Model S1F Non-Metallic Design Level...

WARREN RUPP®, INC. • A Unit of IDEX Corporation • P.O. Box 1568, Mansfield, Ohio 44901-1568 USA • Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com

520-199-000 1/01 ©Copyright 2000 Warren Rupp, Inc. All rights reserved.

SERVICE & OPERATING MANUAL

Model S1F Non-Metallic Design Level 2

Engineering Data and Temperature Limitations ...................................................................... 1

Explanation of Pump Nomenclature ........................................................................................ 2

Performance Curve, Model S1F Non-Metallic Design Level 2 ............................................... 3

Dimensions: S1F Non-Metallic ................................................................................................. 4

Metric Dimensions: S1F Non-Metallic ..................................................................................... 5

Dimensions: S1F Non-Metallic with Spill Prevention ................................................................ 6

Metric Dimensions: S1F Non-Metallic with Spill Prevention .................................................... 7

Principle of Pump Operation .................................................................................................... 8

Installation and Start-up ........................................................................................................... 8

Air Supply ................................................................................................................................. 8

Air Valve Lubrication ................................................................................................................. 8

Air Line Moisture ...................................................................................................................... 8

Air Inlet and Priming ................................................................................................................. 8

Between Uses ................................................................................................................... ....... 8

Installation Guide ...................................................................................................................... 9

Important Safety Information ................................................................................................. 10

Material Codes ....................................................................................................................... 10

Troubleshooting ...................................................................................................................... 11

Warranty ................................................................................................................................. 11

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

Overlay Option Drawing ........................................................................................................ 1 2

Composite Repair Parts List .................................................................................................. 13

RuppGUARD™ Spill Prevention Option for Virgin PTFE Equipped Pumps ......................... 14

RuppGUARD™ Spill Prevention Repair Parts List ............................................................... 14

RuppGUARD™ Spill Prevention Concept ............................................................................. 15

RuppGUARD™ Spill Prevention Option Diaphragm Servicing ............................................ 15

Filling RuppGUARD™ Chambers with Liquid ....................................................................... 15

RuppGUARD™ Spill Prevention Option for TPE Equipped Pumps ..................................... 16

RuppGUARD™ Spill Prevention Repair Parts List ............................................................... 16

RuppGUARD™ Spill Prevention Concept with TPE Diaphragms ........................................ 17

RuppGUARD™ Spill Prevention Option with TPE Diaphragm ............................................. 17

Air Distribution Valve Assembly Drawing ............................................................................... 18

Main Air Valve Assembly Parts List ....................................................................................... 18

Air Distribution Valve Servicing .............................................................................................. 19

Air Distribution Valve with Stroke Indicator Options .............................................................. 20

Air Distribution Valve with Stroke Indicator Parts List ........................................................... 20

Air Distribution Valve with Stroke Indicator Servicing ........................................................... 21

Pilot Valve Assembly Drawing ................................................................................................ 22

Pilot Valve Assembly Parts List .............................................................................................. 22

Pilot Valve Servicing ............................................................................................................... 23

Diaphragm Service Drawing, Non-Overlay .......................................................................... 24

Diaphragm Service Drawing, with Overlay ........................................................................... 24

Diaphragm Servicing .............................................................................................................. 25

Overlay Diaphragm Service .................................................................................................. 25

Pumping Hazardous Liquids .................................................................................................. 26

Converting the pump for piping the exhaust air .................................................................... 26

Exhaust Conversion Drawing ................................................................................................ 26

Converted Exhaust Illustration .............................................................................................. 26

Modular Check Valve Servicing ............................................................................................. 27

Modular Check Valve Drawing ............................................................................................... 27

Dual Port Option Drawing ...................................................................................................... 28

Dual Porting Options .............................................................................................................. 29

Dual porting of both suction and discharge ends of the pump ............................................. 29

Single porting of the suction and dual porting of the pump discharge .................................. 29

Dual porting of the suction and single porting of the pump discharge ................................. 29

Leak Detection Options Drawing ........................................................................................... 30

RuppTech® Electronic Leak Detector Installation ................................................................ 30

Mechanical Leak Detector Installation .................................................................................. 30

RuppTech® Pulse Output Kit Drawing .................................................................................. 31

RuppTech® Pulse Output Kit Option ..................................................................................... 31

Exhaust Port or Auxiliary Muffler Setup ................................................................................. 31

Integral Muffler Setup ............................................................................................................. 31

Table of ContentsCE

U.S. Patent #400,2105,996,627

520-199-000 1/01 Model S1F Non-Metallic Design Level 2 Page 1

Quality SystemISO9001 Certified

EnvironmentalManagement System

ISO14001 Certified

S1F Non-MetallicDesign Level 2Ball ValveAir-PoweredAir-PoweredAir-PoweredAir-PoweredAir-PoweredDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm PumpDouble-Diaphragm Pump

ENGINEERING, PERFORMANCE& CONSTRUCTION DATA

CE

U.S. Patent #5,996,627; 400,210Other U.S. PatentsApplied for

SantopreneSantopreneSantopreneSantopreneSantoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex 212°F -10°F 50° to 212°Flife. Excellent abrasion resistance. 100°C -23°C 10°C to 100°C

PTFEPTFEPTFEPTFEPTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically withTeflon: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 212°F -35°F 50°F to 212°Fchlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 100°C -37°C 10°C to 100°C

PVDFPVDFPVDFPVDFPVDF 200°F -10°F-93°C -13°C

PolypropylenePolypropylenePolypropylenePolypropylenePolypropylene 150°F -40°F65°C 5°C

NylonNylonNylonNylonNylon 150°F -40°F65°C 5°C

MaterialsMaterialsMaterialsMaterialsMaterials Maximum*Maximum*Maximum*Maximum*Maximum* Minimum*Minimum*Minimum*Minimum*Minimum* Optimum**Optimum**Optimum**Optimum**Optimum**

*Definite reduction in service life.**Minimal reduction in service life at ends of range.

Operating TOperating TOperating TOperating TOperating Temperaturesemperaturesemperaturesemperaturesemperatures

For specific applications, always consult “Chemical Resistance Chart” Technical Bulletin

SandPIPER II® pumps are designed to be powered only by compressed air.

INTAKE/DISCHARGE PIPE SIZE1" ANSI Flange

orPN10 25mm DIN Flange

CAPACITY0 to 45 gallons per minute(0 to 170 liters per minute)

AIR VALVENo-lube, no-stall

design

SOLIDS-HANDLINGUp to .25 in. (6mm)

HEADS UP TO100 psi or 231 ft. of water

(7 bar or 70 meters)

DISPLACEMENT/STROKE.17 gallon / .64 liter

CAUTION! Operating temperature limitations are as follows:

Air Inlet Side ViewAir Exhaust Side View


Pump BrandS= SandPIPER II®

Pump Size1F=1" Full Flow

Check Valve TypeB= Ball

Design Level2= Design Level 2

Wetted MaterialK= PVDFN=Nylon

P= Polypropylene

Diaphragm Check Valve Materials1= Santoprene/Santoprene2= PTFE-Santoprene Backup/PTFE3= PTFE Pumping, PTFE-Santoprene

Backup Driver/PTFE

Check Valve SeatK=PVDFN=NylonP=Polypropylene

Non-Wetted Material OptionsA= Painted AluminumJ= Painted Aluminum PTFE

Q= Epoxy Coated Aluminum

K= PTFE Coated Aluminum

L= PTFE Coated Aluminum with PTFECoated Hardware

R= Epoxy Coated Aluminum withPTFE Coated Hardware

Porting OptionsA= ANSI FlangeD=DIN Flange7= Dual Porting (ANSI)8= Top Dual Porting (ANSI)9= Bottom Dual Porting (ANSI)

Pump StyleD=RuppGUARD™ with

Electronic Leak Detection(110V)

E= RuppGUARD™ withElectronic Leak Detection(220V)

M=RuppGUARD™ with MechanicalLeak Detection

S= StandardV= RuppGUARD™ with Visual

Leak Detection

Pump Options0= None1= 3M Muffler2= Mesh Muffler3= High temperature Air

Valve w/EncapsulatedMuffler

4= High temperature AirValve w/3M Muffler

5= High temperatureAirValvew/Mesh Muffler

S1F Non-Metallic · Design Level 2· Ball ValveCheck Diaphragm/ Check Non-Wetted Shipping

MODEL Pump Pump V alve Design Wetted Check Valve Valve Material Porting Pump Pump Kit WeightBrand Size Type Level Material Materials Seat Options Options S tyle Options Options lbs. (kg)

