Sandpiper W09 Service And Operating Manual

SERVICE AND OPERATING MANUAL

Air-Operated Double Diaphragm Pump

Model W09

2" Non-Clog Wastewater

CE

PLEASE NOTE!

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

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 valve 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.

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 surge suppressor is recommended to further reduce 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.

Flap Valve Type 1

IMPORTANT

Read these safety warnings
and inst ru c t i o n s i n t hi s
manual comp le te ly, bef or e
in stal lati on and star t- u p

resp on si bi li ty of the pur ch as er to retain this
manual for re fe re nc e . Failure to com pl y wi th
the recommendations stated in this manual will
damage the pump, and void factory warranty.

mis ce lla ne ous equi pm ent must be grounded .

leakage. Follow recommended torques stated in
this manual.

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.

a product which is hazardous or tox ic, the air
exhaust must be piped to an appropriate area for
safe disposition.

o f t he p um p. I t i s t he

WARNING

Ta k e ac ti on to pr ev e nt
stat ic sparking . Fire or ex­plosion can result, especially
wh en han dl in g flam mab le
liq ui ds . The pump, pip ing,
valve s, contain ers or other

CAUTION

Befor e pump operation , in ­spect all gasketed fasteners
fo r lo ose n ess cau s ed by
ga sket cr e e p . Re - t o r que

loo se fast eners to prev ent

WARNING

Be for e d o i n g a ny ma in­t e n an ce o n t he p um p,
be cer ta in all pre ss ur e is
completely vented from the
pum p, suction, dis ch arg e,

WARNING

In the event of di ap hra gm
ru pt ur e, pum pe d mater ia l
may enter the air end of the
pump, and be discharged into
the atmosphere. If pumping

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 ¾" (19mm) in diameter) between pump and piping to eliminate
strain to pipes.

PULSAFEEDER ENGINEERED PRODUCTS OPERATION • 2883 Brighton-Henrietta Townline Road • Rochester, NY 14623

Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St. • Manseld, OH 44902 USA

Phone: [phone] • Fax: [phone] • www.warrenrupp.com

Tel: [phone] • Fax: [phone] • www.pulsa.com

and must be bled of its pressure.

2" Non-Clog Wastewater Model W09

WARNING

Before maintenance or repair,
sh ut off the com - pr es sed
air line, bleed the pressure,
and disconnect the air line
from the pump. The discharge
li ne m a y b e pr e s sur i z e d

Page 1

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 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.

AIR VALVE LUBRICATION

The air end pilot and distribution valves of this pump are designed to oper­ate without lubrication. However, if poor quality compressed air is interfering with
valve shifting, lubrication may enhance operation. A small amount of non-detergent
lightweight oil (SAE 10 wt. maximum) added at the air inlet port, or the addition of
an FRL unit (filter/regulator/lubricator) will help the pump operate. If the air supply
is contaminated, dirty, or excessively wet, an air dryer will remove most water and
impurities.

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 should eliminate most icing problems.

Figure 1: Loosening locking knobs

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 INSPECTION & CLEAN-OUT

This pump has replaceable flap-type check valves on suction and discharge of
both outer chambers. A special wrench (See Figure 1.) is provided with each pump.
With it, all fasteners (locking knobs) securing the chambers and valves can be
removed. This allows quick and easy access to all four check valves. A standard ¾"
socket wrench can also be used to loosen locking knobs.

This wastewater pump is designed to handle small and large solids, up to nearly
inlet size; dry sludge; and stringy materials. Solids may occasionally become lodged
between the flap valve and seat. By loosening one locking knob holding the cover plate
yoke, the flap valve is accessible to dislodge debris. (See Figure 2.) This also allows
the insertion of a water hose to flush the outer chambers. Flush the pump by opening
all valve covers (note Caution on Page 1) and allowing water to flow in the top and out
the bottom port on each side of the pump.

CHECK VALVE REPLACEMENT

To replace the check valves, remove the four (4) 3/8" hex nuts. When removed, the
flange on the suction side carries the valve and seat as an assembly. On the discharge
side, the valve and seat will remain with the diaphragm housing. If parts are being re­placed, remove the self-locking nuts to gain access. The large rivet head on the valve
faces toward the seat. Replace the hinge pad and retainer if wear is evident. Valves
must sit flat against the seat. Adjust the fit by tightening the 3/8" hex nuts.

Use caution when reassembling check valves. The flap valves are designed for
some preload over the retainer hinge pad. This is to insure proper face contact with
the seat. After all parts are in place, tighten the lock nuts on the assembly. Visual
inspection should show the seat and valve face fitting together without a gap. This fit
is important for dry priming. Once primed, the valves will function normally under dif­ferential pressure.

Figure 2: Check valve clean out

Figure 3: Air distribution valve

2" Non-Clog Wastewater Model W09

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EXTERNALLY SERVICEABLE
MAIN AIR DISTRIBUTION VALVE

The sleeve and spool set is located in the valve body, which is held onto the inter­mediate bracket by four (4) capscrews. Loosening the four (4) hex head capscrews
allows the valve body to drop out of place (See Figure 3).

Once the valve body is off the pump, remove the four capscrews on the endcap
to inspect the spool and sleeve set. The spool of the air distribution valve is closely
sized to the sleeve. The spool must slide freely in the sleeve. Accumulation of dirt and
contaminants may prevent the spool from moving freely. It may stick in a position that
prevents the pump from cycling.

The plungers (visual stroke indicator) are locked in place on each end of the
brass spool. Before removal, mark the spool and the sleeve, so the spool can be
reassembled in the same end from which it was removed. A spring will be on one side
only, within the spool cavity. The plungers in the spool slide through a brass bushing
and o-ring in the cap.

Clean all parts before reassembly. Use a safety solvent and air oil to keep the
parts from oxidizing. Any nicks on the spool should be removed with a fine stone
or crocus cloth.

When removing the stainless steel sleeve, carefully press it out of the body,
preferably using an arbor press. Reinstall it into the body until it bottoms out against
the opposite endcap and bumper. Use new o-rings when reinstalling and apply a light
coating of grease or O-ring lube before placing in the valve body.

Reinstall the bumper(s), spring, and new gaskets. Tighten the four capscrews
to eliminate air leakage. Reinstall the body on the intermediate bracket with
new gaskets.

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.

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.

Figure 4: Locking pin

CAUTION

Locking pin must be

removed before operation.

PILOT VALVE ACTUATOR

Bushings for the pilot valve actuators are threaded into the intermediate bracket from
the outside. 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 fine 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.

MANUAL VALVE OVERRIDE

As the pump shifts, the rods from the main air valve move through the endcap.
A rod on the manual override (see Figure 4) can be locked to one side. A pin is
provided to do so. If the rod is on the left, the left side of the pump is on a discharge
stroke. When the pump is cycling, keep fingers away from the override rod and pump
casting. A shield is installed in this area for protection.

By locking the air valve to one side, air cannot flow through the pump, and the pump
will not shift. Use extreme caution when opening clean-out ports. Vent both air and fluid
pressure in the pump and system, prior to opening.

The manual override can also be used to move air through the pump, at low
pressures, to clear blockages. Typically, about 15 psi (1 bar) of air is all that can
be applied to the pump by manually moving the override rods. The valve override
can also be helpful when checking through the troubleshooting points mentioned
elsewhere in this manual.

Figure 5: Chamber vent

2" Non-Clog Wastewater Model W09

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