)

Air Inlet Side View

AIR VALVE

No-lube, no-stall

design

SOLIDS-HANDLING

Up to .47 in. (12mm)

ENGINEERING, PERFORMANCE & CONSTRUCTION DATA

HEADS UP TO

100 psi or 231 ft. of water

(7 bar or 70 meters)

Operating Temperatures

DISPLACEMENT/STROKE

.36 US gallon / 1.36 liter

Materials Maximum* Minimum* Optimum**

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

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

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

PVDF 200°F -10°F

Polypropylene 150°F -40°F

Polyurethane

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

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

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

-93°C -13°C

65°C 5°C

210°F

99°C

-40°F

-40°C

-40°F to 210°F

-40°C to 99°C

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 1

Explanation of Pump Nomenclature

S15 Non-Metallic · Design Level 2· Ball Valve

Check Diaphragm/ Check Non-Wetted Shipping

MODEL Pump Pump Valve Design Wetted Check Valve Valve Material Porting Pump Pump Kit Weight

Brand Size Type Level Material Materials Seat Options Options Style Options Options lbs. (kg)

S15B2P1PQAS000. S 15 B 2 P 1 P Q A S 0 00. 53 (24) S15B2K1KQAS000. S 15 B 2 K 1 K Q A S 0 00. 65 (29)

S15B2P2PQAS000. S 15 B 2 P 2 P Q A S 0 00. 53 (24) S15B2K2KQAS000. S 15 B 2 K 2 K Q A S 0 00. 65 (29) S15B2P3PQA V000. S 15 B 2 P 3 P Q A V 0 00. 58 (26) S15B2K3KQA V000. S 15 B 2 K 3 K Q A V 0 00. 77 (35) S15B2P4PQA V000. S 15 B 2 P 4 P Q A V 0 00. 58 (26) S15B2K4KQA V000. S 15 B 2 K 4 K Q A V 0 00. 77 (35)

Pump Brand

S=SandPIPER II

Pump Size

15=1½"

Check Valve Type

B=Ball

Design Level

2= Design Level 2

Wetted Material

K=PVDF P=Polypropylene

Diaphragm Check Valve Materials

1= Santoprene/Santoprene 2= PTFE-Santoprene

Backup/PTFE

3= PTFE Pumping, PTFE-

Santoprene Backup Driver/PTFE

4= Santoprene Pumping,

Santoprene Driver/Santoprene

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 2

Check Valve Seat

K=PVDF N=Nylon P=Polypropylene

Non-Wetted Material Options

A=Painted Aluminum J= Painted Aluminum PTFE Q=Epoxy Coated Aluminum K=PTFE Coated Aluminum L= PTFE Coated Aluminum with

PTFE Coated Hardware

R=Epoxy Coated Aluminum with

PTFE Coated Hardware

Porting Options

A=ANSI Flange D= DIN Flange 7= Dual Porting (ANSI) 8= Top Dual Porting (ANSI) 9= Bottom Dual Porting (ANSI)

Pump Style

D= RuppGUARD™ with Electronic

Leak Detection (110V)

E=RuppGUARD™ with Electronic

Leak Detection 220V)

M=RuppGUARD™ with Mechanical

Leak Detection S=Standard V=RuppGUARD™ with Visual

Leak Detection

Pump Options

0= None 1= 3M Muffler 2= Mesh Muffler 3= High temperature Air Valve

w/Encapsulated Muffler 4= High temperature Air Valve

w/3M Muffler 5= High temperature Air Valve

w/Mesh 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 110/120V AC

Pulse Output Kit

P4.=Intrinsically-Safe 220/240V AC

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 110VA C Coil E5.=Solenoid Kit with 110VAC Explosion-

Proof Coil E6.=Solenoid Kit with 220VA C Coil E7.=Solenoid Kit with 220VAC Explosion-

Proof Coil SP.=Stroke Indicator Pins

Performance Curve, Model S15 Non-Metallic Design Level 2

BAR

PSI

100

Head

100 PSI (6.8 Bar)

80 PSI (5.44 Bar)

60 PSI (4.08 Bar)

40 PSI (2.72 Bar)

20 PSI (1.36 Bar)

(17)

(34)

(51)

Air Inlet Pressure

(68)

(85)

U.S. Gallons per minute

(93)

(102)

FEET

METERS

30 25 20 15 10

9.1

7.6 6

4.5 3

1.5

(110)

(93)

(117)

(76)

(99)

70 80 9060

NPSHR

340320300280260240220200180160140120100806040200

Liters per minute

Capacity

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 3

Dimensions: S15 Non-Metallic

Dimensions in Inches Dimensional tolerance: ±1/8"

23 7/8"

Dimension

Standard Pump Pulse Output Kit

Mesh Muffler

Note: Porting Flanges are also avaible with PN10 40mm DIN bolting configuration.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 4

6 9/16" 12 11/16" 7 15/16" 14 1/16"

8 13/16" 14 15/16"

Metric Dimensions: S15 Non-Metallic

Dimensions in Millimeters Dimensional tolerance: ±3mm

606mm

Dimension

Standard Pump Pulse Output Kit

Mesh Muffler

Note: Porting Flanges are also avaible with PN10 40mm DIN bolting configuration.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 5