S1FB2P1PAAS000. S 1F B 2 P 1 P A A S 0 00. 53 (24) S1FB2P2PAAS000. S 1F B 2 P 2 P A A S 0 00. 53 (24) S1FB2K1KAAS000. S 1F B 2 K 1 K A A S 0 00. 65 (29) S1FB2K2KAAS000. S 1F B 2 K 2 K A A S 0 00. 65 (29) S1FB2P3PAAV000. S 1F B 2 P 3 P A A V 0 00. 58 (26) S1FB2K3KAAV000. S 1F B 2 K 3 K A A V 0 00. 77 (35)

Explanation of Pump Nomenclature

Kit Options00.=NoneP0.=0-30VDC Pulse Output KitP1.=Intrinsically-Safe 10-30VDC Pulse Output KitP2.=110/120 or 220/240VAC Pulse Output KitP3.=Intrinsically-Safe 110/120VAC Pulse Output KitP4.=Intrinsically-Safe 220/240VAC Pulse Output KitSP.=Stroke Indicator Pins


5 (8.5)10 (17)

20 (34)

30 (51)

45 (76.5)

15 (25.5)

25 (42.5)

35 (59.5)

40 (68)

35 40 45302520151050

Capacity

U.S. Gallons per minute

Liters per minute

100

100 110 120 130 140 150 160 170 180 190

90

90

80

80

70

70

60

60

50

50

40

40

30

30

20

20

10

10

0

0

BA

R

PS

I

Hea

d

1

2

3

4

5

6

7

0

30

2025

1015

5

9.1

67.6

34.5

1.5

NP

SH

R

FEE

T

ME

TER

S

100 PSI (6.8 Bar)

80 PSI (5.44 Bar)

60 PSI (4.08 Bar)

40 PSI (2.72 Bar)

20 PSI (1.36 Bar) Air Inlet Pressure

Performance Curve, Model S1F Non-MetallicDesign Level 2


Dimensions: S1F Non-Metallic

Dimensions in InchesDimensional tolerance: ±1/8"

DIMENSION A BStandard Pump 5 5/8" 10 1/4"Pulse Output Kit 7 3/8" 12"Mesh Muffler 8 9/16" 11 5/32"Sound Dampening Muffler 18 7/8" 13 7/16"


Metric Dimensions: S1F Non-Metallic

Dimensions in MillimetersDimensional tolerance: ±3mm

DIMENSION A BStandard Pump 143mm 260mmPulse Output Kit 187mm 305mmMesh Muffler 167mm 283mmSound Dampening Muffler 225mm 341mm


Dimensions: S1F Non-Metallicwith RuppGuard™ Spill Prevention

DIMENSION A BStandard Pump 5 5/8" 10 1/4"Pulse Output Kit 7 3/8" 12"Mesh Muffler 6 9/16" 11 1/8"Sound Dampening Muffler 18 7/8" 13 7/16"


Metric Dimensions: S1F Non-Metallicwith RuppGuard™ Spill Prevention

DIMENSION A BStandard Pump 143mm 260mmPulse Output Kit 187mm 305mmMesh Muffler 167mm 283mmSound Dampening Muffler 225mm 341mm


PRINCIPLE OF PUMP OPERATIONThis ball type check valve pump is

powered by compressed air and is a 1:1ratio design. The inner side of onediaphragm chamber is alternatelypressurized while simultaneouslyexhausting the other inner chamber. Thiscauses the diaphragms, which areconnected by a common rod securedby plates to the centers of thediaphragms, to move in a reciprocatingaction. (As one diaphragm performs thedischarge stroke the other diaphragmis pulled to perform the suction strokein the opposite chamber.) Air pressureis applied over the entire inner surfaceof the diaphragm while liquid isdischarged from the opposite side of thediaphragm. The diaphragm operates ina balanced condition during thedischarge stroke which allows the pumpto be operated at discharge heads over200 feet (61 meters) of water.

For maximum diaphragm life, keepthe pump as close to the liquid beingpumped as possible. Positive suctionhead in excess of 10 feet of liquid (3.048meters) may require a back pressureregulating device to maximizediaphragm life.

Alternate pressurizing andexhausting of the diaphragm chamberis performed by an externally mounted,pilot operated, four way spool type airdistribution valve. When the spool shiftsto one end of the valve body, inletpressure is applied to one diaphragmchamber and the other diaphragmchamber exhausts. When the spool

shifts to the opposite end of the valvebody, the pressure to the chambers isreversed. The air distribution valve spoolis moved by a internal pilot valve whichalternately pressurizes one end of theair distribution valve spool whileexhausting the other end. The pilot valveis shifted at each end of the diaphragmstroke when a actuator plunger iscontacted by the diaphragm plate. Thisactuator plunger then pushes the end ofthe pilot valve spool into position toactivate the air distribution valve.

The chambers are connected withmanifolds with a suction and dischargecheck valve for each chamber,maintaining flow in one direction throughthe pump.

INSTALLATION AND START-UPLocate the pump as close to the

product being pumped as possible. Keepthe suction line length and number offittings to a minimum. Do not reduce thesuction line diameter.

For installations of rigid piping, shortsections of flexible hose should beinstalled between the pump and thepiping. The flexible hose reducesvibration and strain to the pumpingsystem. A surge suppressor isrecommended to further reducepulsation in flow.

AIR SUPPLYAir supply pressure cannot exceed

100 psi (7 bar). Connect the pump airinlet to an air supply of sufficient capacityand pressure required for desiredperformance. When the air supply line

is solid piping, use a short length offlexible hose not less than ½" (13mm)in diameter between the pump and thepiping to reduce strain to the piping. Theweight of the air supply line, regulatorsand filters must be supported by somemeans other than the air inlet cap. Failureto provide support for the piping mayresult in damage to the pump. A pressureregulating valve should be installed toinsure air supply pressure does notexceed recommended limits.

AIR VALVE LUBRICATIONThe air distribution valve and the pilot

valve are designed to operate WITHOUTlubrication. This is the preferred mode ofoperation. There may be instances ofpersonal preference or poor quality airsupplies when lubrication of thecompressed air supply is required. Thepump air system will operate withproperly lubricated compressed airsupply. Proper lubrication requires theuse of an air line lubricator (available fromWarren Rupp) set to deliver one drop ofSAE 10 non-detergent oil for every 20SCFM (9.4 liters/sec.) of air the pumpconsumes at the point of operation.Consult the pump’s publishedPerformance Curve to determine this.

AIR LINE MOISTUREWater in the compressed air supply

can create problems such as icing orfreezing of the exhaust air, causing thepump to cycle erratically or stopoperating. Water in the air supply canbe reduced by using a point-of-use airdryer to supplement the user’s air drying

equipment. This device removes waterfrom the compressed air supply andalleviates the icing or freezing problems.

AIR INLET AND PRIMINGTo start the pump, open the air valve

approximately ½ to ¾ turn. After thepump primes, the air valve can be openedto increase air flow as desired. If openingthe valve increases cycling rate, but doesnot increase the rate of flow, cavitationhas occurred. The valve should be closedslightly to obtain the most efficient airflow to pump flow ratio.

BETWEEN USESWhen the pump is used for materials

that tend to settle out or solidify whennot in motion, the pump should be flushedafter each use to prevent damage.(Product remaining in the pump betweenuses could dry out or settle out. Thiscould cause problems with thediaphragms and check valves at restart.)In freezing temperatures the pump mustbe completely drained between uses inall cases.


1

2 3

4

1

2

3

4

Surge Suppressor

020-050-000 Filter/Regulator

020-050-001 Lubricator

020-047-007 Air Dryer

Available from Warren Rupp

CAUTIONThe air exhaust should be piped to an area for safe disposition of the product being pumped, in the event of a diaphragm failure.

INSTALLATION GUIDETop Discharge Ball Valve Unit


MATERIAL CODESThe Last 3 Digits of Part Number

000 ........ Assembly, sub-assembly; and some purchaseditems

010 ........ Cast Iron012 ......... Powered Metal015 ......... Ductile Iron020 ......... Ferritic Malleable Iron025 ........ Music Wire080 ........ Carbon Steel, AISI B-1112100 ........ Alloy 20110 ........ Alloy Type 316 Stainless Steel111 ........ Alloy Type 316 Stainless Steel (Electro Polished)112 ........ Alloy “C” (Hastelloy equivalent)113 ......... Alloy Type 316 Stainless Steel (Hand Polished)114 ......... 303 Stainless Steel115 ......... 302/304 Stainless Steel117 ......... 440-C Stainless Steel (Martensitic)120 ......... 416 Stainless Steel (Wrought Martensitic)123 ......... 410 Stainless Steel (Wrought Martensitic)148 ........ Hardcoat Anodized Aluminum149 ........ 2024-T4 Aluminum150 ........ 6061-T6 Aluminum151 ........ 6063-T6 Aluminum152 ........ 2024-T4 Aluminum (2023-T351)154 ........ Almag 35 Aluminum155 ........ 356-T6 Aluminum156 ........ 356-T6 Aluminum157 ........ Die Cast Aluminum Alloy #380158 ........ Aluminum Alloy SR-319159 ......... Anodized Aluminum162 ......... Brass, Yellow, Screw Machine Stock165 ........ Cast Bronze, 85-5-5-5166 ........ Bronze, SAE 660170 ........ Bronze, Bearing Type, Oil Impregnated175 ........ Die Cast Zinc180 ........ Copper Alloy305 ........ Carbon Steel, Gray Epoxy Coated306 ......... Carbon Steel, Black PTFE Coated307 ........ Aluminum, Gray Epoxy Coated308 ......... Stainless Steel, Black PTFE Coated309 ......... Aluminum, Black PTFE Coated310 ......... Kynar Coated330 ......... Zinc Plated Steel331 ........ Chrome Plated Steel332 ........ Aluminum, Electroless Nickel Plated333 ........ Carbon Steel, Electroless Nickel Plated335 ........ Galvanized Steel336 ........ Zinc Plated Yellow Brass337 ........ Silver Plated Steel340 ........ Nickel Plated342 ........ Filled Nylon353 ......... Geolast; Color: Black354 ........ Injection Molded #203-40 Santoprene - Duro 40D

+/-5; Color: RED355 ........ Thermal Plastic356 ........ Hytrel357 ........ Injection Molded Polyurethane358 ........ Rupplon (Urethane Rubber). Color coded:

PURPLE (Some Applications) (Compression Mold)359 ........ Urethane Rubber360 ........ Buna-N Rubber. Color coded: RED361 ........ Buna-N363 ........ Viton (Flurorel). Color coded: YELLOW364 ........ E.P.D.M. Rubber. Color coded: BLUE365 ........ Neoprene Rubber. Color coded: GREEN366 ........ Food Grade Nitrile

368 ........ Food Grade EPDM370 ........ Butyl Rubber. Color coded: BROWN371 ........ Philthane (Tuftane)374 ......... Carboxylated Nytrile375 ........ Fluorinated Nitrile378 ........ High Density Polypropylene405 ........ Cellulose Fibre408 ........ Cork and Neoprene425 ........ Compressed Fibre426 ........ Blue Gard440 ........ Vegetable Fibre465 ........ Fibre500 ........ Delrin 500501 ........ Delrin 570502 ........ Conductive Acetal, ESD-800503 ........ Conductive Acetal, Glass-Filled505 ........ Acrylic Resin Plastic506 ........ Delrin 150520 ........ Injection Molded PVDF Natural color540 ........ Nylon541 ........ Nylon542 ........ Nylon544 ........ Nylon Injection Molded550 ........ Polyethylene551 ......... Glass Filled Polypropylene552 ......... Unfilled Polypropylene553 ......... Unfilled Polypropylene555 ......... Polyvinyl Chloride556 ......... Black Vinyl570 ......... Rulon II580 ......... Ryton590 ......... Valox591 ......... Nylatron G-S592 ........ Nylatron NSB600 ......... Virgin PTFE601 ......... PTFE (Bronze and moly filled)602 ......... Filled PTFE603 ........ Blue Gylon604 ......... Virgin PTFE607 ........ Envelon606 ......... Injected molded PFA610 ......... Encapsulated Silicon611 ......... Encapsulated Viton632 ......... Neoprene/Hytrel633 ......... Viton/Teflon634 ......... EPDM/Teflon637 ......... PTFE, Viton638 ......... PTFE, Hytrel639 ......... Buna-N643 ......... Santoprene®/EPDM644 ......... Santoprene®

Delrin, Viton and Hytrel are registered tradenames ofE.I. DuPont.

Gylon is a registered tradename of Garlock, Inc.

Nylatron is a registered tradename of Polymer Corp.

Santoprene is a registered tradename of Monsanto Corp.

Rulon II is a registered tradename of Dixion Industries Corp.

Hastelloy-C is a registered tradename of Cabot Corp.

Ryton is a registered tradename of Phillips Chemical Co.

Valox is a registered tradename of General Electric Co.

Warren Rupp, Rupplon, SandPIPER, SandPIPER II, PortaPump,Tranquilizer and SludgeMaster are registered tradenames ofWarren Rupp, Inc.

This pump is pressurizedinternally with air pressureduring operation. Alwaysmake certain that all boltingis in good condition and that

all of the correct bolting is reinstalled duringassembly.

WARNING

Before pump operation,inspect all gasketedfasteners for loosenesscaused by gasket creep.Re-torque loose fasteners

to prevent leakage. Follow recommendedtorques stated in this manual.

CAUTIONWhen used for toxic oraggressive fluids, the pumpshould always be flushedclean prior to disassembly.

WARNING

Before maintenance orrepair, shut off the com-pressed air line, bleed thepressure, and disconnectthe air line from the pump.

The discharge line may be pressurized andmust be bled of its pressure.

WARNING

IMPORTANTRead these safety warningsand instructions in thismanual completely, beforeinstallation and start-upof the pump. It is the

responsibility of the purchaser to retain thismanual for reference. Failure to comply withthe recommendations stated in this manual willdamage the pump, and void factory warranty.

WARNINGAirborne particles and loudnoise hazards.

Wear ear and eye protection.

WARNINGIn the event of diaphragmrupture, pumped materialmay enter the air end of thepump, and be dischargedinto the atmosphere. If

pumping a product which is hazardous or toxic,the air exhaust must be piped to an appropriatearea for safe disposition.

IMPORTANT SAFETYINFORMATION

Before doing any main-tenance on the pump, becertain all pressure iscompletely vented from thepump, suction, discharge,

piping, and all other openings and connections.Be certain the air supply is locked out or madenon-operational, so that it cannot be started whilework is being done on the pump. Be certain thatapproved eye protection and protective clothingare worn all times in the vicinity of the pump.Failure to follow these recommendations mayresult in serious injury or death.

WARNING


TROUBLESHOOTINGPossible Symptoms:• Pump will not cycle.• Pump cycles, but produces no flow.• Pump cycles, but flow rate is

unsatisfactory.• Pump cycle seems unbalanced.• Pump cycle seems to produce

excessive vibration.

What to Check: Excessive suction liftin system.Corrective Action: For lifts exceeding20 feet (6 meters), filling the pumpingchambers with liquid will prime the pumpin most cases.

What to Check: Excessive floodedsuction in system.Corrective Action: For floodedconditions exceeding 10 feet (3 meters)of liquid, install a back pressure device.

What to Check: System head exceedsair supply pressure.Corrective Action: Increase the inlet airpressure to the pump. Most diaphragmpumps are designed for 1:1 pressureratio at zero flow.

What to Check: Air supply pressure orvolume exceeds system head.Corrective Action: Decrease inlet airpressure and volume to the pump ascalculated on the publishedPERFORMANCE CURVE. Pump iscavitating the fluid by fast cycling.

What to Check: Undersized suctionline.

Corrective Action: Meet or exceedpump connection recommendationsshown on the DIMENSIONALDRAWING.

What to Check: Restricted orundersized air line.Corrective Action: Install a larger airline and connection. Refer to air inletrecommendations shown in your pump’sSERVICE MANUAL.

What to Check: Check ESADS, theExternally Serviceable Air DistributionSystem of the pump.Corrective Action: Disassemble andinspect the main air distribution valve,pilot valve and pilot valve actuators. Referto the parts drawing and air valve sectionof the SERVICE MANUAL. Check forclogged discharge or closed valve beforereassembly.

What to Check: Rigid pipe connectionsto pump.Corrective Action: Install flexibleconnectors and a surge suppressor.

What to Check: Blocked air exhaustmuffler.Corrective Action: Remove mufflerscreen, clean or de-ice and reinstall.Refer to the Air Exhaust section of yourpump SERVICE MANUAL.

What to Check: Pumped fluid in airexhaust muffler.Corrective Action: Disassemble pumpchambers. Inspect for diaphragm ruptureor loose diaphragm plate assembly. Referto the Diaphragm Replacement section

of your pump SERVICE MANUAL.

What to Check: Suction side airleakage or air in product.Corrective Action: Visually inspect allsuction side gaskets and pipeconnections.

What to Check: Obstructed checkvalve.Corrective Action: Disassemble the wetend of the pump and manually dislodgeobstruction in the check valve pocket.Refer to the Check Valve section of thepump SERVICE MANUAL fordisassembly instructions.

What to Check: Worn or misalignedcheck valve or check valve seat.Corrective Action: Inspect check valvesand seats for wear and proper seating.Replace if necessary. Refer to CheckValve section of the pump SERVICEMANUAL for disassembly instructions.

What to Check: Blocked suction line.Corrective Action: Remove or flushobstruction. Check and clear all suctionscreens and strainers.

What to Check: Blocked discharge line.Corrective Action: Check forobstruction or closed discharge linevalves.

What to Check: Blocked pumpingchamber.Corrective Action: Disassemble andinspect the wetted chambers of thepump. Remove or flush any obstructions.Refer to the pump SERVICE MANUAL

for disassembly instructions.

What to Check: Entrained air or vaporlock in one or both pumping chambers.Corrective Action: Purge chambersthrough tapped chamber vent plugs.PURGING THE CHAMBERS OF AIRCAN BE DANGEROUS! Contact theWarren Rupp Technical ServicesDepartment before performing thisprocedure. A model with top-porteddischarge will reduce or eliminateproblems with entrained air.

If your pump continues to performbelow your expectations, contact yourlocal Warren Rupp Distributor or factoryTechnical Services Group for a serviceevaluation.

WARRANTYRefer to the enclosed Warren Rupp

Warranty Certificate.


Overlay Option Drawing

Muffler OptionDrawing

Composite Repair Parts DrawingAVAILABLE SERVICE AND CONVERSION KITS476-191-000 AIR END KIT

Seals, O-rings, Gaskets,Retaining Rings, Air Valve Sleeve &Spool Set and Pilot Valve Assembly

476-193-000 AIR END KIT (for Stroke Indicator Option)

Seals, O-rings, Gaskets, RetainingRings, Air Valve Sleeve & Spool Setand Pitot Valve Assembly.

476-145-354 WETTED END KITSantoprene Diaphragms,Santoprene Balls and PTFE Seals.

476-145-654 WETTED END KITSantoprene Diaphragms, PTFE OverlayDiaphragms, TFE Ballsand TFE Seals.

476-146-655 WETTED END KIT (for PolypropyleneRuppGuard™)Santoprene Diaphragms, PTFE OverlayDiaphragms, PTFE Pumping Diaphragms,PTFE Balls and PTFE Seals.

476-184-655 WETTED END KIT (for PVDFRuppGUARD™)Santoprene Diaphragms, PTFE OverlayDiaphragms, PTFE Pumping Diaphragms,PTFE Balls and PTFE Seals.

476-146-354 WETTED END KIT (for PolypropyleneRuppGUARD™)Santoprene Diaphragms, Santoprene PumpingDiaphragms, Santoprene Check Balls & PTFESeals.

476-184-354 WETTED END KIT (for PVDFRuppGUARD™)Santoprene Diaphragms, Santoprene PumpingDiaphragms, Santoprene Check Balls & TFESeals.

HARDWARE KITS

475-175-308 PTFE Coated Stainless SteelCapscrews, Hex Nuts, Washers andSupport Rod

475-176-308 (For use with RuppGUARD™ Spill PreventionOptions)

RuppTech® PULSE OUTPUT KITS(For use with 530-007-000 and 530-025-000 Mufflers,or piped exhaust)475-198-016 DC Kit475-198-017 DC Intrinsically Safe Kit475-198-018 110/120VAC or 220/240VAC Kit475-198-019 110/120VAC Intrinsically Safe Kit475-198-020 220/240VAC Intrinsically Safe Kit(For use with encapsulated 530-030-550 Muffler)475-198-011 DC Kit475-198-012 DC Intrinsically Safe Kit475-198-013 110/120VAC or 220/240VAC Kit475-198-014 110/120VAC Intrinsically Safe Kit475-198-015 220/240VAC Intrinsically Safe Kit

RuppTech® ELECTRONIC LEAK DETECTOR KITS032-033-000 110VAC032-034-000 220VAC


Composite Repair Parts ListITEM PART NUMBER DESCRIPTION QTY1 031-155-000 Air Valve Assembly 1

031-155-002 Air Valve Assembly w/ PTFE coated Hardware 1031-156-000 Air Valve Assembly (No Encapsulated Muffler) 1031-156-002 Air Valve Assembly (No Muffler/ PTFE Hardware) 1031-157-000 Air Valve Assembly (With Stroke Indicator Option) 1031-158-000 Air Valve Assembly (No Muffler w/ Stroke Indicator) 1

2 050-042-354 Ball, Check 4050-042-600 Ball, Check 4

3 095-090-000 Pilot Valve Assembly 14 114-022-157 Intermediate Assembly 1

114-022-307 Intermediate Assembly 1114-022-309 Intermediate Assembly 1114-022-332 Intermediate Assembly 1

5 115-139-080 Bracket, Mounting 2115-139-305 Bracket, Mounting 2115-139-306 Bracket, Mounting 2115-139-333 Bracket, Mounting 2

6 132-032-360 Bumper, Diaphragm 27 135-034-506 Bushing, Plunger 28 165-107-157 Cap, Air Inlet 1

165-107-307 Cap, Air Inlet 1165-107-309 Cap, Air Inlet 1165-107-332 Cap, Air Inlet 1

9 170-020-115 Capscrew, Hex HD 3/8-16 x 2.00 32170-020-308 Capscrew, Hex HD 3/8-16 x 2.00 32



12 171-015-115 Capscrew, Soc HD 3/8-16 x .88 613 171-057-115 Capscrew, Soc HD 5/16-18 x 2.25 4

171-057-308 Capscrew, Soc HD 5/16-18 x 2.25 414 196-157-520 Chamber, Outer 2

196-157-542 Chamber, Outer 2196-157-552 Chamber, Outer 2

15 196-160-157 Chamber, Inner 2196-160-307 Chamber, Inner 2196-160-309 Chamber, Inner 2196-160-332 Chamber, Inner 2

16 286-091-354 Diaphragm 217 286-093-600 Diaphragm, Overlay 218 312-104-520 Elbow 4

312-104-542 Elbow 4312-104-552 Elbow 4

19 360-094-360 Gasket, Air Inlet 120 360-095-360 Gasket, Pilot Valve 1

21 360-096-360 Gasket, Air Vale 122 360-097-360 Gasket, Inner Chamber 223 518-136-520 Manifold 2

518-136-520E Manifold, 25mm DIN 2518-136-542 Manifold 2518-136-542E Manifold, 25mm DIN 2518-136-552 Manifold 2518-136-552E Manifold, 25mm DIN 2

24 530-007-000 Muffler (Mesh) (not shown) 1530-025-000 Muffler (Sound Dampening) 1

25 538-011-555 Nipple, Pipe 126 545-004-115 Nut, Hex 5/16-18 8

545-004-308 Nut, Hex 5/16-18 827 545-005-115 Nut, Hex 3/8-16 40

545-005-308 Nut, Hex 3/8-16 4028 545-008-110 Nut, Hex 1/2-13 16

545-008-308 Nut, Hex 1/2-13 1629 560-001-360 O-ring 230 612-170-520 Assembly, Outer Diaphragm Plate 2

612-170-542 Assembly, Outer Diaphragm Plate 2612-170-552 Assembly, Outer Diaphragm Plate 2

31 612-171-157 Plate, Inner Diaphragm 232 620-018-115 Plunger, Actuator 233 670-048-520 Retainer, Ball 4

670-048-542 Retainer, Ball 4670-048-552 Retainer, Ball 4

34 675-042-115 Ring, Retainer 235 685-054-120 Rod, Diaphragm 136 685-055-115 Rod, Support 2

685-055-308 Rod, Support 237 720-012-360 Seal, Diaphragm Rod 238 720-044-600 Seal, Manifold Spacer 839 720-047-600 Seal, Check Valve 840 722-079-520 Seat, Check Valve 4

722-079-542 Seat, Check Valve 4722-079-552 Seat, Check Valve 4

41 770-062-520 Spacer, Manifold 4770-062-542 Spacer, Manifold 4770-062-552 Spacer, Manifold 4

42 901-009-115 Washer, Flat 5/16" 72901-009-308 Washer, Flat 5/16" 72



NOT SHOWN:535-069-000 Nameplate

ITEM PART NUMBER DESCRIPTION QTY


RuppGUARD ™ Option forVirgin PTFE EquippedPumps Drawing

S1F Spill Prevention Repair Parts List for Virgin PTFE EquippedPumpsItem Part Number Description Qty45 170-114-115 Capscrew, Hex Hd 3/8-16 x 4.25 16

(replace 170-020-115, qty 16 of 32)170-114-308 Capscrew, Hex Hd 3/8-16 x 4.25 16

(replace 170-020-115, qty 16 of 32)46 196-159-552 Chamber, Spill Prevention 2

196-159-600 Chamber, Spill Prevention 248 286-094-600 Diaphragm, Pumping 249 518-137-520 Manifold, Spill Prevention 2

(replace 518-136-520)518-137-520E Manifold, 25mm DIN 2518-137-542 Manifold, Spill Prevention 2


(replace 518-136-552)518-137-552E Manifold, 25mm DIN 2

50 538-022-110 Nipple, Pipe 4538-022-308 Nipple, Pipe 4

51 560-078-611 O-Ring 852 618-003-110 Plug, Pipe 4

618-003-308 Plug, Pipe 453 618-025-110 Plug, Boss 4

618-025-308 Plug, Boss 454 618-031-110 Plug, Boss 4

618-031-308 Plug, Boss 456 835-005-110 Tee, Pipe 4

835-055-308 Tee, Pipe 457 860-056-606 Tube, Sight 258 866-060-110 Connector, Tube 438 720-056-600 Seal, Manifold (Replaces 720-044-600) 4

720-057-600 Seal, Manifold (PVDF only) 4(Replaces 720-044-600)

55 770-064-520 Spacer, Manifold (Replaces 770-062-520) 4770-064-552 Spacer, Manifold (Replaces 770-062-552) 4

*Note: The diaphragm is to be installed with the convexside facing toward the outer chambers. See drawing.

Note:Item 48The diaphragmis to beinstalled withthe convexside facingtoward theouterchambers.


RuppGUARD™ FOR VIRGIN PTFEEQUIPPED PUMPS CONCEPT

The spill prevention option preventsthe air end components from beingcontaminated or damaged when apumping diaphragm ruptures whilepumping caustic or toxic materials. Italso helps to protect the environment.With the installation of optional leakdetectors (either mechanical orelectronic) the diaphragm rupture can bedetected. The pump can then be shutdown and repaired before any caustic ortoxic materials can enter the air end andbe exhausted into the surroundingenvironment.

RuppGUARD™ OPTIONDIAPHRAGM SERVICING

To service the diaphragms first shutoff the suction, then shut off thedischarge lines to the pump. Next shutoff the compressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump. Drainany remaining pumped liquid from thepump. Remove the pump beforeservicing.

Next, drain the fluid from the spillprevention chambers. This can be doneby removing the bottom plug (item 53)from each spill prevention chamber.

After the fluid from the spill preventionchambers has been drained, the wet endcomponents can now be removed. Seediaphragm servicing section for detailedinstructions. The spill prevention optionhas two additional virgin PTFE pumpingdiaphragms (item 48). These diaphragmsare installed with the natural convexcurve toward the outer chamber (items

14 from the pump assembly drawing).The molded directional arrows on thediaphragms must point vertically.

FILLING RuppGUARD™CHAMBERS WITH LIQUID

THE CHAMBERS ARE FILLEDWITH WATER AT THE FACTORY.

If you prefer to substitute anotherliquid, to prevent system contaminationconsult the factory first to determinecompatibility of the substitute with pumpconstruction.

Follow the steps listed here to replacethe liquid in the pump after disassemblyor liquid loss:

1. Drain the fluid in the spill preventionchambers by removing the bottom twoboss plugs (items 53). Replace thebottom two boss plugs after the fluid isdrained.

2. Remove the eight capscrews(item 9) fastening the dischargemanifold and elbows to the outerchambers (items 14). The dischargemanifolds and elbows can now beremoved.

3. Remove the top two boss plugs(items 53). The spill preventionchambers are filled through the exposedports.

4. Apply air pressure to the airdistribution valve. Install safety clip (item1-F) into the smaller unthreaded hole inone end cap (item 1-D). This locks thevalve spool to one side, keeping thepump from shifting.

5. Face the side of the pump withthe installed safety clip. If the safety clipis installed in the top end cap, fill theleft spill containment chamber. If the

safety clip is installed on the bottom endcap, fill the right spill prevention chamber.The volume of fluid is 1198 ml (40.49 fl.oz.). It is important that the exact amountof fluid is used. Too little or too muchfluid causes premature diaphragm failureand erratic pumping.

6. Loosely reinstall one boss plug(item 53) to the filled spill preventionchamber.

7. Shut off air supply. Remove safetyclip. Adjust the air line regulator so thatair pressure slowly fills the pump. Thediaphragm expands, forcing the fluid inthe chamber to be slowly displaced.When the pump shifts to the oppositeside, quickly install the safety clip.

8. Loosen the top boss plug on thefilled chambers. This allows fluid in thechamber to purge trapped air from thechamber. This can be seen by watchingthe column of fluid in the sight tube.When fluid appears at the top of the port,quickly tighten the boss plug. Fluid lossof 1 to 2ml is acceptable.

9. Tilt the pump so the uppermostpipe tee (item 56) is in the verticalposition. Loosen the pipe plug (item 52).This will allow trapped air to purgethrough the pipe tee. When fluid appearsat the tee opening, reinstall the pipeplug.

NOTE: If all air is not purged usingthis procedure, remove the check valvecomponents from the top port of the outerchamber (item 14). Apply manualpressure to the pumping diaphragm byinserting a blunt instrument into the topport of the outer chamber and applyingpressure to the diaphragm. Loosen thepipe plug (item 52) allowing the fluid to

Read these instructionscompletely, before in-stallation and start-up. Itis the responsibility ofthe purchaser to retain

this manual for reference. Failure tocomply with the recommendations statedin this manual will damage the pump, andvoid factory warranty.

IMPORTANT

purge any remaining trapped air.Reinstall the plug.

10. Repeat steps 5 through 9 to fillopposite spill prevention chamber.

11. Reinstall the check valvecomponents, discharge manifold andelbows to the pump. The pump is nowready for operation.


RuppGUARD ™ Option for TPEEquipped Pumps Drawing

S1F Spill Prevention for TPE Equipped Pumps Repair Parts ListItem Part Number Description Qty45 170-114-115 Capscrew, Hex Hd 3/8-16 x 4.25 16

(replace 170-020-115, qty 16 of 32)170-114-308 Capscrew, Hex Hd 3/8-16 x 4.25 16

(replace 170-020-115, qty 16 of 32)46 196-159-552 Chamber, Spill Prevention 2

196-159-600 Chamber, Spill Prevention 249 518-137-520 Manifold, Spill Prevention 2


(replace 518-136-552)518-137-552E Manifold, 25mm DIN 2

50 538-022-110 Nipple, Pipe 4538-022-308 Nipple, Pipe 4

51 560-078-611 O-Ring 852 618-003-110 Plug, Pipe 4

618-003-308 Plug, Pipe 453 618-025-110 Plug, Boss 4

618-025-308 Plug, Boss 454 618-031-110 Plug, Boss 4

618-031-308 Plug, Boss 455 770-066-520 Spacer, Manifold (used w/ overlay) 4

770-066-542 Spacer, Manifold (used w/ overlay) 4770-066-552 Spacer, Manifold (used w/ overlay) 4

56 835-005-110 Tee, Pipe 4835-055-308 Tee, Pipe 4

57 860-056-606 Tube, Sight 258 866-060-110 Connector, Tube 417 286-093-600 Diaphragm, Overlay is not used 248 286-092-354* Diaphragm, Pumping 2

(Replaces 286-094-600)38 720-056-600 Seal, Manifold Replaces 720-044-600) 4

720-057-600 Seal, Manifold (PVDF only) 4(Replaces 720-044-600)

55 770-064-520 Spacer, Manifold (Replaces 770-062-520) 4770-064-552 Spacer, Manifold (Replaces 770-062-552) 4

*Note: The diaphragm is to be installed with the concaveside facing toward the outer chambers. See drawing.

Note:Item 48The diaphragmis to beinstalled withthe concaveside facingtoward theouterchambers.


RuppGUARD™ FOR TPEEQUIPPED PUMPS CONCEPT

The spill prevention option preventsthe air end components from beingcontaminated or damaged when apumping diaphragm ruptures whilepumping caustic or toxic materials. Italso helps to protect the environment.With the installation of optional leakdetectors (either mechanical orelectronic) the diaphragm rupture can bedetected. The pump can then be shutdown and repaired before any caustic ortoxic materials can enter the air end andbe exhausted into the surroundingenvironment.

RuppGUARD™ OPTIONDIAPHRAGM SERVICING

To service the diaphragms first shutoff the suction, then shut off thedischarge lines to the pump. Next shutoff the compressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump. Drainany remaining pumped liquid from thepump. Remove the pump beforeservicing.

Next, drain the fluid from the spillprevention chambers. This can be doneby removing the bottom plug (item 53)from each spill prevention chamber.

After the fluid from the spill preventionchambers has been drained, the wet endcomponents can now be removed. Seediaphragm servicing section for detailedinstructions. The spill prevention optionhas two additional TPE pumpingdiaphragms (item 48). These diaphragmsare installed with the natural concavecurve toward the outer chamber (items

14 from the pump assembly drawing).The molded directional arrows on thediaphragms must point vertically.

FILLING RuppGUARD™CHAMBERS WITH LIQUID

THE CHAMBERS ARE FILLEDWITH WATER AT THE FACTORY.

If you prefer to substitute anotherliquid, to prevent system contaminationconsult the factory first to determinecompatibility of the substitute with pumpconstruction.

Follow the steps listed here to replacethe liquid in the pump after disassemblyor liquid loss:

1. Drain the fluid in the spill preventionchambers by removing the bottom twoboss plugs (items 53). Replace thebottom two boss plugs after the fluid isdrained.

2. Remove the eight capscrews (item9) fastening the discharge manifold andelbows to the outer chambers (items 14).The discharge manifolds and elbows cannow be removed.

3. Remove the top two boss plugs(items 53). The spill preventionchambers are filled through the exposedports.

4. Apply air pressure to the airdistribution valve. Install safety clip (item1-F) into the smaller unthreaded hole inone end cap (item 1-D). This locks thevalve spool to one side, keeping thepump from shifting.

5. Face the side of the pump withthe installed safety clip. If the safety clipis installed in the top end cap, fill theleft spill prevention chamber. If the safetyclip is installed on the bottom end cap,

fill the right spill prevention chamber.6. Loosely reinstall one boss plug

(item 53) to the filled spill preventionchamber.

7. Shut off air supply. Remove safetyclip. Adjust the air line regulator so thatair pressure slowly fills the pump. Thediaphragm expands, forcing the fluid inthe chamber to be slowly displaced.When the pump shifts to the oppositeside, quickly install the safety clip.

8. Loosen the top boss plug on thefilled chambers. This allows fluid in thechamber to purge trapped air from thechamber. This can be seen by watchingthe column of fluid in the sight tube.When fluid appears at the top of the port,quickly tighten the boss plug. Fluid lossof 1 to 2ml is acceptable.

9. Tilt the pump so the uppermostpipe tee (item 56) is in the verticalposition. Loosen the pipe plug (item 52).This will allow trapped air to purgethrough the pipe tee. When fluid appearsat the tee opening, reinstall the pipeplug.

NOTE: If all air is not purged usingthis procedure, remove the check valvecomponents from the top port of the outerchamber (item 14). Apply manualpressure to the pumping diaphragm byinserting a blunt instrument into the topport of the outer chamber and applyingpressure to the diaphragm. Loosen thepipe plug (item 52) allowing the fluid topurge any remaining trapped air.Reinstall the plug.

10. Repeat steps 5 through 9 to fillopposite spill prevention chamber.



IMPORTANT

11. Reinstall the check valvecomponents, discharge manifold andelbows to the pump. The pump is nowready for operation.


Air Distribution Valve Assembly DrawingS1F Design Level 2

1-J

1-D

1-F

1-H

1-B

1-G

1-E

1-C

1-A

1-A

1-C

1-E1-G

1-H

1-G

1-G1-G

1-G

1-G

1-G

Main Air Valve Assembly Parts ListItem Part Number Description Qty1 031-155-000 Main Air Valve Assembly 11-A 031-151-000 Spool Assembly 11-B 095-085-551 Body, Air Valve 11-C 132-031-353 Bumper 21-D 165-106-551 Cap, Muffler 11-E 165-117-552 Cap, End 21-F 530-030-550 Muffler 11-G 560-103-360 O-Ring 81-H 675-055-115 Ring, Retaining 21-J 710-015-115 Screw, Self-tapping 6

For pumps equipped with PTFE Coated Hardware1 031-155-002 Air Valve Assembly 1

(Includes all items used on 031-155-000 except:)1-H 675-055-308 Ring, Retaining 21-J 710-019-308 Screw Selftapping 6

For pumps equipped with PTFE coated hardware option:1 031-156-000 Air Valve Assembly 1

(Includes all items used on 031-155-000 minus items 1-D, 1-F & 1-J)

For pumps with alternate Mesh or Sound Dampening mufflersor piped exhaust:1 031-156-002 Air Valve Assembly 1

(Includes all items used on 031-156-000 except:)1-H 675-055-308 Ring, Retaining 2


AIR DISTRIBUTION VALVESERVICING

To service the air valve first shut offthe compressed air, bleed the pressurefrom the pump, and disconnect the airsupply line from the pump.

STEP #1: See Composite Repair andParts Drawing.

Using a 5/16" Allen wrench, removethe four hex socket capscrews (item 13)and four flat washers (item 43). Removethe air valve assembly (item 1) from thepump.

Remove and inspect gasket (item 21)for cracks or damage. Replace gasket ifneeded.

STEP #2: Disassembly of the air valve.To access the internal air valve

components first remove the two retainingrings (item 1-K) from each end of the airvalve assembly using clip ring pliers.

Next remove the two end caps (item1-E). Inspect the o-rings (item 1-G) forcuts or wear. Replace the o-rings ifnecessary.

Remove the spool (part of item 1-A)from the sleeve. Be careful not to stratchor damage the outer diameter of thespool. Wipe spool with a soft cloth andinspect for scratches or wear.

Inspect the inner diameter of thesleeve (part of item 1-A) for dirt,scratches, or other contaminates.Remove the sleeve if needed and replaceboth the sleeve and spool with a newsleeve and spool set (item 1-A).

STEP #3: Reassembly of the air valve. Install one bumper, (item 1-C) and

one end cap (item 1-E) with an o-ring(item 1-G) into one end of the air valvebody (item 1-B). Install one retaining ring(item 1-H) into the groove on the sameend.

Remove the new sleeve an spool set(item 1-A) from the plastic bag. Carefullyremove the spool from the sleeve. Installthe six o-rings (item 1-G) into the sixgrooves on the sleeve. Apply a lightcoating of grease to the o-rings beforeinstalling the sleeve into the valve body(item 1-B), align the slots in the sleevewith the slots in the valve body. Insertthe spool into the sleeve. Be careful notto scratch or damage the spool duringinstallation. Push the spool in until ittouches the bumper on the opposite end.

Install the remaining bumper, end capwith o-ring, and retaining ring.

Fasten the air valve assembly (item1) and gasket (item 21) to the pump.

Connect the compressed air line tothe pump. The pump is now ready foroperation.



IMPORTANT


Air Valve Assembly Drawing with Stroke Indicator OptionS1F Design Level 2

1-J

1-D

1-F

1-H

1-B

1-G

1-E

1-M1-C

1-A

1-A

1-C1-M

1-E1-G

1-H

1-K

1-G

1-G

1-G

1-G

1-G1-G Pilot Valve Assembly Parts List

Item Part Number Description Qty1 031-157-000 Air Valve Assembly 11-A 031-152-000 Sleeve and Spool Set w/Pins 11-B 095-085-551 Body, Air Valve 11-C 132-031-552 Bumper 21-D 165-106-551 Cap, Muffler 11-E 165-105-147 Cap, End 21-F 530-030-550 Muffler 11-G 560-103-360 O-Ring 81-H 675-055-115 Ring, Retaining 21-J 710-015-115 Screw, Self-Tapping 61-K 210-008-330 Clip, Safety 11-M 560-029-360 O-Ring 2

For Pumps with Alternate Mesh, Sound Dampening Mufflersor Piped Exhaust:1 031-158-000 Air Valve Assembly 1

(includes all items on 031-157-000 minus 1-D, 1-F,&1-J)




IMPORTANTAIR DISTRIBUTION VALVE WITHSTROKE INDICATOR OPTIONSERVICING

To service the air valve first shut offthe compressed air, bleed the pressurefrom the pump, and disconnect the airsupply line from the pump.

