SANDPIPER SSA2-A User Manual

SERVICE and OPERATING MANUAL

II 2GD T5

Model SSA2-A

Table of Contents

Principle of Operation ............................................................................................ 1

Installation and Start-Up ........................................................................................ 1

Air Supply .............................................................................................................. 1

Air Inlet & Priming .................................................................................................. 2

ESADS+Plus

Air Exhaust ............................................................................................................ 3

Between Uses ....................................................................................................... 3

Check Valve Servicing ........................................................................................... 3

Diaphragm Servicing ............................................................................................. 3

Reassembly ........................................................................................................... 3

Pilot Valve .............................................................................................................. 4

®

:

Externally Serviceable Air Distribution System ................................ 2

Type 4

Pilot Valve Actuator ................................................................................................ 4

Service Instructions: Troubleshooting ................................................................... 5

Warranty ................................................................................................................5

Important Safety Information ................................................................................. 6

Recycling ............................................................................................................... 6

Grounding The Pump ............................................................................................ 7

Material Codes ...................................................................................................... 8

Declaration of Conformity ...................................................................................... 9

Composite Repair Parts List ........................................................................... 10-11

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

WARREN RUPP, INC. • A Unit of IDEX Corporation • Mansfield, Ohio 4492

Telephone [phone] • Fax [phone] • warrenrupp.com

©Copyright 2014 IDEX AODD, Inc. All rights reserved.

SERVICE and OPERATING MANUAL

II 2GD T5

PRINCIPLE OF PUMP OPERATION

This flap swing 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 spool. This pushes it into position for
shifting of the air distribution valve.
The chambers are manifolded together with a suction and discharge flap-type
check valve for each chamber, maintaining flow in one direction through the pump.

Model SSA2-A

Type 4

INSTALLATION & START-UP

Locate the pump as close to the product being pumped as possible, keeping
suction line length and number of fittings to a minimum. Do not reduce line size.
For installations of rigid piping, short flexible 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 flow.
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 20 feet (6.096 meters)
or less. For suction lifts exceeding 20 feet of liquid, fill the chambers with liquid prior
to priming.

®

surge suppressor is recommended to further reduce

AIR SUPPLY

Air supply pressures cannot exceed 125 psi (8.61 bar). Connect the pump air inlet
to an air supply of sufficient capacity and pressure required for desired performance.
When the air line is solid piping, use a short length of flexible hose [not less than
(19mm) in diameter] between pump and piping to eliminate strain to pipes.

3

/4"

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AIR INLET & PRIMING

For start-up, open an air valve approximately 1/2 to 3/4 turn. After the unit primes,
an air valve can be opened to increase flow as desired. If opening the valve increases
cycling rate, but does not increase flow rate, cavitation has occurred, and the valve
should be closed slightly.
For the most efficient use of compressed air and the longest diaphragm life, throttle
the air inlet to the lowest cycling rate that does not reduce flow.

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 information found on the name plate of the pump.
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.
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 o­ring 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).
Re-install one end cap, gasket and bumper on the valve body. Using the arbor press
or bench vise that was used in disassembly, carefully press the sleeve back into the
valve body, without shearing the o-rings. You may have to clean the surfaces of the

Model SSA2-A Page 2 ssa2dl4sm-REV0614

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. Reinstall the
spool, opposite end cap, gasket and bumper on the valve body. After inspecting and
cleaning the gasket surfaces on the valve body and intermediate, reinstall the valve
body on the pump using new gaskets. Tighten the four hex head capscrews evenly
and in an alternating cross pattern.

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 flow and reduce pump performance .When the product source is at a higher level
than the pump (flooded suction), pipe the exhaust higher than the product source to
prevent siphoning spills.
Freezing or icing-up of the air exhaust can occur under certain temperature and
humidity conditions. Use of an air dryer unit should eliminate most icing problems.

BETWEEN USES

When used for materials that tend to settle out or transform to solid form, the pump
should be completely 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
valves and diaphragms at re-start. In freezing temperatures, the pump must be drained
between uses in all cases.

CHECK VALVE SERVICING

Valve inspection requires removal of the ten hand knobs around the outer chamber.
Once the knobs have been removed the outer chamber can be pulled away exposing
the flap valves and valve seats. Visual inspection and removal is possible. The flap
valve should be free to swing on the valve seat. Any obstrucion should be removed. The
opposite side check valves can be inspected by following same procedure.
The flap valve can be disassembled by removing the seal retainer. This makes it possible
to inspect the seal ring, retainer and flap valve. Upon reassembly, torque the retainer (item
28-3) into the flap valve (item 28-1) to a maximum of 43 ft/lbs. (58.30 Newton meters).

DIAPHRAGM SERVICING

To inspect or remove a diaphragm the ten hand knobs around the chamber flange
must be backed off. Pulling the outer chamber away exposes the diaphragm. Use
care to keep foreign matter from behind the diaphragm. The opposite diaphragm
may be inspected by the same procedure.
To remove diaphragms, hold the diaphragm plate opposite to the diaphragm
you wish to remove. Unthread the outer plate on the diaphragm being replaced.
Once plate is removed, the diaphragm assembly will pull out of the bracket. Now the
shaft, shaft seal, and pilot valve actuator bushings are easily inspected.

REASSEMBLY

All procedures for reassembling the pump are the reverse of the previous
instructions with further instructions as shown:

1. Attach an -030- diaphragm to one end of the pump's diaphragm rod (685-033-

120) utilizing the threads of the outer diaphragm plate (612-197-111). The natural
sequence of parts in the assembly is outer diaphragm plate, diaphragm and inner
diaphragm plate. Tighten the assembly by hand. Install the diaphragm bumper
(132-002-360) on the diaphragm rod and install the assembly into the pump.
Attach the pump's outer chamber to this side, securing it in place with the
fasteners. Install the second diaphragm and its components to the opposite side
of the pump in the same sequence. Tighten the assembly to a torque value of 40
ft. lbs. (54.23 Newton meters). You can finish the pump assembly at this point after
any additional maintenance is completed.

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