Operation and Maintenance Manual

For All Variations of:

AP300G2–G8, AP300F2L–F8L
& Dual Pump Systems

TABLE OF CONTENTS

Overview on operation of the pump page 2

Identification of pump components page 2
Basic functioning of pump page 3
Panel layout and function review page 4-5
Dual pump panel configuration page 6
Placement of pump in sump and piping concerns (submersed) page 7
Self-priming installation instructions and concerns page 8
Control Panel installation, air supply chart and panel dimensions page 9-10
Pump to Panel connection page 11
Inner control panel identification page 11
Start-up settings; pressure and stroke adjustments page 12
Stroke setting table for flow induced, self-priming and gravity fed page 13
Dual pump stroke settings and adjustment page 14
How to reset stroke settings from scratch page 15
AP300XH High Flow Panel variations page 16
Troubleshooting page 17-24
Most common start-up problems page 17
Pump/wetted end problems page 18
Control panel component identification AP300FI, AP300F6 page 19
Inside control box component identification page 20
Control panel troubleshooting logic sequence page 21
Exhaust valves page 22
Flow inducers page 23
Regulators page 24
Spare parts, panel page 25
Spare parts, all other page 25-30

Page 1 of 30 Aug 2013

 OVERVIEW
The wetted portion of the PITBULL® pump system is based on a pump chamber with two check
valves, one to allow fluid into the chamber and one prevent discharged fluid from flowing back
in. The chamber is hollow.

Main Airline Pump

Chamber

Discharge
Level Control Line
hose connection

Discharge
Check Valve
(inside) Inlet Check
Valve

Pumping Action: The inlet check swings open to allow fluid in. Air inside the pump chamber
exits through an airline in the top (either pulled out under vacuum or pushed out by liquid filling
the chamber; these two modes are described in the next section).

Air inside is vented to panel Compressed air goes in.

FILLING Liquid is DISCHARGING

discharged

Inlet is open Inlet is closed

and pump is and pump is
filling pressurized

Once the chamber is full, it is pressurized with compressed air and the inlet valve is pushed
closed. With the chamber pressurized, the liquid is forced out the discharge check valve. This
pressurization occurs for a set number of seconds, enough to clear the pump chamber, and then
the chamber is depressurized and the cycle starts over.

Page 2 of 30 Aug 2013

 BASIC FUNCTIONING AND COMPONENTS
The function of the control panel (panel picture is on next page)
The control panel is what monitors the liquid level in the sump and controls the flow of
air in and out of the pump chamber.
The level control line is an open ended air line connected to the panel (hose is supplied
with the pump for this purpose). The panel will cycle the pump anytime there is 2+ inches of
liquid over the end of the level control line. Where the end of that control line is placed
determines the operating level in the sump. A built-in connection for the control line is provided
on 2”-6” pumps; run hard-pipe to the proper sump elevation on larger/other pumps.

Level NOTE! IMPORTANT!

control line THERE ARE TWO MODES OF OPERATION
hose 1) GRAVITY FED- liquid runs into the pump on
connection its own. Level control operates at this upper level.
for flow -or-
induced 2) FLOW INDUCED- liquid is sucked into the
pumps. pump. Level control operates at this lower level.
Gravity
mode is
This is the 2” level of liquid over the
connected
control line required to initiate the
near top of
pump cycling. Below this level the
the pump
pump/panel will be idle.
IF THE PUMP IS TO RUN IN THE
GRAVITY FILL MODE…then the
end of the level control line should be
2” at the same elevation as the top of the
pump chamber

Note (on the flow induced unit as

shown) that the control level is just
above the top of the inlet check valve
port. ****If you intend to run a
separate hard pipe as the level control
line, you must make sure that it ends
no lower than the top of the inlet
check valve opening.

When the level control line is submerged in 2” of water, the control panel will begin a fill
stroke followed by a discharge stroke. This makes for one complete pumping cycle. After one
complete cycle, the panel checks for the presence of liquid; if there is liquid it will immediately
cycle again, if there isn’t the panel will wait however long it takes for enough liquid to enter the
sump and reach the 2” level again.
**This means your pump may not cycle steadily. It will cycle to match the inflow feeding the
sump.

Dual pumping systems run exactly as described above except a second pump is filling when
the first is discharging and visa versa.

Page 3 of 30 Aug 2013

A

F
 PANEL LAYOUT

Important: All variations of the AP300 control panels share the same control box/logic
and vary by the size and capacity of the air valves/filtration/flow inducers mounted below the
box. The function of each component is identical, only the size and capacity vary.

A- Control box (common to all)

B- Exhaust valve (EXVS75, 3/4” shown)
C- Piloted discharge pressure regulator (REP50, 1/2” shown) A
D- Main airline connection to filter/autodrain (F50
1/2” shown)
E- Level control line connection (1/2” hose barb-
all panels) K
F- Pilot air supply filter and control pressure
regulator (open box pic below)
G- Control logic
H- Discharge pressure regulator B
I- Flow inducer
J- FV200 supply valve to flow inducer (one per
flow inducer) I
K- Piloting quick exhaust valve
L- Airline and isolation valve going to pump D
E

C J
G F
H

L
AP300 Flow
Induced Panel

AP300 Control Box

(all panels)

Page 4 of 30 Aug 2013

 PANEL FUNCTIONING IN MORE DETAIL
The control panel senses backpressure (approximately 2” inches of water column to initiate) in
the level control line. When it sees enough backpressure (enough liquid) to cycle the pump it
then begins the fill stroke by opening the exhaust valve and if the pump is equipped with a flow
inducer (vacuum fill option), the panel also supplies the flow inducer* with compressed air.

