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SET1
User Manual
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SANDPIPER SET1 User Manual

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SERVICE AND OPERATING MANUAL
Original Instructions
Model SET1
Sanitary Type 3
Table of Contents
Engineering Data, Temperature Limitations, & Performance Curve ...................... 1
Explanation of Pump Nomenclature ...................................................................... 1
Installation and Start-Up ........................................................................................ 3
Air Supply .............................................................................................................. 4
ESADS+Plus
®
:
Externally Serviceable Air Distribution System ................................ 4
Air Exhaust
Warranty ................................................................................................................ 7
Composite Repair Parts List ........................................................................... 10-11
................................................................................................................ 5
Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA • Telephone (419) 524-8388 • Fax (419) 522-7867 • warrenrupp.com
set1dl3sm-rev0611 ©Copyright 2014 IDEX AODD, Inc. All rights reserved.
Quality System
ISO9001 Certified
Environmental
Management System
ISO14001 Certified
MODEL SET1-A
SUCTION/DISCHARGE PIPE SIZE
1½" Sanitary Clamp Fittings
MODEL SET2-A
SUCTION PIPE SIZE
2½" Sanitary Clamp Fittings
DISCHARGE PIPE SIZE
2" Sanitary Clamp Fittings
SET1-A SET2-A BALL VALVE Type 3
Air-Powered Double Diaphragm Sanitary Containment Pumps
ENGINEERING, PERFORMANCE
Pump shown with optional electronic leak detector.
CAPACITY AIR VALVE SOLIDS-HANDLING HEADS UP TO
0 to 52 gallons per minute
(0 to 196 liters per minute)
CAPACITY AIR VALVE SOLIDS-HANDLING HEADS UP TO
0 to 128 gallons per minute
(0 to 484 liters per minute)
No-lube, no-stall
design
No-lube, no-stall
design
¼ in.
¼ in.
(6 mm)
(6 mm)
PERFORMANCE CURVES
(SANDPIPER® pumps are designed to be powered only by compressed air)
Temperature Limit: 212°F -
100°C MAXIMUM
& CONSTRUCTION DATA
125 psi or 289 ft. of water (8.8 Kg/cm
125 psi or 289 ft. of water (8.8 Kg/cm
2
or 88 meters)
2
or 88 meters)
DISPLACEMENT/STROKE
.09 .34
.36 Gallon / 1.36 liter
DISPLACEMENT/STROKE
.36 Gallon / 1.36 liter
SANDPIPER® Model SET1-A
Performance based on water at ambient temperature.Average displacement per pump stroke: .36 gallon (1.36 liters)
Air consumption in SCFM
SANDPIPER® Model SET1-A
Performance based on water at ambient temperature.Average displacement per pump stroke: .09 gallon (.34 liters)
Air consumption in SCFM
MATERIALS OF CONSTRUCTION
Outer Inner
SET1-A Driver Manifold/ Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard- Driver Valve Manifold Cap/ Weight
TGF-3-SS T 302/304SS 316SS
SET2-A
TGF-3-SS T 302/304SS 316SS
Chamber Elbow Chamber Chamber Plate Plate Housing Rod Seat ware Diaphragm Material Gasket Air Valve (lbs)
AL380DC 316SS
*
AL380DC 316SS
*
= Electropolished PS = Plated Steel
*
Meanings of Abbreviations:
= Electroless Nickel Plated T = PTFE AL = Aluminum SS = Stainless Steel DC = Die Cast WN= White Nitrile - Food Grade PP = Polypropylene - Glass Filled
Driver Driver Ball Seat/ Shipping
PS AL380DC 416SS T 304SS T/WN T T AL380DC 65
*
PS AL356T6 416SS T 304SS T/WN T T NONE 185
*
NITRILE TEMPERATURE LIMITATIONS: 190
®Warren Rupp and SANDPIPER are registered tradenames of Warren Rupp, Inc.
Pumping Diaphragm
o
F (88oC) for Continuous Operation
o
280
F (138oC) for Intermittent Operation
set1dl3sm-rev0614 Model SET1 Type 3 Page 1
SET1-A SET2-A SANITARY CONTAINMENT
©Copyright 2006 Warren Rupp, Inc. All rights reserved. ®Warren Rupp and SANDPIPER are registered tradename of Warren Rupp, Inc.