167mm

202mm 225mm 380mm

322mm

357mm

Dimensions: S15 Non-Metallic with RuppGUARD™ Spill Prevention

15 1/4"

28 5/8"

Dimension

Standard Pump

Pulse Output Kit

Mesh Muffler

Note: Porting Flanges are also avaible with PN10 40mm DIN bolting configuration.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 6

6 9/16"

7 15/16" 8 13/16" 14 15/16"

12 11/16"

14 1/16"

Metric Dimensions: S15 Non-Metallic with RuppGUARD™ Spill Prevention

728 mm

Dimension

Standard Pump

Mesh Muffler 225mm

Note: Porting Flanges are also avaible with PN10 40mm DIN bolting configuration.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 7

167mm

202mmPulse Output Kit

322mm 357mm

380mm

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 ART-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 surge suppressor is recommended to further reduce pulsation in flow.

AIR SUPPL Y

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 VAL VE 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.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 8

INSTALLATION GUIDE

Top Discharge Ball Valve Unit

Available from Warren Rupp

Surge Suppressor 020-050-000 Filter/Regulator

2 3

020-050-001 Lubricator

020-047-007 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.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 9

IMPORT ANT SAFETY

INFORMATION

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.

W ARNING

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.

W ARNING

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.

W ARNING

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.

000 ........ Assembly, sub-assembly; and some purchased

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

012 .........Powered Metal

015 .........Ductile Iron

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

025 ........ Music Wire

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

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

110 ........ Alloy Type 316 Stainless Steel

111 ........ Alloy Type 316 Stainless Steel (Electro Polished)

112 ........ Alloy “C” (Hastelloy equivalent)

113 .........Alloy Type 316 Stainless Steel (Hand Polished)

114 .........303 Stainless Steel

115 .........302/304 Stainless Steel

117 .........440-C Stainless Steel (Martensitic)

120 .........416 Stainless Steel (Wrought Martensitic)

123 .........410 Stainless Steel (Wrought Martensitic)

148 ........ Hardcoat Anodized Aluminum

149 ........ 2024-T4 Aluminum

150 ........ 6061-T6 Aluminum

151 ........ 6063-T6 Aluminum

152 ........ 2024-T4 Aluminum (2023-T351)

154 ........ Almag 35 Aluminum

155 ........ 356-T6 Aluminum

156 ........ 356-T6 Aluminum

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

158 ........ Aluminum Alloy SR-319

159 .........Anodized Aluminum

16 2 ......... Brass, Yellow , Screw Machine Stock

165 ........ Cast Bronze, 85-5-5-5

166 ........ Bronze, SAE 660

170 ........ Bronze, Bearing Type, Oil Impregnated

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

180 ........ Copper Alloy

305 ........ Carbon Steel, Gray Epoxy Coated

306 .........Carbon Steel, Black PTFE Coated

307 ........ Aluminum, Gray Epoxy Coated

308 .........Stainless Steel, Black PTFE Coated

309 .........Aluminum, Black PTFE Coated

310 .........Kynar® Coated

330 .........Zinc Plated Steel

331 ........ Chrome Plated Steel

332 ........ Aluminum, Electroless Nickel Plated

333 ........ Carbon Steel, Electroless Nickel Plated

335 ........ Galvanized Steel

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

337 ........ Silver Plated Steel

340 ........ Nickel Plated

342 ........ Filled Nylon

353 .........Geolast; Color: Black

354 ........ Injection Molded #203-40 Santoprene - Duro 40D

355 ........ Thermal Plastic

356 ........ Hytrel

35 7 ........ Injec tion Molded Polyurethane

358 ........ Rupplon (Urethane Rubber). Color coded:

359 ........ Urethane Rubber

360 ........ Buna-N Rubber. Color coded: RED

361 ........ Buna-N

363 ........ Viton (Flurorel). Color coded: YELLOW

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

365 ........ Neoprene Rubber. Color coded: GREEN

366 ........ Food Grade Nitrile

MA TERIAL CODES

The Last 3 Digits of Part Number

items

+/-5; Color: RED

PURPLE (Some Applications) (Compression Mold)

368 ........ Food Grade EPDM

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

371 ........ Philthane (Tuftane)

374 .........Carboxylated Nytrile

375 ........ Fluorinated Nitrile

378 ........ High Density Polypropylene

405 ........ Cellulose Fibre

408 ........ Cork and Neoprene

425 ........ Compressed Fibre

426 ........ Blue Gard

440 ........ Vegetable Fibre

465 ........ Fibre

500 ........ Delrin 500

501 ........ Delrin 570

502 ........ Conductive Acetal, ESD-800

503 ........ Conductive Acetal, Glass-Filled

505 ........ Acrylic Resin Plastic

506 ........ Delrin 150

520 ........ Injection Molded PVDF Natural color

540 ........ Nylon

541 ........ Nylon

542 ........ Nylon

544 ........ Nylon Injection Molded

550 ........ Polyethylene

551 .........Glass Filled Polypropylene

552 .........Unfilled Polypropylene

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

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

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

570 .........Rulon II

580 .........Ryton

590 .........Valox

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

592 ........ Nylatron NSB

60 0 ......... Virgin PTFE

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

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

603 ........ Blue Gylon

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

607 ........ Envelon

606 .........Injected molded PFA

610 ........ Encapsulated Silicon

611 ........ Encapsulated Viton

632 .........Neoprene/Hytrel

633 .........Viton/PTFE

634 .........EPDM/PTFE

637 .........PTFE, Viton

63 8 ......... PTFE, Hytrel

639 .........Buna-N

643 .........Santoprene®/EPDM

644 .........Santoprene

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. Valox is a registered tradename of General Electric Co . Kynar® is a registered tradename of A TOFINA Chemicals, Inc. Warren Rupp, Rupplon, SandPIPER, SandPIPER II, PortaPump,

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

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 10

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 surge suppressor.

