SANDPIPER SET2-A User Manual

SERVICE AND OPERATING MANUAL

Model SET2-A

Sanitary Type 3

PLEASE NOTE!

The photos shown in this manual are for general instruction only. Your specic model may
not be shown. Always refer to the parts list and exploded view drawing for your specic
model when installing, disassembling or servicing your pump.

PRINCIPLE OF OPERATION

All SandPIPER pumps, including this Spill Containment model, operate on the same basic
principle. They are powered by compressed air which alternately pressurizes the inner
sides of the two diaphragm chambers while simultaneously exhausting the opposite inner
chambers causing the diaphragms, which are connected by a shaft, to move endwise.
Since air pressure is applied over the entire surface of the diaphragm which is forcing
liquid to be discharged by its other side, the diaphragm is operating under a balanced
condition during the discharge stroke. This allows the unit to be operated at discharge
heads over 200 feet (61 meters) of water head.
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 is at one end of the valve body, inlet air pressure is connected to one diaphragm
chamber and the other diaphragm chamber is connected to the exhaust. When the spool
is removed to the opposite end of the valve body, the porting of chambers is reversed.
The air distribution valve spool is moved from one end position to the other in the valve
body by means of an internal pilot valve which alternately pressurizes the ends of the air
distribution valve spool while simultaneously exhausting the other ends. The pilot valve is
positively shifted at each end of the diaphragm stroke by the diaphragm plate’s coming in
contact with the end of the pilot valve spool and pushing 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 to maintain ow in one direction through the pump.
This SandPIPER pump differs from others only in that it utilizes four diaphragms instead
of two, the two rod-connected diaphragms being the driver diaphragms, and the other two
(outermost) diaphragms being the actual pumping diaphragms. Each driver diaphragm
(of Neoprene or other elastomer), and the pumping diaphragm (of Teon), are separated
by a chamber lled with liquid which transmits the reciprocating motion of the driver
diaphragm to the pumping diaphragm. The Teon pumping diaphragms, in turn, create
the alternating suction and discharge action to each outer diaphragm chamber. The outer
diaphragms are the only ones in contact with the liquid being pumped.

INSTALLATION PROCEDURES

Position the pump as close as possible to the source of the liquid to be pumped. Avoid
long or undersize suction lines and use the minimum number of ttings. High vacuums
reduce ow rate capability and shorten driver diaphragm service life. Suction head is
not recommended except where NPSH might so dictate.
For permanent installations involving rigid piping, install short exible sections of hose
between the pump and piping. This reduces strains and permits easier removal of the
pump for service when required. At time of installation, inspect all external gasketed

fasteners for looseness caused by gasket creep. Tighten loose fittings securely
to prevent leakage.

FILLING OF DRIVER CHAMBERS WITH LIQUID

THE DRIVER CHAMBERS WILL BE FILLED WITH WATER AT THE FACTORY.
If you prefer to substitute another liquid, to prevent system contamination consult the
factory rst to determine compatibility of the substitute 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 spill containment
chamber. Remove the plugs.

IMPORTANT

Read these safety
w a r n i n g s a n d
in st r uc t io ns in thi s

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

B e f o r e p u m p

operation, inspect all

gasket ed fast eners

for looseness caused

by gasket creep.

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

WARNING

Before maintenance
or repair, shut off the
com-pressed air line,
bleed the pressure,
and discon nect the

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

WARNING

I n t h e e ve n t o f
diaphragm rupture,
pumped material may
enter the air end of

th e p ump, and b e
discharged into the atmosphere. The air
exhaust must be piped to an appropriate
area for safe disposition.

WARNING

Take action to prevent

static sparking. Fire

or ex p lo s i on ca n

re s u l t , e s pe c i a lly

w h e n h a n d l i n g

flammable liquids.
The pump, piping, valves,
co n t a i ners o r ot h e r mis c e l l a neou s
equipment must be grounded.

WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Manseld, Ohio 44901 USA • [phone] Fax [phone]

520-117-000 5/99 Model SET2-A Type 3 Page 1

2. Remove the entire discharge manifold assembly exposing the ports in the outer
diaphragm chambers.

3. With 5-10 PSI of air pressure at inlet, lock the spool to one side with locking pin (safety
clip; item 61). You will ll the opposite side diaphragm from the “Locked Area.”

4. Fill with 2500MI. (84.53 . 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 Teon diaphragm with a blunt tool
through the material ow port in the outer chamber until it does come to the top.
Relieving air pressure will relax diaphragms at this point.

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. (Do not overtighten.) Remember to keep pressure
on the Teon 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.

AIR SUPPLY

Do not connect the unit to an air supply in excess of 125 PSI (8.61 bars). Install
a shutoff valve in the air supply line to permit removal of the unit for servicing. When
connecting an air supply of rigid piping, mount a section of exible line to the pump to
eliminate piping strain. In permanent installations, an air line lter is recommended.

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 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 in formation found on the name plate of the pump.

MODELS WITH 1" SUCTION/DISCHARGE OR LARGER, AND
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 four hex head capscrews (each end) on the end caps of 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.

WARNING

Do not smoke near
t h e pu m p or u se
th e p u m p nea r a n
ope n fla me . Fire or
explosion could result.

WARNING

This pump must not be
used for fluid transfer
into aircraft.

WARNING

This pump is
pressurized internally
wi t h a i r pr e ss u r e
during operation.

Always make certain
that all bolting is in good condition and
that all of the correct bolting is reinstalled
during assembly.

WARNING

When used for toxic or

aggressive fluids, the

pump should always

be flushed clean prior

to disassembly.

WARNING

Befor e d oi n g a ny
main-tenance on the
pump, be certain all
pressure is completely

v e nt ed f ro m t he
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.

Page 2 Model SET2-A Type 3 520-117-000 5/99

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, 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, gasket
and bumper on the valve body. Using the arbor press or bench vise that was used in
disassembly, press the sleeve back into the valve body. You may have to clean the surfaces
of the valve body where the end caps mount. Material may remain from the old gasket.
Old material not cleaned from this area may cause air leakage after reassembly. Take
care that the bumper stays in place allowing the sleeve to press in all the way. Re-install
the spool, the opposite end cap, gasket and bumper 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.

OPERATION

Your SandPIPER pump has been tested prior to shipment and is ready for use as
received. It is completely self-priming and no initial lling with uid is required.

If the unit is to be totally submerged, the air exhaust must be piped above the liquid
level to prevent the liquid and foreign material from entering the air distribution valve
mechanism.

Open the inlet air valve at least one turn to allow sufcient cycling rate for the pump
to prime (30 to 60 cycles per minute). After pumping starts, adjust the inlet air valve
for the desired pumping capacity. When further opening of the inlet air valve increases
cycling rate without increasing the ow rate, the pump is being starved of liquid due to
suction limitations. Further opening of the air inlet valve will waste compressed air. Set
the inlet air valve for lowest cycling rate that does not decrease ow rate for most efcient
operation.

FREEZING OR ICING OF EXHAUST

Icing of the air exhaust can occur under certain conditions of temperature and
humidity on compressed air power equipment. When pump performance suffers because
of icing, use of an air dryer will solve the problem. Icing is more likely to occur at high
discharge pressures.

AIR EXHAUST

SandPIPER pumps can be submerged if the materials of construction are compatible
with the liquid and the exhaust is piped above the liquid level. (See OPERATION, above.)
Piping used for the exhaust should not be smaller than 1" pipe size. Reduced pipe size
can restrict the exhausted air and reduce pump performance.

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.

DIAPHRAGM SERVICING:

Driver Diaphragms

Drain the driver diaphragm chamber by removing the boss plug on the underside
of the driver chamber. Remove eight bolts securing the two manifolds to the chambers.
Remove eight bolts securing the diaphragm chamber. This permits inspection of the Teon
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
by inserting two or three capscrews through the bolt holes so that 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.

520-117-000 5/99 Model SET2-A Type 3 Page 3