F/G-20 Installation
Contents
1. INSTALLATION amp SERVICE Models F 20 F 21 F 22 G 20 G 21 G 22 ME WANNER ENGINEERING INC 1204 Chestnut Avenue Minneapolis MN 55403 TEL 612 332 5681 FAX 612 332 6937 TOLL FREE FAX US only 800 332 6812 www hydra cell com email sales wannereng com F G 20 Contents Page SPeCifications vez2 se eetissdeestetep eset T 2 Dimes S a a E a Aa ee eevee Rasta 4 Installato sea n a a nra a aans oaa 7 Maintenance micaia A ee 11 Service Fluid End penre ennd vesseeuinciiedes tecteiectndessstenest 12 Service Hydraulic End ceecceeeeeeeeeeeeeeeeeneeseeeeseeeeeeneee 15 Troubleshooting 5 ccsisceseessecesescapceneteeseenicensascesestaccanersuneesane 18 F G 20 Specifications Max Pressure Metallic F G 20 1000 psi 70 bar F G 21 22 1500 psi 100 bar Non Metallic All Models 250 psi 17 bar Capacity Max Pressure rpm gpm l min F G 20 X 1750 0 96 3 63 F G 20 E 1750 0 73 2 76 F G 20 S 1750 0 55 2 08 F G 20 B 1750 0 33 1 25 F G 20 G 1750 0 20 0 76 Delivery Max Pressure revs gal revs liter F G 20 X 1823 500 F G 20 E 2397 659 F G 20 S 3182 906 F G 20 B 5303 1400 F G 20 G 8750 2302 Max Inlet Pressure 100 psi 7 bar Max Temperature Metallic Heads 250 F 121 C consult factory for temperatures above 160 F 71 C Non Metallic Heads 140 F 60 C Inlet Port F 20 1 2 inch NPT G 20 1 2 inch BSPT F 20 3 8 inch NPT G 20 3 8 inch BSPT Discharge2. 5 12 a g 2 amp D x 10 T 5 rg N I a N zZz 8 Es 2 6 4 1 2 0 0 200 400 600 800 1000 1200 1400 1600 1800 RPM Dry Lift 4 0 3 5 100 3 0 T 80 gt 2 2 5 2 S 3 2 0 60 E F G 20 E 2 15 F G 20 S F G 20 B 407 F G 20 G 1 0 20 0 5 0 0 200 400 600 800 1000 1200 1400 1600 1800 RPM F20 991 2400 5 1 04 F G 20 Dimensions F 20 G 20 Models with Brass 316 Stainless Steel Hastelloy C 20 5 8 ID for NEMA 56C 20 19 mm ID for IEC 80 F 20 3 8 NPT Outlet G20 3 8 BSPT 0 72 18 3 F 20 1 2 NPT Inlet G20 1 2 BSPT Metallic Pumping Hea d m 3 64 92 5 Inches mm F 20 G 20 Models with Kynar Polypropylene F 20 5 8 ID for NEMA 56C G 20 19 mm ID for IEC 80 Non Metallic Pump Hea d 0 42 10 7 F 20 3 8 NPT Outlet 50 3 8 BSPT 0 72 O 18 3 4 15 105 0 65 oO 16 5 Q F 20 1 2 NPT Inlet G50 1 2 BSPT 9 97 Ms 253 2 a F20 991 2400 5 1 04 F G 20 Dimensions F 21 G 21 Models with Metallic Pumping Head Inches mm 0 33 thru hole 2 25 Brass ra ir m 8 4 316 Stainless Steel K Hastelloy C 5 18 132 8 93 227 12 7 thru hole 2 places F 21
3. Repeat the flushing procedure step b above Fill the reservoir with fresh oil manually turn the pump shaft to circulate the oil and drain once again Refill the reservoir If the oil appears milky there is still contaminant in the reservoir Repeat the flushing procedure until the oil appears clean 5 Prime the Hydraulic Cell a b Cc With the pump horizontal fill the reservoir with the appropriate Hydra oil for the application All air in the oil within the hydraulic cell behind the diaphragm must be forced out by turning the shaft and thus pumping the piston A shaft rotator is included in the Wanner Tool Kit Turn the shaft until a bubble free flow of oil comes from behind the diaphragm Watch the oil level in the reservoir if it gets too low during priming air will be drawn into the piston inside the hydraulic end This will cause the pump to have a loss in flow and you will have to start over again with priming the hydraulic cell Fill oil reservoir completely Add diaphragm seal and install cover plate Wipe excess oil from the cover plate and diaphragm 14 a The oil reservoir diaphragm 71 protrudes down into the pump housing approximately 1 4 to 3 8 in Add oil if required so that when the diaphragm is set into the reservoir all air is pushed out Take care not to allow any oil overflow to get between the pump housing 62 or 66 and the cover 54 This may result in an apparent oil lea
4. 5 8 G 21 819 mm y AT ed isga F 21 3 8 NPT 0 72 18 3 0 65 16 5 Outlet G21 3 8 BSPT F 21 1 2 NPT Inlet G51 1 2 BSPT F 21 G 21 Models with Non Metallic Pump Head Kynar 67 gt Polypropylene 0 65 16 5 Inlet F 21 3 8 NPT Outlet G51 3 8 BSPT 7 F 21 1 2 NPT G 21 1 2 BSPT SND RO 20 33 3 45 thru hole lt 87 6 8 4 A 18 32 9 18 233 2 thru hole 2 places F 21 05 8 G 21 019 mm y eo 24 4 1 91_ F20 991 2400 5 1 04 F G 20 Dimensions F 22 G 22 Models with Metallic Pumping Head Inches mm Brass 316 Stainless Steel Hastelloy C jak F 22 3 8 NPT Outlet G22 3 8 BSPT O O 4 15 105 0 65 16 5 O O O F 22 1 2 NPT G 22 1 2 BSPT 9 72 a 247 F 22 G 22 Models with Non Metallic Pump Head Kynar I Polypropylene 6 50 165 5 149 63 219 2 y 0 42 10 7 4x F 22 05 8 G 22 019 mm 5 63 lt 143 F 22 3 8 NPT Outlet G23 3 8 BSPT F 22 1 2 NPT Inlet G59 1 2 BSPT lt 6 F20 991 2400 5 1 04 F G 20 Installation Location NOTE The numbers in parentheses are the Reference Numbers on the illustrations fo