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 Certificate.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 11

Composite Repair Parts Drawing

AVAILABLE SERVICE AND CONVERSION KITS

476-172-000 AIR END KIT

476-173-000* AIR END KIT (for Stroke Indicator Option)

476-124-354 WETTED END KIT

476-124-654 WETTED END KIT

476-141-354 WETTED END KIT (for Polypropylene

476-141-655 WETTED END KIT (for PVDF

031-141-000 ASSEMBLY, AIR VALVE

HARDWARE KITS

475-168-308 PTFE Coated Stainless Steel

475-169-308 (For use with RuppGUARD Spill Prevention

RuppTech® PULSE OUTPUT KITS

(For use with 530-010-000 and 530-032-000 Mufflers, or piped exhaust)

475-198-001 DC Ki t 475-198-002 DC Intrinsically Safe Kit 475-198-003 110/120VAC or 220/240VAC Kit 475-198-004 110/120VAC Intrinsically Safe Kit 475-198-005 220/240VAC Intrinsically Safe Kit

(For use with encapsulated 530-028-550 Muffler)

475-198-006 DC Ki t 475-198-007 DC Intrinsically Safe Kit 475-198-008 110/120VAC or 220/240VAC Kit 475-198-009 110/120VAC Intrinsically Safe Kit 475-198-010 220/240VAC Intrinsically Safe Kit

RuppTech® ELECTRONIC LEAK DETECTOR KITS

032-037-000 100VAC 50Hz

032-045-000 12-32VDC

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

Seals, O-rings, Gaskets, Retaining Rings, Air Valve Sleeve & Spool Set and Pitot Valve Assembly.

Santoprene Diaphragms, Santoprene Balls and TFE Seals.

Santoprene Diaphragms, PTFE Overlay Diaphragms, TFE Balls and TFE Seals.

RuppGuard)

Santoprene Diaphragms, PTFE Overlay Diaphragms, PTFE Pumping Diaphragms, PTFE Balls and PTFE Seals.

RuppGUARD)

Santoprene Diaphragms, PTFE Overlay Diaphragms, PTFE Pumping Diaphragms, PTFE Balls and PTFE Seals.

(without Encapsulated Muffler, Muffler Cap and six screws)

Capscrews, Hex Nuts, Washers and Support Rod

Options)

or 110-120VAC 50-60Hz or 220-240VAC 50-60Hz

Muffler Option

Drawing

Overlay Option Drawing

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 12

Composite Repair Parts List

ITEM PART NUMBER DESCRIPTION QTY

1 031-140-000 Air Valv e Assembly 1

031-140-002 Air V alve Assembly w/ PTFE coated Hardware 1 031-141-000 Air Valve Assembly (No Encapsulated Muffler) 1 031-141-002 Air V alve Assembly (No Muffler/ PTFE Hardware) 1 031-146-000 Air Valve Assembly (With Stroke Indicator Option) 1

031-147-000 Air Valv e Assembly (No Muffler w/ Stroke Indicator) 1 2 095-088-000 Pilot V alve Assembly 1 3 050-036-354 Ball, Check 4

050-036-357 Ball, Check 4

050-036-600 Ball, Check 4 4 114-021-156 Intermediate Assembly 1

114-021-307 Intermediate Assembly 1

114-021-309 Intermediate Assembly 1 5 115-131-080 Bracket, Mounting 2

115-131-305 Bracket, Mounting 2

115-131-306 Bracket, Mounting 2

115-131-115 Bracket, Mounting (Optional) 2 6 132-031-360 Bumper, Diaphragm 2 7 135-032-506 Bushing, Plunger 2 8 165-099-156 Cap, Air Inlet 1

165-099-307 Cap, Air Inlet 1

165-099-309 Cap, Air Inlet 1 9 170-052-115 Capscrew , Hex HD 3/8-16 x 2.25 4

170-052-308 Capscrew, Hex HD 3/8-16 x 2.25 4 10 170-055-115 Capscrew , Hex HD 1/2-13 x 2.50 16

170-055-308 Capscrew, Hex HD 1/2-13 x 2.50 16 11 170-095-115 Capscrew , Hex HD 1/2-13 x 3.00 32

170-095-308 Capscrew, Hex HD 1/2-13 x 3.00 32 12 171-004-115 Capscrew, Soc HD 1/2-13 x 1.25 6 13 171-053-115 Capscrew, Soc HD 3/8-16 x 2.75 4

