Warren rupp WR10 3/8" User manual

WARREN RUPP®,IDEX AODD, Inc. • A Unit of IDEX Corporation • 800 N. Main St., P.O. Box 1568, Mansfield, Ohio 44901-1568 USA
Telephone [phone] • Fax [phone] • www.warrenrupp.com
• Polypropylene
• Kynar
WR10 3/8"
Bolted Plastic Pumps
Operating Instructions

Table of Contents
Warnings, Cautions & Notices .................................................. 1
Specifications & Performance ................................................... 2
Installation, Operation & Maintenance ...................................... 3
Troubleshooting ........................................................................ 4
Parts List .................................................................................. 5
Pump Drawing, Exploded View ................................................. 6
Materials, Temperature Limits & Compatibility ......................... 7
Declaration of Conformity ......................................................... 8
Notes......................................................................................... 9
Operating and Service Manual
Model 3/8" Bolted Plastic Pumps

Page 1
WARNINGS, CAUTIONS & NOTICES
Please read all cautions, warnings and notes
completely before installation and start-up.
It is the responsibility of the purchaser to retain this
manual for reference. Failure to comply with the
recommendations stated in this manual may damage
the pump and void the factory warranty.
WARNINGS
CAUTIONS
NOTICES
To prevent static sparking the pump, piping,
valves, and containers must be grounded. Fire
or explosion can occur when handling flammable fluids
and whenever discharge of static electricity is a hazard.
Pump exhaust may contain contaminants that
can cause serious injury. Take precautions
to pipe exhaust away from work area if pumping
chemicals, hazardous or flammable materials.
Maximum temperature limits are based on
mechanical stress only. Certain chemicals
will significantly reduce maximum safe operating
temperatures. For chemical compatibility and
temperature limits please refer to the Chemical
Resistance Guide.
Do not exceed the maximum inlet air pressure
as stated on the pump model tag.
The process fluid and cleaning fluids must be
chemically compatible with all wetted pump
components. Please refer to the Chemical Resistance
Guide for additional information.
Thoroughly flush pump before installing into
process lines. FDA and sanitary approved
pumps should be cleaned or sanitized before use.
Noise levels can exceed 85 dBA.
Always wear ear and eye protection when
operating or repairing pumps.
Never allow the piping system to be supported
by the pump manifolds or valve housing.
These components are not designed to support
structural weight and pump failure may result..
Disconnect the compressed air line to the
pump and allow all air pressure to bleed
from pump prior to performing any maintenance
on the pump. Disconnect all intake, discharge and
air lines. Drain the pump and dispose of fluid into a
suitable container.
Check temperature limits for all wetted
components when choosing pump materials.
Temperature limits may vary depending on the material.
All operators of the equipment should
be properly trained to ensure safe working
practices.
Blow out air line for at least 15 seconds
before attaching to pump to make sure that all
debris is removed. Use an in-line air filter.
Tighten both outer pistons at the same
time to ensure a tight fit when installing
PTFE diaphragms. See torque settings for additional
details.
The pump does not require continuous
lubrication.
Before disassembly of clamp band pumps,
mark a line from each liquid chamber to its
corresponding air chamber. This will ensure proper
alignment when reassembling.
Compressed air should not be applied to
the exhaust port. If this happens the pump will
not function.
You must check the tightness of all hardware
prior to installation.
Clamp style pumps fitted with PTFE or XLTPE
come standard from the factory with expanded
PTFE liquid chamber gaskets. PTFE gaskets cannot
be reused.