5. all eight bolts 1 around the manifold b Remove the manifold 3 c Inspect the manifold for warping or wear around the inlet and outlet ports If wear is excessive replace the manifold or return it to Wanner Engineering for resurfacing To check if the manifold is warped place a straightedge across it Awarped manifold should be replaced 2 Inspect Valves 4 17 The inlet and outlet valve assemblies are different the inlet valve is larger and face in opposite directions Inspect each valve as follows a Check the spring retainers 4 17 and replace if worn b Check the valve springs 5 16 If shorter than a new spring replace them do not just stretch the old spring c Check the valve poppets 6 15 If worn excessively replace them d Remove the valve seats 9 13 Aseat puller is included in the Wanner Tool Kit Inspect the valve seats for wear and replace if necessary A new O ring 8 12 should be installed e Check the dampening washers 10 11 and replace if worn f Reinstall the valve assemblies Clean the valve ports and shoulders with emery cloth and lubricate them with lubricating gel or petroleum jelly do not use petroleum products when installing EPDM O rings e Install the O rings 8 12 on the valve seats 9 13 Inlet Valve Insert the spring retainer 17 into the valve plate then insert the spring valve Tetra seal valve seat and dampening washer 16 11 A flat O ring Tetra se
6. flow to the pump is not restricted The opening should be at least the same diameter as the inlet plumbing ID Do not use a line strainer or filter in the suction line unless regular maintenance is assured If used it should have a free flow area of at least three times the free flow area of the inlet Install piping supports where necessary to relieve strain on the inlet line and to minimize vibration Inlet Piping Pressure Feed Provide for permanent or temporary installation of a vacuum pressure gauge to monitor the inlet vacuum or pressure Pressure at the pump inlet should not exceed 250 psi 173 bar if it could get higher install an inlet pressure regulator Do not supply more than one pump from the same inlet line Inlet Calculations Acceleration Head Calculating the Acceleration Head Use the following formula to calculate acceleration head losses Subtract this figure from the NPSHa and compare the result to the NPSHr of the Hydra Cell pump Ha Lx V x N x C K x G where Ha Acceleration head ft of liquid L Actual length of suction line ft not equivalent length V Velocity of liquid in suction line ft sec V GPM x 0 408 pipe ID N RPM of crank shaft C Constant determined by type of pump use 0 628 for the F G 20 21 22 Hydra Cell pump K Constant to compensate for compressibility of the fluid use 1 4 for de aerated or hot water 1 5 for most liquids 2 5 for hydrocarbons w
7. valve cylinder d Slide the assembled valve cylinder plunger and spring 28 31 into the piston 33 e Insert the washer 27 over the plunger f Using the snap ring pliers insert the snap ring 26 into the piston w To Remove Motor from Direct Coupled Unit F20 1 Disassemble Motor from Pump a Remove the four bolts and flat washers that secure the pump and motor together b Install two of the bolts into the threaded holes in the pump flange 51 c Alternately turn the bolts clockwise until the pump and motor separate 2 Reassemble Motor to Pump a Thoroughly clean the motor shaft and the hollow pump shaft b Apply a liberal amount of Loctite Nickel Anti Seize 77164 to the pump shaft Install the shaft key into the motor shaft keyway d Slide the motor shaft into the hollow pump shaft CAUTION When assembling this pump to the direct coupled motor be careful that the shaft key remains in the motor shaft keyway and does not ride up the keyway and contact the shaft seal which would cause premature seal failure Incorrect key placement could also cause the hollow pump shaft to fail Use a screwdriver to move the shaft key back in the motor shaft keyway as the motor and pump are drawn together e Reinstall the four bolts and flat washers O To Service Remainder of Hydraulic End 1 Remove Pump Housing a Remove the manifold valve plate and diaphragm as outlined in the Fluid End Ser