* The flow inducer is a form of vacuum pump that uses compressed air to generate
vacuum. Its purpose is to suck air out of the pump chamber, which pulls liquid in.

Once the fill stroke is complete (usually 3-6 seconds; see pg.14 start-up chart for factory settings)
the panel switches to the discharge stroke by closing the exhaust valve (to trap pressure in the
pump) and also cuts off air to the flow inducer while opening the discharge pressure regulator.
This discharge stroke feeds regulated, compressed air down the main airline and into the pump to
push its contents downstream.

The exhaust and vacuum generator valves are operated by piloting air valves in the control logic
located inside the control panel enclosure.

A couple of important notes; the cycling will only occur when there is enough liquid to fill the
pump chamber- the pump will not cycle (run dry) if no liquid is present unless in the ‘MANUAL
OVERRIDE’ mode. The MANUAL OVERRIDE forces the panel to cycle even if it is out of
liquid.

The cycling of the pump is relatively slow; anywhere from zero to 10 times per minute so don’t
expect the pump to ‘hammer away’. If it is cycling rapidly, it is probably has had the stroke
settings messed up and is putting out less flow than it should.

MANUAL OVERRIDE MODE

This ball valve on the underside of the

control panel is used to put the control panel
“MANUAL OVERRIDE MODE”
Open is Normal operation
Closed is Manual

Page 5 of 30 Aug 2013

 DUAL PUMP CONFIGURATION
PITBULL® dual pump systems function exactly as single pump systems; the same fill
and discharge strokes with the exception that the two pumps work opposite each other. When
one pump fills, the other discharges and visa versa. Once the liquid level has been sensed to be
about 2” above the end of the level control line (2” water column of pressure) the panel will
perform a complete pumping cycle on both pumps.

Component Identification:
The dual control panel uses the same components as the single control panel show on pg 4 with
the addition of duplicates of the REP50 discharge regulator, EXVS75 exhaust valve, flow
inducer, and FV200 flow inducer supply valve.

A- EXVS75exhaust valves
B- Flow inducers
C- FV200 flow inducer supply valves
D- REP50 discharge regulator

A
C

NOTE! Additional ball valves may be installed in this

location on each pump to further throttle (slow) the
discharge of the pump in order for it to match up with the
fill stroke of the opposite pump.

Page 6 of 30 Aug 2013

 INSTALLING THE PUMP
Pump Installation
The pump should be placed on the bottom of the sump, as near level as reasonable and
tilted no greater than 10 degrees.
Try to keep approximately 2X the pump’s piping diameter of open space in front of the
inlet to allow full liquid and solids flow into the port (example: 3” submersible should have 6”
of open space in front of the inlet port).

Discharge Piping
Try to match the discharge piping to the size of the outlet port. Avoid reducing more
than one pipe size unless imperative. The reasons and trade-offs are as follows,
1- for an average flow rate of 50 gpm, the PITBULL® will be discharging liquid at 100+
gpm in discreet bursts so friction losses need to be based on the burst flow, not the
averaged flow over time. Our pipe sizes are oversized for the average flow but
appropriate for the flow in bursts.
2- The PITBULL® will pass large solids. Watch out for pumping bigger stuff than your
piping can take.

**Note: If you are reducing the piping and have potential for large solids, consider adding a
strainer to the pump inlet. CIPC offers threaded inlet adapter (see parts section for numbers)
with big-ported strainers as an option. Or improvise your own.

If pump is a ‘G’ series,

gravity fed unit, the
level control line fitting
will be at the top of the DUAL PUMP NOTE-
pump chamber. Only one level control line
is used for both pumps.
This tube/fitting will not be
present on second pump.

Keep atleast one pipe

diameter open in
front of the inlet

For dual pump configurations it is important to place both

pumps on the same surface/elevation so that each pump has
the same ‘fill’ stroke hydraulics.

Page 7 of 30 Aug 2013

 INSTALLATION OF SELF-PRIMING CONFIGURATION
All the previous information applies to self-priming installation since there is no difference in
how the pump functions. The important installation and set-up difference to account for are;
1) The level control line does not anchor to the pump because the pump is not in the sump.
Instead, the level control line must end in the sump at the liquid level you wish the pump
to hold. TIP- ¾” or larger pipe is often used as the submersed end of the level control
line and the level control hose supplied with the system is connected to the top of the pipe
with the other end in the sump at the desired level. If the pipe is clamped, it can be
adjusted up or down to change the sump level.
2) The suction/down-pipe and its connections must be air-tight. NO LEAKS.
3) On the discharge piping there needs to be an isolation valve. The important reason for
this is when the piping system is dry, the pump can pull air in through the discharge if
any debris is under the discharge check seat. This will waste the vacuum being created
and the suction lift is lost. Close the valve until the pump cycles into the discharge mode;
once liquid is in the piping the check valve will seal well enough to prime.
4) The ‘fill’ time will be longer depending on the suction lift. See page 11 for fill time
settings.

Suction piping must be air tight.

This is a reasonable place to

anchor the level control line
-or-
Install a hard pipe to the sump
wall/cover/etc and connect level
control hose to the pipe.

Install an isolation
valve somewhere
near the discharge
outlet.

Keep suction lift to a

minimum. Avoid going over
7 ft due to performance
losses. Contact factory for
higher lift options.

Page 8 of 30 Aug 2013

 CONTROL PANEL INSTALLATION
Mount the panel using the (4) holes on the top and bottom tabs of the box. Locate the
panel away from falling debris, drips and leaks and in a spot where it can be adjusted or serviced.
Bring an unregulated, 70-100 psi,
unlubricated air supply to the filter/autodrain on
the right side of the panel valve package. Include a
shut-off valve and union or other break in the line so
the panel can be pulled for emergency repair. Please
use the following chart as the minimum air supply
line requirements.