Page 2
Specifications
Consult factory for certified drawings.
Meters Feet
Discharge Head in PSI
153
0
100
90
80
70
60
50
40
30
20
10
0
240
220
200
180
160
140
120
100
80
60
40
20
0
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
6498720
5 101520253035
Capacity in Liters Per Minute
Capacity in U.S. Gallons Per Minute
Displacement Per Stroke, 0.0045 Gal. (0.017 L)
1
3
5
AIR CONSUMPTION IN SCFM
AIR PRESSURE IN PSI
SCFM M3/HR
1 1.7
3 5.1
5 8.5
Flow Rate adjustable to . . 0-6.8 gpm (261 lpm)
Port Size
Inlet and Discharge . . . . . 3/8" Female NPT (BSP)
Air Inlet. . . . . . . . . . . . . . . . 0.25" Female NPT
Air Exhaust . . . . . . . . . . . . . 0.25" Female NPT
Suction Lift . . . . . . . . . . . . . . . 15' (4.57 m) Dry
PTFE . . . . . . . . . . . . . . . . . . . . . 11' (3.40 m) Dry
Max. Particle Size (Diameter) . . 0.10"(2.25 mm)
dB(A) Reading . . . . . . . . . . . . . . . . . . . . 78 dB(A)
Shipping Weights
Polypropylene . . . . . . . . . . . . . . . 3 lbs (1.40 kg)
Kynar . . . . . . . . . . . . . . . . . . . .4.5 lbs. (2.04 kg)
CAUTION: Do not exceed 100 psig (6.8 bars) air supply or liquid pressure.
Performance
2.79
[71]
0.94
[24]
Opposite Side:
1/4" Female NPT Air Exhaust
Removable Foot Pad
5/16" Mounting Hole 3/8" Female NPT
Fluid Discharge Connection
3/8" Female NPT
Fluid Suction
Connection
1/4" Female NPT
Air Inlet Connection
5.32
[135]
0.20
[5]
15.71
[399]
2.07
[53]
4.09
[104]
POLY
5.13
[130]
KYNAR
5.08
[129]
POLY
5.72
[145]
KYNAR
5.67
[144]
2.07
[53]
WR10 SPECIFICATIONS & PERFORMANCE
Dimensions
Front
Inches
[mm]
Side Bottom

Page 3
The pump should be mounted in a vertical
position. In permanent installations, the pump
should be attached to plant piping using a flexible
coupling on both the
intake and discharge
connections to reduce
vibration to the pump
and piping. To further
reduce vibration, a
surge suppressor next
to the pump may
be used.
Suction pipe size
should be at least the
same diameter as the
inlet connection size,
even larger if highly
viscous fluid is to be
pumped. If suction hose
is used, it must be of a
non-collapsible
reinforced type.
Discharge piping should
be of at least the same diameter as the discharge
connection. It is critical, especially on the suction
side of the pump, that all fittings and connections
are air tight or pumping efficiency will be reduced
and priming will be difficult.
Make certain the air supply line and connections
and compressor are capable of supplying the
required pressure and volume of air to operate
the pump at the desired flow rate. The quality of
the compressed air source should be considered.
Air that is contaminated with moisture and dirt
may result in erratic pump performance and
increased maintenance cost as well as frequent
process “down time” when the pump fails to
operate properly.
The pump is powered by compressed air.
Compressed air is directed to the pump air
chamber by the main air valve. The compressed air
is separated from the
fluid by a membrane
called a diaphragm.
The diaphragm in turn
applies pressure on
the fluid and forces it
out of the pump
discharge. While this is
occurring, the opposite
air chamber is
depressurized and
exhausted to
atmosphere and fluid
is drawn into the pump
suction. The cycle again
repeats, thus creating a
constant reciprocating
action which maintains
flow through the pump.
The flow is always in
through the bottom
suction connection and out through the top
discharge connection. Since the air pressure acts
directly on the diaphragms, the pressure applied to
the fluid roughly approximates the air supply
pressure supplied to the main air valve.
INSTALLATION, OPERATION & MAINTENANCE
Installation Pump Operation
Shut Off Valve
Air Stop Valve/
Needle Valve
Filter Separator
Pressure-reducing
Valve
Fluid
Inlet
Discharge Pressure
Gauge
Manometer
Shut Off Valve
Air Connection
Fluid
Discharge
AODD PUMP
Air Exhaust
Air Exhaust Muffler
Pulsation Dampener
Union or Pipe Flange
Connection
Union or Pipe Flange
Connection
Flexible
Connection
Flexible
Connection
Flexible
Connection
Pump Size Minimum Air Line Size Minimum Suction Line Size
1/4" 1/4" 1/4"
3/8" 1/4" 3/8"
1/2" 1/2" 1/2"
1" 1/2" 1"
1-1/2" 1/2" 1-1/2"
2" 1/2" 2"
3" 3/4" 3"
Recommended Piping Connections