171-053-308 Capscrew, Soc HD 3/8-16 x 2.75 4 14 196-147-520 Chamber, Outer 2

196-147-552 Chamber, Outer 2 15 196-148-156 Chamber, Inner 2

196-148-307 Chamber, Inner 2

196-148-309 Chamber, Inner 2 17 286-074-354 Diaphragm, Overlay 2

286-074-357 Diaphragm 2 18 286-075-600 Diaphragm, Overlay 2 19 312-101-520 Elbow 4

312-101-552 Elbow 4 20 360-090-360 Gasket, Air Inlet 1

ITEM PART NUMBER DESCRIPTION QTY

21 360-091-360 Gasket, Inner Chamber 2 22 360-092-360 Gasket, Pilot V alv e 1 23 360-093-360 Gasket, Main Air V alve 1 24 518-130-520 Manifold 2

518-130-520E Manifold, 40mm DIN 2 518-130-552 Manifold 2 518-130-552E Manifold, 40mm DIN 2

25 545-008-110 Nut, Hex 1/2-13 56

545-008-308 Nut, Hex 1/2-13 56 26 560-001-360 O-ring 2 27 612-179-520 Assembly , Outer Diaphragm Plate 2

612-179-552 Assembly, Outer Diaphragm Plate 2 28 612-158-150 Assembly , Inner Diaphragm Plate 2 29 620-017-115 Plunger, Actuator 2 30 670-045-520 Retainer, Ball 4

670-045-552 Retainer, Ball 4 31 685-050-120 Rod, Diaphragm 1 32 685-053-115 Rod, Support 2

685-053-308 Rod, Support 2 33 720-010-375 Seal, Diaphragm Rod 2 34 720-035-600 Seal, Check V alv e 8 35 720-037-600 Seal, Manifold Spacer 8 36 722-074-520 Seat, Check V alv e 4

722-074-552 Seat, Check V alve 4 37 770-052-520 Spacer, Manifold 4

770-050-552 Spacer, Manifold 4 38 901-046-115 Washer, Flat 1/2" 96

901-046-308 Washer, Flat 1/2" 96 39 901-048-115 Washer, Flat 3/8" 8

901-048-308 Washer, Flat 3/8" 8 40 538-035-555 Nipple, Pipe 1" NPT Close 1 41 530-010-000 Muffler 1

NOT SHOWN:

535-069-000 Nameplate

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 13

RuppGUARD™ Option for Virgin PTFE Equipped Pumps Drawing

Note:

All of the diaphragms are to be installed with the concave side facing toward the outer chambers.

*Flat Side of Spill Prevention Chamber (Item 43), to Face Outer Chamber (Item14).

S15 Spill Prevention Repair Parts List for

Discharge

Manifold

ITEM PART NUMBER DESCRIPTION QTY

1 031-146-000 Air Valve Assembly 1

031-147-000 Air Valve Assembly 1

Virgin PTFE Equipped Pumps

(replaces 031-140-000)

(replaces 031-141-000)

2 095-093-000 Pilot Valve Assembly 1

(replaces 095-088-000)

42 170-108-115 Capscrew, Hex HD 1/2-13 x 5.50 16

170-108-308 Capscrew, Hex HD 1/2-13 x 5.50 16

(replaces 170-095-115 Qty 16 of 32)

43 196-149-520* Chamber, Spill Prevention 2

196-149-552* Chamber, Spill Prevention 2

Suction

Manifold

44 286-076-600 Diaphragm, Pumping 2 45 518-131-520 Manifold 2

(replaces 518-130-xxx) 518-131-520E Manifold, 40mm DIN 2 518-131-552 Manifold 2

(replaces 518-130-xxx) 518-131-552E Manifold, 40mm DIN 2

46 538-022-110 Nipple, Pipe 4

538-022-308 Nipple, Pipe 4

47 560-078-611 O-Ring 8 48 618-003-110 Plug, Pipe 4

618-003-308 Plug, Pipe 4

49 618-025-110 Plug, Boss 4

618-025-308 Plug, Boss 4

50 618-031-110 Plug, Boss 4

618-031-308 Plug, Boss 4

51 770-052-600 Spacer, Manifold 4

770-052-552 Spacer, Manifold 4

52 835-055-110 Tee, Pipe 4

835-055-308 Tee, Pipe 4

53 860-055-606 Tube, Sight 2 54 866-060-110 Connector, Tube 4

Note: The diaphragms are to be installed with the concave side facing toward the outer chambers. See drawing.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 14

RuppGUARD™ FOR VIRGIN PTFE EQUIPPED PUMPS CONCEPT

The spill prevention option prevents the air end components from being contaminated or damaged when a pumping diaphragm ruptures while pumping caustic or toxic materials. It also helps to protect the environment. With the installation of optional leak detectors (either mechanical or electronic) the diaphragm rupture can be detected. The pump can then be shut down and repaired before any caustic or toxic materials can enter the air end and be exhausted into the surrounding environment.

RuppGUARD™ OPTION DIAPHRAGM SER VICING

To service the diaphragms first shut off the suction, then shut off the discharge lines to the pump. Next shut off the compressed air supply, bleed the pressure from the pump, and disconnect the air supply line from the pump. Drain any remaining pumped liquid from the pump. Remove the pump before servicing.

Next, drain the fluid from the spill prevention chambers. This can be done by removing the bottom plug (item 49) from each spill prevention chamber.

