SANDPIPER W15 User Manual

SERVICE AND OPERATING MANUAL

®

Models W09 and W15Models W09 and W15

Models W09 and W15

Models W09 and W15Models W09 and W15

Type 1

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 Warren Rupp Tranquilizer

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.

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.

IMPORTANT

Read these safety warnings
and instructions in this
manual completely, before
installation and start-up

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.

of the pump. It is the

WARNING

Take action to prevent
static sparking. Fire or
explosion can result,
especially when handling

piping, valves, containers or other
miscellaneous equipment must be grounded.

flammable liquids. The pump,

CAUTION

Before pump operation,
inspect all gasketed fasteners
for looseness caused by

loose fasteners to prevent leakage. Follow
recommended torques stated in this manual.

gasket creep. Re-torque

WARNING

Before doing any main­tenance on the pump, be
certain all pressure is
completely vented from the

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.

pump, suction, discharge,

WARNING

In the event of diaphragm
rupture, pumped material may
enter the air end of the pump,
and be discharged into the

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

atmosphere. If pumping a

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

and must be bled of its pressure.

line may be pressurized

WARREN RUPP, INC. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, Ohio 44901-1568 USA • [phone] Fax [phone] • www.warrenrupp.com

7/04 520-150-000 Models W09 & W15 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 a
Warren Rupp 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

7/04 520-150-000 Models W09 & W15 Page 2

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

7/04 520-150-000 Models W09 & W15 Page 3

TAPPED CHAMBER VENTS

The chamber vent at the top of each outer chamber (see Figure 5) is used to
purge any entrapped air that might accumulate in the chamber. Entrapped air
could cause unbalanced cycling or loss of prime. The gate valve with 1/2" NPT
(12.7mm) threads accomodates a hose or pipe, to vent accumulated air and
fluid back to the liquid source. Ends of the hose or pipe must be submerged in
the liquid being pumped. Tying the pump sides together into a common hose
only moves the air from side to side.

When air is purged, pumped product will discharge from the hose. When
this occurs, close the gate valve and continue normal operation. The valves
may be left partially open, but pump performance will decrease. The tapped
chamber vents can also be used to flush the chambers between uses.

DIAPHRAGM REPLACEMENT

Diaphragms are in-line accessible for service, without disturbing the suction
and discharge flanges. To access the diaphragm, remove the eight (8) locking
knobs around the diaphragm chamber. Remove the locking knobs at the
manifold elbow connections. The housing assembly will pull off. Diaphragms
can now be inspected or replaced. Clear all foreign matter from behind the
diaphragm before reassembling.

REASSEMBLY AFTER SERVICE

To reassemble the pump, begin with the diaphragm assembly. Stack the
wear pad onto the stud of the outer plate. Next, put the diaphragm on to the
stud, with the natural bulge toward the outer plate. Place the inner plate onto
the stud.

Align the five (5) hexhead capscrews and washers through the inner plate,
diaphragm and wear pad, into the outer plate (See Figure 6). Tighten the
capscrews alternately, side to side and corner to corner, use 242 Loctite and
torque to 190 in/lbs. Place the bumper onto the diaphragm rod.

Once the diaphragm assembly is made, thread the stud (from the outer
plate side) into the diaphragm rod. Use Neverseize

®

or equivalent anti-galling
thread lubricant on threads. Turn the assembly onto the rod until it bottoms out,
and the eight (8) holes around the outside of the diaphragm line up with those
on the outer chamber rim (See Figure 7). Back-off tightening as required for
alignment. Reassemble the other side of the pump in the same way. Tighten all
locking knobs to secure the outer chamber to the inner chamber. Tighten all
knobs alternately, side to side and corner to corner.

WARRANTY

This pump is warranted for a period of five years against defective material
and workmanship. Failure to comply with the recommendations stated in this
manual voids all factory warranty.

Figure 6: Align hexhead capscrews and tighten

Figure 7: Align diaphragm holes with chamber
holes

WARNING

This pump is pressurized
internally with air pressure
during operation. Always
make certain that all bolting
is in good condition and that

reinstalled during assembly.

all of the correct bolting is

©2004 Warren Rupp, Inc. All rights reserved.

®Warren Rupp, SANDPIPER and Tranquilizer are registered tradenames of Warren Rupp, Inc.

®Neverseize is a registered tradename of Loctite

Printed in U.S.A.

7/04 520-150-000 Models W09 & W15 Page 4