Mounting Dimensions for all AP300 Panel Frames

Bolt pattern (see overall dimensions on next page):
7.5” width (between centers)
11” height (between centers) Bolt holes
Bolt hole: ½” diameter (through 1.5” thick frame)

Air Supply Line Sizing Chart

Pump Discharge Size Panel Supply Port Supply line <100 ft Supply line>100 ft
2” and 3” Pumps 3/4” NPT 3/4” pipe, 3/4” hose 3/4” pipe, 3/4” hose
4” Pumps 3/4” NPT 3/4” pipe, 3/4” hose 1” pipe, 1” hose
4” (SH4), 6”x4” Pumps 1” NPT 1” pipe, 1” hose 1” to 1-1/4” pipe,
1-1/4” to 1-1/2” hose
6”, 8” Pumps 1-1/2” NPT 1-1/2” pipe 1-1/2” to 2” pipe

Important- when the proper line size is not possible, adding an air reservoir/receiver close to the
control panel will dampen the air supply and let the pump put out more flow rate and keep the
supply pressure to the panel steadier (for better control function).
The pump consumes air in ‘bursts’. Your airline may be able to deliver the averaged out air
flow, but can’t keep up during the ‘burst’, which causes the pressure to fall way off while the
pump is trying to discharge. A 30-120 gallon receiver (size per pump) is often the low cost cure
for this, without requiring an increased supply line.

Page 9 of 30 Aug 2013

 Mounting Dimensions for all AP300 Panel Frames
Bolt pattern:
7.5” width (between centers)
11” height (between centers)
Bolt hole: ½” diameter (through 1.5” thick frame)

3” 9” 4”
AP300F3 shown

11”

17”

7.5” max
depth

Mounting
holes (4)

3/4” NPT
inlet

11”
3/4” NPT x 3/4”
hose outlet to
pump

16”

Page 10 of 30 Aug
2013
 Connecting the Panel to the Pump
There are two connections to make, the main airline and the control airline. Both airlines
are provided with your system and come as 15’ lengths standard.
1) Run the main airline from the hose barb on the panel under the exhaust valve to the hose
barb on the top of the tank.
2) Run the level control airline from the bottom right side of the panel to the level control
airline hose barb on the side of the pump (or other equal elevation).

Main airline

Avoid sags or low spots that could collect

moisture in this level control line.
For suction lift pumps this line runs to the
sump (see page 7) not the pump!
For gravity fill pumps, this line ends near
the top of the chamber.

** if you intend to hard pipe the two lines instead of

using the hoses, substitute at least 1/2” pipe or 5/8”
tubing (larger OK) for the 1/2” control line hose.
For the main airline, use pipe or tubing with an ID
as big or bigger than the ID of the hose provided (do not restrict!!!).

Control Box
A- Control pressure regulator (set at 70 psi) and filter B
B- *Discharge pressure regulator adjustment A
F- Fill stroke time adjustment and pop-up indicator
D- Discharge stroke time adjustment and pop-up F
indicator
E- Discharge pilot valve adjustable delay
CL- Control logic module
* Discharge pressure regulator (adjustable to 70 psi
max; to go higher than 70psi the control pressure D
must be raised first. Max is 100 psi, and will
shorten maximum stroke time)
CL

E
Page 11 of 30 Aug
2013
 START-UP SETTINGS
The control panel is preset for fill (F) and discharge (D) strokes. The discharge pressure
is preset for 40 psi using the discharge pressure adjustment. When initially starting up the pump,
do not change the fill (F) and discharge (D) stroke settings and only adjust the discharge pressure
(see ‘B’ in photo above) if needed. Please see the section on adjusting settings if you have (1) a
very long pipe run, >300’ or (2) a reduction of two more pipe sizes in the discharge piping. In
those cases you will need to increase the discharge stroke.
Setting the discharge pressure. Try to determine the total dynamic head required for the
application. In simple terms, take the vertical height that the pump must push the liquid and
convert it to psi (there are 2.31 ft per 1 psi), and then add in your calculated or 'guesstimated'
friction loss (guess high if the liquid is viscous) in psi, and finally add 15 psi for a safety margin.
This total should be enough to push the liquid out of the pump at a good flow rate. Note: too
little discharge pressure will cause little (or none) fluid to exit the pump (the pump is essentially
deadheaded). Too much pressure and compressed air is wasted.
Example: The pump is in a sump 6' deep, and must pump to an elevated tank 40' above grade,

through 200' of 2" pipe at an average flow rate of 20 gpm.

The elevation difference is 6' + 40' = 46' and 46/2.31= 20 psi. Now, the flow rate was
said to be 20 gpm, but the PITBULL® has separate fill and discharge cycles and therefore to put
out a 20 gpm flow rate the pump must take in 40 gpm while no fluid is discharging, and then
discharge at 40 gpm while no fluid is filling to pump in order to average the 20 gpm. So, use 40
gpm to calculate friction loss.
**for Dual Pump Systems there is no gap between cycles, so size lines directly for the flow rate.

TIP: If your discharge piping size is the same as the PITBULL® the velocity will be low
enough that friction loss is negligible on shorter runs with watery fluids.

Finally, from a friction loss chart you find that the loss for 40 gpm of water flowing
through 200' of 2" pipe is 3.6 ft/100', or a total of 7.2' (3.1psi). So set the discharge regulator for
20 + 3.1 + 15 = 38.1 psi.;40 is close enough. (Note that the friction loss was small)

Page 12 of 30 Aug
2013
 FACTORY SET STROKE ADJUSTMENTS
Pump Model Fill/Discharge Fill/Discharge Fill/Discharge
Flow Induced Suction lift Gravity filled
S2C/S2S 3.0 sec /2.5 sec 3.5* sec/2.5 sec 4.0 sec/2.5 sec
S3C/S3S 3.5 sec /3.0 sec 4.5* sec/3.0 sec 5.0 sec/3.0 sec
S4C/S4S 4.5 sec /4.0 sec 6* sec/4.0 sec 6.0 sec/4.0 sec
SH4C/SH4S 7.0 sec /5.0 sec 8* sec/5.0 sec 8.0 sec/5.0 sec
S6x4C/S6x4S 5.5 sec /5.0 sec 7* sec/5.0 sec 7.0 sec/5.0 sec
S6C/S6S 8.0 sec /6.0 sec 9* sec/6.0 sec 9.0 sec /6.0 sec
S8C/S8S 9.0 sec /7.0 sec 10* sec/7.0 sec 10.0 sec/7.0 sec
*suction lift times will likely go longer for lifts greater than 4 ft.

To re-set the discharge time.( Most submersed pumps will not require adjustment, and are
factory pre-set) With the pump cycling (level control line flooded) use a small blade screw
driver in the slot adjustment knob to make changes in the fill and discharge strokes. USE
YOUR WATCH WHEN FINE TUNING THE STROKES. Clockwise is longer, CCW
is shorter, the entire range is .5-8 seconds.
Discharge stroke adjustment- align
arrow with approximate time number.
Pop-up indicator *time and set with a watch to set
(above adjuster) accurately- these are not clocks and
pops out during the numbers are not accurate.
the fill stroke Pop-up indicator (below adjuster)
pops out during the discharge stroke.

Fill stroke adjustment; align This piloting valve has an adjustment

arrow with approximate time under the cap. For 4” and larger pumps
number. *Time with a watch to there is a 1 second delay adjusted in.
set accurately- these are not To eliminate delay, turn screw slot
clocks and the numbers are not counter clockwise (2) turns.
accurate. NOTE- for a NET discharge stroke of
. 4 sec the stroke adjustment needs to be
set to 5 sec due to the delay.

IT IS VERY UNLIKEY THE ‘FILL’ STROKE NEEDS ADJUSTING ON A

SUBMERSED PUMP. Typically only the discharge stroke needs lengthening for special
conditions. The fill stroke (the time it takes to fill up the pump chamber) should be constant
unless the liquid is extra thick or the pump is installed in the self-priming configuration with high
suction lift.
If you have a thick liquid, you may need to lengthen the discharge stroke too (more time is
required to push the liquid downstream)

If the discharge pipe run is long or restricted/reduced in size, it is likely you will need to add 20-
50% more time to the discharge stroke. *You may also need to increase the discharge pressure.

Page 13 of 30 Aug
2013
 FACTORY SET STROKE ADJUSTMENTS FOR DUAL PUMP SYSTEMS
(flow induced as standard)

Pump Model Fill Time Discharge Time

S2C/S2S 2.5 seconds 2.5 seconds
S3C/S3S 3.0 seconds 3.0 seconds
S4C/S4S 4.0 seconds 4.0 seconds
SH4C/SH4S 7.0 seconds 7.0 seconds
S6x4C/S6x4S 5.5 seconds 5.5 seconds
S6C/S6S 8.0 seconds 8.0 seconds
S8C/S8S 9.0 seconds 9.0 seconds

The settings above are based on the dual pump system running in the flow induced mode
(the liquid is pulled into the pump instead or running in by gravity. This gives a shorter, more
consistent fill stroke duration).

The time setting for the discharge stroke may be slightly long, and some compressed air
is blown down the line after the pump is emptied. In this case it is best to throttle back the
discharge line (it won’t take much) to create enough back pressure to slow the discharge stroke
down until no more air goes into the line. If that is not an option consult the factory for
additional air throttling valves to slow the discharge rate. *Also check that the discharge
pressure setting is not too high (see previous section) which would push the liquid out faster than
needed.

Page 14 of 30 Aug
2013
 SETTINGS AND ADJUSTMENTS CONTINUED
Fine tuning pressure and discharge strokes (typically not needed): The settings most likely to
need adjustment are the pressure and discharge stroke duration. If inadequate pressure is used
for the conditions, then the pump will push little if any liquid downstream during the discharge
stroke.

Complete Reset of Both Fill and Discharge Strokes

This method works most simply for a single pump but if you have a dual pump system
the same concepts will apply.

Step One- Establish the fill time under your field conditions.
Set the discharge stroke to an excessive time. Check the chart on pg 13 for your pump and then
add another 3 seconds to the discharge setting. This excess time will insure you are starting with
an empty pump on each fill stroke.

Step Two- Find the amount of time needed to refill an empty pump.
Start the fill stroke off at least 1 second short of the recommended fill time (pg 13 again). You
can hear the tone of the flow inducer change once the pump is full (goes up in pitch).
Incrementally increase the fill stroke until you hear this pitch change, or, until liquid starts
coming out the exhaust. At this point the fill time is barely too long; shorten it by about ½
second until the spray goes away and/or the tone doesn’t change. Now the pump is getting full
but not over filled and you can go on to step three.

Step Three- Correct the discharge stroke to match the full fill stroke.
From the previous step the pump is now full at the beginning of each discharge stroke, but we
still have the discharge set intentionally too long. Start shortening the discharge stroke a little at
a time until the same flow inducer tone change and/or exhaust spray occur. At this point the
stroke length is too short to push out all of the liquid but the fill stroke allows for refilling all of
the liquid, so the pump overfills. Lengthen the stroke about ½ second to just make these
symptoms go away.

The pump strokes are now correctly set!

Page 15 of 30 Aug
2013
 AP300XH High Flow Panel Variation
This version of the AP300 control panel is designed for very high flow applications and has the
following differences from the AP300 standard;
1) The piloted discharge regulator is replaced by a 1-1/2” or larger pilot operated regulator
that has much higher flow capacity.
2) The exhaust valve is enlarged to >2” piping, and a double acting operated ball valve or
butterfly valve replaces the EXV200.
3) Inside the control box, NRE125 regulator provides the discharge pressure control.

Use this knob to

adjust the discharge
pressure

AP300XH panel shown without flow inducement

A 2-1/2” or larger exhaust valve Pilot operated discharge

(operated ball valve shown in this regulator REP150, 1-1/2”
picture) replaces the EXV200 size or larger is used.

Please note that all basic functioning of the high flow panel is the same as the standard when it
comes to level control, stroke settings and troubleshooting.

Page 16 of 30 Aug
2013
 TROUBLESHOOTING THE PUMP
THE MOST COMMON PROBLEMS DURING START-UP

If you are having difficulty with the operation of your pump please review the following
list of pump problems. This list contains the most common problems we get calls on and also
represents a group of avoidable conditions

1) Rust, scale, water slugs in the air supply fouling the filter-autodrain/valving because of not
blowing down the air supply until clear, prior to connection. For excessively wet conditions
or corroded piping, a knock-out pot (air receiver or other tank near the panel will help
immensely).
2) Exhaust splatter and fouling due to the pump being deadheaded or close to it.
3) Cycling problems due to improper layout of the airlines, with crimps, undersized airlines
substituted for the hoses supplied, restrictive quick couplings and fittings or excessive
lengths.
4) Erratic cycling due to a small diameter air supply that can't deliver the volume while
maintaining pressure. 'Control' pressure gauge falls below 40 psi during discharge stroke.
5) Pump fails to fill up and discharges a low volume per stroke because of a restriction in the
exhaust path (muffler, looped line etc.).
6) Poor setting of the discharge pressure and/or discharge time for the conditions. Stroke and/or
pressure are way off, usually from being played with unnecessarily. These conditions are all
covered in the installation and start-up of the pump. If you are having one of these problems,
and particularly if you have recently installed the pump, please review the earlier portions of
the manual for correcting the condition.
Given that the preceding section does not address your pump's condition, we suggest the
following process of test/evaluation/elimination to arrive at the source of the problem with the
least amount of servicing.

CHECK VALVE PROBLEMS (see diagrams on next page)

Inlet check valve:
If the inlet check valve is blinded, blocked or stuck closed, the pump will cycle but put
out little or no fluid per stroke.
If the inlet check valve is stuck open, the pump will appear to cycle normally, but the
discharge flow rate will be reduced or non-existent. On a submersed application you will
commonly see turbulence at the inlet (from liquid and possibly air being expelled from the
intake). Depending on liquid depth you may be able to detect a lack of a ‘thunk’ as the inlet
check doesn't close forcefully at the beginning of the discharge stroke.
Discharge check valve:
If the discharge check is plugged or stuck closed, the pump is deadheaded. Because no
liquid is leaving the pump, you may also get liquid spraying from the exhaust because the pump
is completely full of liquid.
If the discharge check is stuck open, the pump will cycle normally, but flow will be much
less as liquid runs back into the pump from the discharge piping. You may get spray out of the
exhaust as the pump ‘overfills’ by filling from two directions, the inlet and the discharge.

Page 17 of 30 Aug
2013
 COMMON CHECK VALVE AND PIPING PROBLEMS

Inlet check stuck open. Pump continues

to cycle but output is low. You may see
turbulence and vigorous bubbling near the
inlet (if sump level is low).

Discharge check stuck open. Pump

continues to cycle but output is low. The
pump is ‘re-pumping’ the same liquid over
and over. It will often overfill under this
condition and have fluid exiting the
exhaust port.

Deadheaded pump. The discharge line is

blocked or greatly restricted. The pump
will cycle, little fluid will go down stream,
and the pump will constantly overfill,
spraying fluid from the exhaust port.
Under this condition the exhaust valve,
flow inducer and airline can get clogged
and need to be cleared.
* check these items if the pump does not
pump at capacity once the discharge line is
cleared.

Page 18 of 30 July2013
 CONTROL PANEL COMPONENT IDENTIFICATION

AP300 Flow Induced Panel

EXVS75
exhaust valve
Level control
airline connection

Flow inducer

F50/AD supply
air filter with
FV200 auto-drain. ½”
Isolation ball flow
valve ¾” inducer
REP50 supply
½” discharge valve
regulator

Quick Relief
Valve
AP300F6 panel

FV200 flow inducer

supply valve

Flow Inducer

F100/AD supply
air filter with
auto-drain. 1”

REP100
1” discharge
Isolation ball regulator
Page 19 valve
of 302” Aug
2013
 INNER CONTROL PANEL COMPONENT IDENTIFICATION

PG1.5S
NRE125 Discharge
Discharge piloting pressure gage
regulator

NREFC125AD
Control filter,
regulator, gage and
auto-drain

AP300L
complete logic PG1.0
module Control
pressure gage

FTD
Fill stroke timer

DTD
Discharge FEPC
stroke timer Dual coalescing
filter element

PB-IND
Pop-out stroke
indicators (2)

NAD125
Autodrain

CV1032
Relief valve MBR.01 R333
Orifice (2) with Discharge
cleanout wire tool piloting valve

Page 20 of 30 Aug
2013
 CONTROL PANEL TROUBLESHOOTING
Start this section only after you have evaluated the pump using pages 11 to 12. This logic
sequence only makes sense if you have already eliminated the standard problems like
deadheading, low air pressure, plugged inlet already discussed. Without doing that first you may
well be wasting your time.

START

Are the pop-up

indicators cycling yes Yes. Confirm that
back and forth? there is 2”+ water over
the control line and
bubbles are coming out
yes no
no
Check to see that sort of
there is 70 psi on the yes
control pressure
regulator Bubbling but not cycling?
If the level control line Test submersing bubbler
is not bubbling, check line deeper. If it has not
#MBR.01 orifice by tripped by 4”, contact
Confirm that the #R333 pilot valve removing and looking factory to replace AP300L
is outputting an air signal to the through end to see light. or details on further steps.
discharge regulator. If not, confirm If blocked, clear orifice
it is getting piloted from the AP300L by using the 0.008 wire
and the NRE125 regulator/gage is cleaning tool provided Pull off control line
turned up to >25 psi. If still no pilot on AP300L at panel. Does
output then pull the pilot tubing cycling stop?
yes
from the top of FV200 valve and
check for piloting air flow. If none,
no
replace AP300L. If flowing, then Check control line for
turn R333 adjustment screw CCW blockage and/or
(2) turns and check its output again. Swap out the AP300L
restrictions creating a logic unit with a spare.
If none, replace R333. false back pressure in
the line
yes for
pilot air or

Inspect REP50/REP100
Confirm that #FV200 supply Call factory for
discharge regulators for
valve for the flow inducer is walk-thru
torn/leaking diaphragms.
outputting an air flow when disassembly of
If they are getting piloted
piloted. If not, inspect, level control
and not opening, they
clean/repair/lube or replace. components.
need repair.

Page 21 of 30 Aug
2013
 TROUBLESHOOTING CONTINUED
G

EXVS75 Exhaust valve:

Failed open- will cause a lack of pressure in the

pump during discharge, because the discharge air H
is coming right back up through the exhaust valve.
The discharge gauge will drop further than normal, A
and liquid may spray from the exhaust. Also, the
fill cycle will be relatively short like in a I
deadheaded condition.
Response- Remove retaining ring and
pin, and then pull the valve cap 'G' up and out. G
Pull the exhaust valve internals out (std. pliers on
J
the top shaft bolt work well) and inspect. Look for
F
1) debris inside valve, 2) worn/missing poppet
seat, 3) worn piston seal and 4) a cut/nicked o-ring B
on the valve cap. K
Failed closed- will cause the pump to slow or stop E
cycling. L
Response- Do the same
disassembly/inspection of the exhaust valve as M
above. C
N
H – Piston cup seal O
A – Exhaust valve internals
I – Return spring
B – Cotter pin
J – Shaft
C – Exhaust valve body P
K – Guide bushing
D – Spring D-ring
L – Wiper shaft seal
E – Clevis pin D
M – Seal housing o-ring
F – Valve cap o-ring
N – Shaft seal housing
G – Valve cap O – Poppet back
P – Poppet seat

B
EXV200 Exhaust valve

This valve operates with the same in principle

as the EXVS75. Failure modes will also be the
same.
I
C
A – Piston cup seal
B – Return spring
C – Shaft
D – Guide bushing D
E – Wiper shaft seal
F – Spacer E
G – Poppet back
F
H – Poppet seat
I – Cylinder G

Page 22 of 30 H Aug
2013
 FLOW INDUCER TROUBLESHOOTING AND REPAIR
Flow Inducers with side vacuum port

The bore must be clear/smooth or the

vacuum flow will not happen even if the
Inspect the nozzle unit sounds like it is working. Remove the
to confirm the ID top and look through the bore. Clean with
is truly clear. water/soap if needed and/or use a plastic
bristle cylinder brush.

Check between exhaust valve and right

angle turn into the bore for debris clogging
the path.

With the top section removed you can

easily see down through the bore.

Flow Inducers with top vacuum port

This style flow inducer has the air supply in the side and
pulls vacuum in the top and exhaust out the bottom. There
are (3) sections, suction, supply and exhaust.
Suction
First inspect the flow path by looking through from the
suction out the exhaust. If all clear, then there is either an
air supply problem or an adjustment problem (this is
assuming there is nothing connected to the exhaust; remove
any muffler or tubing before troubleshooting).
Compressed air
supply section Air supply- remove the supply hose from the hose barb and
confirm there is plenty of air flow and pressure (need 60 psi
or more).

Adjustment- loosen the locking ring and with fingers only,

Lock ring. screw the exhaust section up into the fatter supply section
Exhaust section; until it bottoms. This is ‘0’ degrees; from here start
screws into supply unscrewing. At 270 degrees out from ‘0’ (3/4 of a turn)
section. Make there will be good flow and suction. Maximum flow and
sure exhaust is maximum air consumption will occur at 2 full turns out.
unrestricted. 1.75 turns is generally the maximum needed.

Page 23 of 30 Aug
2013
REP50, REP100 and REP150 Regulators

Piloted discharge regulators: All (3) regulators

regardless of size function and fail in the same way.
When debris is stuck under the poppet, the
regulator will allow excess air pressure by, which it Diaphragms
REP100 example
will try to vent out of its bonnet, causing a
significant leak (hissing) at the bonnet. Also you
may hear the leaking air escaping out the exhaust
valve.
When the diaphragms are torn, different symptoms
will occur. If the top diaphragm is torn, the pilot air
signal will blow through, making an audible leak
and most likely the regulator will not open and pass
air downstream. If the lower diaphragm is torn,
there will also be an air leak but is likely the
regulator will open.
Clean or repair using the appropriate repair kits for
the REP50 thru150K (contains both diaphragms,
poppet assembly).

Poppet seat

Page 24 of 30 Aug
2013
 AP300 CONTROL PANEL SPARE PARTS AND COMPONENTS
Note: all panels share the enclosure and internal logic components. The differences are in the
size of discharge regulators and exhaust valves. All other parts are interchangeable.

Part # Description
****** Complete control panel with all valving and filtration
(All Models: AP300G2–G8, and AP300F2L–F8L)
AP300L Control logic module
MBR.01 Bubbler orifice (orifices (2) and clean-out tool)
NREFC125AD Combination coalescing control filter, regulator and auto-drain
FEPC Control filter element, dual particulate and coalescing.
FTD Fill stroke timer
DTD Discharge stroke timer.
PB-IND Pop-out logic indicator (F or D)
NRE125 Discharge piloting regulator
NAD125 Control filter auto-drain.
PG1.5S Discharge pressure gage.
PG1.0 Control supply pressure gage.
CV1032 Level control line relief valve.
R333 Discharge piloting valve time delay
EXVS75 Complete 3/4" stainless exhaust valve, viton seat, nitrile seal.
EXVS75IN Complete drop in replacement internal assembly
EXVS75S 3/4" SS exhaust valve seat, and seal rebuild kit
EXV200 2" exhaust valve.
EXV200K 2" exhaust valve rebuild kit
REP50 1/2" piloted discharge regulator.
REP50K 1/2" piloted discharge regulator repair kit.
REP100 1" piloted discharge regulator.
REP100K 1" piloted discharge regulator repair kit.
REP150 1-1/2" piloted discharge regulator.
REP150K 1-1/2" discharge regulator (pilot operated) repair kit.

FLOW INDUCERS
F2L Flow inducers for 2" pumps
F3L Flow inducers for 3" pumps
F4L Flow inducers for 4" pumps
F6L Flow inducers for SH4, 6x4 and 6” pumps
F8L Flow inducers for 8” and larger pumps

* Flow inducers should be exhausted into large diameter, rubber hose or approved mufflers.

Page 25 of 30 Aug
2013
MUFFLERS
ST-6B Muffler for F2–F3 flow inducers
ST-12C Muffler for F4–F8 flow inducers

AIR SUPPLY FILTERS

F50/AD 1/2" filter with high flow autodrain
FE50 40 micron filter element for F50 filter
F100/AD 1" filter with high flow autodrain
FE100 40 micron filter element for F100 filter
F150/AD 1-1/2" filter with high flow autodrain
FE150 40 micron filter element for F150 filter

INLET TRANSFER ADAPTERS

2CTAD 2” carbon steel adapter (Fig 14A & 14B)

2SSTA 2” 316SS adapter (Fig 14A & 14B)
3CTAD 3” carbon steel adapter (Fig 14A & 14B)
3SSTA 3” 316SS adapter (Fig 14A & 14B)
4CTAD 4” carbon steel adapter (Fig 14A & 14B)
4SSTA 4” 316SS adapter (Fig 14A & 14B)

Adder for threaded inlet adapter plate (same adapter as on inlet of transfer pumps).
Includes: plate with male threaded end, valve plate gasket, extra length bolts for check valve flapper posts(sealing
bolts). Pump is capable of dry-piping inlet with this adapter. Note size and construction of pump.

Fig 14A Fig 14B

Page 26 of 30 Aug
2013
 CIPC CHECK VALVES
CIPC recommends that customer’s stock inlet and discharge check valve internals, and in cases of
expected high wear such as abrasive slurries we recommend entire spare check valves. Following
is a list of CIPC check valve part numbers and descriptions.
Part # Size Description
2CVP/C(_) 2" CIPC steel swing check, plate style,
full port, complete assembly for S2C pumps. (Fig 20A)
2CVP/S(_) 2" CIPC 316SS swing check, plate style,
full port, complete assembly for S2S pumps. (Fig 20A)
2CVF/(_) 2" Flapper (316SS) (Fig 20B, 20D exploded )
Seat adders for check valve flappers

** Pumps are built with NITRILE seats as standard **

(N) Nitrile seat for 2" check
(V) Viton seat for 2" check.
(T) Teflon seat for 2" check.
(UHD) Heavy duty urethane seat for 2” check
(E) EPDM seat for 2" check.
2CVSK(_) 2" Seat kit (2 seats), for 2” checks
(N) Nitrile seat for 2" check
(V) Viton seat for 2" check
(T) Teflon seat for 2" check
(UHD) Heavy duty urethane seat for 2” check
(E) EPDM seat for 2" check
2CVGK 2" Flange gasket kit (4 gaskets) for 2” check valve (Fig 20C)

** (3) gaskets required for submersible (1 spare) & (4) required for transfer pumps
** CIPC strongly recommends that new gaskets be installed whenever reassembling check valves.

Fig 20A Fig 20B Fig20C Fig20D

Seat Material Selection Properties:

Nitrile Good all-purpose elastomer. Medium chemical, oil and solvent resistance, good
strength, temperatures up to 170°F.
Viton Excellent resistance to oxidizers and solvents. Medium strength, temperatures up to
250°F.
Teflon Best chemical resistance of all. Inert to acid bases and solvents. Lower cycle life,
non-elastomeric, temperatures up to 300°F.
Urethane HD Best resistance to abrasion. Toughest of the elastomers, with mild chemical
resistance, temperatures up to 150°F.
EPDM Good heat and acid/base resistance. Tougher than Viton but poor solvent resistance,
temperatures up to 300°F.

Page 27 of 30 July2013
 CIPC CHECK VALVES CONTINUED
3CVP/C(_) 3" CIPC steel swing check, plate style,
full port, complete assembly for S3C pumps. (Fig 20A)
3CVP/S(_) 3" CIPC 316SS swing check, plate style,
full port, complete assembly for S3S pumps. (Fig 20A)
3CVF/(_) 3" Flapper (316SS) (Fig 20B, 20D exploded )
Seat adders for check valve flappers

** Pumps are built with NITRILE seats as standard **

(N) Nitrile seat for 3" check
(V) Viton seat for 3" check
(T) Teflon seat for 3" check
(UHD) Heavy duty urethane seat for 3” check
(E) EPDM seat for 3" check
3CVSK(_) 3" Seat kit (2 seats), for 3” checks
(N) Nitrile seat for 3" check
(V) Viton seat for 3" check
(T) Teflon seat for 3" check
(UHD) Heavy duty urethane seat for 3” check
(E) EPDM seat for 3" check
3CVGK 3" Flange gasket kit (4 gaskets) for 3” check valve (Fig 20C)

** (3) gaskets required for submersible (1 spare) & (4) required for transfer pumps
** CIPC strongly recommends that new gaskets be installed whenever reassembling check valves.

Fig 20A Fig 20B Fig20C Fig20D

Seat Material Selection Properties:

Nitrile Good all-purpose elastomer. Medium chemical, oil and solvent resistance, good
strength, temperatures up to 170°F.
Viton Excellent resistance to oxidizers and solvents. Medium strength, temperatures up to
250°F.
Teflon Best chemical resistance of all. Inert to acid bases and solvents. Lower cycle life,
non-elastomeric, temperatures up to 300°F.
Urethane HD Best resistance to abrasion. Toughest of the elastomers, with mild chemical
resistance, temperatures up to 150°F.
EPDM Good heat and acid/base resistance. Tougher than Viton but poor solvent resistance,
temperatures up to 300°F.

Page 28 of 30 Aug 2013

 CIPC CHECK VALVES CONTINUED
4CVP/C(_) 4" CIPC steel swing check, plate style,
full port, complete assembly for S4C pumps. (Fig 20A)
4CVP/S(_) 4" CIPC 316SS swing check, plate style,
full port, complete assembly for S4S pumps. (Fig 20A)
4CVF/(_) 4" Flapper (316SS) (Fig 20B, 20D exploded )
Seat adders for check valve flappers

** Pumps are built with NITRILE seats as standard **

(N) Nitrile seat for 4" check
(V) Viton seat for 4" check.
(T) Teflon seat for 4" check.
(UHD) Heavy duty urethane seat for 4" check.
(E) EPDM seat for 4" check.
4CVSK(_) 4" Seat kit (2 seats), for 4” checks
(N) Nitrile seat for 4" check
(V) Viton seat for 4" check.
(T) Teflon seat for 4" check.
(UHD) Heavy duty urethane seat for 4” check.
(E) EPDM seat for 4" check
4CVGK 4" Flange gasket kit (4 gaskets) for 4” check valve (Fig 20C)

** (3) gaskets required for submersible (1 spare) & (4) required for transfer pumps
** CIPC strongly recommends that new gaskets be installed whenever reassembling check valves.

Fig 20A Fig 20B Fig20C Fig20D

Seat Material Selection Properties:

Nitrile Good all-purpose elastomer. Medium chemical, oil and solvent resistance, good
strength, temperatures up to 170°F.
Viton Excellent resistance to oxidizers and solvents. Medium strength, temperatures up to
250°F.
Teflon Best chemical resistance of all. Inert to acid bases and solvents. Lower cycle life,
non-elastomeric, temperatures up to 300°F.
Urethane HD Best resistance to abrasion. Toughest of the elastomers, with mild chemical
resistance, temperatures up to 150°F.
EPDM Good heat and acid/base resistance. Tougher than Viton but poor solvent resistance,
temperatures up to 300°F.

Page 29 of 30 Aug 2013

 CIPC SIDE INLET CHECK VALVE ASSEMBLIES

4SICV 4" CIPC side inlet internal swing check, stainless steel,
for 4” high flow side inlet pumps
4SICV-DT 4” CIPC side inlet internal swing check, stainless steel, with low level
downtube, for 4” high flow side inlet pumps

6SICV 6" CIPC side inlet internal swing check, stainless steel,
for 6x4, 6” side inlet pumps
6SICV-DT 6” CIPC side inlet internal swing check, stainless steel, with low level
downtube, for 6x4, 6” side inlet pumps

8SICV 8" CIPC side inlet internal swing check, stainless steel,
for 8” side inlet pumps
8SICV-DT 8” CIPC side inlet internal swing check, stainless steel, with low level
downtube, for 8” side inlet pumps

To order, contact CIPC with your pump serial number

CIPC WAFER CHECK VALVES

4WCV 4" CIPC stainless steel wafer swing check,
full port, for 4” high flow and 6x4 pumps
6WCV 6" CIPC stainless steel wafer swing check,
full port, for 6” pumps
8WCV 8" CIPC stainless steel wafer swing check,
full port, for 8” pumps

To order, contact CIPC with your pump serial number

ALL RUBBER FLAPPER CHECK VALVES

For 2”, 3”, and 4” pumps

These all rubber hinged designed check valve flappers are used in place of our standard
plate style flapper. Designed to be used on stringy or irregular shaped products they may build up
around our standard check valve flapper. Designed only for specific qualifying applications.

Contact CIPC with your specific pumping application.

NON-METALLIC CHECK VALVES FOR VINYLESTER PUMPS

Contact CIPC with your pump serial number for current available products
for your pump.

Page 30 of 30 Aug 2013