After the fluid from the spill prevention chambers has been drained, the wet end components can now be removed. See diaphragm servicing section for detailed instructions. The spill prevention option has two additional virgin PTFE pumping diaphragms (item 44). These diaphragms are installed with the natural concave curve toward the outer chamber (items

14 from the pump assembly drawing). The molded directional arrows on the diaphragms must point vertically.

FILLING RuppGUARD™ CHAMBERS WITH LIQUID

THE CHAMBERS ARE FILLED

WITH WATER AT THE FACTORY.

If you prefer to substitute another liquid, to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction.

Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss:

1. Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs (items 49). Replace the bottom two boss plugs after the fluid is drained.

2. Remove the eight capscrews (item

10) fastening the discharge manifold and elbows to the outer chambers (items 14). The discharge manifolds and elbows can now be removed.

3. Remove the top two boss plugs (items 49). The spill prevention chambers are filled through the exposed ports.

4. Apply air pressure to the air distribution valve. Install safety clip (item 1-N) into the smaller unthreaded hole in one end cap (item 1-D). This locks the valve spool to one side, keeping the pump from shifting.

5. Face the side of the pump with the installed safety clip. If the safety clip is installed in the top end cap, fill the left spill containment chamber. If the safety clip is installed on the bottom end

cap, fill the right spill prevention chamber. The volume of fluid is 1420 ml (48.01 fl. oz.). It is important that the exact amount of fluid is used. Too little or too much fluid causes premature diaphragm failure and erratic pumping.

6. Loosely reinstall one boss plug (item 49) to the filled spill prevention chamber.

7. Shut off air supply. Remove safety clip. Adjust the air line regulator so that air pressure slowly fills the pump. The diaphragm expands, forcing the fluid in the chamber to be slowly displaced. When the pump shifts to the opposite side, quickly install the safety clip.

8. Loosen the top boss plug on the filled chambers. This allows fluid in the chamber to purge trapped air from the chamber. This can be seen by watching the column of fluid in the sight tube. When fluid appears at the top of the port, quickly tighten the boss plug. Fluid loss of 1 to 2ml is acceptable.

9. Tilt the pump so the uppermost pipe tee (item 52) is in the vertical position. Loosen the pipe plug (item 48). This will allow trapped air to purge through the pipe tee. When fluid appears at the tee opening, reinstall the pipe plug.

NOTE: If all air is not purged using this procedure, remove the check valve components from the top port of the outer chamber (item 14). Apply manual pressure to the pumping diaphragm by inserting a blunt instrument into the top port of the outer chamber and applying pressure to the diaphragm. Loosen the pipe plug (item 48) allowing the fluid to

purge any remaining trapped air.

Reinstall the plug.

10. Repeat steps 5 through 9 to fill

opposite spill prevention chamber.

11. Reinstall the check valve components, discharge manifold and elbows 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 .

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 15

RuppGUARD™ Option for TPE Equipped Pumps Drawing

Note:

All of the diaphragms are to be installed with the concave side facing toward the outer chambers.

*Flat Side of Spill Prevention Chamber (Item 43), to Face Outer Chamber (Item 15).

Discharge

Manifold

ITEM PART NUMBER DESCRIPTION QTY

1 031-146-000 Air Valve Assembly 1

031-147-000 Air Valve Assembly 1

42 170-108-115 Capscrew, Hex HD 1/2-13 x 5.50 16

TPE Equipped Pumps Repair Parts List

(replaces 031-140-000)

(replaces 031-141-000)

170-108-308 Capscrew, Hex HD 1/2-13 x 5.50 16

S15 Spill Prevention for

43 196-149-520* Chamber, Spill Prevention 2

196-149-552* Chamber, Spill Prevention 2

45 518-131-520 Manifold 2

(replaces 170-095-115 Qty 16 of 32)

(replace 518-130-xxx) 518-131-520E Manifold, 40mm DIN 2 518-131-552 Manifold 2

Suction

Manifold

518-131-55E Manifold, 40mm DIN 2

46 538-022-110 Nipple, Pipe 4

538-022-308 Nipple, Pipe 4

(replaces 518-130-xxx)

47 560-078-611 O-Ring 8

48 618-003-110 Plug, Pipe 4

618-003-308 Plug, Pipe 4

49 618-025-110 Plug, Boss 4

618-025-308 Plug, Boss 4

50 618-031-110 Plug, Boss 4

618-031-308 Plug, Boss 4

51 770-052-600 Spacer, Manifold 4

770-052-552 Spacer, Manifold 4

52 835-005-110 Tee, Pipe 4

835-055-308 Tee, Pipe 4

53 860-056-606 Tube, Sight 2 54 866-060-110 Connector, Tube 4 55 286-081-354 Diaphragm, Pumping 2

Note: The diaphragms are to be installed with the concave side facing toward the outer chambers. See drawing.

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 16

RuppGUARD™ FOR TPE EQUIPPED PUMPS CONCEPT

RuppGUARD™ OPTION DIAPHRAGM SER VICING

Next, drain the fluid from the spill prevention chambers. This can be done by removing the bottom plug (item 49) from each spill prevention chamber.