STEP #1: See Composite Repair andParts Drawing.

Using a 5/16" Allen wrench, removethe four hex socket capscrews (item 13)and four flat washers (item 43). Removethe air valve assembly (item 1) from thepump.

Remove and inspect gasket (item 21)for cracks or damage. Replace gasket ifneeded.

STEP #2: Disassembly of the air valve.To access the internal air valve

components first remove the two retainingrings (item 1-K) from each end of the airvalve assembly using clip ring pliers.

Next remove the two end caps (item1-E). Inspect the o-rings (item 1-G) forcuts or wear. Replace the o-rings ifnecessary.

Remove the spool (part of item 1-A)from the sleeve. Be careful not to scratchor damage the outer diameter of thespool. Wipe spool with a soft cloth andinspect for scratches or wear.

Inspect the inner diameter of thesleeve (part of item 1-A) for dirt,scratches, or other contaminates.Remove the sleeve if needed and replaceboth the sleeve and spool with a newsleeve and spool set (item 1-A).

STEP #3: Reassembly of the air valve. Install one bumper (item 1-C) and

one end cap (item 1-E) with an o-ring(item 1-G) into one end of the air valvebody (item 1-B). Install one retaining ring(item 1-H) into the groove on the sameend. Insert the safety clip (item 1-K)through the small unthreaded hole in theend cap.

Remove the new sleeve an spool set(item 1-A) from the plastic bag. Carefullyremove the spool from the sleeve. Installthe six o-rings (item 1-G) into the sixgrooves on the sleeve. Apply a lightcoating of grease to the o-rings beforeinstalling the sleeve into the valve body(item 1-B), align the slots in the sleevewith the slots in the valve body. Insertthe spool into the sleeve. Be careful notto scratch or damage the spool duringinstallation. Push the spool in until thepin touches the safety clip on theopposite end.

Install the remaining bumper, end capwith o-ring, and retaining ring.

Fasten the air valve assembly (item1) and gasket (item 21) to the pump.

Connect the compressed air line tothe pump. The pump is now ready foroperation.


Pilot Valve Assembly Parts ListItem Part Number Description Qty3 095-090-000 Pilot Valve Assembly3-A 095-084-551 Body, Pilot Valve 13-B 135-037-506 Bushing 23-C 675-057-115 Ring, Spiral Retaining 23-D 770-065-175 Spacer 53-E 775-041-506 Spool, Pilot 13-F 917-003-374 Wiper 6

3-C

3-F

3-F

3-F

3-F

3-F

3-F

3-A

3-E

3-C

3-B

3-D

3-D

3-D

3-D

3-D

3-B

Pilot Valve Assembly Drawing




IMPORTANTPILOT VALVE SERVICING

To service the pilot valve first shut offthe compressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump. Insertthe safety clip (item 1-F from AirDistribution Valve assembly drawing)into the smaller unthreaded holes in theend cap (item 1-D from air distributionvalve assembly drawing).

Step #1: See PUMP ASSEMBLYDRAWING.

Using a 9/16

" wrench or socket,remove the four capscrews (items 11)and four flat washers (items 43). Removethe air inlet cap (item 8) and air inletgasket (item 19). The pilot valveassembly (item 3) can now be removedfor inspection or service.

Step #2: Disassembly of the pilotvalve.

Remove the pilot valve spool (item3-E). Wipe clean, and inspect for dirt,scratches or wear. Replace the spool ifnecessary.

Remove the two spiral retaining rings(items 3-C) from each end of the pilotvalve body by inserting the tip of a smallflat screw driver under the notch in theretaining ring. Lift and push the ringclockwise in a circular motion.

Remove the two pilot valve bushings(items 3-B), five spacers (items 3-D),and six spool wipers (items 3-F) bypushing gently from other end of thepilot valve body. Inspect the wipers forcuts and/or wear. Replace any wipersas necessary.

Step #3: Re-assembly of the pilotvalve.

First install a spiral retaining ring toone end of the pilot valve body. Spreadthe spiral and insert one end into thegroove in the pilot valve body. Twist thering in a clockwise motion until the fullring is snapped into the groove. Installone bushing making sure the step sidefaces toward the wiper. Apply a lightcoating of grease to the outside diameterof each wiper. Next, gently push in thewipers and spacers until they are againstthe installed retaining ring in the oppositeend of the pilot valve body. Install theremaining bushing making sure the stepside faces the wiper. Install the remainingspiral retaining ring using the samemethod described.

Apply a light coating of grease to theinner diameter of each wiper. Also applya light coating of grease to the outerdiameter of the pilot valve spool and gentlypush the spool through each wiper.

Step #4: Inspect the actuatorplungers.

See PUMP ASSEMBLY DRAWING.The actuator plungers (items 32) can

be reached through the stem cavity ofthe pilot valve in the intermediateassembly (item 4).

Remove the plungers (items 32) fromthe bushings (item 7) in each end of thecavity. Inspect the installed o-ring (items29) for cuts and/or wear. Replace the o-rings if necessary. Apply a light coatingof grease to each o-ring and re-installthe plungers in to the bushings. Pushthe plungers in as far as they will go.

Step #5: Re-install the pilot valvessembly into the intermediate assembly.

Be careful to align the ends of thestem between the plungers wheninserting the stem of the pilot valve intothe cavity of the intermediate.

Re-install the gasket (item 19), airinlet cap (item 8), capscrews andwashers (items 11 and 43).

Connect the air supply to the pump.Remove the safety clip (item 1-F) fromthe end cap (item 1-D). The pump is nowready for operation.


Diaphragm Service Drawing,Non-Overlay

Diaphragm Service Drawing,with Overlay


DIAPHRAGM SERVICINGTo service the diaphragms first shut

off the suction, then shut off thedischarge lines to the pump. Shut off thecompressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump. Drainany remaining liquid from the pump.

Step #1: See the pump compositerepair parts drawing, and the diaphragmservicing illustration.

Using a 9/16" wrench or socket,remove the 16 capscrews (items 9), hexnuts and washers that fasten the elbows(items 18) to the outer chambers (items14). Remove the elbows with themanifolds and spacers attached.

Step #2: Removing the outerchambers.

Using a 9/16" wrench or socket,remove the 16 capscrews (items 9), hexnuts and washers that fasten the outerchambers, diaphragms, and innerchambers (items 15) together.

Step #3: Removing the diaphragmassemblies.

Use a 13/8" (35mm) wrench or sixpointed socket to remove the diaphragmassemblies (outer plate, diaphragm, andinner plate) from the diaphragm rod (item35) by turning counterclockwise.

Insert a 1/4-20 capscrew or set screwinto the smaller tapped hole in the innerdiaphragm plate (item 31). Insert theprotruding stud and the 1/4-20 fastenerloosely into a vise. Use a 13/8" wrench orsocket to remove the outer diaphragm

plate (item 30) by turningcounterclockwise. Inspect thediaphragm (item 16) for cuts, punctures,abrasive wear or chemical attack.Replace the diaphragms if necessary.

Step #4: Installing the diaphragms.Push the threaded stud of the outer

diaphragm plate through the center holeof the diaphragm. Thread the inner plateclockwise onto the stud. Use a torquewrench to tighten the diaphragmassembly together to 20 ft. Lbs. (27.11Newton meters). Allow a minimum of 15minutes to elapse after torquing, then re-torque the assembly to compensate forstress relaxation in the clampedassembly.

Step #5: Installing the diaphragmassemblies to the pump.

Make sure the bumper (item 6) isinstalled over the diaphragm rod.

Thread the stud of the one diaphragmassembly clockwise into the tapped holeat the end of the diaphragm rod (item35) until the inner diaphragm plate is flushto the end of the rod. Insert rod into pump.

Align the bolt holes in the diaphragmwith the bolt pattern in the inner chamber(item 15). Make sure the moldeddirectional arrows on the diaphragm pointvertically.

Fasten the outer chamber (item 14)to the pump, using the capscrews (items9), hex nuts and flat washers.