8. 1 04 F G 20 Installation Minimizing Acceleration Head and Frictional Losses To minimize the acceleration head e Keep inlet lines less than 3 ft 1 m long e Use at least 5 8 16mm I D inlet hose e Use soft hose low pressure hose noncollapsing for the inlet lines e Minimize fittings elbows valves tees etc e Use a suction stabilizer on the inlet Net Positive Suction Head NPSHa must be equal to or greater than NPSHr If not the pressure in the pump inlet will be lower than the vapor pressure of the fluid and cavitation will occur Calculating the NPSHa Use the following formula to calculate the NPSHa NPSHa Pt Hz Hf Ha Pvp where Pt Atmospheric pressure Hz Vertical distance from surface liquid to pump centerline if liquid is below pump centerline the Hz is negative Hf Friction losses in suction piping Ha Acceleration head at pump suction Pvp Absolute vapor pressure of liquid at pumping temperature NOTES e In good practice NPSHa should be 2 ft greater than NPSHr All values must be expressed in feet of liquid Atmospheric Pressure at Various Altitudes Altitude Pressure Altitude Pressure ft ft of H O ft ft of H O 0 33 9 1500 32 1 500 33 3 2000 31 5 1000 32 8 5000 28 2 Discharge Piping Note Consult the Factory before manifolding two or more pumps together Hose and Routing Use the shortest most direct route for the discharge line Select pipe or h
9. 5681 FAX 612 332 6937 TOLL FREE FAX US only 800 332 6812 www hydra cell com email sales wannereng com 20 Limited Warranty Wanner Engineering Inc extends to the original purchaser of equipment manufacturerd by it and bearing its name a limited one year warranty from the date of purchase against defects in material or workmanship provided that the equipment is installed and operated in accordance with the recommendations and instructions of Wanner Engineering Inc Wanner Engineering Inc will repair or replace at its option defective parts without charge if such parts are returned with transportation charges prepaid to Wanner Engineering Inc 1204 Chestnut Avenue Minneapolis Minnesota 55403 This warranty does not cover 1 The electric motors if any which are covered by the separate warranties of the manufacturers of these components 2 Normal wear and or damage caused by or related to abrasion corrosion abuse negligence accident faulty installation or tampering in a manner which impairs normal operation 3 Transportation costs This limited warranty is exclusive and is in lieu of any other warranties express or implied including warranty of merchantability or warranty of fitness for a particular purpose and of any noncontractual liabilities including product liabilities based on negligence or strict liability Every form of liability for direct special incidental or consequential damages or l
10. Port Shaft Diameter F 20 5 8 inch hollow shaft for NEMA 56C C Face motor with feet F 21 22 5 8 inch G 20 19 mm for IEC 80 B5 Flange motor with feet G 21 22 19 mm Shaft Rotation Bi directional Bearings Radial ball Oil Capacity 1 8 US quart 0 12 liters Weight Metallic Head 12 Ibs 5 5 kg Non Metallic Head 9 lbs 4 1 kg Calculating Required Horsepower kW 2 x rpm 9pmxpsi electric motor HP 63 000 1 460 2 x rpm __lpmxbar electric motor kW 84 428 511 rpm equals pump shaft rom HP kW is required application power Use caution when sizing motors with variable speed drives Note Performance and specification ratings apply to all configurations unless specifically noted otherwise F20 991 2400 5 1 04 F G 20 Specifications Performance RPM 0 200 400 600 800 1000 1200 1400 1600 1800 1 2 4 0 1 0 4 FA F G 20 X 100 PSI 7bar 3 5 500 PSI 35bar n i 1000 PSI 70 bar 1500 PSI 100 bar 0 8 30 a E 2 5 2 06 N 2 S 2 0 0 4 fe 1 0 0 2 0 5 0 Note Performance and specification ratings apply to all configurations unless specifically noted otherwise Liters per Minute Net Positive Suction Head NPSHr 20 6 18 F G 20 X F G 20 E 5 16 F G 20 S F G 20 B F G 20 G Ea zc T a 5
11. al 14 goes between the retainer and seat e Outlet Valve Insert the dampening washer valve seat Tetra seal valve and spring then the retainer Install the flat O ring between the retainer and seat 13 3 Inspect and Replace Diaphragm 22 a b g Use a 3 mm Allen wrench to remove the two capscrews 20 from the valve plate 21 Lift the diaphragm by one edge and turn the pump shaft until the diaphragm moves up to top dead center This will expose machined cross holes in the plunger shaft behind the diaphragm NOTE If the pump has a hollow shaft use the shaft rotator from the Wanner Tool Kit Insert the plunger holder from the Wanner Tool Kit through one of the machined cross holes to hold the diaphragm up The proper size tool is included in the Wanner Tool Kit Don t remove the tool until the new diaphragm is installed in step G below Unscrew the diaphragm Use an 8 mm or 5 16 in open end wrench and turn counterclockwise Inspect the diaphragm carefully A damaged diaphragm generally indicates a pumping system problem and replacing only the diaphragm will not solve the larger problem Inspect the diaphragm for the following e Small puncture Usually caused by a sharp foreign object in the fluid or by an ice particle e Diaphragm pulled away from the sides Usually caused by fluid being frozen in the pump or by overpressurization of the pump e Diaphragm becoming stiff and losing f