After the fluid from the spill prevention chambers has been drained, the wet end components can now be removed. See diaphragm servicing section for detailed instructions. The spill prevention option has two additional TPE pumping diaphragms (item 55). These diaphragms are installed with the natural concave curve toward the outer chamber (items

14 from the pump assembly drawing). The molded directional arrows on the diaphragms must point vertically.

FILLING RuppGUARD™ CHAMBERS WITH LIQUID

THE CHAMBERS ARE FILLED

WITH WATER AT THE FACTORY.

If you prefer to substitute another liquid, to prevent system contamination consult the factory first to determine compatibility of the substitute with pump construction.

Follow the steps listed here to replace the liquid in the pump after disassembly or liquid loss:

1. Drain the fluid in the spill prevention chambers by removing the bottom two boss plugs (items 49). Replace the bottom two boss plugs after the fluid is drained.

2. Remove the eight capscrews (item

10) fastening the discharge manifold and elbows to the outer chambers (items 14). The discharge manifolds and elbows can now be removed.

3. Remove the top two boss plugs (items 49). The spill prevention chambers are filled through the exposed ports.

5. Face the side of the pump with the installed safety clip. If the safety clip is installed in the top end cap, fill the left spill prevention chamber. If the safety clip is installed on the bottom end cap,

fill the right spill prevention chamber.

6. Loosely reinstall one boss plug (item 49) to the filled spill prevention chamber.

10. Repeat steps 5 through 9 to fill

opposite spill prevention chamber.

11. Reinstall the check valve components, discharge manifold and elbows 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 .

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 17

Air Distribution Valve Assembly Drawing S15 Design Level 2

1-J

1-H

1-D

1-G

1-F

1-E

1-C

1-B

1-G

1-A

1-C

1-E

1-G

Main Air Valve Assembly Parts List

ITEM PART NUMBER DESCRIPTION QTY

1 031-140-000 Main Air Valve Assembly 1 1-A 031-139-000 Spool Assembly 1 1-B 095-094-551 Body, Air Valve 1 1-C 132-029-552 Bumper 2 1-D 165-096-551 Cap, Muffler 1 1-E 165-115-552 Cap, End 2 1-F 530-028-550 Muffler 1 1-G 560-020-360 O-Ring 8 1-H 675-044-115 Ring, Retaining 2 1-J 710-015-115 Screw, Self-tapping 4

For pumps equipped with PTFE Coated Hardware

1 031-140-002 Air Valve Assembly 1

(Includes all items used on 031-155-000 except:) 1-H 675-055-308 Ring, Retaining 2 1- J 710-015-308 Screw Self tapping 4

For pumps equipped with PTFE coated hardware option:

1 031-141-000 Air Valve Assembly 1

(Includes all items used on 031-155-000 minus

items 1-D, 1-F & 1-J)

For pumps with alternate Mesh or Sound Dampening mufflers or piped exhaust:

1 031-156-002 Air Valve Assembly 1

(Includes all items used on 031-156-000 except:) 1-H 675-055-308 Ring, Retaining 2

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 18

AIR DISTRIBUTION VALVE SERVICING

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

STEP #1: See Composite Repair and Parts Drawing.

Using a 5/16" Allen wrench, remove the four hex socket capscrews (item 13) and four flat washers (item 39). Remove the air valve assembly from the pump.

Remove and inspect gasket (item 23) for cracks or damage. Replace gasket if needed.

STEP #2: Disassembly of the air valve.

To access the internal air valve components first remove the two retaining rings (item 1-H) from each end of the air valve assembly using clip ring pliers.

Next remove the two end caps (item 1-E). Inspect the o-rings (item 1-G) for cuts or wear. Replace the o-rings if necessary.

Remove the two bumpers (item 1-C). Inspect the bumpers for cuts, wear or abrasion. Replace if necessary.

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

Inspect the inner diameter of the sleeve (part of item 1-A) for dirt, scratches, or other contaminates. Remove the sleeve if needed and replace both the sleeve and spool with a new sleeve and spool set (item 1-A).

STEP #3: Reassembly of the air valve.

Install one end cap (item 1-E) with an o-ring (item 1-G) and one bumper (item 1-C) into one end of the air valve body (item 1-B). Install one retaining ring (item 1-H) into the groove on the same end.

Remove the new sleeve an spool set (item 1-A) from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings (item 1-G) 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 (item 1-B), 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 it touches the bumper on the opposite end.

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

Fasten the air valve assembly (item

1) and gasket (item 23) to the pump.

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 .

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 19

Air Valve Assembly Drawing with Stroke Indicator Option S15 Design Level 2

Note: Stroke Indicator is standard on RuppGUARD™ Spill Prev ention models

Pilot V alve Assembly Parts List

ITEM PART NUMBER DESCRIPTION QTY

1 031-146-000 Air Valve Assembly 1 1-A 031-143-000 Sleeve and Spool Set w/Pins 1 1-B 095-094-551 Body, Air Valve 1 1-C 132-029-552 Bumper 2 1-D 165-096-551 Cap, Muffler 1 1-E 165-098-147 Cap, End 2 1-F 530-028-550 Muffler 1 1-G 560-020-360 O-Ring 8 1-H 675-044-115 Ring, Retaining 2 1-J 710-015-115 Screw, Self-Tapping 4 1-K 210-008-330 Clip, Safety 1 1-M 560-029-360 O-Ring 2

For Pumps with PTFE Coated Hardware:

1 031-146-002 Air Valve Assembly 1 1-J 710-015-308 Screw, Self Tapping 4

(includes all other items on 031-146-000 above.)