Page 4
TROUBLESHOOTING
Symptom
Pump cycles once
Pump will not operate
Pump cycles and will not
prime or flow
Pump running
sluggish/stalling
Product leaking through
exhaust
Premature diaphragm
failure
Breaking and bending
shafts
Potential Cause(s)
1Incorrect pilot o-ring placement
2Inner diaphragm plate installed backwards
3Deadhead (system pressure meets or exceeds
air supply pressure)
4Air valve or center block gaskets installed incorrectly
1Pump is over lubricated
2Lack of air (line size, PSI, CFM)
3Worn o-rings
4Wrong type of lubrication (attack on o-rings)
5Debris in air valve
6Clogged manifolds
7Incorrect o-ring placement
8Deadhead (system pressure meets or exceeds
air supply pressure)
1Cavitation on suction side
2Valve ball(s) not seating properly or sticking
3Valve ball(s) missing (pushed into chamber)
4Valve ball(s)/seat(s) damaged or attacked by product
5Clogged suction line
1Over lubrication
2Icing
3Clogged manifolds
4Deadhead (system pressure meets or exceeds
air supply pressure)
5Cavitation on suction side
6Lack of air (line size, PSI, CFM)
1Diaphragm failure, or diaphragm plates loose
2Diaphragm stretched around center hole or bolt holes
3Excessive air supply pressure
1Cavitation
2Excessive flooded suction pressure
3Misapplication (chemical/physical incompatibility)
4Wrong type of lubrication (attack on air side)
5Incorrect diaphragm plates or plates on backwards
6Incorrect shaft with corresponding elastomer
7Start up at full air pressure
1Build up of solids in water chamber
2Loose diaphragm plates
Recommendation(s)
1Reinstall pilot o-rings in correct positions
2Reinstall inner diaphragm plate correctly
3Check system for pressure ratio to pump
4Install gaskets with holes properly aligned
1Set lubricator on lowest possible setting or remove
• Elima-Matic is designed for lube free operation
2Check the air line size and length, compressor
capacity (HP vs. cfm required)
3Replace o-rings
4Check compatibility of o-rings with lubrication
5Clean air valve/filter
6Clean suction or discharge manifolds/piping
7Reinstall o-rings in correct position
8Increase air supply pressure
1Check suction condition (move pump closer to product)
2Clean out around valve ball cage and valve seat area
• Replace valve ball or valve seat if damaged
• Use heavier valve ball material
3Worn valve ball or valve seat
• Worn fingers in valve ball cage (replace part)
4Check Chemical Resistance Guide for compatibility
5Clean suction manifold and/or piping
1Set lubricator on lowest possible setting or remove
• Elima-Matic is designed for lube free operation
2Clean or replace exhaust muffler
3Clean manifolds to allow proper air flow
4Check system to locate deadhead (equilibrium)
• Increase air supply pressure
5Check suction (move pump closer to product)
6Check the air line size, length, compressor capacity
1Replace diaphragms, check for damage and ensure
diaphragm plates are tight
2Check for excessive inlet pressure or air pressure
• Tighten bolts to recommended torque
3Check Operating Manual for recommendations
1Enlarge pipe diameter on suction side of pump
1,2 Move pump closer to product
• Raise pump/place pump on top of tank to reduce
inlet pressure
2Add accumulation tank or pulsation dampener
as close to the pump as possible
3,4 Consult Chemical Resistance Chart for compatibility
with products, cleaners, temperature limitations
and lubrication
5,6 Check Operating Manual to check for correct part
and installation
7Start up pump slowly (manually or with Smart Start)
1Flush pump, start pump slow
2Tighten diaphragm plates when replacing diaphragms