Model SET1 Type 3 Page 2 set1dl3sm-rev0614
SERVICE AND OPERATING MANUAL
PRINCIPLE OF OPERATION
This ball check valve pump is powered by compressed air and is a 1:1
pressure ratio design. It alternately pressurizes the inner side of one diaphragm
chamber, while simultaneously exhausting the other inner chamber. This causes the diaphragms, which are connected by a common rod, to move endwise. Air pressure is applied over the entire surface of the diaphragm, while liquid is discharged from the opposite side. The diaphragm operates under a balanced condition during the discharge stroke, which allows the unit to be operated at discharge heads over 200 feet (61 meters) of water head.
Since the diaphragms are connected by a common rod, secured by plates to the center of the diaphragms, one diaphragm performs the discharge stroke, while the other is pulled to perform the suction stroke in the opposite chamber.
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. This will maximize diaphragm life.
Alternate pressuring and exhausting of the diaphragm chamber is performed by means of an externally mounted, pilot operated, four-way spool type air distribution valve. When the spool shifts to one end of the valve body, inlet air 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 porting of chambers is reversed. The air distribution valve spool is moved by an internal pilot valve which alternately pressurizes one side of the air distribution valve spool, while exhausting the other side. The pilot valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in contact with the end of the pilot valve spool. This pushes it into position for shifting of the air distribution valve.
The chambers are manifolded together with a suction and discharge check valve for each chamber, maintaining ow in one direction through the pump.
This SandPIPER pump differs from others in that it utilizes four diaphragms instead of two. The two rod-connected diaphragms are the driver diaphragms, and the other two (outermost) diaphragms are the actual pumping diaphragms. Each driver diaphragm (of Neoprene or other elastomer), and the pumping diaphragm (of TFE), are separated by a chamber lled with liquid which transmits the reciprocating motion of the driver diaphragm to the pumping diaphragm. The
pumping diaphragms, create the alternating suction and discharge action to each
outer diaphragm chamber. The pumping diaphragms are the only ones in contact with the liquid being pumped.
Original Instructions
Model SET1
Sanitary Type 3
INSTALLATION & START-UP
Locate the pump as close to the product being pumped as possible, keeping suction line length and number of ttings to a minimum. Do not reduce line size.
For installations of rigid piping, short exible sections of hose should be installed between pump and piping. This reduces vibration and strain to the piping system. A Warren Rupp Tranquilizer pulsation in ow.
This pump was tested at the factory prior to shipment and is ready for operation. It is completely self-priming from a dry start for suction lifts of 10-15 feet (9-14 meters) or less. For suction lifts exceeding 15 feet of liquid, ll the chambers with liquid prior to priming.
®
surge suppressor is recommended to further reduce
set1dl3sm-rev0614 Model SET1 Type 3 Page 3
AIR SUPPLY
Air supply pressures cannot exceed 125 psi (8.61 bar). Connect the pump air inlet (see Fig. 1) to an air supply of sufcient capacity and pressure required for desired performance. When the air line is solid piping, use a short length of exible hose (not less than ¾" [19mm] in diameter) between pump and piping to eliminate strain to pipes.
AIR INLET & PRIMING
For start-up, open an air valve approximately ½ to ¾ turn. After the unit primes, an air valve can be opened to increase ow as desired. If opening the valve increases cycling rate, but does not increase ow rate, cavitation has occurred, and the valve should be
closed slightly.
For the most efcient use of compressed air and the longest diaphragm life, throttle the air inlet to the lowest cycling rate that does not reduce ow.
A NOTE ABOUT AIR VALVE LUBRICATION
The SandPIPER pump’s pilot valve and main air valve assemblies 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 supplies. Proper lubrication of the compressed air supply would entail the use of an air line lubricator (available from Warren Rupp) set to deliver one drop of 10 wt., non-detergent oil for every 20 SCFM of air the pump consumed at its point of operation. Consult the pump’s published Performance Curve to determine this.
It is important to remember to inspect the sleeve and spool set routinely. It should move back and forth freely. This is most important when the air supply is lubricated. If a lubricator is used, oil accumulation will, over time, collect any debris from the compressed air. This can prevent the pump from operating properly.
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. This can be addressed by using a point of use air dryer (available from Warren Rupp) to supplement a plant’s air drying equipment. This device will remove excess water from the compressed air supply and alleviate the icing or freezing problem.
ESADS: EXTERNALLY SERVICEABLE AIR DISTRIBUTION SYSTEM
Please refer to the exploded view drawing and parts list in the Service Manual supplied with your pump. If you need replacement or additional copies, contact your local Warren Rupp Distributor, or the Warren Rupp factory Literature Department at the number shown below. To receive the correct manual, you must specify the MODEL and
TYPE information found on the name plate of the pump.
MODELS WITH 1" SUCTION/DISCHARGE OR LARGER, AND NON-METAL CENTER SECTIONS
The main air valve sleeve and spool set is located in the valve body mounted on the pump with four hex head capscrews. The valve body assembly is removed from the pump by removing these four hex head capscrews.
With the valve body assembly off the pump, access to the sleeve and spool set is made by removing a retaining ring (each end) securing the end cap on the valve body assembly. With the end caps removed, slide the spool back and forth in the sleeve. The spool is closely sized to the sleeve and must move freely to allow for proper pump
operation. An accumulation of oil, dirt or other contaminants from the pump’s air
supply, or from a failed diaphragm, may prevent the spool from moving freely. This can
cause the spool to stick in a position that prevents the pump from operating. If this is
the case, the sleeve and spool set should be removed from the valve body for cleaning
and further inspection.
Remove the spool from the sleeve. Using an arbor press or bench vise (with an improvised mandrel), press the sleeve from the valve body. Take care not to damage the sleeve. At this point, inspect the o-rings on the sleeve for nicks, tears or abrasions. Damage of this sort could happen during assembly or servicing. A sheared or cut o-ring can allow the pump’s compressed air supply to leak or bypass within the air valve assembly, causing the pump to leak compressed air from the pump air exhaust or not cycle properly. This is most noticeable at pump dead head or high discharge pressure conditions. Replace any of these o-rings as required or set up a routine,
Model SET1 Type 3 Page 4 set1dl3sm-rev0614
preventive maintenance schedule to do so on a regular basis. This practice should include cleaning the spool and sleeve components with a safety solvent or equivalent, inspecting for signs of wear or damage, and replacing worn components.
To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve with an o-ring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant). Press the set into the valve body easily, without shearing the o-rings. Re-install one end cap, and retaining ring on the valve body. Using the arbor press or bench vise that was used in disassembly, press the sleeve back into the valve body. Re-install the spool, keeping the counter-bored end toward you, and install the spring, opposite end cap and retaining ring on the valve body. After inspecting and cleaning the gasket surfaces on the valve body and intermediate, re-install the valve body on the pump using new gaskets. Tighten the four hex head capscrews evenly and in an alternating cross pattern, at 150 in./lbs.
(16.94 Newton meters).
AIR EXHAUST
If a diaphragm fails, the pumped liquid or fumes can enter the air end of the pump, and be exhausted into the atmosphere. When pumping hazardous or toxic materials, pipe the exhaust to an appropriate area for safe disposition.
This pump can be submerged if materials of construction are compatible with the liquid. The air exhaust must be piped above the liquid level. Piping used for the air exhaust must not be smaller than 1" (2.54 cm). Reducing the pipe size will restrict air ow and reduce pump performance. When the product source is at a higher level than the pump (ooded suction), pipe the exhaust higher than the product source to prevent
siphoning spills.
Freezing or icing of the air exhaust can occur under certain temperature and humidity conditions. Use of a Warren Rupp Extractor/Dryer unit should eliminate most icing problems. Check the exhaust periodically for build-up of ice or contaminants (see Fig. 2).
BETWEEN USES
When used for materials that tend to settle out or transform to solid form, the pump
should be completely ushed after each use, to prevent damage. Product remaining in the pump between uses could dry out or settle out. This could cause problems with valves and diaphragms at re-start. In freezing temperatures, the pump must be drained between uses in all cases.
FILLING OF DRIVER CHAMBER WITH LIQUID
The driver chambers are lled at the factory with water.
If you need to substitute another liquid to prevent system contamination, rst consult the factory for chemical compatibility with pump construction.
Follow the steps listed below to replace the liquid in the pump after disassembly or liquid loss:
1. Filling is accomplished through the pipe plugs at the top of the liquid driver
chamber (see Fig. 3).
2. After the driver uid has been emptied from the pump, the driver diaphragms will
naturally come to center.
3. Remove the entire discharge manifold assembly exposing the ports in the outer
diaphragm chambers.
4. Fill either side with 600 ml. (20.3 . oz.) by volume with the driver liquid. It is imperative that the driver liquid chambers be lled with the correct amount of driver liquid as too little or too much will cause premature diaphragm failure and erratic pumping.
5. After lling with the proper amount of liquid, if the liquid does not come to the top of the ll hole, pressure should be applied to the Virgin PTFE diaphragm with a blunt tool through the discharge material ow port in the outer chamber until it does come to the top (see Fig. 4). To facilitate this lling, a taper punch can be used in the hole of the
rod to manually shift the pump.
6. When the driver uid rises to the top of the ll plug hole, screw the boss plug, with o-ring installed, into the chamber (see Fig. 5). (Do not overtighten.) Remember to keep pressure on the Virgin PTFE diaphragm until the boss plug is tight to prevent air from drawing back into the chamber.
7. Filling the opposite side is accomplished in the same manner as described in 5 and 6. The correct amount of uid will come to the top of the ll hole. Screw in the boss plug.
set1dl3sm-rev0614 Model SET1 Type 3 Page 5
CHECK VALVE SERVICING
Need for inspection or service is usually indicated by poor priming, unstable cycling,
reduced performance or the pump’s cycling but not pumping.
Remove the six ange bolts securing the inlet and outlet anges to the manifold. Inspect the surfaces of both check valve and seat for wear or damage that could prevent proper sealing. If pump is to prime properly, valves must seat air tight (see Fig. 6).
DIAPHRAGM SERVICING
Driver Diaphragms:
Drain the driver diaphragm chamber by removing the boss plug on the underside of the driver chamber. NOTE: This is also the part used for leak detector probes. Remove twelve bolts securing the two manifolds to the chambers. Remove eight bolts securing the diaphragm chamber. This permits inspection of the TFE diaphragm and the driver diaphragm. Loosen the plate which secures the diaphragm and plate to the rod by keeping the diaphragm engaged with the inner diaphragm chamber. Insert two or three capscrews through the bolt holes so the diaphragm cannot rotate when loosening. The diaphragm plates, diaphragm and bumper will now come off the assembly. Repeat all actions if the other diaphragm needs to be inspected or replaced.
NOTE: See “Filling of Driver Chamber with Liquid” for the correct procedure to recharge the pump for operation.
Reassembly is the reverse of the tear down. During reassembly, be sure the rubber bumper is on the rod on each side. Install the diaphragm with the natural bulge to the
outside as marked on the diaphragm. Be sure that the large radius side of each plate
is toward the diaphragm. Place the sealing washer between the inner diaphragm plate and the end of the rod. Tighten the plate to approximately 25 ft. lbs. (3.456 pounds/sq. cm.). Torque while allowing the diaphragm to turn freely with the plate. Hold the opposite side with a wrench on the plate to prevent rotation of the rod. If the opposite chamber is assembled, this will not be necessary.
When reassembling the outer chambers and the manifold, the bolts securing the manifold ange to the chamber should be snugged prior to tightening the manifold ange. Finish tightening the manifold ange bolts after the chamber bolting is secured.
PILOT VALVE
The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing (see Fig. 9).
Most problems with the pilot valve can be corrected by replacing the o-rings. Always
grease the spool prior to inserting it into the sleeve. If the sleeve is removed from
the body, reinsertion must be at the chamfered side. Grease the o-rings to slide the sleeve into the valve body. Securely insert the retaining ring around the sleeve. When reinserting the pilot valve, push both plungers (located inside the intermediate bracket)
out of the path of the pilot valve spool ends to avoid damage.
PILOT VALVE ACTUATOR
Bushings for the pilot valve actuators are held in the inner chambers with retaining rings. An o-ring is behind each bushing. If the plunger has any sideways motion check o-rings and bushings for deterioration or wear. The plunger may be removed for inspection or replacement. First remove the air distribution valve body and the pilot valve body from the pump. The plungers can be located by looking into the intermediate. It may be necessary to use a ne piece of wire to pull them out. The bushing can be turned out through the inner chamber by removing the outer chamber assembly. Replace the bushings if pins have bent (see Fig. 10 and Fig. 11).
Model SET1 Type 3 Page 6 set1dl3sm-rev0614
SERVICE INSTRUCTIONS: TROUBLE SHOOTING
1. Pump will not cycle
A. Check to make sure the unit has enough pressure to operate and that the air inlet valve is open.
B. Check the discharge line to insure that the discharge line is neither closed nor blocked. C. If the spool in the air distribution valve is not shifting, check the main spool. It must
slide freely. D. Excessive air leakage in the pump can prevent cycling. This condition will be evident. Air leakage into the discharge line indicates a ruptured diaphragm. Air leakage from the exhaust port indicates leakage in the air distribution valve. See further service instructions.
E. Blockage in the liquid chamber can impede movement of diaphragm.
2. Pump cycles but will not pump
A. Suction side of pump pulling in air. Check the suction line for air leaks and be sure that the end of the suction line is submerged. Check ange bolting. Check valve anges and manifold to chamber ange joints.
B. Make certain the suction line or strainer is not plugged. Restriction at the suction is
indicated by a high vacuum reading when a vacuum gauge is installed in the suction line. C. Check valves may not be seating properly. To check, remove the suction line and cover the suction port with your hand. If the unit does not pull a good suction (vacuum), the check valves should be inspected for proper seating. D. Static suction lift may be too high. Priming can be improved by elevating the suction and discharge lines higher than the check valves and pouring liquid into the unit through the suction inlet. When priming at high suction lifts or with long suction lines operate the pump at maximum cycle rate. E. Incorrect driver uid level or air has not been properly purged.
3. Low performance
A. Capacity is reduced as the discharge pressure increases, as indicated on the
performance curve. Performance capability varies with available inlet air supply. Check air pressure at the pump inlet when the pump is operating to make certain that adequate
air supply is maintained. B. Check vacuum at the pump suction. Capacity is reduced as vacuum increases.
Reduced ow rate due to starved suction will be evident when cycle rate can be varied without change in capacity. This condition will be more prevalent when pumping viscous liquids. When pumping thick, heavy materials the suction line must be kept as large in diameter and as short as possible, to keep suction loss minimal. C. Low ow rate and slow cycling rate indicate restricted ow through the discharge line. Low ow rate and fast cycling rate indicate restriction in the suction line or air leakage
into suction.
D. Unstable cycling indicates improper check valve seating on one chamber. This condition is conrmed when unstable cycling repeats consistently on alternate exhausts. Cycling that is not consistently unstable may indicate partial exhaust restriction due to freezing and thawing of exhaust air. Use of an anti-freeze lubricant in an air line lubricator should solve this problem. E. Incorrect driver uid level or air has not been properly purged. For additional information, see the Warren Rupp Trouble Shooting Guide.
WARRANTY
This pump is warranted for a period of ve years against defective material and workmanship. Failure to comply with the recommendations stated in this manual voids all factory warranty.
set1dl3sm-rev0614 Model SET1 Type 3 Page 7
IMPORTANT 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.
CAUTION
Pump not designed,
tested or certied to be
powered by compressed natural gas. Powering the pump with natural
gas will void the warranty.
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If pumping a product which is hazardous or toxic, the air exhaust must be piped to an appropriate area for safe disposition.
WARNING
Take action to prevent static sparking. Fire or explosion can result, especially when
handling ammable liquids.
The pump, piping, valves, containers or other miscellaneous equipment must be grounded. (See page 32)
WARNING
This pump is pressurized
internally with air pressure
during operation. Always
make certain that all bolting
is in good condition and
that all of the correct
bolting is reinstalled during assembly.
WARNING
When used for toxic or
aggressive uids, the pump
should always be ushed
clean prior to disassembly.
WARNING
Before doing any
maintenance on the pump,
be certain all pressure is
completely vented from the
pump, suction, discharge,
piping, and all other openings and connections. Be certain the air supply is locked out or made non-operational, so that it cannot be started while work is being done on the pump. Be certain that approved eye protection and protective clothing are worn all times in the vicinity of the pump. Failure to follow these recommendations may result in serious injury or death.
WARNING
Airborne particles and
loud noise hazards.
Wear ear and eye
protection.
WARNING
Before maintenance or repair, shut off the compressed air line, bleed the pressure, and
disconnect the air line from the pump. The discharge line may be pressurized and must be bled of its pressure.
kg
WARNING
Use safe practices when lifting
RECYCLING
Many components of SANDPIPER® AODD pumps are made of recyclable materials (see chart on page 9 for material specications). We encourage pump users to recycle worn out parts and pumps whenever possible, after any hazardous pumped uids are thoroughly ushed.
Model SET1 Type 3 Page 8 set1dl3sm-rev0614
MATERIAL CODES
THE LAST 3 DIGITS OF PART NUMBER
000 Assembly, sub-assembly;
and some purchased items 010 Cast Iron 012 Powered Metal 015 Ductile Iron 020 Ferritic Malleable Iron 025 Music Wire 080 Carbon Steel, AISI B-1112 100 Alloy 20 110 Alloy Type 316 Stainless Steel 111 Alloy Type 316 Stainless Steel
(Electro Polished) 112 Alloy C 113 Alloy Type 316 Stainless Steel
(Hand Polished) 114 303 Stainless Steel 115 302/304 Stainless Steel 117 440-C Stainless Steel (Martensitic) 120 416 Stainless Steel
(Wrought Martensitic) 123 410 Stainless Steel
(Wrought Martensitic) 148 Hardcoat Anodized Aluminum 149 2024-T4 Aluminum 150 6061-T6 Aluminum 151 6063-T6 Aluminum 152 2024-T4 Aluminum (2023-T351) 154 Almag 35 Aluminum 155 356-T6 Aluminum 156 356-T6 Aluminum 157 Die Cast Aluminum Alloy #380 158 Aluminum Alloy SR-319 159 Anodized Aluminum 162 Brass, Yellow, Screw Machine Stock 165 Cast Bronze, 85-5-5-5 166 Bronze, SAE 660 170 Bronze, Bearing Type, Oil Impregnated 175 Die Cast Zinc 180 Copper Alloy 305 Carbon Steel, Black Epoxy Coated 306 Carbon Steel, Black PTFE Coated 307 Aluminum, Black Epoxy Coated 308 Stainless Steel, Black PTFE Coated 309 Aluminum, Black PTFE Coated 310 PVDF Coated 313 Aluminum, White Epoxy Coated 330 Zinc Plated Steel 331 Chrome Plated Steel 332 Aluminum, Electroless Nickel Plated 333 Carbon Steel, Electroless
Nickel Plated 335 Galvanized Steel 336 Zinc Plated Yellow Brass 337 Silver Plated Steel 340 Nickel Plated 342 Filled Nylon 351 Food Grade Santoprene; Color: NATURAL
353 Geolast; Color: BLACK 354 Injection Molded #203-40
Santoprene- Duro 40D +/-5; Color: RED 355 Thermal Plastic 356 Hytrel; Color: BLUE 357 Injection Molded Polyurethane;
Color: GREEN 358 Urethane Rubber; Color: NATURAL
(Some Applications)
(Compression Mold) 359 Urethane Rubber; Color: NATURAL 360 Nitrile Rubber; Color Coded: RED 361 Nitrile 363 FKM (Fluorocarbon).