For Pumps with Alternate Mesh, Sound Dampening Mufflers or Piped Exhaust:

1 031-147-000 Air Valve Assembly 1

(includes all items on 031-146-000 minus 1-D, 1-F, &1-J)

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 20

AIR DISTRIBUTION V AL VE WITH STROKE INDICA T OR OPTION SERVICING

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

STEP #1: See Composite Repair and Parts Drawing.

Using a 5/16" Allen wrench, remove the four hex socket capscrews (item 13) and four flat washers (item 39). Remove the air valve assembly from the pump.

Remove and inspect gasket (item 23) for cracks or damage. Replace gasket if needed.

STEP #2: Disassembly of the air valve.

To access the internal air valve components first remove the two retaining rings (item 1-H) from each end of the air valve assembly using clip ring pliers.

Next remove the two end caps (item 1-E). Inspect the o-rings (item 1-G) for cuts or wear. Replace the o-rings if necessary.

Remove the two bumpers (item 1-C). Inspect the bumper for cuts, wear or abrasions. Replace if necessary.

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

STEP #3: Reassembly of the air valve.

Install one bumper (item 1-C) and one end cap (item 1-E) with an o-ring (item 1-G) into one end of the air valve body (item 1-B). Install one retaining ring (item 1-H) into the groove on the same end. Insert the safety clip (item 1-K) through the small unthreaded hole in the end cap.

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

Fasten the air valve assembly (item

1) and gasket (item 23) to the pump.

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 .

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 21

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

56 893-097-000 Solenoid Valve, NEMA4 1 57 219-001-000 Solenoid Coil, 24VDC 1

219-004-000 Solenoid Coil, 24VAC/12VDC 1 219-002-000 Solenoid Coil, 120VA C 1

219-003-000 Solenoid Coil, 240VA C 1 58 241-001-000 Connector, conduit 1 59 170-061-115 Capscrew, Hex HD 3/8-16 x 1.75 4 60 618-052-506 Plug 2

For Explosion Proof Solenoid Valve

(Connector not required for explosion proof coil; coil is integral with valve) 56 893-098-001 Solenoid Valve, NEMA 7/9, 24VDC 1

893-098-002 Solenoid Valve, NEMA 7/9, 24VAC/12VDC 1

893-098-003 Solenoid Valve, NEMA 7/9, 120VAC 1

893-098-004 Solenoid Valve, NEMA 7/9, 220VAC 1

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 22

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).

OPERATION

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 Terminal Neutral (Negative)

3rd Terminal for ground.

#1 Terminal Power (Positive)

BEFORE INST ALLA TION

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

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 23

Pilot V alve Assembly Drawing

Pilot V alve Assembly Parts List

ITEM PART NUMBER DESCRIPTION QTY

2 095-088-000 Pilot Valve Assembly 2-A 095-081-551 Body, Pilot Valve 1 2-B 135-033-506 Bushing 2 2-C 675-055-115 Ring, Spiral Retaining 2 2-D 770-049-175 Spacer 5 2-E 917-001-374 Wiper 6 2-F 775-033-506 Spool, Pilot 1

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 24

PILOT V ALVE SER VICING

To 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-N from Air Distribution Valve assembly drawing) into the smaller unthreaded holes in the end cap (item 1-C from air distribution valve assembly drawing).

one end of the pilot valve body. 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

Connect the air supply to the pump. Remove the safety clip (item 1-N) from the end cap (item 1-C). 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 .

retaining ring using clip ring pilers.

Step #1: See PUMP ASSEMBLY

DRAWING.

Using a 9/16" wrench or socket, remove the four capscrews (items 9) and four flat washers (items 39). Remove the

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.

air inlet cap (item 8) and air inlet gasket (item 20). The pilot valve assembly (item

2) can now be removed for inspection or service.

Step #4: Inspect the actuator plungers.

See PUMP ASSEMBLY DRAWING.

The actuator plungers (items 29) can

Step #2: Disassembly of the pilot

valve.

Remove the pilot valve spool (item 2-F). Wipe clean, and inspect for dirt, scratches or wear. Replace the spool if necessary.

Remove the two retaining rings (items 2-C) from each end of the pilot valve body using clip ring pilers.

Remove the two pilot valve bushings (items 2-B), five spacers (items 2-D),

be reached through the stem cavity of the pilot valve in the intermediate assembly (item 4).

Remove the plungers (items 29) from the bushings (item 7) in each end of the cavity. Inspect the installed o-ring (items

26) for cuts and/or wear. Replace the orings if necessary. 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.

and six spool wipers (items 2-F) by pushing gently from other end of the pilot valve body. Inspect the wipers for cuts and/or wear. Replace any wipers as necessary.

Step #5: Re-install the pilot valve ssembly 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

Step #3: Re-assembly of the pilot

valve.

First install a spiral retaining ring to

the cavity of the intermediate.

Re-install the gasket (item 20), air inlet cap (item 8), capscrews and washers (items 9 and 39).