Page 5
E8 PARTS LIST
AIR VALVE ASSEMBLY
Item Description Qty. Standard: Polypropylene
Air Valve Assembly (Includes items 1-10) 1 E800
1 Valve Body 1 10-048
2 Valve Spool 1 E500B ASY (Includes (2) P98-104A)
3 Valve Spool U-Cup 2 P98-104A
4 End Cap 2 E800D (Includes (1) E800D ASY)
5 End Cap O-Ring 2 E500E
8 Air Diverter 1 10-075
9 Valve Insert 1 E500H
10 Valve Gasket 1 E800J
11 Valve Screw 4 10-050
Item Description Qty. Standard: Polypropylene
12 Center Section 1 E801A
18 Pilot Shaft 1 E803A
19 Pilot Shaft Spacer 5 E503C
20 Pilot Shaft O-Ring 6 E503B
21 Pilot Shaft Snap Ring 2 E503D
22 Shaft Retainer 2 E801B
25 Shaft Retainer Screw 4 E501C
33 Muffler 1 06-034
Item Description Qty. TPE PTFE
34 Main Shaft O-Ring 2 E503B E503B
35 Main Shaft 1 10-028 10-028
37 Inner Diaphragm Plate 2 C126 C126
38 Outer Diaphragm Plate 2 10-023 (Poly), 10-040 (Kynar) 10-023 (Poly), 10-040 (Kynar)
40 Diaphragm 2 10-032 (XL), 10-033 (Geolast) 10-044 (PTFE)
Item Description Qty. Standard: Polypropylene Option 1: Kynar
44 Water Chamber 2 10-002 10-036
45 Water Chamber Bolt (Long) 4 10-052 10-052
46 Water Chamber Bolt (Short) 12 10-051 10-051
50 Valve Seat 4 10-022 (Poly) 10-039 (Kynar)
51 Valve Seat Seal 8 10-073 (XL), 10-045 (PTFE) 10-073 (XL), 10-045 (PTFE)
52 Valve Stem 4 10-005 10-038
53 Spring 4 10-030 10-030
60 Manifold 2 10-003 10-037
62 Foot Pad 4 10-035 10-035
AIR END ASSEMBLY
DIAPHRAGM ASSEMBLY
WET END ASSEMBLY

Page 6
DETAIL B
DETAIL B
DETAIL A
45
46 44
38
40 37 34 33
12
10
9
62
1
11
23
5
4
35
8
60 in-lbs
(6.8 N-m)
Torque
Settings
25 in-lbs
(2.8 N-m)
40 in-lbs
(4.5 N-m)
Water Chamber Bolts 40 in-lbs (4.5 N-m)
Diaphragm Plates — Rubber 60 in-lbs (6.8 N-m)
Diaphragm Plates — PTFE 60 in-lbs (6.8 N-m)
Air Valve Cap Screws 25 in-lbs (2.8 N-m)
Description Qty Part Number
Valve Spool U-Cup 2 P98-104A
End Cap O-Ring 2 E500E
Air Diverter 1 10-075
Valve Insert 1 E500H
Valve Gasket 1 E800J
Pilot Shaft O-Ring 6 E503B
Main Shaft O-Ring 2 E503B
E8 EXPLODED VIEW
E8 Repair and Maintenance Kits
Torque Settings
Air End Kit- Part #: E8 AIR KIT
Part Number Description
E8P XL KIT XL Elastomer Kit
E8 G KIT Geolast Elastomer Kit
E8P TX KIT PTFE Elastomer Kit
Wetted End Kits
Detail A Detail B
25 22
18 19 20 21
60 50 52
53 5151