Color Coded: YELLOW 364 E.P.D.M. Rubber. Color Coded: BLUE 365 Neoprene Rubber;
Color Coded: GREEN 366 Food Grade Nitrile; Color: WHITE 368 Food Grade EPDM; Color: GRAY 370 Butyl Rubber
Color Coded: BROWN 371 Philthane (Tuftane) 374 Carboxylated Nitrile 375 Fluorinated Nitrile 378 High Density Polypropylene 379 Conductive Nitrile;
Color Coded: RED & SILVER 384 Conductive Neoprene;
Color Coded: GREEN & SILVER 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; Color: BLACK 503 Conductive Acetal, Glass-Filled Color: BLACK; Color Coded: YELLOW 505 Acrylic Resin Plastic 506 Delrin 150 520 Injection Molded PVDF; Color: NATURAL 521 Injection Molded Conductive PVDF;
Color: BLACK; Color Coded: LIGHT
GREEN 540 Nylon 541 Nylon 542 Nylon 544 Nylon Injection Molded 550 Polyethylene 551 Glass Filled Polypropylene; Color: BLACK 552 UnlledPolypropylene;Color:NATURAL 555 Polyvinyl Chloride 556 Black Vinyl
557 Conductive Polypropylene;
Color: BLACK; Color Coded: SILVER 558 Conductive HDPE; Color: BLACK Color Coded: SILVER 559 Conductive Polypropylene; Color: BLACK Color Coded: SILVER 570 Rulon II 580 Ryton 590 Valox 591 Nylatron G-S 592 Nylatron NSB 600 PTFE (virgin material)
Tetrauorocarbon(TFE) 601 PTFE(Bronzeandmolylled)
602 Filled PTFE 603 Blue Gylon 604 PTFE 606 PTFE 607 Envelon 608 Conductive PTFE; Color: BLACK 610 PTFE Encapsulated Silicon 611 PTFE Encapsulated FKM 632 Neoprene/Hytrel 633 FKM/PTFE 634 EPDM/PTFE 635 Neoprene/PTFE 637 PTFE , FKM/PTFE 638 PTFE , Hytrel/PTFE 639 Nitrile/TFE 643 Santoprene®/EPDM 644 Santoprene®/PTFE 656 Santoprene Diaphragm and
Check Balls/EPDM Seats 661 EPDM/Santoprene 666 FDA Nitrile Diaphragm,
PTFE Overlay, Balls, and Seals 668 PTFE, FDA Santoprene/PTFE
Delrin is a registered tradename of E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of Polymer Corp.
Santoprene is a registered tradename of Exxon Mobil Corp.
Rulon II is a registered tradename of Dixion Industries Corp.
Ryton is a registered tradename of Phillips Chemical Co.
Valox is a registered tradename of General Electric Co.
PortaPump, Tranquilizer and SludgeMaster are registered tradenames of Warren Rupp, Inc.
set1dl3sm-rev0614 Model SET1 Type 3 Page 9
ITEM TOTAL NO. PART NUMBER DESCRIPTION RQD.
1 095-051-558 Body, Spool Valve 1 2 031-039-000 Sleeve & Spool Set 1 3 560-058-360 O-Ring 8 4 165-038-558 Cap, End 2 5 675-043-115 Ring, Retaining 2 6 165-042-332 Cap, Valve Body 1 7 360-056-360 Gasket 1 8 360-057-360 Gasket 1 9 360-058-360 Gasket 1 10 095-074-001 Pilot Valve Body Assembly* 1 10-A 095-071-557 Pilot Valve Body 1 10-B 755-025-000 Sleeve (with O-Ring) 1 10-C 560-033-360 O-Ring (Sleeve) 4 10-D 775-014-000 Spool (with O-Ring) 1 10-E 560-023-360 O-Ring (Spool) 4 10-F 675-037-080 Retaining Ring 1 11 170-063-115 Capscrew, Hex Head 1
12 901-035-115 Washer, Flat 7 13 542-001-115 Nut, Square 1 14 170-033-115 Capscrew, Hex Head 4 15 901-005-115 Washer, Flat 4 16 170-043-115 Capscrew, Hex Head 6 17 114-011-332 Bracket, Intermediate 1 18 196-066-332 Chamber, Inner 1 19 196-064-332 Chamber, Inner 1
20 560-040-360 O-Ring 2 21 560-001-360 O-Ring 2 22 135-013-162 Bushing 2 23 675-042-115 Ring, Retainer 2 24 620-007-114 Plunger, Actuator 2 25 132-022-360 Bumper 2 26 070-012-170 Bearing, Sleeve 2 27 720-010-375 Seal, U-Cup 2 28 196-065-111 Chamber, Outer 2 29 901-012-180 Washer, Sealing 2 30 115-078-115 Bracket, Foot 1 31 675-040-360 Ring, Sealing 2 32 685-039-120 Rod, Diaphragm 1 33 132-019-360 Bumper 2 34 612-101-111 Plate, Outer Diaphragm 2
35 612-022-330 Plate, Inner Diaphragm 2
36 286-008-366 Diaphragm 2 286-008-368 Diaphragm 2 37 722-045-600 Seat, Valve 4 38 050-024-600 Ball, Check Valve 4 39 518-077-110 Manifold, Suction 1
REPAIR PARTS LIST AND DRAWING
Original Instructions
Model SET1
Sanitary Type 3
Model SET1 Type 3 Page 10 set1dl3sm-rev0614
ITEM TOTAL NO. PART NO. DESCRIPTION RQD.
40 518-076-110 Manifold, Discharge 1 41 312-052-111 Elbow, Suction 2 42 312-051-111 Elbow, Discharge 2
43 361-005-600 Gasket Seal, Suction 2 44 361-006-600 Gasket Seal, Discharge 2
45 200-032-115 Clamp, Suction 2 46 200-033-115 Clamp, Discharge 2 47 542-002-114 Stud Nut 4 48 542-011-000 Stud Nut Assembly 16 49 542-004-000 Stud Nut Assembly 12 50 170-044-115 Capscrew, Hex Head 4 51 900-004-115 Washer, Lock 4 52 545-004-115 Hex Nut 4 53 618-003-110 Pipe Plug 1 54 312-044-555 45° Elbow 1 55 538-025-555 Nipple, Pipe 1 56 530-018-000 Mufer, Exhaust 1 57 780-027-025 Spring 1 58 807-048-115 Stud 2
59 286-040-604 Diaphragm 2
60 196-077-600 Chamber, Driver 2 61 618-025-110 Boss Plug 4 61-A 560-078-611 O-Ring 4
Not Shown: 031-030-000 Valve Body Assembly 1 Includes Items 1,2,3,4,5, & 57 535-015-000 Name Plate 1 705-002-000 Screw, Drive 4
Repair Parts shown in bold face
(darker) type are more likely to need
replacement after extended periods of normal use. The pump owner may
prefer to maintain a limited inventory of
these parts in his own stock to reduce repair downtime to a minimum.
IMPORTANT: When ordering repair parts
always furnish pump model number, serial number and type number.
* Available only in kit form. Order 031-060-000 which includes Items 7, 8, 9, 24 and 25.
set1dl3sm-rev0614 Model SET1 Type 3 Page 11
SPHERICAL END TOWARDS CLAMP
NOTE: When electronic leak detector is used with this model pump, the probes
must be tted into special
boss plugs, to replace item 61, bottom. Order one kit 475-098-000 for each pump.
61-A
This equipment has FDA-Approved Mate­rials of Construction and is
USDA acceptable for use in federally
inspected meat and poultry plants.
61-A
SPHERICAL END TOWARDS CLAMP
Model SET1 Type 3 Page 12 set1dl3sm-rev0614
Declaration of Conformity
Manufacturer:
Warren Rupp, Inc.
Mansfield, Ohio, 44902 USA
certifies that Air-Operated Double Diaphragm Pump Series: HDB, HDF,
M Non-Metallic, S Non-Metallic, M Metallic, S Metallic, T Series, G Series, RS Series
U Series, EH and SH High Pressure, W Series, SMA and SPA Submersibles,
and Tranquilizer Surge Suppressors comply with the European Community
Directive 2006/42/EC on Machinery, according to Annex VIII. This product
has used Harmonized Standard EN809:1998+A1:2009, Pumps and Pump Units
for Liquids - Common Safety Requirements, to verify conformance.
Signature of authorized person
David Roseberry Printed name of authorized person
Revision Level: F
®
, 800 N. Main Street
October 20, 2005 Date of issue
Engineering Manager Title
April 19, 2012 Date of revision
set1dl3sm-rev0614 Model SET1 Type 3 Page 13
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