On the opposite side of the pump,pull the diaphragm rod out as far aspossible. Make sure the bumper (item6) is installed over the diaphragm rod.

Thread the stud of the remainingdiaphragm assembly clockwise into thetapped hole at the end of the diaphragmrod (item 35) as far as possible and stillallow for alignment of the bolt holes inthe diaphragm with the bolt pattern inthe inner chamber. The moldeddirectional arrows on the diaphragm mustpoint vertically.

Fasten the remaining outer chamber(item 14) to the pump, using thecapscrews (items 9), hex nuts and flatwashers.

Step #6: Re-install the elbow/spacer/manifold assemblies to the pump, usingthe capscrews (items 9), hex nuts andflat washers.

The pump is now ready to be re-installed, connected and returned tooperation.

OVERLAY DIAPHRAGM SERVICINGThe PTFE overlay diaphragm (item

17) is designed to fit snugly over theexterior of the standard TPE diaphragm(item 16).

The molded directional arrows on theoverlay diaphragm must point vertically.

Follow the same proceduresdescribed for the standard diaphragm forremoval and installation.



IMPORTANT


SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING



MUFFLER

LIQUIDLEVEL

SUCTIONLINE

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

MUFFLER

PUMPING HAZARDOUS LIQUIDSWhen a diaphragm fails, the pumped

liquid or fumes enter the air end of thepump. Fumes are exhausted into thesurrounding environment. When pumpinghazardous or toxic materials, theexhaust air must be piped to anappropriate area for safe disposal. Seeillustration #1 at right.

This pump can be submerged if thepump materials of construction arecompatible with the liquid being pumped.The air exhaust must be piped above theliquid level. See illustration #2 at right.Piping used for the air exhaust must notbe smaller than 1" (2.54 cm) diameter.Reducing the pipe size will restrict airflow and reduce pump performance.When the pumped product source is ata higher level than the pump (floodedsuction condition), pipe the exhausthigher than the product source to preventsiphoning spills. See illustration #3 atright.

CONVERTING THE PUMP FORPIPING THE EXHAUST AIR

The following steps are necessary toconvert the pump to pipe the exhaust airaway from the pump.

Use a #8 Torx or flat screwdriver toremove the six self-tapping screws (item1-L).

Remove the muffler cap and muffler(items 1-E and 1-G). The ½" NPT moldedthreads in the air distribution valve body(item 1-B).

Piping or hose may now be installed.

IMPORTANT INSTALLATIONNOTE: The manufacturer recommendsinstalling a flexible hose or connectionbetween the pump and any rigidplumbing. This reduces stresses on themolded plastic threads of the air exhaustport. Failure to do so may result indamage to the air distribution valve body.

Any piping or hose connected to thepump’s air exhaust port must bephysically supported. Failure to supportthese connections could also result indamage to the air distribution valve body.

CONVERTED EXHAUSTILLUSTRATION

Illustration #1

Illustration #2

Illustration #3

Exhaust Conversion Drawing


Modular Check Valve DrawingMODULAR CHECK VALVESERVICING

Before servicing the check valves, firstshut off the suction line and then thedischarge line to the pump. Next, shutoff the compressed air supply, bleed airpressure from the pump, and disconnectthe air supply line from the pump. Drainany remaining fluid from the pump. Thepump can now be removed for service.

To access the modular check valve,remove the elbows (items 18 from pumpcomposite repair parts drawing). Use a9/16" wrench or socket to remove thefasteners. Once the elbows are removed,the modular check valves can be seenin the cavities of the outer chamber(items 14).

Next remove the check valve seal(item 39). Inspect the seal for cuts orpinched areas. Replace seal as needed.

Disassemble the component parts ofeach modular check valve. Inspect thecheck valve retainer (item 33) for cuts,abrasive wear, or embedded materials.Replace as needed.

Inspect the check balls (items 2) forwear, abrasion, or cuts on the sphericalsurface. The check valve seats (items40) should be inspected for cuts, abrasivewear, or embedded material on thesurfaces of both the external and internalchamfers. The spherical surface of thecheck balls must seat flush to thesurface of the inner chamfer on the checkvalve seats for the pump to operate topeak efficiency. Replace any worn ordamaged parts as necessary.

Remove the remaining check valveseal (item 39). Inspect the seal for cutsor pinched areas. Replace seal asneeded.

Re-assemble the modular checkvalve. The seat should fit snugly into theretainer.

Place a check valve seal (item 39)into the cavity of the outer chamber (item14). Make sure the chamfer side of theseal faces out. Insert the modular checkvalve into the outer chamber with theretainer facing up. Install a check valveseal (item 39). Make sure the chamferside of the seal faces the chamfer onthe check valve seat or retainer.

The pump can now reassembled,reconnected and returned to operation.


Dual Port Option Drawing

1" ANSI STYLE FLANGE CONNECTIONFOUR ø.62 HOLES ON A ø3.12 BOLT CIRCLE

1" ANSI STYLE FLANGE CONNECTIONFOUR ø.62 HOLES ON A ø3.12 BOLT CIRCLE


DUAL PORTING OPTIONSSeveral dual porting options are

possible. The pump can be convertedto a dual port arrangement on both thesuction and the discharge ends. Theporting can be configured to a singlesuction and a dual discharge. The portingcan be changed to a dual suction and asingle discharge.

The above changes are possiblebecause the porting flange of the elbows(items 18) are designed to mate withstandard 125# ANSI style 4-bolt, 1" pipeflanges.

Dual porting of both suction anddischarge ends of the pump

Converting the pump from thestandard single suction and dischargeporting configuration to dual porting ateach end is easy. Simply remove themanifold seals, spacers, and manifolds(items 38, 41, and 23 from pumpassembly drawing) from the pump.

The discharge and suction elbowscan be rotated at 90° increments (seearrows and optional positioning in theDual Porting Drawing.

Single porting of the suction anddual porting of the pump discharge

To convert the pump from thestandard single suction and singledischarge porting configuration to a dualdischarge porting arrangement removethe only the discharge manifolds,spacers, and manifold seals. Positionthe discharge elbows in the desireddirection at 90° increments. (See arrowsand optional positioning in the DualPorting Drawing.)

Dual porting of the suction andsingle porting of the pumpdischarge

To convert the pump from thestandard single suction and singledischarge porting configuration to a dualsuction porting arrangement remove theonly the suction (bottom) manifolds,spacers, and manifold seals.

Position the suction elbows in thedesired direction at 90° increments. (Seearrows and optional positioning in theDual Porting Drawing.)



IMPORTANT


Leak Detection Options Drawing

RuppTech® LEAK DETECTION OPTION A (ELECTRONIC)

Follow instructions found elsewhere in this manual, “Filling theRuppGUARD™ Spill Prevention Chambers” when installing leakdetectors.

Electronic Leak Detector InstallationKit 032-033-000 110VACKit 032-034-000 220VACTo install electronic leak detectors, remove the bottom ¼" NPT

pipe plug on the visual sight tube (item 56). Insert leak detector intothe ¼" pipe tee (item 55).

LEAK DETECTION OPTION B (MECHANICAL)

Follow instructions found elsewhere in this manual, “Filling theRuppGUARD™ Spill Prevention Chambers” when installing leakdetectors.

Mechanical Leak Detector InstallationKit 031-023-110To install mechanical leak detectors, remove the bottom ¼" NPT

pipe plug on the visual sight tube (item 56). Insert leak detector intothe ¼" pipe tee (item 55).

MUFFLER CAP

For pumps with530-030-550ENCLOSED MUFFLER

710-014-330Self-tapping Screws(Qty of 4)

612-187-552Mounting Plate

For pumps withALTERNATE MUFFLERS

710-009-115Self-tapping Screws(Qty of 4)

612-186-552Mounting Plate


PULSE OUTPUT KIT OPTIONThis pump can be fitted with a Pulse Output Kit. This converts the mechanical

strokes of the pump to an electrical signal which interfaces with the RuppTech®Stroke Counter/ Batch Controller or user control devices such as a PLC.

The Pulse Output Kits mount directly onto the Muffler Cap on the Air DistributionValve Assembly or onto the Air Distribution Valve Assembly when the threadedexhaust port or an auxiliary muffler is being used.

See the individual kits listed on the Pump Repair Parts List for further information.

RuppTech® Pulse Output Kit Drawing

Exhaust Port or AuxiliaryMuffler Setup

Integral Muffler Setup

PULSE OUTPUT KIT

PULSE OUTPUT KIT

ADAPTER PLATE

MUFFLER CAP

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