Page 7
MATERIALS,TEMPERATURELIMITS&COMPATIBILITY
ELASTOMERS
DIAPHRAGMS ●●● ●●●●●
VALVE BALLS ●●●●●●●●●
VALVE SEATS ●●●●●●●●●●●●
VALVE SEAT O-RINGS ●●●●●●
Aluminum Polyurethane
PTFE Thermoplastics
Polypropylene Buna-N Neoprene EPDM 316 Stainless Steel
PVDF
Versa-Tuff ™ Tef-Matic™ FDA Hytrel® (FKM) Fluorocarbon Encapsulated Silicone
Temperature Limits Wetted Material Compatibility
Diaphragms, Valve Balls, Valve Seats & Valve Seat O-rings
Santoprene (TPE XL)
Fluid Numeric Wetted Section
Solutions pH Level Construction Metals
14
ALKALINE 13 STAINLESS
12 STEEL
CAUSTIC 11
10
CAST IRON
BASIC 9
8
NEUTRAL 7 ALUMINUM
6
5
CAST IRON
4
ACID 3
2 STAINLESS
1 STEEL
0
Materials of Construction — Pumps
MODEL Acetal® Aluminum Cast Iron Hastelloy C Polypropylene PVDF Stainless Steel
E6 (1/4") ■■ ■
E8 (3/8") ● ●
E5 (1/2") ●●●●▲ ●▲ ●
E7 (3/4") ●
E1 (1") ●●●▲ ●▲ ●
E4 (1-1/4" – 1-1/2") ■■●■ ● ● ●■
E2 (2") ●■ ●■ ●■ ●●●■▲▼
E2-FV (2") ■
E3 (3") ●■ ■●■ ●●●■
●Bolted Construction ■ Clamped Construction ▲ Split Manifold Model Available ▼ High Pressure Model Available
FUSION™
NEOPRENE 0°F (-18°C) to +200°F (93°C)
BUNA-N +10°F (-12°C) to +180°F (82°C)
NORDEL -60°F (-51°C) to +280°F (138°C)
(FKM) FLUOROCARBON -40°F (-40°C) to +350°F (176°C)
PTFE +40°F (+4°C) to +220°F (105°C)
POLYURETHANE +10°F (-12°C) to +170°F (77°C)
SANTOPRENE (TPE XL) -20°F (-29°C) to +300°F (149°C)
PFA -20°F (-29°C) to +300°F (149°C)
FDA HYTREL -20°F (-29°C) to +220°F (104°C)
METALLIC PUMPS can operate past 212°F (100°C). However, if you are
operating above these limits, consult the factory for assistance.
PLASTIC PUMPS can operate to the following temperature limits:
• ACETAL 32°F (0°C) to 220°F (104°C)
• POLYPROPYLENE 32°F (0°C) to 175°F (79°C)
• PVDF 10°F (-12°C) to 225°F (107°C)
NOTE: These are average temperatures. Chemicals and solvents can have an
effect on temperature limit

Declaration of Conformity
CE
Warren Rupp®, IDEX AODD, Inc., 800 N. Main Street, P.O. Box 1568,
Manseld, Ohio, 44901-1568 USA, certies that Air-Operated
Double Diaphragm Pump Series: HDB, HDF, M Non-Metallic,
S Non-Metallic, M Metallic, S Metallic, T Series, G Series, U Series,
EH and SH High Pressure, W Series, SMA and SPA Submersibles,
and Tranquilizer Surge Supressors comply with the European
Community Directive 98/37/EC, Safety of Machinery. This product
has used Harmonized Standard EN 809, Pumps and Pump Units
for Liquids - Common Safety Requirements, to verify conformance.
Signature of authorized person Date of issue
Printed name of authorized person
Revision level B
Title
David Roseberry Engineering Manager
October 20, 2005
Date of revision
April 1, 2009

©2009 IDEX AODD, Inc. wr10om-0609
Kynar is a registered tradename of Penwalt Corp. Geolast is a registered tradename of AES. Warren Rupp is a registered tradename of IDEX AODD, inc.
WARREN RUPP, INC.
A Unit of IDEX Corporation
800 North Main Street
Mansfield, OH 44901-1568 USA
[phone]
Fax: [phone]
www.warrenrupp.com