12. and elbows in inlet line NPSHa is less than NPSHr e Fluid too hot for inlet suction piping system e Air entrained in fluid piping system e Aeration and turbulence in supply tank e Inlet suction vacuum too high Symptoms of Cavitation e Excessive pump valve noise e Premature failure of spring or retainer 4 5 16 17 e Volume or pressure drop e Rough running pump Drop in Volume or Pressure A drop in volume or pressure can be caused by one or more of the following e Air leak in suction piping e Clogged suction line or suction strainer e Suction line inlet above fluid level in tank e Inadequate fluid supply Pump not operating at proper RPM e Relief valve bypassing fluid e Worn pump valve parts e Foreign material in inlet or outlet valves e Loss of oil prime in cells because of low oil level e Ruptured diaphragm 22 e Cavitation e Warped manifold from overpressurized system e O rings forced out of their grooves from overpressurization e Air leak in suction line strainer or gasket e Cracked suction hose e Empty supply tank e Excessive aeration and turbulence in supply tank e Abrasives in the fluid e Valve incompatible with corrosives in the fluid e Pump running too fast e Worn and slipping drive belt s e Worn spray nozzle s Pump Runs Rough Worn pump valves e Airlock in outlet system e Oil level low Wrong weight of oil for cold operating temperatures change to lighter weight e Cavitatio
13. ccording to the guidelines below When changing remove the drain plug 69 Allow all oil and contaminant to drain out Hours Between Oil Changes Various Process Fluid Temperatures lt 90 F lt 139 F lt 180 F Pressure RPM 32 C 60 C 82 C Metallic Pump Head lt 1000 psi 70 bar lt 1200 6 000 4 000 2 000 lt 1800 3 000 2 000 1 500 lt 1500 psi 100 bar lt 1200 3 000 2 000 1 500 lt 1800 1 500 1 000 1 000 Non Metallic Pump Head lt 250 psi 17 bar lt 1200 3 000 2 000 lt 1800 1 500 1 000 NOTE Minimum oil viscosity for proper hydraulic end lubrication is 16 20 cST 80 100 SSU CAUTION Do not turn the drive shaft while the oil reservoir is empty There should be no trapped air under the oil reservoir diaphragm 71 Refer to Service Procedure 6 Fill and Seal the Oil Reservoir in the Fluid End Service Section Use the appropriate Hydra Oil for the application contact Wanner Engineering if in doubt CAUTION If you are losing oil but don t see any external leakage or if the oil becomes discolored and contaminated the diaphragm 22 may be damaged Refer to the Fluid End Service Section Do not operate the pump with a damaged diaphragm CAUTION Do not leave contaminated oil in the pump housing or leave the housing empty Remove contaminated oil as soon as discovered and replace it with clean oil Check the inlet pressure or vacuum periodically with a gauge CAUTION Protec
14. e temperature buildup in the bypassed fluid CAUTION Never install shutoff valves in the bypass line or between the pump and pressure regulator or relief valve Provide for permanent or temporary installation of a pressure gauge to monitor the discharge pressure at the pump For additional system protection install a safety relief valve in the discharge line downstream from the pressure regulator F20 991 2400 5 1 04 F G 20 Installation Before Initial Start Up Before you start the pump be sure that All shut off valves are open and the pump has an adequate supply of fluid All connections are tight The oil reservoir beneath the reservoir diaphragm 71 is completely full NOTE The reservoir is filled and sealed at the factory If you are unsure about the oil level remove the cover 70 and slowly lift the diaphragm 71 Refer to Service Procedure 6 Fill and Seal the Oil Reservoir in the Fluid End Service Section The relief valve on the outlet of the pump is adjusted so the pump starts under minimum pressure All pulleys and belts are properly aligned and belts are tensioned according to specification All pulleys and belts have adequate safety guards 10 Initial Start Up Procedure 1 2 o Turn on power to the pump motor Check the inlet pressure or vacuum To maintain maximum flow inlet vacuum must not exceed 7 in Hg Inlet pressure must not exceed 250 psi 17 3 bar Listen for any erra
15. ended period This will remove any accumulated condensation and sediment from the oil reservoir Drain and refill the hydraulic end with the appropriate Hydra Oil and operate the pump for a short period to assure smooth performance F20 991 2400 5 1 04 F G 20 Service Fluid End See Hydraulic End for pump housings Piston Assembly see Detail A Ga Valve Assemblies see Detail B see also Detail C DETAIL C Nonmetallic a Pump Head C DETAIL A DETAIL B Piston Assembly Valve Assemblies OUTLET VALVE Plastic Retainer Plastic Retainer INLET VALVE Metal Bolt Torque Specifications Retainer F 20 21 22 G 20 21 22 Ref No in Ibs Ncm 1 90 1 017 20 14 158 22 10 113 23 14 158 12 F20 991 2400 5 1 04 F G 20 Service Fluid End NOTE The number in parentheses are the Reference numbers on the illustration at right also shown in the Parts Manual This section explains how to disassemble and inspect all easily serviceable parts of the pump Repair procedures for the hydraulic end oil reservoir of the pump are included in a later section of the manual NOTE All bolts nuts and screws are metric sizes CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic For assistance contact Wanner Engineering 612 332 5681 or the distributor in your area 1 Remove Manifold 3 a Remove
16. explains how to disassemble and inspect the hydraulic end oil reservoir of the pump CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic For assistance contact Wanner Engineering 612 332 5681 or the distributor in your area Depending on the repair you are attempting you may or may not have to remove the motor from a direct drive pump motor unit Internal piston components 26 32 can be serviced without removing the motor or crankshaft The motor and crankshaft must be removed to service the connecting rod 59 piston 33 crankshaft 58 front bearing 60 back bearing 57 or seal 56 To Service Piston Without Removing Motor or Crankshaft 1 Disassemble Piston Remove the manifold valve plate diaphragm plate and diaphragm and drain the oil from the pump see the Fluid End Service Section a Remove the snap ring 26 from the piston using a standard 1 snap ring pliers b Pull out the valve plunger 29 This also removes the washer 27 and spring 28 c 31 and pull the cylinder out of the piston Be careful not to damage the piston d Inspect all parts and replace the O ring and any other parts that are worn or may be damaged 2 Reassemble Piston Tip the pump so the piston is upright b Drop the ball 32 into the opening in the bottom of the piston c Insert the valve plunger 29 into the valve cylinder 31 Slide the spring 28 over the plunger inside the
17. ith high compressibility G Gravitational constant 32 2 ft sec Friction Losses Calculating Friction Losses in Suction Piping When following the above recommendations under inlet Piping for minimum hose pipe I D and maximum length frictional losses in the suction piping are negligible i e Hf 0 if you are pumping a water like fluid When pumping more viscous fluids such as lubricating oils sealants adhesives syrups varnishes etc frictional losses in the suction piping may become significant As Hf increases the available NPSH NPSHa will decrease and cavitation will occur In general frictional losses increase with increasing viscosity increasing suction line length increasing pump flowrate and decreasing suction line diameter Changes in suction line diameter have the greatest impact on frictional losses a 25 increase in suction line diameter cuts losses by more than two times and a 50 increase cuts losses by a factor of five times Consult the factory before pumping viscous fluids Minimizing Acceleration Head and Frictional Losses To minimize the acceleration head and frictional losses e Keep inlet lines less than 1 ft 0 3 m long suction stabilizer required for longer inlet lines Use at least 5 8 in 16 mm I D inlet hose e Use soft hose low pressure hose noncollapsing for the inlet lines e Minimize fittings elbows valves tees etc e Use a suction stabilizer on the inlet F20 991 2400 5
18. k later when the pump is put into use and heats up Install the cover 70 using the four bolts Wipe off any excess oil that got squeezed out onto the outside of the pump housing NOTE The diaphragm 71 will flex up and down slightly as the pump operates The vent holes in the reservoir cover 70 allow this action to freely occur 7 Reinstall Valve Plate 21 and Manifold 3 a Reinstall the valve plate 21 with the valve assemblies installed as outlined above onto the diaphragm plate 24 Reinstall the O rings 18 19 onto the valve plate 21 Use petroleum jelly or lubricating gel to hold them in place do not use petroleum products when installing EPDM O rings Reinstall the manifold onto the valve plate Insert all bolts 1 around the edge of the manifold and alternately tighten opposite bolts until all are secure Torque to 90 in lbs Recheck all bolts for tightness F20 991 2400 5 1 04 F G 20 Service Hydraulic End F G 21Pump Housing I F G 20 and F G 2P Pump Housing F G 21 and F G 22 Shaft and Keyway See Fluid End for Piston Assembly Bolt Torque Specifications F 20 21 22 G 20 21 22 Ref No in Ibs Ncm 50 35 396 52 14 158 72 10 113 75 35 396 15 F20 991 2400 5 1 04 F G 20 Service Hydraulic End NOTE The numbers in parentheses are the Reference numbers on the illustration at right also shown in the Parts Manual This section
19. lexibility Usually caused by pumping a fluid that is incompatible with the diaphragm material e Diaphragm edge chewed away Usually caused by overpressurizing the system CAUTION If a diaphragm has ruptured and foreign material or water has entered the oil reservoir do not operate the pump Check the diaphragm then flush the reservoir completely as outlined below and refill it with fresh oil Never let the pump stand with foreign material or water in the reservoir or with the reservoir empty Clean away any spilled oil Apply Loctite 242 Threadlocker to the threads of the new diaphragm or the old one as appropriate Install the diaphragm and tighten to 10 in lbs F20 991 2400 5 1 04 F G 20 Service Fluid End 6 Fill and Seal the Oil Reservoir 4 Flush Contaminant from Hydraulic End only if a diaphragm has ruptured a With the valve plate and manifold still removed see above remove the oil drain cap 69 and the oil reservoir cover 70 and diaphragm 71 Allow all oil and contaminant to drain out Fill the reservoir with kerosene or solvent manually turn the pump shaft to circulate the kerosene and drain Dispose of this contaminated fluid properly CAUTION If you have an EPDM diaphragm or if food grade oil is in the reservoir do not use kerosene or solvents Instead flush with the same lubricant that is in the reservoir Pumps with an EPDM diaphragm have an E as the 7th digit of the Model No
20. n Air in suction line e Restriction in inlet suction line e Hydraulic cells not primed after changing diaphragm 22 e Foreign material in inlet or outlet valve Damaged diaphragm 22 e Broken valve spring 5 16 Premature Failure of Diaphragm 22 Frozen pump e Puncture by a foreign object Elastomer incompatible with fluid being pumped Pump running too fast e Excess pressure Water in Oil Reservoir Condensation e Ruptured diaphragm 22 e Hydraulic cell not properly primed after diaphragm 22 replacement e Frozen pump Strong Water Pulsations NOTE Small pulsations are normal with a single acting pump Foreign object lodged in pump valve e Loss of prime in hydraulic cell because of low oil level Air in suction line e Valve spring 5 16 broken e Cavitation e Aeration or turbulence in supply tank F20 991 2400 5 1 04 F G 20 Troubleshooting Valve Wear Normal wear Pump Runs But Fluid Doesn t Flow Unit air locked es of Oil External seepage Rupture of diaphragm 22 Frozen pump e Worn shaft seal Oil drain fill cap or oil reservoir cover loose Valve plate and manifold bolts loose Premature Failure of Valve Spring or Retainer Cavitation Foreign object in the pump Pump running too fast Spring retainer material incompatible with fluid being pumped F20 991 2400 5 1 04 ME WANNER ENGINEERING INC 1204 Chestnut Avenue Minneapolis MN 55403 TEL 612 332
21. nd the inside surface of the opening in the back cover 54 where the seal will rest Press the new seal into the back cover Inspect the bearing 57 If pitted or damaged replace it 17 a Screw the plunger puller from the Wanner Tool Kit or Repair Kit into the plunger 29 Pull out to expose the cross hole in the plunger Rotate the shaft until the piston is at top dead center Insert the diaphragm wrench from the Wanner Tool Kit or similar dowel type object through the plunger hole to hold the plunger away from the diaphragm plate 24 and to keep the plunger from turning when the diaphragm is being installed Apply a small amount of Loctite 242 to the threads of the diaphragm be sure the threads are clean Set the diaphragm 22 on the plunger 29 ridge side out Screw the diaphragm onto the plunger Hold the diaphragm wrench and tighten the diaphragm to 10 in lbs of torque Fill the reservoir with fresh oil and prime the pump as outlined in the Fluid End Service Section 6 Reassemble Pump Fill and seal the oil reservoir then reassemble the pump as outlined in the Fluid End Service Section F20 991 2400 5 1 04 F G 20 Troubleshooting Cavitation e Inadequate fluid supply caused by Inlet line collapsed or clogged Clogged line strainer Inlet line too small or too long Air leak in inlet line Worn or damaged inlet hose Suction line too long Too many valves
22. ose with a working pressure rating of at least 1 5 times the maximum system pressure EXAMPLE Select a 1500 psi 103 bar W P rated hose for systems to be operated at 1000 psi 69 bar gauge pressure Use about 6 ft 1 8 m of flexible hose between the pump and rigid piping to absorb vibration expansion or contraction Support the pump and piping independently Size the discharge line so that the velocity of the fluid will not exceed 7 10 ft sec 2 3 m sec For pipe in inches Velocity ft sec 0 408 x GPM Pipe ID For pipe in mm Velocity m sec 21 2 x LPM Pipe ID Pressure Regulation Install a pressure regulator or unloader in the discharge line Bypass pressure must not exceed the pressure limit of the pump Size the regulator so that when fully open it will be large enough to relieve the full capacity of the pump without overpressurizing the system Locate the valve as close to the pump as possible and ahead of any other valves Adjust the pressure regulating valve to no more than 10 over the maximum working pressure of the system Do not exceed the manufacturer s pressure rating for the pump or regulator Route the bypass line to the supply tank or to the suction line as far as possible from the pump to reduce the chance of turbulence If the pump will be operating for a long time with the discharge closed and fluid bypassing install a thermal protector set to trip at 140 F in the bypass line to prevent sever
23. oss is expressly excluded and denied 2004 Wanner Engineering Inc Printed in USA F20 991 2400 5 1 04
24. stand from the supply tank and support them separately Install a separate inlet line from the supply tank to each pump Install the inlet and bypass lines so they empty into the supply tank below the lowest water level on the opposite side of the baffle from the pump suction line If a line strainer is used in the system install it in the inlet line to the supply tank To reduce aeration and turbulence install a completely submerged baffle plate to separate the incoming and outgoing liquids Install a vortex breaker in the supply tank over the outlet port to the pump Place a cover over the supply tank to prevent foreign objects from falling into it Hose and Routing Size the suction line at least one size larger than the pump inlet and so that the velocity will not exceed 1 3 ft sec 0 3 to 0 9 m s For pipe in inches Velocity ft sec 0 408 x GPM Pipe ID For pipe in mm Velocity m sec 21 2 x LPM Pipe ID Keep the suction line as short and direct as possible Use flexible hose and or expansion joints to absorb vibration expansion or contraction If possible keep the suction line level Do not have any high points to collect vapor unless these high points are vented To reduce turbulence and resistance do not use 90 elbows If turns are necessary in the suction line use 45 elbows or arrange sweeping curves in the flexible inlet hose If a block valve is used be sure it is fully opened so that the
25. t the pump from freezing Refer also to the Shutdown Procedure 11 Shutdown Procedure During Freezing Temperatures Take all safety precautions to assure safe handling of the fluid being pumped Provide adequate catch basins for fluid drainage and use appropriate plumbing from drain ports etc when flushing the pump and system with a compatible antifreeze 1 Adjust the discharge pressure regulating valve so the pump runs under minimum pressure Stop the pump 2 Drain supply tank open any draincocks in system piping and collect drainage Drain as much fluid from the pump manifold and plumbing attached directly to the pump manifold by loosening fittings or removing plugs or gauges 3 Close draincocks in system piping and tighten or replace any fittings gauges or plugs 4 Fill supply tank with enough antifreeze to fill system piping and pump NOTE Disconnect the system return line from the supply tank and connect it to a separate reservoir 5 Start the pump and allow it to run until the system is filled with antifreeze NOTE If the system has an airlock and the pump fails to prime follow step 4 of the Initial Start up Procedure to clear the air 6 When mostly antifreeze is flowing from the system return line stop the pump Connect the system return line back to the supply tank and circulate the antifreeze for a short period 7 Itis also good practice to change the oil in the hydraulic end before storage for an ext
26. tallation and operation of the pumping system Shut Off Valves Never install shut off valves between the pump and discharge pressure regulator or in the regulator bypass line Freezing Conditions Protect the pump from freezing See also the Maintenance Section Consult the Factory for the following situations Extreme temperature applications above 160 F or below 40 F Pressure feeding of pumps Viscous or abrasive fluid applications Chemical compatibility problems Hot ambient temperatures above 110 F Conditions where pump oil may exceed 200 F because of a combination of hot ambient temperatures hot fluid temperature and full horsepower load an oil cooler may be required DISCHARGE N nA a F20 991 2400 5 1 04 F G 20 Installation Inlet Piping Suction Feed CAUTION When pumping at temperatures above 160 F 71 C use a pressure feed system Install draincocks at any low points of the suction line to permit draining in freezing conditions Provide for permanent or temporary installation of a vacuum gauge to monitor the inlet suction To maintain maximum flow vacuum at the pump inlet should not exceed 7 in Hg 180 mm Hg Do not supply more than one pump from the same inlet line Supply Tank Use a supply tank that is large enough to provide time for any trapped air in the fluid to escape The tank size should be at least twice the maximum pump flow rate Isolate the pump and motor
27. tic noise and look for unsteady flow If the system has an air lock and the pump fails to prime a Turn off the power b Remove the pressure gauge or plug from the tee fitting at the pump outlet refer to the illustration on page 3 NOTE Fluid may come out of this port when the plug is removed Provide an adequate catch basin for fluid Spillage if required Fluid will come out of this port when the pump is started so we recommend that you attach adequate plumbing from this port so fluid will not be sprayed or lost Use high pressure rated hose and fittings from this port Take all safety precautions to assure safe handling of the fluid being pumped c Jog the system on and off until the fluid coming from this port is air free d Turn off the power e Remove the plumbing that was temporarily installed and reinstall the pressure gauge or plug Adjust the discharge pressure regulator to the desired operating and bypass pressures Do not exceed the maximum pressure rating of the pump After the pressure regulator is adjusted set the pop off safety relief valve at 100 psi higher than the desired operating pressure Pumps fitted with Teflon diaphragms require 2 psi 0 14 bar minimum inlet pressure F20 991 2400 5 1 04 F G 20 Maintenance NOTE The numbers in parentheses are the Ref Nos on the illustrations in the Parts Manual Periodically Change the oil after the first 100 hours of operation then change a
28. und later in this manual and in the Parts Manual Locate the pump as close to the supply source as possible Install it in a lighted clean space where it will be easy to inspect and maintain Allow room for checking the oil level changing the oil and removing the manifold 3 and valve plate 21 Mounting The pump shaft can be rotated in either direction To prevent vibration securely attach the pump or motor to a rigid base On a belt drive system align the sheaves accurately poor alignment wastes horsepower and shortens the belt and bearing life Make sure the belts are properly tightened as specified by the belt manufacturer On a direct drive system align the shafts accurately On aclose coupled system coat the motor shaft liberally with Loctite Nickel Anti Seize 77164 Pressure Pressure Regulator AD Vacuum Pressure Gauge BYPASS LINE er A T Important Precautions Adequate Fluid Supply To avoid cavitation and premature pump failure be sure that the pump will have an adequate fluid supply and that the inlet line will not be obstructed See Inlet Piping Positive Displacement This is a positive displacement pump To avoid severe system damage if the discharge line ever becomes blocked install a relief valve downstream from the pump See Discharge Piping Safety Guards Install adequate safety guards over all pulleys belts and couplings Follow all codes and regulations regarding ins
29. vice Section b Drain the oil from the pump housing by removing the drain plug 69 and the oil reservoir cover 70 and diaphragm 71 Stand the pump on end with the drive shaft up d Remove the bolts 52 that secure the cover 54 to the housing 62 or 66 Use a 5 mm socket wrench Save the O rings 53 e Remove the cover and the cover O ring 55 f Remove the crankshaft 58 by pulling it through the connecting rod 59 O F20 991 2400 5 1 04 F G 20 Service Hydraulic End 5 Reinstall Diaphragm 2 Remove and Replace Piston To remove the piston 33 first remove the connecting rod 59 and pin 61 by pressing the pin through the connecting rod Reverse the process to reinstall the piston Refer to Steps 5 and 6 below to replace the diaphragm and reassemble the pump 3 Reassemble Housing and Casting NOTE Inspect the shaft seal 56 before continuing If it looks damaged in any way replace it Refer to Replace Shaft Seal below Stand the pump on end With the piston and connecting rod in place reinstall the crankshaft by threading it through the connecting rod Reinstall the cover cover O ring and bolts with their O rings 4 Replace Shaft Seal a b 9 Press the back bearing 57 and seal 56 out of the cover 54 Discard the seal Apply a coating of Loctite High Performance Pipe Sealant With Teflon or a comparable product to the outer surface of a new seal a
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