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 25

Diaphragm Service Drawing,

Non-Overlay

with Overlay

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 26

DIAPHRAGM SERVICING

To 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 9/16" wrench or socket, remove the 16 capscrews (items 10), hex nuts and washers that fasten the elbows (items 19) to the outer chambers (items

14). Remove the elbows with the manifolds and spacers attached.

plate (item 27) by turning counterclockwise. Inspect the diaphragm (item 17) 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. Use a torque wrench to tighten the diaphragm assembly together to 480 in Lbs. (54.23 Newton meters). Allow a minimum of 15 minutes to elapse after torquing, then retorque the assembly to compensate for stress relaxation in the clamped assembly.

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. The molded directional arrows on the diaphragm must point vertically.

Fasten the remaining outer chamber (item 14) to the pump, using the capscrews (items 11), hex nuts and flat washers.

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

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 .

Step #2: Removing the outer

chambers.

Using a 9/16" wrench or socket, remove the 16 capscrews (items 11), hex nuts and washers that fasten the outer chambers, diaphragms, and inner chambers (items 15) together.

Step #3: Removing the diaphragm assemblies.

Use a 13/8" (35mm) 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 1/4-20 capscrew or set screw into the smaller tapped hole in the inner diaphragm plate (item 28). Insert the protruding stud and the 1/4-20 fastener loosely into a vise. Use a 13/8" wrench or socket to remove the outer diaphragm

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 27

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 inner chamber (item 15). Make sure the molded directional arrows on the diaphragm point vertically.

Fasten the outer chamber (item 14) to the pump, using the capscrews (items

11), hex nuts and flat washers.

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.

The pump is now ready to be reinstalled, connected and returned to operation.

OVERLAY DIAPHRAGM SER VICING

The PTFE overlay diaphragm (item

18) is designed to fit snugly over the exterior of the standard TPE diaphragm (item 17).

The molded directional arrows on the overlay diaphragm must point vertically.

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

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 1" (2.54 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 EXHA UST ILLUSTRATION

PUMP INSTALLATION AREA

1" DIAMETER AIR

EXHAUST PIPING

Illustration #1

LIQUID LEVEL

SUCTION

LINE

SAFE AIR EXHAUST DISPOSAL AREA

MUFFLER

1" DIAMETER AIR 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 #8 Torx or flat screwdriver to

MUFFLER

remove the six self-tapping screws (item 1-L).

Remove the muffler cap and muffler (items 1-E and 1-G). The 1" NPT molded

LIQUID LEVEL

1" DIAMETER AIR EXHAUST PIPING

threads in the air distribution valve body (item 1-B).

Piping or hose may now be installed.

Illustration #3

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 28

SUCTION

LINE

MODULAR CHECK VALVE 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.

To access the modular check valve, remove the elbows (items 19 from pump composite repair parts drawing). Use a

/16" 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 30) for cuts, abrasive wear, or embedded materials. Replace as needed.

Inspect the check balls (items 3) for wear, abrasion, or cuts on the spherical surface. The check valve seats (items

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

Re-assemble the modular check valve. The seat should fit snugly into the retainer.

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 seal faces the chamfer on the check valve seat or retainer.

The pump can now reassembled, reconnected and returned to operation.

Modular Check Valve Drawing

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 29

Dual P ort Option Drawing

1½" ANSI STYLE FLANGE CONNECTION FOUR ø.62 HOLES ON A ø3.88 BOLT CIRCLE

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 30

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 19) are designed to mate with standard 125# ANSI style 4-bolt, 1½" pipe flanges.

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, spacers, and manifolds (items 35, 37, and 24 from pump assembly drawing) from the pump.

The discharge and suction elbows can be rotated at 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, spacers, 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, spacers, 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 .

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 31

RuppTech® Leak Detection Options Drawing

For pumps with 530-028-550 ENCLOSED MUFFLER

ALTERNATE MUFFLERS

MUFFLER CAP

For pumps with

710-009-115 Self-tapping Screws (Qty of 4)

612-185-552 Mounting Plate

RuppTech® LEAK DETECTION OPTION A (ELECTRONIC)

Follow instructions found elsewhere in this manual, Filling the RuppGUARD Spill Prevention Chambers when installing leak detectors.

RuppTech

ELECTRONIC LEAK DETECTOR INSTALLATION

Kit 032-037-000 100VAC 50Hz

or 110-120VAC 50/60Hz

or 220-240VAC 50/60Hz Kit 032-045-000 12-32VDC To install electronic leak detectors, remove the bottom ¼" NPT

pipe plug on the visual sight tube (item 53). Insert leak detector into the ¼" pipe tee (item 52).

RuppTech® LEAK DETECTION OPTION B (MECHANICAL)

Follow instructions found elsewhere in this manual, Filling the

RuppGUARD Spill Prevention Chambers when installing leak detectors.

RuppTech

MECHANICAL LEAK DETECTOR INSTALLATION

Kit 031-023-110 To install mechanical leak detectors, remove the bottom ¼" NPT

pipe plug on the visual sight tube (item 53). Insert leak detector into the ¼" pipe tee (item 52).

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 32

RuppTech® 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

520-193-000 9/02 Model S15 Non-Metallic Design Level 2 Page 33

SANDPIPER S15 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual